Part 2

DISASSEMBLY





25. REMOVE U/D CLUTCH ASSEMBLY
Remove the U/D clutch assembly, the thrust bearing and the 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, 4 discs and 4 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 11 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. Using SST, remove the needle-roller bearing.
SST 09387-00040 (09387-01010, 09387-01030, 09387-01040)





29. REMOVE BRAKE APPLY PIPE
a. Remove a 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 the 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, 4 discs and 4 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 2nd brake piston.

NOTICE:
- Blowing of air may cause the piston to jump-out. When removing the piston, hold it with your hand using 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 together with the spring seat.
Standard free length: 16.61 mm (0.6539 inch)
39. REMOVE 1ST & REVERSE BRAKE





a. Remove the flange, 5 discs and 5 plates.





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

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.





c. Remove the return spring.





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

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





e. Remove 2 O-rings from the 1st & reverse brake piston.
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
a. Remove the 2 thrust bearings, the bearing race and the 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 again the nut and can not loosen the nut.





b. Using SST, remove the 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 (09951-00450)





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 COUNTER DRIVE GEAR
a. Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00600), 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 RH.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09958-04011), 09950-60010 (09951-00600)





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.
44. 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.
45. 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.





46. REMOVE APPLY PIPE
Remove the bolt, the clamp and the apply pipe from the transaxle case.





47. REMOVE OIL SEPARATOR
a. Remove the 3 bolts and oil separator from the transaxle case.