Part 3

OVERHAUL
51. REMOVE TRANSAXLE REAR COVER SUB-ASSY [35102/98-3]





a. Remove the 11 bolts.
b. Tap in 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 a torx socket wrench (T30), remove the 2 screws and transaxle rear cover plate.





e. Using SST, remove the needle-roller bearing from the transaxle rear cover.
SST 09387-00040 (09387-01010, 09387-01030, 09387-01040)
52. REMOVE UNDERDRIVE BRAKE PISTON [34253 / 98-4]





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.





53. REMOVE BRAKE APPLY TUBE [35666D / 98-9]
a. Remove a bolt, clamp and 2 brake apply tubes.
b. Remove the brake apply tube from the clamp.
54. REMOVE FRONT CLUTCH APPLY TUBE [35895 / 98-9]





55. REMOVE GOVERNOR APPLY GASKET NO.1 [35148 / 98-3]
a. Using a screwdriver, remove the 2 apply gaskets.
56. REMOVE DIRECT CLUTCH ASSY





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





b. Remove the bearing race from the direct clutch.
54. REMOVE REAR PLANETARY SUN GEAR ASSY [35730 / 98-8]





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





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





c. Remove the thrust washer No. 1 from the rear planetary sun gear.
58. REMOVE 1 WAY CLUTCH ASSY [35790 / 98-6]





a. Remove the 1-way clutch and the thrust bearing from the transaxle case.





b. Remove the 1-way inner race from the 1-way clutch assy.





59. REMOVE 1 WAY CLUTCH SLEEVE OUTER [35798A / 98-6]
a. Remove the 1-way clutch sleeve outer.
60. REMOVE 2ND BRAKE CLUTCH DISC [35677 / 98-6]





a. Using a screwdriver, remove the 2ND brake hole snap ring from the transaxle case.





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





61. INSPECT 2ND BRAKE CLUTCH DISC [35677 / 98-6]
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, re-place all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

62. REMOVE SECOND BRAKE PISTON ASSY





a. Using a screwdriver, remove the 2ND brake cylinder hole snap ring from the transaxle case.





b. Remove the 2nd brake piston assy from the transaxle case.





63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC [35677A / 98-7]
a. Remove the flange, 5 discs and 5 plates from the transaxle case.





64. INSECT 1ST & REVERSE BRAKE CLUTCH DISC [35677A / 98-7]
a. Check to see if the sliding surface of the disc, plate, and flange are worn or burnt.
If necessary, replace them.

NOTICE:
- IF the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

65. REMOVE REAR PLANETARY GEAR ASSY [35760 / 98-8]





a. Using a screwdriver, remove the snap ring.





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





c. Remove the planetary carrier thrust washer No. 1 from the rear planetary gear.





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





66. REMOVE INPUT SUN GEAR [35714B / 98-6]
a. Remove the 2 thrust bearings, the bearing race and the input sun gear from the transaxle case.
67. REMOVE FRONT PLANETARY GEAR ASSY [35720 / 98-8]





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

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





b. Using SST, remove the nut.
SST 09387-00030, 09387-00080





c. Using SST and a press, remove the front planetary gear assy from the counter drive gear.
SST 09950 60010 (09951-00450)





d. Remove front planetary gear assy from the brake hub.





68. REMOVE FRONT PLANETARY RING GEAR [35743 / 98-8]
a. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
69. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC [35677A / 98-7]





a. Using SST, a press and a snap ring expander, remove 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.





b. Remove the 1st & reverse brake return spring from the 1st & reverse brake piston.





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

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





d. Remove 2 O-rings from the 1st & reverse brake position.





70. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY [35068 / 98-7]
a. Using vernier calipers, measure the free length of the 1st & reverse brake return spring together with the spring seat.
Standard free length: 15.51 mm (0.6106 inch)
71. REMOVE COUNTER DRIVE GEAR [35782C / 98-8]





a. Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00580), 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.
SST 09950-60010 (09951-00580), 09950-00020, 09950-00030





d. Using a brass bar and a hammer, remove the 2 counter drive bearing outer races from the transaxle case.





72. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING [35782D / 98-8]
a. Using a screwdriver, remove the snap ring from the transaxle case.
73. REMOVE BREATHER PLUG NO.2 (ATM) [35104C / 98-3]





74. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE [35882A / 98-9]
a. Remove the bolt, the transaxle apply tube clamp No. 2 and the differential gear loop apply tube from the transaxle case.