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20. INSTALL SECOND BRAKE INTO CASE
(a) Install the flange, facing the flat end toward the oil
pump side.
(b) Install the discs and plates.
Install in order: P=Plate D=Disc
Flange± D±P±D±P±D±P 17. CHECK OPERATION OF NO. 2 ONE±WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely
clockwise and lock counterclockwise.
18. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with
one of cutouts.
21. INSTALL PISTON RETURN SPRING
Each spring end is installed onto the protrusion with
the case. 19. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the two band guides so that its tip touches the
case.
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23. INSTALL SNAP RING
(a) Place the snap ring into the case so that the end gap
is installed into the groove.
(b) While compressing the piston return springs over the
drum with hammer handles, install the snap ring into
the groove.
(c) Be sure the end gap of the snap ring is not aligned with
one of the cutouts.
26. INSTALL NO±1 ONE±WAY CLUTCH AND SECOND
BRAKE HUB
(a) Align the flukes of the discs in the 2nd brake.
(b) Align the spline of the hub with the flukes of the discs
and install the hub to the 2nd brake discs. 25. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case,
and be sure that the piston moves. 22. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it
into the case.
24. INSTALL SECOND BRAKE DRUM GASKET
Install a new gasket until it makes contact with the sec-
ond brake drum.
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28. INSTALL FRONT PLANETARY GEAR ONTO RING
GEAR
(a) Coat the races and bearing with petroleum jelly, and
install them onto the ring gear.
Bearing and race:(c) Check the distance between the surfaces of the
2nd brake hub and rear planetary gear.
Distance: Approx. 5 mm (0.20 in.)
(b) Coat the race and bearing with petroleum jelly, and install
them onto the planetary gear.
Bearing and race: 27. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the
one±way clutch.
(c) Install the planetary gear onto the ring gear.Outer Diameter
Outer DiameterInner DiameterInner Diameter
Front Race
mm (in.)
Rear Race
mm (in.)
Bearing
Bearing
Race
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29. INSTALL FRONT PLANETARY GEAR ASSEMBLY
ONTO SUN GEAR
(a) If the planetary gear and other parts are installed cor-
rectly into the case, the end of the bushing with the
ring gear flange will be flush with a shoulder of the
intermediate shaft or under.
(b) Coat the race with petroleum jelly and install it
onto the tip of ring gear flange.
Race: Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)
32. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
(a) Coat the races and bearing with petroleum jelly, and
install them onto both sides of the clutch drum.
Bearing and race: mm (in.) 31. INSTALL SECOND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin. through the oil pump mounting bolt
hole. 30. INSTALL INTERMEDIATE SHAFT OIL SEAL RING
Outer Diameter
Inner Diameter
Bearing
Race
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Page 429 of 2389
(d) Mesh the hub with the flukes of the direct clutch
while turning the clutch drum or forward
clutch.
(e) If the flukes of the discs are meshed with the hut
correctly, the end of the bushing with the direct
clutch drum will be flush with the surface of the
for ward clutch.
(f) Place the direct clutch and forward clutch into
the case.
(g) Rotate the forward clutch to mesh the front
planetar ring gear and discs. (b) Coat the clutch drum thrust washer with petro-
leum jelly and install it with the oil groove facing
upward onto the direct clutch drum.
(c) Align the flukes of discs in the direct clutch. Bearing and race:
Outer DiameterInner Diametermm (in.)
Bearing
Race
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(c) Place the oil pump through the input shaft, and
align the bolt holes of the pump body with the
transmission case.
(d) Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
NOTICE: Do not push on the oil pump strongly or the
oil seal ring will stick to the direct clutch drum.
33. INSTALL OIL PUMP INTO CASE
(a) Coat the race with petroleum jelly and install it onto
stator shaft.(h) Check the distance between the A and6 as
shown in the illustration.
Distance: Approx. 3 mm (0.118 in.)
(e) Install and tighten the seven bolts.
Torque: 225 kg±cm (16 ft±Ib, 22 N±m)
(b) Coat a new O±ring with ATF and install it to oil
pump.
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34. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.
Thrust play: 0.3 ± 0.9 mm (0.012 ± 0.035 in.)
HINT: There are two thickness of races for the end of stator
shaft.
If the thrust play is in excess of standard, select one of them.
Race thicknesses: 0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
36. INSTALL SECOND COAST BRAKE PISTON
(a) Coat the new O±rings. with ATF and install them on
the cover.
(b) Install the outer spring with the piston.
(c) Place the cover into the bore.
(d) Using SST, install the snap ring while pressing the cover.
SST 09350±32014 109351±32050
(e) Check that the front end of the piston rod contact:
the center of the second brake band depression.
37. CHECK SECOND COAST BRAKE PISTON STROKE
(a) Apply a small amount of paint to the piston rod at the
point it meets the case as shown in the illustration. 35. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
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(b) Using SST, measure the piston stroke applying
and releasing the compressed air (4 ± 8 kg/
cm2, 5 7 ± 114 psi or 392 ± 785 kPa) as shown.
SST 09240±00020
Piston stroke: 1.5 ± 3.0 mm (0.059 ± 0.118 in).
If the stroke is more than standard value, replace
the piston rod with a longer one.
Piston rod length: 72.9 mm (2.870 in)
71.4 mm (2.811 in)
41. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to
damage the O±ring. Check for full seating.
NOTICE: In subsequent work, to avoid breaking the cable
fitting do not roll the case over the cable.
(b) Place the cover with the gasket and tighten the
bolts gradually in sequence.
HINT: Each bolt length (mm (in.)) is indicated in
the figure.
39. INSTALL NEW SECOND BRAKE APPLY GASKET
40. (A 1401.)
INSTALL NEW GOVERNOR OIL STRAINER 38. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Install the springs and pistons into the bore.
Free length mm (in)
None
Yellow Green Inner
Outer
Orange Spring
Yellow Color
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