Part 2

22. MEASURE PISTON STROKE OF SECOND COAST BRAKE

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

b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm 57 - 114 psi or 392 - 785 kPa) as shown.

SST 09240-00020

Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.)

If the piston stroke exceeds the limit, inspect the second coast brake band.

23. REMOVE SECOND COAST BRAKE PISTON

a. Using SST, remove the snap ring.

SST 09350-32014 (09351-32050)

b. Remove the cover.
c. Remove the piston and outer return spring.
d. Remove the two O-rings from the cover.

24. STAND TRANSAXLE ENGINE SIDE UPWARD
25. REMOVE OIL PUMP

NOTE: Before removing the oil pump, remove the second coast brake piston.

a. Remove the seven bolts.

b. Using SST, pull out the oil pump from the transaxle case.

SST 09350-32014 (09351-32061)

26. REMOVE O-RING FROM OIL PUMP

27. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH

28. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH
a. Separate the direct clutch and forward clutch.
b. Remove the thrust washer from direct clutch.

29. REMOVE BEARINGS FROM FORWARD CLUTCH

30. REMOVE SECOND COAST BRAKE BAND
a. Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting.
b. Remove the brake band.

HINT: For the method of inspection. Second Coast Brake

31. REMOVE FRONT PLANETARY RING GEAR
32. REMOVE FRONT PLANETARY GEAR

a. Remove the front planetary gear.

b. Remove the two bearings from the planetary gear.

33. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM

a. Remove the sun gear and sun gear input drum.

b. Remove the thrust washer from sun gear input drum.

34. CHECK OPERATION OF SECOND BRAKE PISTON
Apply compressed air into the case passage and confirm that the piston moves.

If the piston does not move, disassemble and inspect.

35. REMOVE SECOND COAST BRAKE BAND GUIDE
36. REMOVE SECOND BRAKE DRUM

a. Remove the snap ring.

b. Remove the second brake drum.

37. REMOVE SECOND BRAKE PISTON RETURN SPRING

38. REMOVE NO.1 ONE-WAY CLUTCH

39. REMOVE PLATES, DISCS AND FLANGE

HINT: For the method of inspection. Second Brake

40. REMOVE SECOND BRAKE DRUM GASKET
Remove the gasket.

41. REMOVE NO.2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR

a. Remove the snap ring.

b. Remove the No.2 one-way clutch and rear planetary gear.

c. Remove the thrust washer from the rear planetary gear.

42. REMOVE REAR PLANETARY RING GEAR
a. Remove the rear planetary ring gear.
b. Remove the bearing from the ring gear.

43. CHECK FIRST AND REVERSE BRAKE

a. Check the operation of the first and reverse brake piston

Apply compressed air into the case passage and confirm that the piston moves.

If the piston does not move, disassemble and inspect.

b. Using a filler gauge, check the pack clearance of the first and reverse brake.

Clearance: A540E 0.85 - 2.05 mm (0.033 - 0.081 in.)
A540H 1.04 - 2.16 mm (0.041 - 0.085 in.)

If the pack clearance is not within specification, disassemble and inspect.

44. REMOVE FLANGE, DISCS AND PLATES OF FIRST AND REVERSE BRAKE

a. Remove the snap ring.

b. Remove the flange, seven discs and seven plates.

HINT: For the method of inspection. First and Reverse Brake

45. TURN TRANSAXLE CASE AROUND
46. REMOVE OVERDRIVE UNIT

a. Remove the thirteen bolts.

b. Tap on the circumference of the overdrive case with a plastic hammer to remove the overdrive case and gasket.

c. Remove the overdrive planetary gear from transaxle case.

d. Remove the overdrive brake drum from the transaxle case.

e. Remove the overdrive clutch apply gasket and overdrive brake apply gasket.

47. REMOVE FIRST AND REVERSE BRAKE PISTON
a. Remove the piston return spring.

- Place SST, and compress the return spring evenly by tightening the bolt gradually.

SST 09350-32014 (09351-32040)

- Using snap ring pliers, remove the snap ring.
- Remove SST.
- Remove the return spring from the case.

b. Apply compressed air into the passage of the case to remove the piston.

HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.