Part 2 of 3

30. REMOVE APPLY TUBE
a. Remove the bolt and apply tube bracket.





b. Using a screwdriver, remove the apply tube.

HINT: Tape the screwdriver tip before use.





31. 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.





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kg/cm2, 57 - 114 psi).
SST 09240-00020

Piston stroke: 1.5 - 3.5 mm (0.059 - 0.138 inch)

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





32. REMOVE SECOND COAST BRAKE PISTON
a. Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)





b. Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the cover into a rag.





c. Remove the cover, piston and spring.
d. Remove the 2 O-rings from the cover.





33. REMOVE DIRECT CLUTCH WITH FORWARD CLUTCH
a. Remove the direct clutch with the forward clutch from the case.





b. Remove the direct clutch from the forward clutch.





c. Remove the thrust washer and 2 assembled bearings and races from the forward clutch.





34. REMOVE SECOND COAST BRAKE BAND
a. Pull out the pin.
b. Remove the brake band.





35. REMOVE FRONT PLANETARY RING GEAR
a. Remove the front planetary ring gear.





b. Remove the bearing and race from the ring gear.





36. REMOVE FRONT PLANETARY GEAR
a. Remove the front planetary gear with the bearing and race.





b. Remove the bearing and race from the planetary gear.





37. REMOVE SUN GEAR, SUN GEAR INPUT DRUM AND THRUST WASHER





38. REMOVE SECOND BRAKE HUB AND NO.1 ONEWAY CLUTCH





39. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.





40. REMOVE SECOND BRAKE
a. Using a screwdriver, remove the snap ring.

HINT: Tape the screwdriver tip before use.





b. Remove the second brake drum.

HINT: If the brake drum is difficult to remove, lightly tap it with a wooden block.





c. Remove the return spring.





d. Remove the plates, discs and flange.





41. REMOVE REAR PLANETARY GEAR
a. Using 2 screwdrivers, remove the snap ring.

HINT: Tape the screwdriver tip before use.





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





c. Remove the 2 thrust washers from the gear.





d. Remove the bearing and race from the planetary ring gear.





42. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE
Using a feeler gauge, measure the first and reverse brake pack clearance.

Pack clearance (reference): 2.42 - 3.18 mm (0.0952 - 0.1252 inch)

If the pack clearance is non-standard, check the disc.





43. REMOVE FIRST AND REVERSE BRAKE PACK
a. Using a screwdriver, remove the snap ring.

HINT: Tape the screwdriver tip before use.





b. Remove the flange, plates and discs.





44. REMOVE TRANSAXLE REAR CASE
a. Remove the 13 bolts.





b. Tap off the circumference of the cover with a plastic hammer to remove the rear case from the transaxle case, and remove the cover.





45. REMOVE INTERMEDIATE SHAFT
a. Using a chisel and hammer, unstake the intermediate shaft lock nut.





b. Using SST, remove the lock nut.
SST 09330-00021, 09350-32014 (09351-32032)





c. Remove the intermediate shaft.





46. REMOVE COUNTER DRIVE GEAR
Using SST and a press, remove the counter drive gear.
SST 09950-20017





47. REMOVE FRONT BEARING





48. REMOVE COUNTER DRIVEN GEAR
a. Using a chisel and hammer, unstake the counter shaft lock nut on both sides.





b. Using SST to hold the counter shaft, remove the lock nut of the driven gear side.
SST 09350-32014 (09351-32170)





c. Using SST to hold the driven gear, remove the lock nut of the another side.
SST 09330-00021, 09350-32014 (09351-32032, 09351-32170)





d. Using SST, remove the driven gear.
SST 09350-32014 (09351-32061)





e. Remove the thrust needle bearing.





49. REMOVE COUNTER SHAFT ASSEMBLY
a. Pull out the counter shaft assembly.





b. Remove the thrust bearing with race from the counter shaft assembly.