Part 1

COMPONENTS

DISASSEMBLY OF OVERDRIVE BRAKE




1. REMOVE PISTON RETURN SPRING
a. While pushing the return spring, remove the snap ring with a screwdriver.
b. Remove the piston return spring.




2. REMOVE PLATES, DISCS AND FLANGE




3. REMOVE PISTON FROM DRUM
Apply compressed air to oil hole to remove the piston.

HINT: Blow with the gun slightly away from the oil hole, and be careful that the piston dose not tilt.




4. REMOVE O-RINGS
Remove the inner and outer O-rings from the piston.




INSPECTION OF OVERDRIVE BRAKE

INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least fifteen minutes.

DISASSEMBLY OF OVERDRIVE DIRECT CLUTCH




1. CHECK PISTON STROKE OF DIRECT CLUTCH

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

Piston stroke: 1.75 - 2.49 mm
(0.0689 - 0.0980 in.)

SST 09350-32014 (09351-32190)

If the piston stroke is greater than the maximum, inspect each component.




2. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE




3. REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE




4. REMOVE SNAP RING WITH SCREWDRIVER




5. REMOVE FLANGES, DISCS AND PLATES
6. REMOVE PISTON RETURN SPRING




a. Place SST on the spring retainer and compress the spring with a shop press.

SST 09350-32014 (09351-32070, 09351-32200)

b. Remove the snap ring.




c. Remove the piston return spring.




7. REMOVE PISTON FROM CLUTCH DRUM
a. Install the clutch drum on the case.
b. Apply compressed air to the pressure apply hole of the case.
c. Remove the piston from the clutch drum.
If the piston does not come out completely, use needle-nose pliers to remove it.

d. Remove the clutch drum from the case.




8. REMOVE O-RINGS
Remove the two O-rings from the piston.

INSPECTION OF OVERDRIVE DIRECT CLUTCH




1. INSPECT OVERDRIVE DIRECT CLUTCH
a. Check that the check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low- pressure compressed air.




2. INSPECT DISCS, PLATES AND FLANGES
Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.

HINT:
- If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least fifteen minutes.




3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the two direct clutch bushings.

Maximum inside diameter: 22.13 mm (0.8713 in.)

If the inside diameter is greater than the maximum, replace the direct clutch drum.

ASSEMBLY OF OVERDRIVE DIRECT CLUTCH
1. INSTALL CLUTCH PISTON




a. Install new O-rings to the piston. Coat the O-rings with ATF.




b. Press the piston into the drum with the cup side up, being careful not to damage the O-ring.

2. INSTALL PISTON RETURN SPRING




a. Install the return spring and set snap ring in place.




b. Place SST on the spring retainer, and compress the spring with a shop press.

SST 09350-32014 (09351-32070, 09351-32200)

c. Install the snap ring with a screwdriver. Be sure end gap of snap ring is aligned with the groove of the clutch drum.




3. INSTALL PLATES, DISCS AND FLANGE

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




4. INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the groove of the clutch drum.

5. INSTALL BEARING AND RACE




a. Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum.

Bearing: Outer diameter 46.3 mm (1.823 in.)
Inner diameter 26.2 mm (1.031 in.)




b. Coat the race with petroleum jelly and install it to the case.

Race: Outer diameter 43.0 mm (1.693 in.)
Inner diameter 24.5 mm (0.965 in.)




6. INSTALL DIRECT CLUTCH ON CASE




7. RECHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

Piston stroke: 1.75 - 2.49 mm
(0.0689 - 0.0980 in.)

SST 09350-32014 (09351-32190)

DISASSEMBLY OF COUNTER DRIVE GEAR




1. CHECK OPERATION OF ONE-WAY CLUTCH
a. Install the overdrive direct clutch into the one-way clutch.
b. Hold the overdrive direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise.
c. Remove the overdrive direct clutch.

2. CHECK COUNTER DRIVE GEAR PRELOAD




a. Hold the overdrive planetary gear in a vise with soft jaws.

HINT: Do not let the counter drive gear touch the vise.




b. Using a tension gauge, measure the preload.

Preload (at starting): 940 - 1,560 g
(2.1 - 3.4 lb, 9.2 - 15.3 N)

HINT: Turn the counter drive gear right and left several times before measuring the preload.




3. REMOVE O/D ONE-WAY CLUTCH AND OUTER RACE

a. Remove the snap ring.




b. Remove the retaining plate.
c. Remove the O/D one-way clutch with outer race.




d. Remove the two retainers from both sides of the O/D one-way clutch.




e. Remove the O/D one-way clutch from the outer race.

HINT: Note the direction of the one-way clutch.




4. REMOVE NO.3 PLANETARY THRUST WASHER
5. REMOVE PLUGS FROM PLANETARY GEAR
Remove the four plugs with a magnetic finger.

HINT: Be careful not to lose them.

6. REMOVE ADJUSTING NUT AND LOCKING WASHER




a. Pry off the locking washer.




b. Using SST, loosen the adjusting nut.

SST 09350-32014 (09351-32080)

c. Remove the adjusting nut and locking washer.




7. REMOVE INTERMEDIATE SHAFT BEARING
Using SST, press out the bearing from the shaft.

SST 09950-00020




8. REMOVE COUNTER DRIVE GEAR AND FRONT BEARING
Press out the gear and bearing together.

9. REMOVE REAR BEARING




a. Using SST, press out the bearing.

SST 09950-00020




b. Tag the bearings to show the location for reassembly.

10. REMOVE OVERDRIVE PLANETARY RING GEAR FROM COUNTER DRIVE GEAR




a. While pulling up the ring gear, compress the snap ring with needle-nose pliers and remove it from the groove.
b. Remove the ring gear from the counter drive gear.




c. Remove the snap ring from the ring gear.

11. REMOVE OUTER RACES FROM COUNTER DRIVE GEAR




a. Drive out the two races with a brass bar and hammer.




b. Tag the races to show the location for reassembly.