Part 2

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. General Repair Notes and Instructions

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, refer to AT-66.

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 over- drive 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.

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

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

48. REMOVE SNAP RING FROM TRANSAXLE CASE

49. REMOVE PARKING LOCK PAWL BRACKET
50. REMOVE MANUAL VALVE SHAFT

a. Using a cold chisel and hammer, cut the collar.

b. Remove the retaining spring.

c. Using a hammer and pin punch, drive out the pin.

d. Slide out the shaft from the transaxle case and remove the manual valve lever and parking lock rod.

51. REMOVE MANUAL VALVE SHAFT OIL SEAL
Using a screwdriver, remove the oil seal.

52. REMOVE PIN, SPRING AND PARKING LOCK PAWL

REMOVAL OF DIFFERENTIAL COMPONENT PARTS

1. MEASURE DIFFERENTIAL TOTAL PRELOAD
Using a torque meter measure the total preload, and make a note of it.

2. REMOVE LH BEARING RETAINER

a. Remove the six bolts.

b. Using a large screwdriver, remove the LH bearing retainer.

NOTE: Wrap the screwdriver in a rag, etc. to avoid damage to the case and retainer.

3. (A540E) REMOVE RH RETAINER

a. Remove the six bolts.

b. Using a large screwdriver, remove the RH retainer.

NOTE: Wrap the screwdriver in a rag, etc. to avoid damage to the case and retainer.

4. REMOVE CARRIER COVER

a. Remove the eleven bolts.

b. Tap the carrier cover with a plastic hammer to remove it.

5. REMOVE DIFFERENTIAL CASE

a. (A540E)
Remove the differential case, outer race and shim from the transaxle case.

(A540H)
Remove the differential assembly.

b. Remove the two apply gaskets.

6. REMOVE DRIVE PINION CAP

a. Remove the bolt.

b. Using pliers, pull Out the drive pinion cap.
c. Remove the O-rings from the cap.

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 1 minus the drive pinion preload equals 1.3 - 2.0 kg.cm (1.1 - 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 COUNTER DRIVEN GEAR