Part 2

DISASSEMBLY





25. REMOVE U/D CLUTCH ASSEMBLY
Remove the U/D clutch assembly, thrust bearing and bearing race from the transaxle case.
26. REMOVE ONE-WAY CLUTCH NO. 2





a. Using a screwdriver, remove the snap ring.





b. Remove the one-way clutch No. 2 from the transaxle case.





c. Remove the outer race retainer from the one-way clutch No. 2.
27. REMOVE U/D BRAKE





a. Using a screwdriver, remove the snap ring.





b. Remove the flange, 3 discs and 3 plates from the transaxle case.





c. Using SST, a snap ring expander and a press, remove the snap ring.
SST 09387-00020





d. Remove the piston return spring.
28. REMOVE TRANSAXLE REAR COVER
a. Remove the 1 bolts.





b. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.





c. Remove the 2 oil seal rings from the transaxle rear cover.
d. Remove the 2 screws and plate.





e. Using SST, remove the needle roller bearing.
SST 09387-00040 (09387-01010, 09387-01030, 09387-01040)





29. REMOVE BRAKE APPLY PIPE
Remove the bolt, clamp and 2 brake apply pipes.





30. REMOVE TRANSAXLE CASE APPLY GASKET
Using a screwdriver, remove the 2 apply gaskets.
31. REMOVE DIRECT CLUTCH ASSEMBLY





a. Remove the thrust bearing and direct clutch from the transaxle case.





b. Remove the bearing race from the direct clutch.
32. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY





a. Remove the rear planetary sun gear assembly from the transaxle case.





b. Remove the thrust bearing from the rear planetary sun gear.





c. Remove the thrust washer No. 1 and thrust bearing from the rear planetary sun gear.
33. REMOVE ONE-WAY CLUTCH NO.1





a. Remove the one-way clutch No.1 from the transaxle case.





b. Remove the inner race from the one-way clutch No. 1.





34. REMOVE ONE-WAY CLUTCH OUTER SLEEVE
35. REMOVE 2ND BRAKE





a. Using a screwdriver, remove the snap ring.





b. Remove the flange, 3 discs and 3 plates from the transaxle case.
36. REMOVE 2ND BRAKE CYLINDER





a. Using a screwdriver, remove the snap ring.





b. Remove the 2nd brake cylinder from the transaxle.
37. REMOVE 2ND BRAKE PISTON





a. Using SST, a press and a screwdriver, remove the snap ring.
SST 09387-00060





b. Remove the return spring.





c. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.

NOTICE:
^ Blowing off the air may cause the piston's jumping out. When removing the piston, hold it by hand with a waste cloth.
^ Take care not to splash ATF when air-blowing.





d. Remove the 2 O-rings from the 2nd brake piston.





38. CHECK 2ND BRAKE PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 16.61 mm (0.6539 inch)





39. REMOVE 1ST AND REVERSE BRAKE FLANGE, DISC AND PLATE
Remove the flange, 5 discs and 5 plates.
40. REMOVE REAR PLANETARY GEAR





a. Using a screwdriver, remove the snap ring.





b. Remove the rear planetary gear from the transaxle case.





c. Remove the thrust washer No. 2 from the rear planetary gear.





d. Remove the bearing race from the rear planetary gear.





41. REMOVE FRONT PLANETARY SUN GEAR
Remove the 2 thrust bearings, bearing race and front planetary sun gear from the transaxle case.
42. REMOVE FRONT PLANETARY GEAR ASSEMBLY AND BRAKE HUB





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

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





b. Using SST, remove the lock nut.
SST 09387-00030, 09387-00080
c. Remove the lock washer.





d. Using SST and a press, remove the front planetary gear assembly from the counter drive gear.
SST 09950-60010 (09951-00440)





e. Remove the front planetary gear.





f. Using a screwdriver, remove the snap ring.
g. Remove the front planetary ring gear from the brake hub.
43. REMOVE 1ST AND REVERSE BRAKE





a. Using SST, a press and a snap ring expander, remove the snap ring and piston return spring.
SST 09387-00070

NOTICE:
^ Stop the press when the spring sheet is lowered by 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.





b. Remove the return spring.





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

NOTICE:
^ Blowing off the air may cause the piston's jumping out. When removing the piston, hold it by hand with a waste cloth.
^ Take care not to splash ATF when air-blowing.





d. Remove 2 O-rings from the 1st and reverse brake piston.
44. REMOVE COUNTER DRIVE GEAR





a. Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)





b. As shown in the illustration, tighten 2 bolts evenly and make a 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 RH.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09958-04011), 09950-60010 (09951-00590)





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





e. Using a screwdriver, remove the snap ring from the transaxle case.
45. REMOVE U/D BRAKE PISTON





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)





d. Remove the 2 oil seal rings from the transaxle case.
46. REMOVE U/D CYLINDRICAL ROLLER BEARING





a. Using SST, remove the cylindrical roller bearing from the transaxle case.
SST 09514-35011





b. Remove the oil seal ring from the transaxle housing.





47. REMOVE DIFFERENTIAL GEAR LUBE APPLY PIPE
Remove the bolt, clamp and apply pipe from the transaxle case.