Part 2

Transmission Overhaul Procedure Continued





82. Remove the rear planetary gear rear thrust roller bearing and 2 bearing races from the rear planetary gear assembly.





83. Separate the 2nd brake cylinder, 1 way clutch and the planetary gear.





84. Remove the retainer from the 1 way clutch No.2.





85. Remove the front planetary sun gear and thrust roller bearing from the transaxle case.





86. Using a screwdriver, remove the 1st and reverse brake disc snap ring.





87. Check the 1st and reverse brake discs, plates and flange. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flange.





88. Using a press and a screwdriver, remove 1st and reverse return spring sub-assembly snap ring.
89. Remove the 1st and reverse brake return spring sub-assembly from the transaxle case.





90. Using vernier calipers, or an equivalent, measure the free length of the spring together with the spring seat. The free length should be 13.96 mm (0.5496 inch). If the length is not as specified, replace the spring.
91. Using compressed air at low pressure 392 kPa (57 psi) push out the 1st and reverse brake piston No.2 from the transaxle case.





92. Remove the 2 O-rings from the 1st and reverse brake piston No.2.





93. Engage the counter driven gear with the parking lock pawl.





94. Using a punch and hammer, unstake the counter drive gear lock washer.





95. Remove the counter drive gear nut and lock washer.





96. Using a press, remove the planetary gear assembly.





97. Install 2 M6 bolts 40-80 mm in length with a 1.0 mm thread pitch into the counter drive gear.
98. Tighten the bolts to remove the counter drive gear and front planetary sun gear.
99. Remove the 2 radial ball bearings from the counter drive gear and front planetary sun gear.





100. Remove the 3 parking lock pawl bracket retaining bolts.
101. Remove the bracket and cam guide sleeve.





102. Remove the manual valve lever shaft retainer spring.





103. Using a screwdriver, unstake and remove the spacer.





104. Using a pin punch and hammer, drive out the retaining pin.
105. Remove the manual valve lever shaft and manual valve lever sub-assembly.





106. Remove the parking lock rod sub-assembly from the manual valve lever.





107. Remove the manual valve lever shaft from the transaxle case.





108. Using a screwdriver, remove the parking lock pawl shaft.
109. Remove the parking lock pawl torsion spring and parking lock pawl.





110. Remove the counter driven gear, front drive pinion and thrust roller bearing from the transaxle case.





111. Using a brass bar and hammer, remove the differential drive pinion plug.





112. Using a press, remove the counter driven gear from the differential drive pinion.





113. Using a screwdriver, remove the manual valve lever shaft oil seal.





114. Using a bearing puller and slide hammer, remove the 2 right side counter drive gear bearing inner races from the transaxle case.
115. Using a bearing puller and slide hammer, remove the left side counter drive gear bearing outer race from the transaxle case.





116. Using a bearing puller and slide hammer, remove the counter drive gear bearing rear outer race from the transaxle case.





117. Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.
118. Remove the remaining oil seals from the transaxle case.





119. Using a seal driver and hammer, install a new transaxle case oil seal. Oil seal installation depth is 3.5 - 4.5 mm (0.086 - 0.126 inch).





120. Using a seal driver and hammer, install a new front transaxle case oil seal. Oil seal installation depth is 2.2 - 3.2 mm (0.138 - 0.178 inch).





121. Using a bearing driver and hammer, install the front drive pinion rear tapered roller bearing into the transaxle case.





122. Using a screwdriver, install the counter drive gear hole snap ring in the transaxle case.





123. Using a bearing driver and hammer, install the counter drive gear left side bearing outer race in the transaxle case.





124. Using a bearing driver and hammer, install the right counter drive gear bearing outer race in the transaxle case.





125. Using a seal driver and hammer, install a new manual valve lever shaft oil seal flush with the transaxle case.





126. Important: The differential drive pinion should be press fit until it comes in contact with the counter driven gear.
Using a press, install the counter driven gear on the differential drive pinion.

127. Important: The plug should be installed to a depth of 2.5 - 2.6 mm (0.0984 - 0.1023 inch).

Using a socket and soft faced hammer, install a new differential drive pinion plug in the differential drive pinion.





