Part 2

AUTOMATIC TRANSAXLE UNIT Continued

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

52. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air into the oil passage of the case to remove the 1st & reverse brake piston.

HINT: Hold the 1st and reverse piston so it is not slant and blow with the gun slightly away from the oil hole.

(b) If the 1st & reverse piston does not pop out with compressed air, use needle-nose pliers to remove it.

53. REMOVE TRANSMISSION CASE COVER REAR
(a) Remove the 13 bolts from the transaxle case.

(b) Tap off the circumference of the transmission case cover rear with a plastic hammer to remove the rear case from the transaxle case, and remove the transmission case cover rear.

54. REMOVE INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Using a chisel and hammer, unstake the counter drive gear nut.

(b) Using SST, remove the counter drive gear nut.
SST 09330-00021, 09350-32014 (09351-32032)

55. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00380), 09950-70010 (09951-07100)

56. REMOVE COUNTER DRIVE GEAR BEARING
(a) Remove the snap ring from the counter drive gear bearing.
(b) Remove the counter drive gear bearing from the counter drive gear.

57. REMOVE COUNTER DRIVEN GEAR
(a) Using a chisel and hammer, unstake the counter driven gear nut.

(b) Using SST to hold the counter shaft assembly, remove the counter driven gear nut on the counter driven gear side.
SST 09350-32014 (09351-32170)

(d) Remove the thrust needle roller bearing from the transaxle case.

58. REMOVE COUNTER SHAFT ASSEMBLY
(a) Pull out the counter shaft assembly from the transaxle case.

(b) Remove the thrust needle roller bearing from the counter shaft assembly.

59. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH

60. REMOVE UNDERDRIVE CLUTCH ASSEMBLY
(a) Remove the underdrive clutch assembly from the transaxle case.

61. REMOVE UNDERDRIVE 1 WAY CLUTCH RETAINER
(a) Remove the underdrive 1 way clutch retainer from the transaxle case.

62. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSEMBLY

63. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Remove the underdrive 1 way clutch assembly and underdrive clutch drum thrust washer from the underdrive clutch drum sub-assembly.

64. REMOVE OVERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 overdrive clutch drum oil seal rings from the transaxle case.

65. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

66. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using SST and a press, press in the flange until the snap ring is free from the flange.
SST 09350-32014 (09351-32070)
(b) Using a screwdriver, remove the underdrive clutch flange No. 2 hole snap ring from the transaxle case.

68. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Remove the underdrive brake return spring sub-assembly from the transaxle case.

69. REMOVE UNDERDRIVE BRAKE PISTON
(a) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the underdrive brake piston into a rag.

(b) Using a screwdriver, remove the 2 O-rings from the underdrive brake piston.

70. REMOVE PARKING LOCK PAWL
(a) Remove the 2 bolts, pawl stopper plate, torsion spring and spring guide sleeve from the transaxle case.

(b) Remove the bolt and pawl shaft clamp from the transaxle case.

71. REMOVE PARKING LOCK SLEEVE
(a) Remove the spring guide sleeve from the transaxle case.

72. REMOVE CAM GUIDE SLEEVE
(a) Remove the cam guide sleeve from the transaxle case.

73. REMOVE B-4 ACCUMULATOR PISTON
(a) Using a "TORX" wrench, remove the 7 screws.

(b) Remove the 2 bolts.
(c) Remove the transmission case plate No. 2 and transmission case plate No. 2 gasket from the transaxle case.

(d) Remove the B-4 accumulator piston and compression spring from the transaxle case.
(e) Remove the O-ring from the B-4 accumulator piston.

74. REMOVE TRANSMISSION CASE PLATE NO.3
(a) Remove the bolt and transmission case plate No. 3 from the transaxle case.

75. REMOVE COUNTER DRIVEN GEAR CYLINDRICAL ROLLER BEARING
(a) Using SST, remove the counter driven gear cylindrical roller bearing from the transaxle case.
SST 09308-00010

76. REMOVE TRANSAXLE APPLY TUBE CLAMP NO.1
(a) Remove the 2 bolts and 2 transaxle apply tube clamps No. 1 from the transaxle housing.

