29/9/22, 10:17 SIS 2.

2022/09/12 Transmission Planetary - Assemble (KENR5792-00)

SMCS - 3160 i09628683

Assembly Procedure
Required Tools 

Tool  Part Number  Part Description  Qty 

A  138-7575  Link Bracket  2 
C  136-1452  Retaining Ring Pliers  1 
D  5P-5197  Retaining Ring Pliers  1 
E  1P-1863  Retaining Ring Pliers  1 
F  1P-0520  Driver Group  1 
H  1P-0510  Driver Group  1 

Table 1

Note: Cleanliness is an important factor. Before assembly, clean all parts thoroughly in cleaning fluid. Allow the parts to air dry. Wiping cloths or
rags should not be used to dry parts. Lint may be deposited on the parts causing later trouble. Inspect all parts. If any parts are worn or damaged,
use new parts for replacement. During assembly, put clean transmission oil on all internal parts.

Illustration 1 g00340875

1. Raise the temperature of bearing (122) and install bearing (122) on input shaft (118), as shown.

2. Apply clean transmission oil to seals (120) and to seal ring (121). Install seals (120) and seal ring (121) on input shaft (118).

Illustration 2 g00327703

3. Install dowels (119) in housing (117). The dowels must protrude from the housing by 10.5 ± 0.5 mm (0.41 ± 0.02 inch).

4. Carefully install input shaft (118) in housing (117).

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Illustration 3 g00325045

5. Install retaining ring (116) in order to hold the input shaft and the bearing in place in housing (117).

Illustration 4 g00325046

6. Install seal rings (114) and (115) on clutch piston (111).

Illustration 5 g01174770

7. Install sun gear (113), clutch piston (111), coupling gear (110), and reaction dowels (112).
Note: Make sure that the lips of the seals on clutch piston (111) are facing downward.

Illustration 6 g01293746

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Illustration 7 g00325012

8. Install bearings (107) in planetary gears (106). Install the gear assemblies, thrust disc (105), thrust disc (108), and planetary shafts (104) in
carrier assembly (101).

9. Use a suitable hammer and a punch to install spring pins (109) that hold planetary shafts (104) in carrier assembly (101). Make sure that the
spring pins are flush with the counterbore in the carrier.

Illustration 8 g00325010

10. Install seal rings (103) on carrier assembly (101).

Illustration 9 g00325009

11. Install seal ring (102) on ring carrier (100).

Illustration 10 g00325005

12. Install ring carrier (100) in carrier assembly (101).

13. Install carrier assembly (101). Align the sun gear on the input shaft with ring carrier (101).

Illustration 11 g00327872

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Note: The dowels have been removed for photographic purposes.

14. Install one clutch plate (99) in the housing. Align the small hole in the clutch plate is aligned with the small hole in the housing, as shown.

Illustration 12 g00325004

15. Install friction discs (98) and the remaining clutch plates (99) in alternating order.

Illustration 13 g00324979

16. Raise the temperature of bearing (95) and install bearing (95) on sun gear (96), as shown. Make sure that the groove in bearing (95) is facing
upward.

Illustration 14 g00324981

17. Install retaining ring (94) in carrier assembly (85).

Illustration 15 g00328188

18. Use Tooling (E) to expand retaining ring (94). Use Tooling (C) and a suitable press to install bearing (95) and sun gear (96) as a unit. Make
sure that retaining ring (94) is installed in the groove in bearing (95).

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Illustration 16 g00324967

Illustration 17 g00324965

19. Install bearings (93) in planetary gears (92). Install the gear assemblies, thrust discs (91), and planetary shafts (89) in carrier assembly (85).

20. Use a suitable hammer and a punch to install spring pins (90) that hold planetary shafts (89) in carrier assembly (85). Make sure that the
spring pins are flush with the counterbore in the carrier.

Illustration 18 g00324964

Illustration 19 g00328226

21. Install retaining ring (88) on carrier assembly (85).

22. Use steel rods (86) to compress retaining ring (88). Install carrier assembly (85) in ring gear (87) until the retaining ring fits into the groove in
the ring gear.

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Illustration 20 g00328227

23. Install plastic thrust disc (123) that is used between the reverse planetary carrier and the forward planetary carrier.

Illustration 21 g01174811

24. Install carrier assembly (85) and ring gear (87) as a unit.

Illustration 22 g00328234

25. Install the O-ring seal, plate (97), springs (83), and spring rods (76).

Illustration 23 g00328291

26. Use Tooling (E) to install retaining ring (82) on the input shaft.

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Illustration 24 g00328292

27. Install ring gear (84).

Illustration 25 g03076863

28. Install friction discs (79) and clutch plates (80) in alternating order. Start with a friction disc. Make sure that the top clutch plate is installed so
that the small holes are over the spring rods, as shown.

Illustration 26 g03070638

29. Install seal rings (78) and (77) on clutch piston (76).

30. Install clutch piston (77). Make sure that the lips of the seals are facing downward (toward the clutch housing).

Illustration 27 g01174715

31. Install the O-ring seal in housing (75). Use Tooling (A) and a suitable lifting device to install housing (75), as shown. The weight of housing
(75) is approximately 29 kg (64 lb).

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Illustration 28 g00324905

32. If bearings (74) were removed, lower the temperature of the two bearings. Then, put the bearings in position in both ends of output shaft (70).

