INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

INSPECT REAR PLANETARY GEAR ASSEMBLY

INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

INSPECT NO. 4 BRAKE DISC

INSPECT INTERMEDIATE SHAFT

INSPECT NO. 3 ONE WAY CLUTCH ASSEMBLY

INSPECT CENTER PLANETARY GEAR ASSEMBLY

INSPECT NO. 2 BRAKE DISC

INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

INSPECT NO. 2 BRAKE PISTON

INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

INSPECT FRONT PLANETARY GEAR ASSEMBLY

INSPECT ONE WAY CLUTCH ASSEMBLY

INSPECT NO. 1 BRAKE PISTON

INSPECT NO. 1 BRAKE DISC

INSPECT 2ND BRAKE DISC SET

INSPECT NO. 2 ONE WAY CLUTCH ASSEMBLY

INSPECT INDIVIDUAL PISTON OPERATION

Using vernier calipers, measure the free length of the spring together with the spring seat.

• Standard free length:
• 23.74 mm (0.94 in.)

If the free length is shorter than the standard free length, replace the brake piston return spring sub-assembly.

Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.

• Standard clearance:
• 0.2 to 0.6 mm (0.008 to 0.024 in.)

If the clearance is greater than the standard clearance, replace the planetary gear assembly.

Using a dial indicator, measure the inside diameter of the rear planetary gear bushing.

• Standard inside diameter:
• 18.025 mm (0.710 in.)

If the inside diameter is greater than the standard inside diameter, replace the rear planetary gear assembly.

Make sure that the 1st and reverse brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Using vernier calipers, measure the level difference (dimension A) between the upper surface of the brake apply tube and the hitting surface of the No. 4 brake flange at both ends across the 1st and reverse brake piston diameter, and calculate the average.

• NOTICE:

• The 1st and reverse brake piston must be securely installed to the end face of the transmission case.

• HINT:

• Dimension A = 23.32 to 24.18 mm (0.9181 to 0.952 in.)

Using vernier calipers, measure the thickness (dimension B) of the brake flanges, the 4 No. 4 brake plates and the 5 No. 4 brake discs altogether the both ends across a diameter, and calculate the average.

• HINT:

• Dimension B = 23.64 to 26.00 mm (0.9307 to 1.0236 in.)

• Pack Clearance = Dimension A - Dimension B - 0.18 mm (0.0071 in.) + 1.8 mm (0.071 in.)

• Pack Clearance:
• 0.5 to 0.8 mm (0.0197 to 0.0315 in.)

If the pack clearance is outside the standard range, select and install a brake flange that brings the pack clearance to be within the standard range.

• HINT:

• There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

• Thickness H:

• NO.	Thickness H	NO.	Thickness H
  0	0 mm (0 in.)	8	0.8 mm (0.03150 in.)
  2	0.2 mm (0.00787 in.)	10	1.0 mm (0.03937 in.)
  4	0.4 mm (0.01575 in.)	12	1.2 mm (0.04724 in.)
  6	0.6 mm (0.02362 in.)	14	1.4 mm (0.05512 in.)

Check whether the sliding surfaces of the discs, the plates, and the flanges are worn or burnt.

If necessary, replace them.

• NOTICE:

Using a dial indicator, check the intermediate shaft runout.

• Standard runout:
• A:
• 0.03 mm (0.0012 in.)
• B:
• 0.03 mm (0.0012 in.)
• C:
• 0.03 mm (0.0012 in.)
• D:
• 0.03 mm (0.0012 in.)

If the runout exceeds the specification, replace the intermediate shaft with a new one.

Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

• Standard diameter:
• A:
• 22.962 to 22.975 mm (0.904 to 0.905 in.)
• B:
• 22.962 to 22.975 mm (0.904 to 0.905 in.)
• C:
• 27.759 to 27.775 mm (1.0929 to 1.0935 in.)
• D:
• 27.759 to 27.775 mm (1.0929 to 1.0935 in.)

If the outer diameter is outside the standard range, replace the intermediate shaft with a new one.

Hold the rear planetary ring gear flange sub-assembly and turn the one way clutch assembly.

Check that the one way clutch assembly turns freely counterclockwise and locks clockwise.

