Part 3

OVERHAUL





61. REMOVE INPUT SUN GEAR [35714B/98-6]
a. Remove the 2 thrust bearings, the bearing race and the input sun gear from the transaxle case.
62. REMOVE FRONT PLANETARY GEAR ASSY [35720/98-8]





a. Using a chisel and a hammer, unstake the lock washer.

NOTICE:b Push down all claws of the washer. Otherwise SST can not be fully pressed against the nut and can not loosen the nut.





b. Using SST, remove the nut.
SST 09387-00030, 09387-00080





c. Using SST and a press, remove the front planetary gear assy from the counter drive gear.
SST 09950 60010 (09951-00450)





d. Remove front planetary gear assy from the brake hub.





63. REMOVE FRONT PLANETARY RING GEAR [35743/98-8]
a. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.





64. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC [35677A/98-7]
a. 1MZ-FE
Remove the flange, 7 discs and 7 plates from the transaxle case.
b. 2AZ-FE:
Remove the flange, 5 discs and 5 plates from the transaxle case.





65. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC [35677A/98-7]
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.





66. REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY [35068/98-7]
a. Using SST, a press and a snap ring expander, remove snap ring and the piston return spring.
SST 09387-0070

NOTICE:
- Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from deforming.
- Do not expand the snap ring excessively.





67. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY [35068/9-7l
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 15.51 mm (0.6106 inch)
68. REMOVE 1ST & REVERSE BRAKE PISTON [35623H/98-7]





a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove 1st & reverse brake piston.

NOTICE:
- Blowing off the air may cause the piston lump-out. When removing the piston, hold it with your hand using a waste cloth.
- Take care not to splash ATF when air-blowing.





b. Remove 2 O-rings from the 1st & reverse brake piston.
69. REMOVE COUNTER DRIVE GEAR [35782C/98-8]





a. Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100)





b. As shown in the illustration, tighten 2 bolts evenly and make clearance of approximately 20.0 mm (0.797 inch) between the counter drive gear and the inner race.





c. Using SST, remove the tapered roller bearing.
SST 09950-60010 (09951-00580), 09950-00020, 09950-00030





d. Using a brass bar and a hammer, remove the 2 bearing outer races.





70. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING [35782D/98-8]
a. Using a screwdriver, remove the snap ring from the transaxle case.
71. REMOVE BREATHER PLUG NO.2 (ATM) [35104C/98-3]
72. REMOVE UNDERDRIVE BRAKE PISTON [34253/98-4]





a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D brake piston.





b. Remove the 2 O-rings from the U/D brake piston.





c. Using SST, remove the needle-roller bearing from the transaxle case.
SST 09387-00040 (09387-01020, 09387-01030, 09387-01040)





73. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING [34244/98-8]
a. Remove the 2 oil seal rings from the transaxle case.





74. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING [34301B/98-4]
a. Using SST, remove the cylindrical roller bearing from the transaxle case.
SST 09514-35011





75. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING [34346/98-8]
a. Remove the oil seal ring from the transaxle housing.





76. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE [35882A/98-9]
a. Remove the bolt, the clamp and the apply tube from the transaxle case.








77. BEARING POSITION





78. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE [35882A/98-9]
a. Install the apply tube, and clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)

NOTICE: Make sure to insert the pipe to the stopper.





79. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING [34346/98-8]
a. Install the new oil seal ring to the transaxle housing.





80. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING [34301B/98-4]
a. Using SST and a press, install the U/D cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)

NOTICE: Do not apply excessive pressure to it.





81. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING [34244/98-8]
a. Install the new 2 oil seal rings to the transaxle case.
82. INSTALL UNDERDRIVE BRAKE PISTON [34253/98-4]





a. Wind a vinyl tape around SST at the place 4.0 mm (0.157 inch) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).
SST 09950-60010 (09951-00320)

NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.





b. Using SST and a press, install the needle-roller bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

NOTICE: When the wound vinyl tape contacts the transaxle case, stop press-fitting.





c. Coat 2 new O-rings with AFT, install them to the U/D brake piston.





d. Install the U/D brake piston to the transaxle case.





e. Using SST, a snap ring expander and a press, install the piston return spring and snap ring to the transaxle case.
SST 09387-00020

NOTICE: Do not apply excessive pressure to it.

83. INSTALL BREATHER PLUG NO.2 (ATM) [35104C/98-3]





84. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING [35782D/98-8]
a. Using a screwdriver, install the snap ring to the transaxle case.
85. INSTALL COUNTER DRIVE GEAR [35782C/98-8]





a. Using SST and a press, install the 2 bearings outer races to the transaxle case.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)

NOTICE:
- Press-fit the bearing race until it contacts the snap ring.
- Do not apply excessive pressure to it.





b. Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09649-17010

NOTICE:
- Press fit the bearing inner race until contacts the counter drive gear.
- Do not apply excessive pressure to it.





c. Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09950-70010 (09951-07150), 09950-60020 (09951-0750)

NOTICE: Do not apply excessive pressure to it.

86. INSTALL 1ST & REVERSE BRAKE PISTON [35623H/98-7]





a. Coat 2 new O-rings with ATF.
b. Install the 2 O-ring to the 1st & reverse brake piston.





c. Coat a 1st & reverse brake piston with AFT, install it to the transaxle case.





87. INSTALL 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY [35068/98-7]
a. Using SST, a press and snap ring expander, install the piston return spring and snap ring to the transaxle case.
SST 09387-00070

NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deform.
- Do not expand the snap ring excessively.





88. INSTALL FRONT PLANETARY RING GEAR [35743/98-8]
a. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
89. INSTALL FRONT PLANETARY GEAR ASSY [35720/98-8]





a. Install the front planetary gear assy to the brake hub.





b. Using SST and a press, press-fit the front planetary gear assy.
SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)

NOTICE: Do not apply excessive pressure to it.





c. Install the washer, as shown in the illustration.





d. Using SST, install the nut.
SST 09387-0030, 09387-00080
Torque: 268 Nm (2,732 kgf-cm, 198 ft. lbs.)





e. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing 0.51 - 1.02 Nm (5.1 - 10.0 kgf-cm, 4.4 - 8.7 inch lbs.)
Used Bearing 0.3 - 0.5 Nm (3.1 - 5.1 kgf-cm, 2.7 - 4.4 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 inch).





f. Using a chisel and hammer, stake the front planetary gear washer.





90. INSTALL INPUT SUN GEAR [35714B/98-6]
a. Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assy.





Bearing and race diameter: mm (in.)