Illustration 29 g03076920

33. Use Tooling (H) to install bearings (74) to a depth of 12.0 ± 0.5 mm (0.47 ± 0.02 inch). After assembly, the inside diameter of bearings (74)
must be 34.988 ± 0.039 mm (1.3770 ± 0.0020 inch).

Illustration 30 g00328423
Note: Make sure that the locating dowel fits into the notch in the bearing. Also, the groove in the bearing must face the top of the output shaft.

34. Raise the temperature of bearing (73) and install bearing (73) on output shaft (70), as shown.

Illustration 31 g00324903

35. Install sun gear (71) on output shaft (70).

36. Use Tooling (E) to install retaining ring (72).

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Illustration 32 g00324893

37. Install output shaft (70) over the input shaft.

Illustration 33 g00324892

38. Install retaining ring (69) that holds output shaft (70) to the input shaft.

Illustration 34 g00324891

Illustration 35 g03070436

39. Install bearings (67) in planetary gears (66). Install the gear assemblies, thrust discs (65), and planetary shafts (64) in carrier assembly (57).

40. Use a suitable hammer and a punch to install spring pins (68) that hold planetary shafts (64) in carrier assembly (57). Make sure that the
spring pins are flush with the counterbore in the carrier.

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Illustration 36 g03070356

41. Install retaining ring (63) on carrier assembly (57).

Illustration 37 g03070259

42. Install seal ring (62) onto carrier assembly (57). Set carrier assembly (57) into ring gear 61.

43. Use steel rods (60) to compress the retaining ring. Install carrier assembly (57) in ring gear (61) until the retaining ring fits into the groove in
the ring gear.

Illustration 38 g03067205

44. Install carrier assembly (57). Make sure that all of the gear teeth are correctly engaged.

45. Install reaction dowels (58) and springs (59).

Illustration 39 g03067176

46. Install friction discs (56) and clutch plates (55) in alternating order. Start with a friction disc. Make sure that the top clutch plate is installed so
that the small holes are over the spring rods, as shown.

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Illustration 40 g03067134

47. Install seal rings (53) and seal ring (54) on clutch piston (52). Install clutch piston (52) into housing (51). Make sure that the lips of the seals
are facing downward (toward the housing).

Illustration 41 g03067003

48. Install the O-ring seal in housing (51). Use Tooling (A) and a suitable lifting device to install housing (51), as shown. The weight of housing
(51) is approximately 29 kg (64 lb).

Illustration 42 g03066952

49. Install reaction plate (50) and install retaining ring (49).

Illustration 43 g03066942

50. Install ring gear (34).

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Illustration 44 g06760878

51. Install friction discs (48) and clutch plates (47) in alternating order. Start with a friction disc.

Illustration 45 g03651532

52. Install sun gear (45).

Illustration 46 g00324828

53. Install retaining ring (44) on the output shaft.

Illustration 47 g00339654

54. Install seal ring (43) and seal ring (42) on piston (41).

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Illustration 48 g03066717

55. Install piston (41) and seal rings (40) on the clutch housing.

Illustration 49 g00324826

56. Install clutch housing (35) on sun gear shaft (39).

57. Stack disc springs (38) and install the disc springs in clutch housing (35). Make sure that the outside edge of the disc springs contact each
other first.

58. Install retainer plate (36) on the gear shaft.

Illustration 50 g00324825

59. Use steel spacers and a suitable press to compress retainer plate (36) and the disc springs. Install retaining ring (37) in the clutch housing.

Illustration 51 g00324824

60. Install retaining ring (33) on clutch housing (35).

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Illustration 52 g00324823

61. Install clutch housing (35) in ring gear (34). Use Tooling (C) to install retaining ring (33).

Illustration 53 g03078059
Note: The dowels have been removed for photographic purposes.

62. Install one clutch plate (32) in the housing. Align the small hole in the clutch plate so that it is aligned with the small hole in the housing, as
shown.

Illustration 54 g03651539

63. Install friction discs (31) and the remaining clutch plates (32) in alternating order. Install springs (46).

Illustration 55 g00339593

64. Lower the temperature of bearing (29). Install bearing (29) in housing (28). Install retaining ring (30).

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Illustration 56 g01174668

65. Use Tooling (A) and a suitable lifting device to install housing (28), as shown. The weight of housing (28) is approximately 29 kg (64 lb).

Illustration 57 g00324767

66. Use two screwdrivers to lift clutch housing (35).

Illustration 58 g01174667

67. Use Tooling (E) to install retaining ring (27) on the output shaft.

Illustration 59 g01174666

68. Use Tooling (D) to install retaining ring (26) on the output shaft.

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Illustration 60 g03066621

Illustration 61 g03066604

69. Install bearings (24) in planetary gears (25). Install the gear assemblies, thrust discs (23), and planetary shafts (22) in carrier assembly (20).

70. Use a suitable hammer and a punch to install the spring pins that hold planetary shafts (22) in carrier assembly (20). Make sure that the
spring pins are flush with the counterbore in the carrier.

Illustration 62 g03063218

71. Install metal seal ring (21) in the carrier assembly.

Illustration 63 g03063116

72. Install carrier assembly (20).

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Illustration 64 g03063156

73. Install ring gear (18) and O-ring seal (19).

Illustration 65 g03078247

74. Install reaction dowels (15) and springs (14).

Illustration 66 g03078277

Illustration 67 g03078253

75. Install clutch plates (17) and friction discs (16) in alternating order. Start with a clutch plate. Make sure that the top clutch plate (13) is installed
so that the small holes are over the spring rods, as shown.

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