1. 8x1.25 mm, 11 bolts
2. 6x1.0 mm, 3 bolts
3. RIGHT COVER
4. GASKET UNDER THE RIGHT COVER. Replace
5. REFERENCE PIN
6. 8x1.25mm, 4 bolts
7. INTERCASE ASSEMBLY
8. ROLLER
9. GASKET UNDER GEARBOX CASE. Replace
10. CONTROL SHAFT ASSEMBLY
11. REFERENCE PIN
12. GEARBOX CASE
13. O-rings. Replace
14. RETAINING RING HOLDER
15. O-rings. Replace
16. REVERSE BRAKE PISTON
17. SPRING HOLDER/RETURN SPRING ASSEMBLY
18. RETAINING RING
19. SEALING RING (RUBBER). Replace
20. FORWARD CLUTCH ASSEMBLY
21. CLUTCH END CAP
22. RETAINING RING
23. SUND GEAR/DRIVE SHAFT ASSEMBLY
24. THRUST NEEDLE BEARING
25. THRUST WASHER
26. CARRIER ASSEMBLY
27. THRUST WASHER
28. THRUST NEEDLE BEARING
29. THRUST WASHER
30. BELLELEE SPRING
31. PLATE
32. DISC
33. REVERSE BRAKE END PLATE
34. RETAINING RING
35. KING GEAR
36. STRONG GASKET, 25x31 mm. Selected by location
37. RETAINING RING
38. MANUAL VALVE BODY PIPES
39. O-rings. Replace
40. O-ring. Replace
41. RETAINING RING
42. MANUAL VALVE BODY
43. 6x1.0 mm, BOLT
Note:
- Thoroughly clean all parts with solvent or carburetor cleaner and dry with compressed air.
- Purge all channels.
- When removing the right cover/intermediate housing, replace the following:
- - O-rings
- - Right cover gasket
- - Gearbox housing gasket
- - Sealing washers
1. Remove the side cover (three 6mm bolts, eleven 8mm bolts).
2. Remove tubes A and B from the manual valve body.
3. Remove the snap ring securing the ring gear, then remove the thrust washer and ring gear.
4. Remove the retaining ring that secures the reverse brake discs and plates, then remove the reverse brake end plate, brake discs and plates, and belleville spring.
5. Remove the carrier assembly with thrust washers and thrust needle bearing from the forward clutch.
6. Remove the sun gear/drive shaft assembly with a puller.
7. Remove the retaining ring securing the forward clutch and remove the retaining ring securing the forward clutch end cap, then remove the forward clutch end cap.
8. Install the carrier onto the forward clutch, then secure the carrier assembly with the circlip to the forward clutch end cap.
9. Remove the forward clutch and carrier assembly together.
10. Install the special tool and remove the circlip securing the reverse brake return spring retainer as shown.
1. REVERSE BRAKE RETURN COMPRESSOR TOOL, 07TAE-P4V0110
11. Compress the return springs, then remove the circlip.
Note: If the spring retainer tab is on the reverse brake piston, the spring retainer may be damaged. Make sure the spring retainer tab is not on the piston.
1. SPECIAL TOOLS
2. PISTON
3. SPRING HOLDER TAB
12. Remove the special tool, then remove the spring retainer/return spring assembly.
13. Turn out a plug from a control opening for check of pressure in a brake of a backing.
14. Supply compressed air to the control hole and remove the piston from the reverse brake.
1. SPRING HOLDER/RETURN SPRING ASSEMBLY
2. REVERSE BRAKE PISTON
3. O-rings. Replace
4. REVERSE BRAKE PRESSURE INSPECTION PORT
5. 8x1.25mm, 18Nm (1.8 kgf/m)
6. SEALING WASHER. Replace
15. Remove the circlip retainer from the drive pulley shaft.
16. Remove the manual valve body (five bolts).
17. Remove the roller and slide the control shaft assembly away from the transmission case, then remove the intermediate case (four bolts).