128. Install the counter drive gear and drive pinion thrust bearing in the transaxle case.





129. Apply T-IV automatic transmission fluid to the parking lock pawl shaft.
130. Install the parking lock pawl, torsion spring and shaft in the transaxle case.





131. Install the manual valve lever shaft in the transaxle case.





132. Install the parking lock rod sub-assembly to the manual valve lever.
133. Apply T-IV automatic transmission fluid to the manual valve lever sub-assembly shaft.
134. Install the manual valve lever and a new manual valve lever spacer on the manual valve lever shaft.





135. Using a pin punch and hammer, install the pin.
136. Turn the spacer and manual valve lever shaft to align the small hole to locate the staking position in the spacer with the staking position mark on the manual valve lever shaft.
137. Using a pin punch, stake the spacer through the small hole.
138. Ensure that the spacer does not turn freely.





139. Install the manual valve lever shaft retaining spring.





140. Notice: Refer to Fastener Notice in Service Precautions.

Install the cam guide sleeve, parking lock pawl bracket and the 3 retaining bolts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).





141. Using a press, install the counter drive gear to the transaxle case.





142. Using a press, install the planetary gear assembly to the transaxle case.





143. Engage the counter driven gear with the parking lock pawl.





144. Install a new lock washer and nut.
^ Tighten the nut to 280 Nm (207 ft. lbs.).





145. While turning the counter drive gear, measure the rotating torque.
Rotating torque should be 0.20 - 0.49 Nm (2 - 4 inch lbs.).





146. Using a punch and hammer, stake the lock washer.





147. Install 2 new O-rings on the 1st and reverse brake piston No.2.





148. Install the 1st and reverse brake piston in the transaxle case.





149. Install the 1st and reverse brake return spring sub-assembly into the transaxle.
150. Using a press and a screwdriver, install the snap ring.





151. Install the 4 1st and reverse brake plates (3), 4 brakes discs (1) and the flange (2) in the order shown into the transaxle case.
152. Using a screwdriver, install the snap ring.





153. Important: While applying 392 kPa (57 psi) of compressed air, measure the pack clearance.

The pack clearance should be within 0.806 - 1.206 mm (0.0317 - 0.0475 inch). If the pack clearance is not as specified, install a new flange.
There are 4 thicknesses available, 3.4 mm (0.134 inch), 3.6 mm (0.142 inch), 3.8 mm (0.150 inch), 4.0 mm (0.157 inch).

Using a dial indicator, measure the pack clearance using compressed air.





154. Install the front planetary sun gear and roller bearing on the planetary gear assembly.





155. Install the outer race retainer to the 1 way clutch No.2.





156. Install the 1 way clutch No. 2 and the 2nd brake piston assembly to the rear planetary gear assembly.





157. Install the thrust bearing race No.2, planetary gear rear needle roller bearing and the thrust bearing race No.1 to the rear planetary gear assembly.





158. Install the rear planetary gear assembly in the transaxle case.

Important: Align the oil hole (1) of the 2nd brake piston assembly with the oil hole (1) in the transaxle case, then install the assembly into the transaxle case.
159. Using a screwdriver, install the snap ring.





160. Check that the rear planetary gear assembly turns freely counterclockwise (1) and locks clockwise (2).





161. Install the 2nd brake piston sleeve in the transaxle case.





162. Install the 3 2nd brake discs (1), 3 2nd brake plates (3) and the flange (2) in the order shown into the transaxle case.
163. Using a screwdriver, install the snap ring into the transaxle case.





164. Important: While applying 392 kPa (57 psi) of compressed air, measure the pack clearance. The pack clearance should be within 0.847 - 1.247 mm (0.0333 - 0.0491 inch). If the pack clearance is not as specified, install a new flange.
There are 4 thicknesses available, 3.0 mm (0.118 inch), 3.2 mm (0.126 inch), 3.4 mm (0.134 inch), 3.6 mm (0.142 inch).

Using a dial indicator, measure the pack clearance of the 2nd brake using compressed air.