3. Transmission End Cover/Int, Housing Disassemble & Service

Forward Clutch, Reverse Brake, and Intermediate Housing Removal

Special Tools Required
Reverse brake spring compressor 07TAE-P4V0110

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the end cover.
2. Remove the manual valve body lines.
3. Remove the planetary carrier/input shaft assembly, then remove the ring gear.
4. Remove the reverse brake snap ring, then remove the reverse brake end plate, brake discs, brake plates, and disc spring.
5. Remove the snap ring securing the forward clutch end plate, then remove the forward clutch end plate, discs and plates.
6. Remove the snap ring securing the forward clutch to the drive pulley shaft, then remove the forward clutch.





7. Install the special tool to remove the snap ring securing the reverse brake return spring retainer.





8. Compress the return spring with the special tool, then remove the snap ring. Be sure the special tool set over the reverse brake return springs.





9. Remove the special tool, then remove the spring retainer/return spring assembly (A).
10. Apply air pressure to reverse brake pressure circuit hole (B) to remove the reverse brake piston (C).
11. Remove the snap ring retainer from the drive pulley shaft.
12. Remove the drive pulley speed sensor.
13. Remove the manual valve body and separator plate.
14. Remove the roller. Push the control shaft toward the outside of the transmission housing if the transmission range switch is removed.
15. Remove the intermediate housing, then remove the ATF feed pipes from the transmission housing.

Manual Valve Body Disassembly, Inspection, and Reassembly





1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
2. Inspect the manual valve body for wear, scratches, and scoring.
3. If the manual valve body is worn or damaged, replace it.
4. Coat all parts with ATF during reassembly.

Control Shaft Removal and Installation
1. Remove the transmission range switch from the control shaft.





2. Remove the bolt (A) and lock washer (B).
3. Remove the control lever (C) from the control shaft (D).
4. Remove the control shaft assembly from the transmission housing (E).
5. Inspect the oil seal (F), and replace it if it is worn or damaged.
6. Inspect the end of the control shaft tips together for squeeze. If the end of the control shaft is squeezed, worn or damaged, replace the control shaft assembly.
7. Install the control shaft assembly in the transmission housing.
8. Install the control lever to the control shaft.
9. Install and tighten the bolt with the new lock washer, then bend the lock tab of the lock washer.

NOTE: Do not install the transmission range switch, install it after installing the end cover in the transmission assembly.

Planetary Carrier Bearing Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100





1. Remove the snap ring securing the planetary carrier Marina.





2. Remove the planetary carrier bearing.





3. Install the new bearing with the special tools.
4. Install the snap ring to secure the bearing on the planetary carrier.






Intermediate Housing, Reverse Brake, and Forward Clutch Installation

Special Tools Required
^ Reverse brake spring compressor 07TAE-P4V0110

1. Install 8 x 50 mm ATF feed pipe in the transmission housing, and install the 10.9 x 39.6 mm ATF feed pipes with new O-rings in the transmission housing.
2. Install the two dowel pins and new transmission housing gasket on the transmission housing.
3. Push the control shaft toward the outside of the transmission housing, then install the intermediate housing.
4. Install the manual valve body separator plate and two dowel pins on the intermediate housing, and install the manual valve body (four bolts) with the detent spring (one bolt).
5. Put the control shaft back, then install the roller in the intermediate housing with aligning the groove on the control shaft.





6. Install the new O-rings (A) on the reverse brake piston (B), then install the piston in the intermediate housing (C).
7. Install the spring retainer/return spring assembly (D); Install the return springs on the spring guide (E) on the reverse brake piston.





8. Install the special tool through the drive pulley shaft to compress the return spring. Be sure the special tool (spring compressor attachment) is set over the return springs, not over the reverse brake piston.





9. Compress the return springs, making sure that the special tool is set over the return springs and the spring retainer tabs do not ride on the reverse brake piston.
10. Install the snap ring in the intermediate housing above the spring retainer.





11. Verify that the snap ring end gap (A) is 15 mm (0.59 inch) or more.
12. Inspect the brake discs, brake plates, and brake end plate for wear, damage, and discoloration.
^ If the discs or plates are worn or damaged, replace the disc and plates as a set.
^ If the end plate is worn, damaged, or discolored, replace the end plate.
13. Soak the reverse brake discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the brake is free of dirt and other foreign matter.





14. Install the disc spring (A) in the direction shown.
15. Starting with the reverse brake plate (B), alternately install the plates and discs (C). Install the reverse brake end plate (D).





16. Install the snap ring by installing its end gap in the direction (A) shown.
17. Verify that the inside diameter (B) of the snap ring is 143.5 mm (5.65 inch) and above.





18. Verify that the snap ring end gap (A) is 18 mm (0.71 inch) and above.





19. Set a dial indicator (A) on the reverse brake end plate (B).
20. Zero the dial indicator with lifting the top disc (C) up to contact the reverse brake end plate to the snap ring (D).
21. Release the end plate to lower the end plate, and place a steel plate across the width of the reverse brake end plate.





22. Press the steel plate (A) down with 39 N (4 kgf, 9 lbs) using a force gauge, and read the dial indicator (B). the dial indicator reads the clearance (C) between the reverse brake end plate (D) and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.





23. If the clearance is out of the service limit, select a new reverse brake end plate from the following table, then recheck.

NOTE: If the thickest end plate is installed, but the clearance is still over the service limit, replace the reverse brake discs and plates as a set.

24. After replacing the reverse brake end plate, make sure that the clearance is within tolerance.





25. Install the snap ring retainer (A) over the drive pulley shaft (B).
26. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install the new O-ring (C) in the drive pulley shaft O-ring grooves, then remove the tape.
27. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.





28. Verify that the snap ring outside diameter (A) is 41.4 mm (1.63 inch) or less.





29. Install the ring gear (A) on the forward clutch (B).
30. Install the input shaft/planetary carrier assembly (C) through the drive pulley shaft (D) with aligning the sun gear (E) to the clutch discs and aligning the planetary carrier to the reverse brake discs.





31. Install the manual valve body lines (A) with new O-rings (B) on the manual valve body (C) and intermediate housing (D).
32. Install the ATF feed pipe (E) with new O-rings (F) on the manual valve body.
33. Install the two dowel pins (G) and the new end cover gasket (H) on the intermediate housing, and install the new O-rings (I) over the ATF feed pipes (J).
34. Install the end cover (K).
35. Install the drive pulley speed sensor with a new 0ring.