Part 2

11. Remove the one-way clutch after taking out the snap ring.





12. Remove the needle bearing after taking out the snap ring.

2-4 BRAKE





Separate the 2-4 brake piston and piston retainer.

ONE-WAY CLUTCH INNER RACE





1. Remove the seal ring.
2. Remove the needle bearing using ST.
ST 398527700 PULLER ASSY

ONE-WAY CLUTCH OUTER RACE





1. Remove the one-way clutch after taking out the snap ring.





2. Remove the needle bearing after taking out the snap ring.

ASSEMBLY

HIGH CLUTCH AND REVERSE CLUTCH
1. Install the seal ring and lip seal to the high clutch piston and reverse clutch piston.





2. Install the high clutch piston to reverse clutch piston.





3. Install the reverse clutch piston to high clutch drum. Align the groove on reverse clutch piston with the groove on high clutch drum during installation.





4. Install the spring retainer to high clutch piston.





5. Install the ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON GUIDE





6. Install the cover to high clutch piston without folding the high clutch piston seal.
7. Install the snap ring using ST1 and ST2.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON GUIDE
8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. 9. Set the micro gauge to retaining plate, and read its scale.

NOTE: The value, which is read in the gauge at this time, is zero point.

10. Scale and record the weight Z of a flat board which will be put on retaining plate.

NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 250 N (25.5 kgs, 56.2 lbs.).





11. Put the flat board on retaining plate.
12. Using the following formula, calculate N indicated on the push/pull gauge.
N = 250 N (25.5 kgs, 56.2 lbs.) - Z
N: Value indicated on push/pull gauge
250 N (25.5 kgs, 56.2 lbs.): Load applied to clutch plate
Z: Flat board weight





13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.





14. Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
15. Install the snap ring to high clutch drum.





16. Apply compressed air intermittently to check for operation.





17. Measure and record the clearance B between the retaining plate and snap ring. (High clutch) At this time, do not press down the retaining plate.





18. Piston stroke calculation Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 2.0 - 2.3 mm (0.079 - 0.091 inch)
Limit thickness: 2.6 mm (0.102 inch)

19. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
20. Set the micro gauge to retaining plate, and read its scale.

NOTE: The value, which is read in the gauge at this time, is zero point.





21. Scale and record the weight Z of a flat board which will be put on retaining plate.

NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 150 N (15.3 kgs, 33.7 lbs.).
22. Put the flat board on retaining plate.
23. Using the following formula, calculate N indicated on the push/pull gauge.
N = 150 N (15.3 kgs, 33.7 lbs.) - Z
N: Value indicated on push/pull gauge
150 N (15.3 kgs, 33.7 lbs.): Load applied to clutch plate
Z: Flat board weight





24. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.





25. Install the driven plate, drive plate, retaining plate and snap ring.





26. Apply compressed air intermittently to check for operation.





27. Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down the retaining plate.





28. Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.
T=A+ B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard: 1.1 - 1.4 mm (0.043 - 0.055 inch)
Limit thickness: 1.6 mm (0.063 inch)

PLANETARY GEAR AND LOW CLUTCH
1. Apply ATF, to D-ring and install it to low clutch piston.





2. Install the low clutch piston to low clutch drum.





3. Install the spring retainer to low clutch piston.





4. Install the ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON GUIDE





5. Set the cover on the piston with a press using ST1 and ST2, and attach the snap ring. At this time, be careful not to fold the cover seal during installation.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON GUIDE





6. Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.





7. Check the low clutch for operation.
1. Remove the one-way clutch.
2. Set the one-way clutch inner race, and apply compressed air for checking.





8. Check the low clutch clearance.
1. Place the same thickness of shim on both sides to prevent pressure plate from tilting.
2. Check the clearance between retaining plate and low clutch operation.
Initial standard: 0.7 - 1.1mm(0.028 - 0.043 inch)
Limit thickness: 1.5 mm (0.059 inch)





If the clearance is out of specification, select a suitable retaining plate.





9. Install the washer to rear internal gear.





10. Install the rear internal gear.





11. Install the thrust rust needle bearing in correct direction.





12. Install the washer by aligning protrusion of washer and hole of rear planetary carrier.





13. Install the rear planetary carrier to low clutch drum.





14. Install the thrust needle bearing in correct direction.





15. Install the rear sun gear in proper direction.





16. Install the thrust needle bearing in proper direction.





17. Install the front planetary carrier to low clutch drum.





18. Install the snap ring to low clutch drum.





19. Install the needle bearing, and then secure with the snap ring.
20. Install the one-way clutch and one-way clutch inner race, and then secure with the snap ring.





21. Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.

2-4 BRAKE
1. Apply ATF, to D-ring, and install it to 2-4 brake piston.





2. Install the 2-4 brake piston to 2-4 brake piston retainer.

ONE-WAY CLUTCH INNER RACE





1. Install the needle bearing to inner race using ST and press.
ST 398497701 SEAT
2. Apply Vaseline to the groove of inner race and seal ring.





3. Install two seal rings to one-way clutch inner race.

ONE-WAY CLUTCH OUTER RACE





1. Install the needle bearing, and then secure with the snap ring.
2. Install the one-way clutch, and then secure with the snap ring.





3. Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.

INSPECTION

HIGH CLUTCH AND REVERSE CLUTCH
Check the following items:
^ Drive plate facing for wear and damage
^ Driven plate for discoloration (burned color)
^ Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston and drum check ball for operation
^ Adjust the total end play.

PLANETARY GEAR AND LOW CLUTCH
Check the following items:
^ Drive plate facing for wear and damage
^ Driven plate for discoloration (burned color)
^ Snap ring for wear, return spring for setting and breakage, and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston check ball for operation
^ Measure the total end play and adjust it within specifications.

2-4 BRAKE
Check the following items:
^ Drive plate facing for wear and damage
^ Driven plate for discoloration (burned color)
^ Snap ring for wear and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Measure the total end play and adjust it within specifications.

ONE-WAY CLUTCH
^ Make sure the snap ring is not worn and the seal rings are not deformed.
^ Measure the total end play and adjust it within specifications.

LOW & REVERSE BRAKE
Check the following items:
^ Drive plate facing for wear and damage
^ Driven plate for discoloration (burned color)
^ Snap ring for wear and spring retainer for deformation