Part 2 of 3

22. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.





23. INSTALL COUNTER SHAFT ASSEMBLY
a. Align the flukes of the discs in the underdrive clutch.
b. Install the thrust bearing with the race, with the bearing facing upward.

Bearing:
Outer diameter 43.9 mm (1.728 inch)
Inner diameter 31.0 mm (1.220 inch)

b. Install the counter shaft assembly.





24. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.

Height: 30.3 - 32.5 mm (1.193 - 1.280 inch)





25. INSTALL THRUST NEEDLE BEARING

Bearing:
Outer diameter 58.0 mm (2.283 inch)
Inner diameter 41.0 mm (1.614 inch)





26. INSTALL COUNTER DRIVEN GEAR
Using SST and a press, press in the driven gear.
SST 09350-32014 (09351-32100, 09351-32140)





27. TIGHTEN NEW LOCK NUT
a. Using SST to hold the driven gear, tighten a new lock nut.
SST 09350-32014 (09351-32032)

Torque: 180 Nm (1,835 kgf-cm, 133 ft. lbs.)

b. Remove the SST.





28. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.

End play: 0.2 - 0.9 mm (0.008 - 0.035 inch)





29. STAKE LOCK NUT
Using a punch and hammer, stake the lock nut.





30. INSTALL TRANSAXLE REAR COVER
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
b. Apply sealant to the rear cover.

Sealant: Part No. 08826-00090, THREE BOND 1281 or equivalent





c. Install and tighten the 13 bolts.

Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)

HINT: Each bolt length (mm) is indicated in the illustration.

Bolt length:
25 mm (0.98 inch)
32 mm (1.26 inch)

3-Speed Gear Unit Installation





1. CHECK INTERMEDIATE SHAFT
Make sure that the intermediate shaft turns smoothly.





2. INSTALL FIRST AND REVERSE BRAKE PACK
a. Install the discs and plates in order.
D = Disc P = Plate

P-D-P-D-P-D-P-D-P-D-P-D





b. Install the outer flange, the flat end facing downward.





c. Using a screwdriver, install the snap ring.

HINT: Be sure the snap ring end gap is not aligned with one of the cutouts.





3. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE
Using a feeler gauge, measure the first and reverse brake pack clearance.

Pack clearance (reference): 1.19 - 2.35 mm (0.0469 - 0.0886 inch)

If the pack clearance is non-standard, parts have been misassembled. Check them.





4. INSTALL BEARING AND RACE TO REAR PLANETARY RING GEAR
Coat the races and bearing with petroleum jelly, and install them onto the ring gear.

Bearing and Races









5. INSTALL REAR PLANETARY GEAR
a. Coat thrust washer with petroleum jelly and install it onto the planetary gear.

HINT: Make sure that the different lug shapes match the openings on the gear.





b. Align the spline of the planetary gear with the flukes of the discs and install the planetary gear into the first and reverse brake discs.





c. Check that part A of the rear planetary gear is below the upper surface of the flange.





6. INSTALL NO.2 ONE-WAY CLUTCH
a. Place the one-way clutch into the case, the shiny side facing upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
c. Check that the planetary gear turns freely clockwise and locks counterclockwise.





d. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.





e. Be sure the end gap of the snap ring is not aligned with one of the cutouts.





7. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, the flat side facing upward.





b. Install the discs and plates in order.
D = Disc P = Plate

D-P-D-P-D-P






c. Install each of the springs over the protrusions in the case.





d. Install the band guide so that its tip touches the case.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





e. Align groove of the drum with the bolt and place it into the case.





f. Place the snap ring into the case so that the end gap is installed into the groove.
g. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.





8. INSTALL SECOND BRAKE DRUM GASKET
Drive in a new drum gasket until it makes contact with the second brake drum.





9. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.





10. INSTALL SECOND BRAKE HUB AND NO.1 ONEWAY CLUTCH
a. Using a screwdriver, align the flukes of the discs in the second brake.





b. Align the spline of the hub with the flukes of the discs and install the hub to the second brake discs.





11. CHECK SECOND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the second brake hub and rear planetary gear.

Distance: Approx. 5 Nm (0.20 inch)





12. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.





b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.





13. INSTALL FRONT PLANETARY GEAR
a. Coat the race and bearing with petroleum jelly and install them onto the planetary gear.

Bearing:
Inner diameter 28.1 Nm (1.106 inch)
Outer diameter 45.0 Nm (1.772 inch)





b. Install the planetary gear.





14. INSTALL FRONT PLANETARY RING GEAR
a. Coat the races and bearing with petroleum jelly and install them onto the planetary ring gear.

Bearing and Races









b. Install the ring gear.





HINT: If the planetary ring gear and the other parts are installed correctly into the case, the and of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.





c. Coat the races and bearing with petroleum jelly and install them onto the tip of ring gear flange.

Bearing and Races









15. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin.