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REDUCTION BRAKE DISASSEMBLY/ASSEMBLY

D6E051719500A07

1. Perform the preinspection before disassembly.

(See Reduction Brake Preinspection.)

2. Disassemble in the order indicated in the table.

3. Assemble in the reverse order of disassembly.

1 | Snap ring
2 | Retaining plate
3 | Drive and driven plates
4 | Snap ring (See Snap Ring Disassembly Note.)
5 | Spring and retainer component
6 | Reduction brake piston (See Reduction Brake Piston Disassembly Note.)

## Snap Ring Disassembly Note

1. Install the SST as shown.

  Caution

  • Depress the spring and retainer component only enough to remove the snap ring.
  Overpressing will damage the spring and retainer component assembly edges.

2. Compress the spring and retainer component.

3. Remove the snap ring.

4. Remove the SST and remove spring and retainer component.

## Reduction Brake Piston Disassembly Note

• Remove the reduction brake piston by applying compressed air through the fluid passage.

Air pressure

  392 kPa {4.0 kgf/cm2, 57 psi} max.

## Assembly Procedure

1. Measure the facing thickness in three places, and determine the average of the three readings.

Reduction brake drive plate thickness

  Standard: 1.80 mm {0.071 in}
  Minimum: 1.65 mm {0.065 in}

  • If not within the specification, replace the drive plates.

2. Measure the spring free length.

Reduction brake springs and retainer component free length

  Standard: 18.2 mm {0.717 in}
  Minimum: 16.2 mm {0.638 in}

  • If not within the specification, replace the spring and retainer component.

  Caution

  • Installing the reduction brake piston may damage its seal. Carefully install the reduction brake piston by pushing evenly around the circumference.

3. Apply ATF to the circumference of the reduction brake piston seal, and install the piston to the transaxle case.

4. Install the spring and retainer component to the transaxle case.

5. Install the SST as shown.

  Caution

  • Depress the spring and retainer component only enough to install the snap ring.
  Overpressing will damage the spring and retainer component assembly edges.

6. Compress the spring and retainer component.

  Caution

  • The transaxle body may be damaged if installed incorrectly. Make sure to install the transaxle body in such a way that the end of the snap ring does not enter the area shown in the figure.

7. Install the snap ring.

8. Remove the SST.

9. Install the drive and driven plates in the following order.

  Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive

10. Install the retaining plate and the snap ring.

11. Measure the reduction brake clearance.

  (1) Set the dial gauge to the reduction brake.
  (2) Set the measuring point of the dial gauge to the retaining plate.
  (3) Apply compressed air to the part indicated in the figure and let the reduction brake piston stroke three times.

  Air pressure

  392 kPa {4.0 kgf/cm2, 57 psi} max.

  (4) Apply compressed air and operate the reduction brake piston. Read the value when the indicator of the dial gauge stops.
  (5) Release the compressed air and read the dial gauge when the reduction brake piston is not operating.
  (6) Calculate the reduction brake clearance according to the following formula:
  Step (4) value-Step (5) value= reduction brake clearance.
  (7) Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below.
Reduction brake clearance

  1.50-1.80 mm {0.059-0.070 in}

  • If not within the specification, remove the snap ring and measure its thickness.

  (8) Add the thickness to the average value calculated in step (7), and select the snap ring whose range includes the value.

Snap ring size for reduction brake clearance

Range mm {in} | Snap ring sizes mm {in}
--- | ---
2.920-3.120 {0.115-0.122} | 1.2 {0.047}
3.120-3.320 {0.123-0.130} | 1.4 {0.055}
3.320-3.520 {0.131-0.138} | 1.6 {0.063}
3.520-3.720 {0.139-0.146} | 1.8 {0.071}
3.720-3.920 {0.147-0.154} | 2.0 {0.079}
3.920-4.120 {0.155-0.162} | 2.2 {0.087}

  (9) Install the selected snap ring and perform steps (2) to (7) again. Verify that the calculated value satisfies the clearance specification.

12. Inspect the reduction brake operation by applying compressed air as shown.

  Air pressure
  392 kPa {4.0 kgf/cm2, 57 psi} max.