I am half way through the dis-assembly of my AW4 to the point where the manual says to pull the sun gear, input drum, one-way clutch, and thrust washer out as a unit. Well those parts are not budging! I can wiggle them a little, and I can rotate them. It feels solid like there is a snap ring holding it but the last snap ring I found was holding the planetary gear in place so that has already been removed. Maybe I missed a step somewhere, but for the last 2 hours I can't find anything that it could be.
I am investigating the source of a bunch of large shavings I found in the pan. Up to this point everything has come out easily and nothing has looked worn.
Any ideas on getting this part to pull out?
When tearing down the AW4, I found it necessary to make a few tools:
Using 1/4" aluminum rod 12" long, drill & tap the end (as close to on-center as possible) #4-40, and put a headless setscrew in. This will help with the large snaprings inside the case - put the setscrews in the holes in the snaprings, and squeeze the sticks together.
Using a steel bar (about 1"x1/2"x12", think, is what I used,) drill & tap the center 1/2"-20 through. Use 8" of 1/2"-20 threaded rod, put a nut on the end, pin or solder in place. (I pinned mine - more secure.)
You'll drill pairs of holes in various locations to pass the "grab bolts," but you're making a multi-purpose "bridge puller." The 1/2"-20 is a good thread for the ram screw, drill your other holes to about 7/16" or 1/2". You'll need (as I recall) threaded rod in M6-1.0, M8-1.25, and probably M10-1.5, with nuts & washers to match (get about 60cm/24" if you can, min. 30cm/12" if you cannot.)
Put the whole kit in a small box when you're done, expand as you find the need. The materials and work are MUCH cheaper than the "special tools" they tell you you need.
If you can't find the AW4 manual, hit me backchannel. I think I just scanned one, I just haven't made a .pdf of it yet. (I'm converting my Archives to digital format.)
The AW4 is actually one of the simpler slushboxen I've had on the bench - but it's just cranky enough that I wouldn't recommend it for a "first effort overhaul." So, be careful, be attentive, and be clean!