Part 2 of 3

3-Speed Gear Unit Installation





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





2. INSTALL DISCS, PLATES AND FLANGE
a. Install the inner flange, facing the flat end upward.





b. Install discs and plates in order.
D = Disc P = Plate

A241E: D-P-D-P-D-P-D-P-D-P-D
A244E: D-P-D-P-D-P-D-P-D





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





3. INSTALL SNAP RING

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





4. CONFIRM THAT FIRST AND REVERSE BRAKE PISTON MOVES
Using compressed air, confirm that the first and reverse brake piston moves smoothly.





5. INSTALL REAR PLANETARY RING TO CASE
a. Coat the races and bearing with petroleum jelly, and install them onto the ring gear.

Bearing and Race Diameters









b. Using a screwdriver, align the flukes of the discs.





c. Install the rear planetary ring gear into the case.





6. 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 splined of the planetary gear with the flukes of the discs and install the planetary gear into the first and reverse brake discs.





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





7. 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.





8. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of the cutouts.





9. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, the flat side facing upward.





b. Install the discs and plates in order.
D = Disc P = Plate

A241E: D-P-D-P-D-P
A244E: D-P-P-D-P-P





10. INSTALL SECOND BRAKE PISTON RETURN SPRING
Install each of the springs over the protrusions in the case.





11. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the band guide so that its tip touches the case.





12. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.





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

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





14. INSTALL SECOND BRAKE DRUM GASKET
Drive in a new drum gasket until it makes contact with the second brake drum.





15. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.





16. INSTALL SECOND BRAKE HUB AND NO.1 ONEWAY CLUTCH
a. Using a screwdriver, align the flukes of the discs in the second brake.





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





17. CHECK SECOND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the second brake hub and rear planetary gear.

Distance: Approximately 5 mm (0.20 inch)





18. 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.





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

Bearing and Race Diameters









b. Install the planetary gear.





20. INSTALL FRONT PLANETARY RING GEAR
a. Coat the races and bearing with petroleum jelly and install them onto the planetary ring gear.

Bearing and Race Diameters









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 a shoulder of the intermediate shaft or under.





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

Bearing and Race Diameters









21. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.





22. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
a. Coat the races and bearing with petroleum jelly, and install them onto the forward clutch drum.

Bearing and Race Diameters









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 with the hub correctly, the end of the bushing with the direct clutch drum 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: Approximately 3 mm (0.118 inch)