Part 3

Transmission Disassemble




97. Using a screwdriver, remove the governor apply gaskets (1, 2, 3).




98. Remove the bolt (2), clamp and brake apply tube (2).
99. Remove the clutch apply tube (3).
100. Remove the brake apply tube from the clamp.




101. Remove the thrust bearing (2) and the direct clutch assembly (1) from the transaxle case.




102. Using a screwdriver, remove the snap ring (1) from the intermediate shaft.




103. Remove the flange, discs, plates and cushion plate from the intermediate shaft.




104. Using a screwdriver, remove the snap ring from the intermediate shaft.
105. Remove the flange, discs and plates from the intermediate shaft.




106. Using a press (1), remove overdrive clutch return spring.

Note:
* Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove. This prevents the spring seat from being deformed.
* Do not expand the snap ring excessively.

107. Using a snap ring expander, remove the snap ring from the direct clutch drum.




108. Remove the clutch balancer (1) from the overdrive direct clutch drum.




109. Remove the overdrive clutch return spring (1) from the overdrive direct clutch drum.




110. Install the intermediate shaft on the transaxle rear cover.
111. Holding the direct clutch piston by hand, apply compressed air to the transaxle rear cover (1) to remove the direct clutch piston.




112. Holding the direct clutch drum by hand, apply compressed air to the transaxle rear cover (1) to remove the direct clutch drum.




113. Using a screwdriver, remove the O-ring (1) from the direct clutch drum.




114. Remove the thrust bearing race (1), thrust bearing (2), and overdrive direct clutch hub (3) from the planetary gear assembly.




115. Remove the rear planetary sun gear assembly (1) from the transaxle case.




116. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.




117. Remove the number 2 planetary carrier thrust washer (1) from the rear planetary sun gear assembly (2).




118. Remove the one-way clutch assembly (2) and the thrust needle roller bearing (1) from the transaxle case.




119. Remove the one-way clutch inner race (1) from the one-way clutch assembly.




120. Remove the one-way clutch sleeve (1) from the transaxle case.




121. Remove the number 1 planetary carrier thrust washer (1) from the planetary gear assembly.




122. Using a screwdriver, remove the snap ring (1).
123. Remove the flange, discs and plates from the transaxle case.




124. Using a screwdriver, remove the snap ring (1).




125. Remove the 2nd brake piston assembly (1) from the transaxle case.




126. Using a suitable tool (1), remove the 2nd brake piston return spring.




127. Remove the 2nd brake piston return spring sub-assembly (1).




128. Hold the 2nd brake piston and apply compressed air to the 2nd brake cylinder to remove the 2nd brake piston.




129. Remove the O-rings (1, 2) from the 2nd brake piston.




130. Using a screwdriver, remove the snap ring (1).




131. Remove the rear planetary gear assembly (1) from the transaxle case.




132. Remove the thrust needle roller bearings (4), number 2 thrust bearing races, number 3 thrust bearing race, and input sun gear (2) from the transaxle case.




133. Remove the flange, discs and plates from the transaxle case.




134. Using a chisel and hammer, unstake the lock washer (1).




135. Using a DT-49189 - counter gear nut wrench (1, 2), remove the nut and washer.




136. Using a press (1), remove the front planetary gear assembly from the counter drive gear.




137. Remove the front planetary gear assembly (1) from the brake hub.




138. Using a screwdriver, remove the snap ring (1) and front planetary ring gear from the brake hub.




139. Using a press (1), compress the 1st and reverse brake return spring.

Note:
* Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.

140. Using snap ring pliers, remove the snap ring.
141. Remove the return spring.





Note:
* Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a piece of cloth.
* Take care not to splash ATF when applying compressed air.

142. Apply compressed air to the transaxle case (2) to remove the 1st and reverse brake piston.




143. Remove the O-rings (1, 2) from the 1st and reverse brake piston.




144. Using a press (1), remove the counter drive gear from the transaxle case.