Overdrive Unit
Overdrive Unit:
COMPONENTS
DISASSEMBLY OF OVERDRIVE BRAKE
1. REMOVE OVERDRIVE BRAKE DRUM
2. REMOVE PISTON RETURN SPRING ASSEMBLY
a. While pushing the return spring, remove the snap ring with a screwdriver.
b. Remove the return spring.
3. REMOVE CUSHION PLATE
4. REMOVE PLATES, DISCS AND FLANGE
5. BLOW OUT PISTON FROM DRUM
Apply compressed air to oil hole to remove the piston.
NOTE: Blow with the gun slightly away from the oil hole, and be careful that the piston doesn't tilt.
6. REMOVE O-RING FROM PISTON
INSPECTION OF OVERDRIVE BRAKE
INSPECT DISC. PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt.
If a disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange are not worn or burnt.
If necessary, replace them.
NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATF.
DISASSEMBLY OF OVERDRIVE DIRECT CLUTCH
1. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE
2. REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE
3. REMOVE SNAP RING WITH SCREWDRIVER
4. REMOVE FLANGES, DISCS AND PLATES
5. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
a. Place SST on the spring retainer and compress the spring with a shop press.
SST 09350 - 32013 (09351 - 32070, 09351 - 32200)
b. Remove the snap ring with a screwdriver.
6. ASSEMBLE OVERDRIVE DIRECT CLUTCH DRUM ON CASE AND BLOW OUT PISTON
a. Install the clutch drum on the case.
b. Apply compressed air to the pressure apply hole with the case.
c. Remove the overdrive direct clutch drum from the case.
If the piston does not come out completely, use needle-nose pliers to remove it.
7. REMOVE O-rings FROM PISTON
INSPECTION OF OVERDRIVE DIRECT CLUTCH
1. INSPECT OVERDRIVE DIRECT CLUTCH PISTON
a. Check that check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low-pressure compressed air.
2. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt.
If a disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange are not worn or burnt.
If necessary, replace them.
NOTE: Do not allow the discs to dry out.
Prepare new discs by soaking them at least two hours in ATF.
ASSEMBLY OF OVERDRIVE DIRECT CLUTCH
1. INSTALL CLUTCH PISTON IN OVERDRIVE DIRECT CLUTCH DRUM
a. Install new O-rings on the piston. Coat the O-ring with ATF.
b. Press the piston into the drum with the cup side up, being careful not to damage the 0- ring.
2. INSTALL PISTON RETURN SPRING AND SET SNAP RING IN PLACE
3. COMPRESS RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the spring with a shop press.
SST 09350 - 32013 (09351 - 32070, 09351 - 32200)
b. Install the snap ring with your hands. Be sure end gap of snap ring is aligned with the groove of the clutch drum.
4. INSTALL FLANGE. DISCS AND PLATE
Install in order: Flange - disc - plate - plate - disc - flange
5. INSTALL SNAP RING WITH SCREWDRIVER
Be sure end gap of snap ring is aligned with the groove of the clutch drum.
6. INSTALL OVERDRIVE DIRECT CLUTCH TO OVERDRIVE CASE
a. Coat the race with petroleum jelly and install it to the OD case.
b. Coat the assembled bearing and race with petroleum jelly and install it facing the race side downward to the clutch drum.
c. Install the OD clutch drum to the OD case.
7. CHECK OPERATION OF OVERDRIVE DIRECT CLUTCH PISTON
Apply compressed air into the case passage and confirm that the piston moves.
If the piston does not move, disassemble and inspect.
REPLACEMENT OF COUNTER DRIVE GEAR AND BEARING
1. PRY OFF LOCKING WASHER WITH SCREWDRIVER
2. HOLD SHAFT IN VISE WITH SOFT JAWS, AND LOOSEN ADJUSTING NUT WITH SST
SST 09350 - 32013 (09351 - 32080)
3. REMOVE ADJUSTING NUT AND WASHER
4. REMOVE INTERMEDIATE SHAFT BEARING
Using SST, press out the bearing from the shaft.
SST 09950 - 00020
5. REMOVE COUNTER DRIVE GEAR AND FRONT BEARING
Using a press, press out the gear and bearing together.
6. REMOVE REAR BEARING
Using SST, press out the bearing.
SST 09950 - 00020
7. REMOVE OVERDRIVE PLANETARY RING GEAR FROM COUNTER DRIVE GEAR
a. While pulling up the ring gear, compress the snap ring with needle-nose pliers and remove it from the groove.
b. Remove the ring gear from the counter drive gear.
8. REMOVE TWO OUTER RACES FROM COUNTER DRIVE GEAR
Drive out the races with a brass bar and hammer.
9. REMOVE SNAP RING FROM COUNTER DRIVE GEAR
10. INSTALL SNAP RING INTO COUNTER DRIVE GEAR
11. INSTALL TWO OUTER RACES INTO COUNTER DRIVE GEAR
Using SST, press the outer races into the gear.
SST 09350 - 32013 (09351 - 32090, 09351 - 32120)
NOTE: Press in the outer races until they touch the snap ring. Tap the races in straight, so that they do not tilt.
