Part 1

DISASSEMBLY





1. REMOVE PISTON RETURN SPRING
a. While pushing the return spring, remove the snap ring with a screwdriver.
b. Remove the piston return spring.





2. REMOVE 2 PLATES, 2 DISCS AND FLANGE





3. REMOVE C(0) PISTON FROM DRUM
Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) to oil hole to remove the C(0) piston.

HINT: Blow with the gun slightly away from the oil hole, and be careful that the piston does not tilt.





4. REMOVE O-RING
Using a screwdriver, remove the inner and outer O-rings from the C(0) piston.





5. CHECK PISTON STROKE OF O/D DIRECT CLUTCH
Install a dial indicator and measuring terminal Special Service Tool (SST) together, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 5 - 8 kgf/cm2, 57 - 114 psi).
Piston stroke: 1.75 - 2.49 mm (0.0689 - 0.0980 inch)
SST 09350-32014 (09351-32190)
If the piston stroke is greater than the maximum, inspect each component.





6. REMOVE O/D DIRECT CLUTCH FROM CASE





7. REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE





8. REMOVE SNAP RING WITH SCREWDRIVER





9. REMOVE FLANGE, 3 DISCS AND 3 PLATES
10. REMOVE PISTON RETURN SPRING





a. Place SST on the spring retainer and compress the spring with a press.
SST 09350-32014 (09351-32070, 09351-32200)

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 deforming.
^ Do not expand the snap ring excessively.

b. Using a screwdriver, remove the snap ring.





c. Remove the piston return spring.





11. REMOVE PISTON FROM CLUTCH DRUM
a. Install the clutch drum on the case.
b. Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) to the pressure apply hole of the case.
c. Remove the piston from the clutch drum.
If the piston does not come out completely, use needle-nose pliers to remove it.
d. Remove the clutch drum from the case.





12. REMOVE O-RING
Using a screwdriver, remove the 2 O-rings from the piston.





13. CHECK OPERATION OF ONE-WAY CLUTCH
a. Install the O/D direct clutch into the one-way clutch.
b. Hold the O/D direct clutch and turn the intermediate shaft.
The shaft should turn freely clockwise and should lock counterclockwise.
c. Remove the O/D direct clutch.
14. CHECK COUNTER DRIVE GEAR PRELOAD





a. Hold the O/D planetary gear in a vise with soft jaws.

HINT: Do not let the counter drive gear touch the vise.





b. Using a tension gauge, measure the preload.
Preload (at starting): 9.2 - 15.3 N (940 - 1,560 g, 2.1 - 3.4 lbs.)

HINT: Turn the counter drive gear right and left several times before measuring the preload.

15. REMOVE O/D ONE-WAY CLUTCH AND OUTER RACE





a. Using a screwdriver, remove the snap ring.





b. Remove the retaining plate.
c. Remove the O/D one-way clutch with the outer race.





d. Remove the 2 retainers from both sides of the O/D one-way clutch.





e. Remove the O/D one-way clutch from the outer race.

HINT: Note the direction of the one-way clutch.

16. REMOVE NO. 3 PLANETARY THRUST WASHER





17. REMOVE PLUG FROM PLANETARY GEAR
Using a magnetic finger, remove the 4 plugs.

NOTICE: Be careful not to lose them.

18. REMOVE ADJUSTING NUT AND LOCKING WASHER





a. Using a screwdriver and hammer, pry off the locking washer.





b. Using SST, loosen the adjusting nut.
SST 09350-32014 (09351-32080)
c. Remove the adjusting nut and locking washer.





19. REMOVE INTERMEDIATE SHAFT BEARING
Using SST and a press, press out the bearing from the shaft.
SST 09950-00020





20. REMOVE COUNTER DRIVE GEAR AND FRONT BEARING
Using a press, press out the gear and bearing together.
21. REMOVE REAR BEARING





a. Using SST, press out the bearing.
SST 09950-00020





b. Tag the bearings to show the location for reassembly.
22. REMOVE O/D PLANETARY RING GEAR FROM COUNTER DRIVE GEAR





a. While pulling up the ring gear, using needle-nose pliers, compress the snap ring and remove it from the groove.
b. Remove the ring gear from the counter drive gear.





c. Remove the snap ring from the ring gear.
23. REMOVE OUTER RACE FROM COUNTER DRIVE GEAR





a. Using a brass bar and hammer, drive out the 2 races.





b. Tag the races to show the location for reassembly.





24. REMOVE SNAP RING FROM COUNTER DRIVE GEAR
Using a screwdriver, remove the snap ring.
25. REMOVE C(0) ACCUMULATOR PISTON FROM OVER DRIVE CASE





a. Using snap ring pliers, remove the snap ring.





b. Remove the retaining plate and 2 springs.
c. Remove the accumulator piston.





d. Using a screwdriver, remove the O-ring from the piston.





