Part 2

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




42. BE CAREFUL WHEN REMOVING THRUST WASHERS FROM BOTH SIDES OF PLANETARY CARRIER




43. REMOVE REAR PLANETARY RING GEAR




44. REMOVE BEARINGS AND RACES




45. CHECK OPERATION OF 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.




46. REMOVE SNAP RING HOLDING FLANGE TO CASE




47. REMOVE FLANGES, PLATES AND DISCS




48. TURN TRANSMISSION CASE AROUND
49. REMOVE ELEVEN BOLTS HOLDING OVERDRIVE UNIT TO TRANSMISSION CASE
50. REMOVE OVERDRIVE UNIT WITH ALL PARTS




a. Tap on the overdrive case circumference with a plastic hammer to remove the unit from the transmission case.
b. Remove the overdrive planetary gear and counter gear if they remained in the transmission.

HINT: The overdrive unit is heavy, so be careful not to drop it.




c. Remove the overdrive brake drum from the transmission case.




d. Remove the overdrive planetary gear and counter gear if they remain in the transmission.




51. REMOVE OVERDRIVE CLUTCH APPLY GASKET AND OVERDRIVE BRAKE APPLY GASKET
52. REMOVE PISTON RETURN SPRING




a. Place SST, and compress the return springs evenly by tightening the bolt gradually.

SST 09350-32014 (09351-32040)




b. Using snap ring pliers, remove the snap ring.
c. Remove SST.
d. Remove the return spring from the case.

53. REMOVE FIRST AND REVERSE BRAKE PISTON




a. 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.




b. If the piston does not pop out with compressed air, use needle-nose pliers to remove it




c. Remove the two O-rings from the piston.




54. REMOVE PARKING LOCK PAWL BRACKET




55. REMOVE PARKING LOCK ROD




56. REMOVE PIN, SPRING AND PARKING LOCK PAWL
57. REMOVE MANUAL VALVE SHAFT




a. Remove the retaining spring.




b. Using a hammer and chisel, pry and turn the collar.
c. Using a hammer and punch, drive out the pin.




d. Slide out the shaft and remove the manual valve lever from the case.




58. REMOVE MANUAL SHAFT OIL SEAL
Remove the oil seal with a screwdriver.

59. (A140L)
REMOVE GOVERNOR PRESSURE ADAPTOR




a. Remove the torsion spring with long nose pliers.





b. Remove the governor pressure adaptor from the case.

DISASSEMBLY OF DIFFERENTIAL




1. REMOVE CARRIER COVER




2. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload, and note the measurement value.




3. MEASURE BACKLASH OF SIDE GEAR
Measure each side gear backlash while holding one pinion toward the case.

Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)




4. REMOVE LH BEARING RETAINER
a. Remove the six bolts.
b. Tap the retainer with a plastic hammer to remove it.
c. Remove the O-ring from the retainer.




5. REMOVE RH SIDE BEARING CAP
Remove the two bolts and the side bearing cap.




6. REMOVE DIFFERENTIAL CASE, OUTER RACE AND ADJUSTING SHIM
Remove the differential case, the outer race and the adjusting shim from the case.




7. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload. Pre load (at starting):

Reused bearing 5 - 8 kg-cm
(4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)

The total preload measured in step 2 minus the drive pinion preload equals 1.5 - 2.0 kg-cm (1.3 - 1.7 in-lb, 0.1 - 0.2 N.m).

If the result is not within this specification, the side bearing preload is bad.




8. REMOVE DRIVE PINION CAP
9. REMOVE COUNTER DRIVEN GEAR




a. Using a chisel, loosen the staked part of the nut.




b. Install SST onto the gear.

SST 09350-32014 (09351-32031)

c. Using SST to hold the gear, remove the nut.

SST 09330-00021




d. Using SST, remove the gear and bearing.

SST 09350-32014 (09351-32061)




10. REMOVE OUTER RACE FROM CASE
Using SST, remove the outer race.

SST 09350-32014 (09308-10010)




11. REMOVE OIL SLINGER




12. REMOVE SPACER




13. (A140E) REMOVE ROTOR SENSOR
14. REMOVE DRIVE PINION




a. Using SST, remove the snap ring.

SST 09350-32014 (09351-32050)




b. Insert a brass bar into case hole to tap out the drive pinion.
c. Tap the drive pinion and remove the bearing cage from the bore.




15. (A1401)
REMOVE GOVERNOR BODY DRIVE GEAR
Using a press, press out the governor body drive gear.




16. REMOVE BEARING CAGE FROM DRIVE PINION
17. REMOVE O-RING FROM BEARING CAGE