Part 2

26. INSTALL COUNTER DRIVEN GEAR
Using SST and a press, press in the driven gear.
SST 09350-32014(09351 - 32100,0935 - 32140)





27. TIGHTEN NEW LOCK NUT
a. Using SST to hold the driven gear, tighten a new lock nut.
SST 09350 - 32014(09351 - 32032)

Torque: 180 Nm (1,835 kgf-cm, 133 ft. lbs.)

b. Remove the SST





28. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.

End play: 0.2 - 0.9 mm (0.008 - 0.035 inch.)





29. STAKE LOCK NUT
Using a punch and hammer, stake the lock nut.





30. INSTALL TRANSAXLE REAR COVER
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
b. Apply FIPG sealant to the rear cover.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent





c. Install and tighten the 13 bolts.

Torque: 10 Nm (1100 kgf -cm, 7 ft. lbs.)

HINT: Each bolt length (mm) is indicated inch the illustration.

Bolt length:
25 mm (0.98 inch.)
32 mm (1.26 inch.)





31. CHECK INTERMEDIATE SHAFT Make sure that the intermediate shaft turns smoothly.





32. INSTALL 1ST& REVERSE BRAKE PACK
a. Install the discs and plates inch order.

Install in order: D = Disc P = Plate P-D-P-D-P-D-P-D-P-D-P-D





b. Install the outer flange, the flat end facing downward.





c. Using a screwdriver, install the snap ring.

HINT: Be sure the snap ring end gap is not aligned with one of the cut outs.





33. CHECK PACK CLEARANCE OF 1ST & REVERSE BRAKE
Using a feeler gauge, measure the 1st & reverse brake pack clearance.

Pack clearance (reference): 1.19 - 2.25 mm (0.0469 - 0.0886 inch.)

If the pack clearance is non-standard, parts have been misassembled. Check them.





34. INSTALL BEARING AND RACE TO REAR PLANETARY RING GEAR
Coat the races and bearing with petroleum jelly, and install them onto the ring gear.

Bearing and races:








35. INSTALL REAR PLANETARY GEAR
a. Coat thrust washer with petroleum jelly and install it onto the planetary gear.

HINT: Make sure that the different lug shapes match the openings on the gear.





b. Align the spline of the planetary gear with the flukes of the discs and install the planetary gear into the 1st & reverse brake discs.





c. Check the part "A" of the rear planetary gear is below the upper surface of the flange.





36. INSTALL NO.2 ONE-WAY CLUTCH
a. Place the one-way clutch into the case, the shiny side facing upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350 - 32014 (09351 - 32050)
c. Check that the planetary gear turns freely clockwise and locks counterclockwise.





d. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.





e. Be sure the end gap of the snap ring is not aligned with one of the cutouts.





37. INSTALL 2ND BRAKE INTO CASE
a. Install the flange, the flat side facing upward.





b. Install the discs and plates in order.

Install in order: D = Disc P = Plate D-P-D-P-D-P





c. Install each of the springs over the protrusions in the case.





d. Install the band guide so that its tip touches the case.
e. Install the bolt.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





f. Align groove of the drum with the bolt and place it into the case.





g. Place the snap ring into the case so that the end gap is installed into the groove.
h. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.






38. INSTALL 2ND BRAKE DRUM GASKET
Install a new drum gasket until it makes contact with the 2nd brake drum.






39. CONFIRM THAT 2ND BRAKE PISTON MOVES
Using compressed air, confirm that the 2nd brake piston moves smoothly.





40. INSTALL 2ND BRAKE HUB AND NO.1 ONE-WAY CLUTCH
a. Using a screwdriver, align the flukes of the discs inch the 2nd brake.





b. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.





41. CHECK 2ND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 inch.)

42. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM



a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.





b. While turning the sun gear clockwise, install it into the No. 1 one-way clutch.





43. INSTALL FRONT PLANETARY GEAR
a. Coat the race and bearing with petroleum jelly and install them onto the planetary gear.

Bearing:
Inner diameter: 28.1 mm (1.106 inch.)
Outer diameter: 45.0 mm (1.772 inch.)





b. Install the planetary gear.


44. INSTALL FRONT PLANETARY RING GEAR



a. Coat the races and bearing with petroleum jelly and install them onto the planetary ring gear.

Bearing and races:








b. Install the ring gear.





HINT: If the planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.





c. Coat the races and bearing with petroleum jelly and install them onto the tip of ring gear flange.

Bearings and races:






45. INSTALL 2ND COAST BRAKE BAND



a. Place the band into the case.
b. Install the pin.


46. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH



a. Coat the races and bearing with petroleum jelly, and install them onto the forward clutch drum.

Bearing:
Inner Diameter: 30.7 mm (1.209 inch.)
Outer Diameter: 46.0 mm (1.811 inch.)





b. Coat the clutch drum thrust washer with petroleum jelly, and install it onto the direct clutch drum with the oil groove facing upward.





c. Using a screwdriver, align the flukes of the discs in the direct clutch.





d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

HINT: If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.





e. Place the direct clutch and forward clutch into the case.
f. While rotating the forward clutch to mesh the front planetary ring gear and discs, install them.





g. Check the distance between A and B.

Distance: Approx. 3 mm (0.118 inch.)


47. INSTALL 2ND COAST BRAKE PISTON



a. Install 2 new O-rings to the cover.

HINT: Coat the O-rings with ATF before installing.





b. Install the spring, piston and cover into the bore.





c. Using SST, install the snap ring.
SST 09350 - 32014 (09351 - 32050)


48. MEASURE PISTON STROKE OF 2ND COAST BRAKE



a. Apply a small amount of paint to the piston rod at the point it meets the case.





b. Using SST, measure the piston stroke while applying and 2 releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm 57 - 114 psi).
SST 09240 - 00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch.)

If the piston stroke exceeds the limit, select a new piston rod.





49. INSTALL NEW APPLY GASKET





50. INSTALL DIFFERENTIAL