If there is a problem with the one way clutch, replace the one way clutch.

Using a feeler gauge, measure the center planetary gear pinion thrust clearance.

• Standard clearance:
• 0.12 to 0.68 mm (0.005 to 0.027 in.)

If the clearance is greater than the standard clearance, replace the center planetary gear assembly.

Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.

If necessary, replace them.

• NOTICE:

Using vernier calipers, measure the free length of the spring together with the spring seat.

• Standard free length:
• 22.66 mm (0.8921 in.)

If the free length is shorter than the standard free length, replace the No. 2 brake piston return spring sub-assembly.

Inspect piston stroke of the No. 2 brake piston.

Make sure that the No. 2 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Using SST and a dial indicator, measure the moving distance (dimension A) of the clutch disc at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

• SST
• 09350-30020(09350-06120)

• Piston stroke:
• 0.6 to 0.9 mm (0.024 to 0.035 in.)

If the piston stroke is outside the standard range, select and install a brake flange that brings the piston stroke within the standard range.

• HINT:

• There are 8 types of flanges that can be used to adjust the piston stroke. Select one with the most appropriate thickness.

• Flange thickness:

• No.	Thickness
  0	2.0 mm (0.079 in.)
  1	2.1 mm (0.083 in.)
  2	2.2 mm (0.087 in.)
  3	2.3 mm (0.091 in.)
  4	2.4 mm (0.094 in.)
  5	2.5 mm (0.098 in.)
  6	2.6 mm (0.102 in.)
  7	2.7 mm (0.106 in.)

Using vernier calipers, measure the free length of the spring together with the spring seat.

• Standard free length:
• 17.05 mm (0.671 in.)

If the free length is shorter than the standard free length, replace the brake piston return spring sub-assembly.

Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

• Standard clearance:
• 0.20 to 0.60 mm (0.008 to 0.024 in.)

If the clearance is greater than the standard clearance, replace the front planetary gear assembly.

Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

• Standard inside diameter:
• 48.78 mm (1.9205 in.)

If the inside diameter is greater than the standard inside diameter, replace the front planetary gear assembly.

Install the one way clutch assembly to the one way clutch inner race.

Hold the one way clutch inner race and turn the one way clutch assembly.

Check that the one way clutch assembly turns freely counterclockwise and locks clockwise.

If there is a problem with the one way clutch, replace the one way clutch.

Remove the one way clutch assembly from the one way clutch inner race.

Inspect piston stroke of the No. 1 brake piston.

Make sure the No. 1 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Using vernier calipers, measure the level difference (dimension A) between the upper surface of the No. 1 brake piston and the hitting surface of the No. 1 brake flange at both ends across the No. 1 brake piston diameter.

Using vernier calipers, measure the thickness (dimension B) of the brake flange, the No. 1 brake plates and the 3 No. 1 brake discs altogether at the both ends across a diameter, and calculate the average.

• HINT:

• Dimension A = 15.27 to 15.92 mm (0.60118 to 0.62677 in.)

• Dimension B = 14.50 to 15.54 mm (0.57087 to 0.61180 in.)

• Piston stroke = Dimension A - Dimension B

• Piston stroke:
• 0.42 to 0.72 mm (0.017 to 0.028 in.)

If the piston stroke is outside the specified range, parts may have been assembled incorrectly, so check and reassemble them again.

If the piston stroke is not still outside the specified range, select another flange that brings the piston stroke within the specified range.

• HINT:

• There are 4 different thicknesses for the flange.

• Flange thickness:

• No.	Thickness
  0	2.0 mm (0.079 in.)
  1	2.2 mm (0.087 in.)
  2	2.4 mm (0.094 in.)
  3	2.6 mm (0.102 in.)

Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.

If necessary, replace them.

• NOTICE:

Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.

If necessary, replace them.

• NOTICE:

Hold the reverse clutch hub and turn the No. 2 one way clutch assembly.

Check that the No. 2 one way clutch assembly turns freely clockwise and locks counterclockwise.

If there is a problem with the one way clutch, replace the one way clutch.

Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

• HINT:

• When inspecting the O/D direct clutch, check the operating sound with the C3 accumulator piston hole closed.

• If there is no sound, disassemble and check the installation condition of the parts.