26. REMOVE 2 OIL SEAL RINGS

INSPECTION





1. INSPECT DISC, PLATE AND FLANGE OF O/D BRAKE
Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.

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





2. INSPECT O/D DIRECT CLUTCH
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.





3. INSPECT DISC, PLATE AND FLANGE OF O/D DIRECT CLUTCH
Check if the sliding surface of the discs, plates and flanges are worn or burnt. If necessary, replace them.

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





4. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the 2 direct clutch bushings.
Maximum inside diameter: 22.13 mm (0.8713 inch)
If the inside diameter is greater than the maximum, replace the direct clutch drum.





5. MEASURE PLANETARY PINION GEAR THRUST CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.16 - 0.56 mm (0.0063 - 0.0220 inch)
Maximum clearance: 0.61 mm (0.0240 inch)
If the clearance is greater than the maximum, replace the planetary gear assembly.

REASSEMBLY





1. INSTALL OIL SEAL RING ON O/D CASE
Install the 2 oil seal rings to the O/D case groove, then snug them down by squeezing their ends together.

HINT: After installing the oil seal rings, check that they move smoothly.

2. INSTALL C(0) ACCUMULATOR PISTON TO O/D CASE





a. Install a new O-ring to the accumulator piston.
b. Coat the O-ring with ATF.





c. Install the accumulator piston, 2 springs and retaining plate.





d. Using snap ring pliers, install the snap ring.





3. INSTALL SNAP RING INTO COUNTER GEAR
Using a screwdriver, install the snap ring.





4. INSTALL OUTER RACES INTO COUNTER DRIVE GEAR
Using SST and a press, press in the 2 outer races to both sides of the gear.
SST 09350-32014 (09351-32120, 09351-32150)

HINT: Press in the 2 outer races until they touch the snap ring. Tap the races in straight, so that they do not tilt.

5. INSTALL O/D PLANETARY RING GEAR INTO COUNTER DRIVE GEAR





a. Install the snap ring to the ring gear.





b. While pushing down the ring gear, using needle-nose pliers, squeeze the snap ring and install it into the groove.





6. INSTALL REAR BEARING
Using SST and a press, press in the bearing onto the shaft.
SST 09350-32014 (09351-32120)

HINT: Press in the bearing until the side surface of the inner race touches the planetary carrier.

7. INSTALL COUNTER DRIVE GEAR AND FRONT BEARING





a. Install the gear onto the shaft, and mesh the ring gear with the planetary pinions.
b. Place the front bearing on to the shaft.





c. Using SST and a press, press in the bearing until there is slight play between the bearings.
SST 09350-32014 (09351-32120)

HINT: Hold the ring gear to prevent it from failing.





8. INSTALL INTERMEDIATE SHAFT BEARING
Using SST and a press, press in the bearing until it slightly touches the front bearing of the counter drive gear.
SST 09350-32014 (09351-32120)

HINT: The counter drive gear can be turned lightly.





9. PLACE NEW LOCKING WASHER
10. INSTALL ADJUSTING NUT AND ADJUST PRELOAD OF COUNTER DRIVE GEAR
a. Hold the O/D planetary gear in a vise with soft jaws.





b. Using SST, tighten the adjusting nut until the following gear starting load is reached on the tension gauge.
SST 09350-32014 (09351-32080)
Preload (at starting): 9.2 - 15.3 N (940 - 1,560 g, 2.1 - 3.4 lbs.)

HINT: Turn the counter drive gear right and left several times before measuring the preload.





c. Using a screwdriver and hammer, lock the adjusting nut with one locking washer tab. Bend the locking washer tab until it is flat with the adjusting nut groove.





11. INSTALL NO. 3 O/D PLANETARY THRUST WASHER
12. INSTALL PINION SHAFT PLUG
Install the 4 plugs into the pinion shaft.
13. INSTALL O/D ONE-WAY CLUTCH AND RETAINING PLATE





a. Install the one-way clutch into the outer race.





b. Install the 2 retainers on both sides of the one-way clutch.





c. Install the one-way clutch into the O/D planetary gear.

HINT: Be sure that the one-way clutch is installed in the correct direction.

d. Install the retaining plate.





e. Using a screwdriver, install the snap ring.





14. CHECK OPERATION OF O/D ONE-WAY CLUTCH
a. Install the O/D direct clutch into the one-way clutch.
b. Hold the O/D direct clutch and turn the intermediate shaft.
The shaft should turn freely clockwise and should lock counterclockwise.
c. Remove the O/D direct clutch.