Part 1

REASSEMBLY

1. BEARING POSITION

Bearing Diameter:

2. INSTALL NO. 4 BRAKE PISTON
a. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
b. Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
c. Install the No. 4 brake piston to the reaction sleeve.

3. INSTALL BRAKE REACTION SLEEVE
a. Coat a new O-ring with ATF, and install it to the reaction sleeve.
b. With the No. 1 brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case.

NOTICE: Be careful not to damage the O-rings.

4. INSTALL 1ST AND REVERSE BRAKE PISTON
a. Coat a new O-ring with ATF.
b. Install the O-ring on the 1st and reverse brake piston.
c. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

NOTICE: Be careful not to damage the O-ring.

d. Place the piston return spring onto the No. 4 brake piston.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Place SST on the spring retainer, and compress the return spring.
SST 09350-30020 (09350-07050)
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)

6. INSTALL REAR PLANETARY GEAR ASSEMBLY
a. Install the thrust needle roller bearing.

Standard Thrust Needle Roller Bearing Diameter:

b. Install the thrust needle roller bearing.
c. Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear.

Standard Bearing And Race Diameter:

d. Install the rear planetary gear assembly

7. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
a. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

b. Using vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.

NOTICE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.

HINT: Length A = 36.35 to 37.09 mm (1.431 to 1.460 inch)

c. Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.

HINT:
Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.010 to 0.071 inch)
Length B = 36.04 to 37.14 mm (1.419 to 1.462 inch)
Pack clearance: 0.8 to 1.1 mm (0.031 to 0.043 inch)

d. If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

H Thickness:

8. INSTALL NO. 4 BRAKE DISC
a. Install the 7 plates, 8 discs and 2 flanges. Install in order: F - D - P - D - P - D - P - D - P - D - P - D - P - D - P - D - F

HINT: P = Plate, D = Disc, F = Flange

9. INSTALL BRAKE PLATE STOPPER SPRING
a. Install the brake stopper spring.

10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft.

Standard Bearing And Race Diameter:

11. INSTALL NO. 3-WAY CLUTCH ASSEMBLY
a. Install the No. 3-way clutch assembly and the 1-way clutch inner race to the intermediate shaft.

12. INSTALL INTERMEDIATE SHAFT
a. Install the intermediate shaft with the No. 3-way clutch assembly to the case.

b. Using SST, install the snap ring.
SST 09350-30020 (09350-07050, 09350-07060)

13. INSTALL CENTER PLANETARY GEAR ASSEMBLY
a. Install the center planetary gear assembly and planetary sun gear to the case.
b. Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear.

Standard Race Diameter:

14. INSTALL NO. 2 BRAKE PISTON
a. Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.
b. Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.
c. Install the No. 2 brake piston to the case.

15. INSTALL NO. 2 BRAKE DISC
a. Install the flange, 3 plates, 3 discs and brake piston return spring.
Install in order: D - P - D - P - D - P - F

HINT: P = Plate, D = Disc, F = Flange

b. Using SST and press, install the No. 2 brake spring snap ring.
SST 09351-40010

16. INSTALL NO. 1 BRAKE PISTON
a. Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.
b. Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.

17. INSTALL BRAKE PISTON RETURN SPRING SUB ASSEMBLY
a. Install the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder on the transmission case.

18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING
a. Using SST and a press, install the brake piston return spring snap ring.
SST 09351-40010

19. INSTALL NO. 1 BRAKE DISC
a. Install the 3 plates, 3 discs and flange.
Install in order: P - D - P - D - P - D - P - D - F

HINT: P = Plate, D = Disc, F = Flange

20. INSTALL CENTER PLANETARY RING GEAR
a. Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear.

b. Using a screwdriver, install the snap ring.

21. INSTALL FRONT PLANETARY RING GEAR
a. Install the front planetary ring gear and thrust needle roller bearing on the case.

Standard Thrust Needle Roller Bearing Diameter:

22. INSTALL FRONT PLANETARY GEAR ASSEMBLY
a. Install the thrust needle roller bearing and thrust washer.
b. Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear.

Standard Thrust Needle Roller Bearing And Race Diameter:

c. Install the front planetary gear assembly and 1-way clutch inner race from the case.

23. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON
a. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.

b. Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.
Standard piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 inch)
If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange.

HINT: There are 4 different thicknesses for the flange.

Standard Flange Thickness:

24. INSTALL 2ND BRAKE PISTON
a. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
b. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands.

c. Using SST and press, install the snap ring.
SST 09351-40010

NOTICE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

25. INSTALL 2ND BRAKE CYLINDER
a. Install the 2nd brake cylinder to the case.

26. INSTALL 1-WAY CLUTCH ASSEMBLY
a. Install the 1-way clutch and thrust washer to the case.

27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING
a. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)

28. INSTALL NO. 3 BRAKE DISC
a. Install the flanges, 4 discs, 4 plates and cushion plate to the case.
Install in order: C - P - D - P - D - P - D - P - D - F

HINT: P = Plate, D = Disc, F = Flange C = Cushion

29. INSTALL NO. 3 BRAKE SNAP RING
a. Using a screwdriver, install the snap ring.

30. INSTALL NO. 2-WAY CLUTCH ASSEMBLY
a. Coat the race with petroleum jelly and install it onto the No. 2 clutch drum thrust washer.
b. Install the No. 2-way clutch assembly washer.

31. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY
a. Install the thrust needle roller bearing.
b. Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.

Standard Thrust Needle Roller Bearing And Diameter:

c. Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.