12. INSTALL OVERDRIVE PLANETARY RING GEAR INTO COUNTER DRIVE GEAR
While pushing down the ring gear, squeeze the snap ring end with a needle-nose pliers, and install it into the groove.
NOTE: When the snap ring is fully seated, the end will be free.
13. INSTALL REAR BEARING
Using SST, press in the bearing into the shaft.
SST 09350 - 32013 (09351 - 32120)
NOTE: Press in the bearing until the side surface of the inner race touches the shaft.
14. 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 onto the shaft.
NOTE: Hold the ring gear to prevent it from falling.
c. Using SST, press in the bearing until axial play between the bearings is 0.5 mm (0.020 in.).
SST 09350 - 32013 (09351 - 32120)
15. INSTALL INTERMEDIATE SHAFT BEARING
Using SST, press in the bearing until it slightly touches the front bearing of the counter drive gear.
SST 09350 - 32013 (09351 - 32120)
NOTE: The counter drive gear can be turned lightly.
16. PLACE LOCKING WASHER AND ADJUSTING NUT ONTO INTERMEDIATE SHAFT
17. ADJUST PRELOAD OF COUNTER DRIVE GEAR
a. Place SST onto the adjusting nut and hold the shaft in a vise with soft jaws.
SST 09350 - 32013 (09351 - 32080)
b. Tighten the adjusting nut to the point where the following gear starting load occurs with SST.
Preload (at starting): 920 - 1,530 g (2.0 - 3.4 lb, 9 - 15 N)
NOTE: Turn the counter drive gear right and left several times before measuring the preload.
18. LOCK ADJUSTING NUT WITH ONE TAB ON LOCKING WASHER
Bend the locking washer tab until it is even with the adjusting nut groove.
DISASSEMBLY OF OVERDRIVE ONE-WAY CLUTCH
1. CHECK OPERATION OF ONE-WAY CLUTCH
a. While turning the overdrive gear clockwise, install the overdrive clutch into the one-way clutch.
b. Hold the overdrive clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise.
2. REMOVE SNAP RING AND RETAINING PATE
3. REMOVE ONE-WAY CLUTCH AND OUTER RACE TOGETHER
4. REMOVE NO. 3 OVERDRIVE PLANETARY THRUST WASHER
5. REMOVE ONE-WAY CLUTCH FROM OUTER RACE
Note the direction of the one-way clutch.
6. REMOVE THE FOUR PLUGS WITH MAGNETIC FINGER
NOTE: Be careful not to lose them.
ASSEMBLY OF OVERDRIVE ONE-WAY CLUTCH
1. INSTALL THE FOUR PLUGS INTO HOLE OF PINION SHAFT
2. INSTALL NO.3 OVERDRIVE PLANETARY THRUST WASHER
Install the thrust washer, facing the groove toward the over drive case.
3. ASSEMBLE OVERDRIVE ONE-WAY CLUTCH
a. Install the one-way clutch into the outer race.
b. Install a retainer on both sides of the one- way clutch
4. INSTALL OVERDRIVE ONE-WAY CLUTCH INTO HUB
Be sure that the one-way clutch is installed in the correct direction.
5. INSTALL RETAINING PLATE AND SNAP RING
6. CHECK OPERATION OF ONE-WAY CLUTCH
a. Install the overdrive clutch into the one-way clutch .
b. Hold the overdrive clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise.
c. Remove overdrive clutch from the one-way clutch.
DISASSEMBLY OF OVERDRIVE CASE
1. REMOVE ACCUMULATOR PISTON OF OVERDRIVE CLUTCH
a. Remove the snap ring, retaining plate and springs.
b. Remove the accumulator piston, using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa). Force air into the hole shown and remove the piston.
2. REMOVE THE TWO OIL SEAL RINGS FROM CASE
Spread the rings apart and remove them.
ASSEMBLY OF OVERDRIVE CASE
1. INSTALL THE TWO OIL SEAL RINGS ON OVERDRIVE CASE
Spread the rings apart and install them into the groove.
2. INSTALL ACCUMULATOR PISTON OF OVERDRIVE CLUTCH
a. Install the accumulator piston.
b. Install the piston springs, retaining plate and snap ring.
ASSEMBLY OF OVERDRIVE BRAKE
1. INSTALL NEW O-rings ONTO PISTON
2. INSTALL PISTON INTO DRUM
a. Coat the O-rings with ATF.
b. Press the piston into the drum, being careful not to damage the O-rings.
3. INSTALL FLANGE. DISCS AND PLATES
a. Install the flange, facing the flat end upward.
b. Install in order: Plate - disc - plate - plate - plate - disc - plate - plate
c. Install the cushion plate facing the rounded end upward.
4. INSTALL PISTON RETURN SPRING
5. INSTALL SNAP RING INTO CASE
Be sure the end gap of the snap ring is not aligned with one of cutouts.
6. INSTALL OVERDRIVE GEAR ASSEMBLY ONTO CASE
While turning the overdrive gear clockwise, install the overdrive gear assembly to the case.
If the overdrive gear assembly is properly installed to the overdrive case, the clearance between them will be about 24 mm (0.94 in.).
7. INSTALL OVERDRIVE BRAKE DRUM
Align the pin of overdrive brake drum to the hole of transaxle case, and install it.