77. REMOVE TRANSAXLE APPLY TUBE CLAMP NO.2
(a) Remove the bolt and transaxle apply tube clamp No.2 from the transaxle housing.

78. REMOVE TRANSMISSION LUBE APPLY TUBE
(a) Using a screwdriver, remove the transmission lube apply tube from the transaxle housing.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to bend or damage the tube.

79. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Using a screwdriver, remove the differential gear lube apply tube transaxle housing.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to bend or damage the tube.

80. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Remove the bolt, seal washer and roller bearing retainer from the transaxle housing.

(b) Using SST, remove the underdrive cylindrical roller bearing from the transaxle housing.
SST 09308-00010

81. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using a screwdriver, remove the transaxle housing oil seal from the transaxle housing.

82. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using a screwdriver, remove the transaxle case oil seal from the transaxle case.

83. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Setting SST to the cut-out portion on the speedometer drive gear, remove the front drive pinion front tapered roller bearing from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00340)
(b) Remove the speedometer drive gear from the differential case.

(c) Using SST and a hammer, drive out the front drive pinion front tapered roller bearing outer race.
SST 09350-32014 (09351-32090)

84. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Setting SST to the cut-out portion on the differential case, remove the front drive pinion rear tapered roller bearing from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00410)

(b) Using SST and a hammer, drive out the front drive pinion rear tapered roller bearing outer race and plate washer.
SST 09350-32014 (09351-32130, 09351-32150)

85. BEARING POSITION

INSPECTION

1. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
(a) Remove the 2 oil cleaner magnets and use them to collect any steel chips. Carefully examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle:
Steel (magnetic) bearing, gear and plate wear
Brass (non-magnetic) bushing wear

2. INSPECT PISTON STROKE OF 2ND COAST BRAKE
(a) Apply a small amount of paint to the piston rod at the point where it meets the case.

(b) Using SST, measure the piston stroke while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
SST 09240-00020
Piston stroke: 1.5 to 3.0 mm (0.059 to 0.118 in.)

If the piston stroke exceeds the limit, inspect the brake band.

3. INSPECT 2ND COAST BRAKE BAND ASSEMBLY
(a) If the lining of the 2nd coast brake band assembly is peeling off or discolored, or even if a part of the printed numbers are defaced, replace the 2nd coast brake band assembly.

4. INSPECT FRONT PLANETARY GEAR ASSEMBLY
(a) Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.2 to 0.5 mm (0.008 to 0.020 in.)
Maximum clearance: 0.55 mm (0.022 in.)

If the clearance is greater than the maximum, replace the front planetary gear assembly.

5. INSPECT 1 WAY CLUTCH ASSEMBLY
(a) Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock if turned counterclockwise.

6. INSPECT 2ND BRAKE PISTON
(a) Using compressed air, check that the 2nd brake piston moves smoothly.

7. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.

HINT:
^ If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

8. INSPECT REAR PLANETARY GEAR ASSEMBLY
(a) Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.2 to 0.5 mm (0.008 to 0.020 in.)
Maximum clearance: 0.55 mm (0.022 in.)

If the clearance is greater than maximum, replace the rear planetary gear assembly.

9. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
(a) Using a feeler gauge, measure the first & reverse brake pack clearance.
Pack clearance: 1.19 to 2.25 mm (0.0469 to 0.0886 in.)

If the pack clearance is non-standard, check the disc.

10. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.

HINT:
^ If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

11. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH
(a) Set a dial indicator (long type pick or SST).
SST 09350-32014 (09351-32190)

(b) While applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi), measure the underdrive clutch piston stroke.
Piston stroke: 1.5 to 1.9 mm (0.059 to 0.075 in.)
(c) If the piston stroke is non-standard, select another flange.

HINT: There are 4 different flange thickness.

Flange thickness:

12. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Hold the 1 way clutch drum and turn the 1 way clutch. Check that the 1 way clutch must be able to turn free counterclockwise and will lock if turned clockwise.