Oil Pump, 2ND Coast Brake & 2ND Brake

Oil Pump, 2nd Coast Brake & 2nd Brake





COMPONENTS

DISASSEMBLY





1. Remove oil seal from oil pump assembly, using suitable tool.

CAUTION: Be careful not to scratch oil pump assembly.

NOTE: Do not reuse old seal.





2. Remove thrust washer from oil pump assembly.





3. Remove snap ring, using a flat-bladed screwdriver.





4. Remove 2nd coast brake flange, 2nd coast brake disc and 2nd coast brake plate.





5. Compress return spring with a press, using Tool.
Tool number : KV31102400 (J-34285 and J-34285-87)
6. Remove snap ring, using suitable snap ring pliers.





7. Remove return spring.





8. While pushing the 2nd coast brake piston by hand, apply compressed air (4kg/cm2) into the oil passage as shown and remove 2nd coast brake piston.

CAUTION: Be careful not to damage the O-ring and 2nd coast brake piston.

9. Remove O-rings from 2nd coast brake piston.

NOTE: Do not reuse O-rings.





10. Remove snap ring, using suitable tool.





11. Remove 2nd brake flange, 2nd brake discs and 2nd brake plates.





12. Remove return spring.





13. Remove snap ring, using suitable tool.

CAUTION: Be careful not to damage oil pump assembly and 2nd brake piston.





14. While pushing the 2nd brake piston by hand, apply compressed air (4kg/cm2 ) into the oil passage as shown and remove 2nd brake piston (With 2nd brake sleeve).

CAUTION: Be careful not to damage 2nd brake piston and 2nd brake sleeve.

15. Remove O-rings from 2nd brake piston and 2nd brake sleeve.

NOTE: Do no reuse O-rings.

INSPECTION
^ Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or burnt, replace it

NOTE: Replace new clutch discs by soaking them at least 2 hours in ATF.

ASSEMBLY





1. Install new O-rings in 2nd brake sleeve and 2nd brake piston.

NOTE:
^ Do not reuse O-ring.
^ Apply ATF to O-ring.

2. Coat the inner surfaces of oil pump assembly with ATF.
3. Press 2nd brake piston and 2nd brake sleeve into oil pump assembly.





4. Install snap ring, using suitable tool.

CAUTION: Be careful not to damage oil pump assembly.





5. Place return spring on 2nd brake piston with the spring side up.





6. Install 2nd brake flange, 2nd brake discs and 2nd brake plates.





7. Install snap ring, using suitable tool.





8. Install new O-rings in 2nd coast brake piston.

NOTE:
^ Do not reuse O-rings.
^ Apply ATF to O-rings.

9. Coat the inner surfaces of oil pump assembly with ATF.
10. Press 2nd coast brake piston into oil pump assembly.





11. Install return spring.





12. Compress return spring, using Tool.
Tool number : KV31102400 (J-34285 and J-34285-87)
13. Install snap ring, using suitable snap ring pliers.





14. Install 2nd coast brake flange, 2nd coast brake disc and 2nd coast brake plate.





15. Compress return spring with a press, using Tool.
Tool number : KV31102400 (J-34285 and J-34285-87)
16. Install snap ring, using suitable tool.





17. Set a dial indicator as shown.
18. When applying compressed air (4Kg/cm2) into the oil passage as shown, measure 2nd brake piston stroke and check 2nd brake piston moves smoothly.
Piston stroke : 1.10 - 1.50 mm (0.0433 - 0.0591 inch)
If 2nd brake piston stroke is out standards, select another flange. Refer to "2ND BRAKE".





19. Set a dial indicator as shown.
20. When applying compressed air (4Kg/cm2) into the oil passage as shown, measure 2nd coast brake piston stroke and check 2nd coast brake piston moves smoothly.
Piston stroke : 0.76 - 1.44 mm (0.0299 - 0.0567 inch)





21. Install thrust washer facing the flat surface up.

NOTE: Apply petroleum jelly to thrust washer.





22. Install new oil seal into oil pump assembly until it is flush with the oil pump face, using Tool.
Tool number : ST30720000 (J-25405)

NOTE:
^ Do not reuse oil seal.
^ Apply ATF to oil seal.