Part 2 of 2

36. REMOVE NO. 2 ONE -WAY CLUTCH AND REAR PLANETARY GEAR





37. REMOVE THRUST WASHERS OF PLANETARY CARRIER BOTH SIDES





38. REMOVE REAR PLANETARY RING GEAR





39. REMOVE BEARINGS AND RACES
40. CHECK OPERATION OF FIRST AND REVERSE BRAKE PISTON





Apply compressed air into the case passage and confirm that the piston moves.
If the piston does not move, disassemble and inspect.





41. REMOVE SNAP RING HOLDING FLANGE TO CASE





42. REMOVE FLANGES, PLATES AND DISCS
43. TURN TRANSAXLE CASE AROUND
44. REMOVE TRANSAXLE REAR COVER, INTERMEDIATE SHAFT AND GASKET





a. Remove the 11 bolts.





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





c. Remove the intermediate shaft which remains in the transaxle.





45. REMOVE SNAP RING
Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)

46. REMOVE FIRST AND REVERSE BRAKE PISTON





a. Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)
b. Using snap ring pliers, remove the snap ring.
c. Remove SST.
d. Remove the return spring from the case.





e. Apply compressed air into the passage of the case to remove the piston.

HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.

f. If the piston does not pop out with compressed air, use needle-nose pliers to remove it.





g. Remove the 2 O-rings from the piston.





47. REMOVE PARKING LOCK PAWL BRACKET





48. REMOVE PARKING LOCK ROD





49. REMOVE PIN, SPRING AND PARKING LOCK PAWL
50. REMOVE MANUAL VALVE SHAFT





a. Remove the retaining spring.





b. Using a hammer and screwdriver, pry open and turn the collar.





c. Using a hammer and punch, drive out the pin.





d. Slide out the shaft and remove the manual valve lever from the case.





51. REMOVE MANUAL SHAFT OIL SEAL
Remove the oil seal with a screwdriver.
52. REMOVE GOVERNOR PRESSURE ADAPTOR





a. Remove the torsion spring with long nose pliers.





b. Remove the governor pressure adapter from the case.

Differential Disassembly





1. REMOVE CARRIER COVER





2. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload, and make a note of it.





3. MEASURE BACKLASH OF SIDE GEAR
Measure each side gear backlash while holding one pinion toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

4. REMOVE LH BEARING RETAINER





a. Remove the 6 bolts (Al31L) or 5 bolts (Al32L).
b. Remove the retainer by tapping it with a plastic hammer.
c. Remove the O-ring from the retainer.

5. REMOVE DIFFERENTIAL CASE





a. Remove the 2 bolts and side bearing cap.





b. Remove the differential case, outer race and adjusting shim from the case.





6. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.

Preload (starting):
Reused bearing 0.5 - 0.8 Nm (6 - 8 kg-cm2, 4.3 - 6.9 inch lbs.)
The total preload measured in step 2, minus the drive pinion preload, should be between 0.1 - 2.0 kg-cm2, 1.3 - 1.7 inch lbs.). If the result in not within this specification, the side bearing preload is wrong.





7. REMOVE DRIVE PINION CAP
Remove the bolt and pull out the drive pinion cap.
8. REMOVE COUNTER DRIVEN GEAR





a. Using a chisel, loosen the staked part of the nut.





b. Using SST to hold the gear, remove the nut.
SST 09330-00021, 09350-32014 (03951-32032)





c. Using SST, remove the gear and bearing.
SST 09350-32014 (09351-32061)

9. REMOVE OUTER RACE AND SLINGER





a. Using SST, remove the outer race.
SST 09350 - 32014 (09308-10010)
b. Remove the oil slinger.





10. REMOVE SPACER
11. REMOVE DRIVE PINION





a. Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)





b. Install the brass bar into the case hole to tap out the drive pinion.





c. Remove the drive pinion.





d. Remove the O-ring from the cage.