Part 1

U341E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

(a) Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle housing.
(b) Remove the O-ring from the speedometer driven hole cover sub-assembly.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Remove the nut and washer and remove the control shaft lever.

(b) Using a screwdriver, pry out the lock plate and remove the manual valve shaft nut.

(a) Remove the bolt and speed sensor from the transaxle case.
4. REMOVE OIL COOLER TUBE UNION

(a) Remove the 2 oil cooler tube unions from the transaxle case.
(b) Remove the O-ring from oil cooler tube union.
5. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 4 No. 1 transaxle case plugs from the transaxle housing and transaxle case.

(b) Remove the No. 1 transaxle case plug from the transaxle case.
(c) Remove the O-ring from No. 1 transaxle case plug.
6. REMOVE BREATHER PLUG HOSE

(a) Remove the breather plug hose from the breather plug.
7. REMOVE BREATHER PLUG
(a) Remove the breather plug from the transaxle case.
8. SECURE AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the transaxle onto wooden blocks.
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Remove the 19 bolts and remove the oil pan and oil pan gasket.

(b) Remove the 2 oil cleaner magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Carefully look at the foreign matter and particles in the oil pan and on the magnets to predict the type of wear which might be found in the transaxle.
Steel (magnetic): bearing, gear and clutch plate wear
Brass (non-magnetic): bearing wear
10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Remove the 3 bolts and remove the oil strainer assembly.

(b) Remove the oil strainer gasket from the oil strainer assembly.
11. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Disconnect the 5 solenoid connectors.
(b) Remove the bolt and lock plate and remove the ATF temperature sensor.

(d) Remove the 13 bolts and the valve body assembly from the transaxle case.
12. REMOVE TRANSMISSION WIRE

(a) Remove the bolt and the transmission wire from the transaxle case.

(b) Remove the O-ring from the transmission wire.
13. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET

(a) Remove the transaxle case 2nd brake gasket from the transaxle case.
14. REMOVE TRANSAXLE CASE GASKET

(a) Remove the transaxle case gasket from the transaxle case.
15. REMOVE BRAKE DRUM GASKET

(a) Remove the brake drum gasket from the transaxle case.
16. REMOVE CHECK BALL BODY

(a) Remove the check ball body and spring from the transaxle case.
17. REMOVE B-2 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-2 accumulator piston and spring.

NOTICE:
- Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

(b) Remove the 2 O-rings from the B-2 accumulator piston.
18. REMOVE C-3 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-3 accumulator piston and spring.

NOTICE:
- Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

(b) Remove the 2 O-rings from the C-3 accumulator piston.
19. REMOVE C-2 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-2 accumulator piston and the spring.

NOTICE:
- Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

(b) Remove the 2 O-rings from the C-2 accumulator piston.
20. REMOVE TRANSAXLE HOUSING

(a) Remove the 14 bolts.
(b) Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
NOTE: The differential gear assembly may be accidentally removed when the transaxle housing is removed.

21. INSPECT INPUT SHAFT END PLAY

(a) Measure the end play in the axial direction.
End play:
0.38 to 1.29 mm (0.0149 to 0.0507 in.)
If the end play is not as specified, replace the stator shaft thrust needle roller bearing and the forward clutch hub thrust needle roller bearing.
22. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 7 bolts and the oil pump assembly from the transaxle case.
23. REMOVE DIFFERENTIAL GEAR ASSEMBLY

(a) Remove the differential gear assembly from the transaxle case.
24. REMOVE OVERDRIVE BRAKE GASKET

(a) Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.
25. REMOVE INPUT SHAFT ASSEMBLY

(a) Remove the input shaft assembly from the transaxle case.
26. REMOVE STATOR SHAFT THRUST NEEDLE ROLLER BEARING

(a) Remove the stator shaft thrust needle roller bearing from the input shaft.
27. REMOVE FRONT CLUTCH DISC

(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the input shaft.
28. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using SST on the clutch balancer, compress the return spring with a press.
SST: 09320-89010
NOTE: Do not compress the return spring excessively.

(b) Using a snap ring expander, remove the snap ring.

(a) Place the input shaft onto the oil pump.
(b) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.
HINT: If the piston cannot be removed because it is tilted, either apply compressed air again while keeping the piston level or remove the piston using needle-nose pliers with their tips wrapped in protective tape.

30. REMOVE FORWARD CLUTCH PISTON O-RING

(a) Using a screwdriver, remove the clutch piston O-ring from the forward clutch piston.
31. REMOVE INPUT SHAFT OIL SEAL RING

(a) Using a screwdriver, remove the input shaft oil seal ring from the input shaft.
32. REMOVE FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING

(a) Remove the forward clutch hub thrust needle roller bearing from the forward clutch hub.
33. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Using a dial indicator, measure the intermediate shaft end play.
End play:
0.21 to 0.96 mm (0.00826 to 0.0377 in.)
If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.
34. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY

(a) Remove the forward clutch hub from the transaxle case.
35. REMOVE REAR TRANSAXLE COVER ASSEMBLY

(a) Remove the 11 bolts.
(b) Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.
36. REMOVE REAR TRANSAXLE COVER PLUG

(a) Remove the 4 rear transaxle cover plugs from the rear transaxle cover.
(b) Using a screwdriver, remove the O-ring from each rear transaxle cover plug.
37. REMOVE OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using SST, a press and a screwdriver, remove the snap ring.
SST: 09387-00070
NOTE: Stop the press when the overdrive brake piston is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the overdrive brake piston from being deformed.

(b) Remove the overdrive brake return spring from the rear transaxle cover.
38. REMOVE 2ND COAST AND OVERDRIVE BRAKE PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the rear transaxle cover to remove the overdrive brake piston.

NOTICE:
- Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

39. REMOVE 2ND COAST AND OVERDRIVE O-RING

(a) Using a screwdriver, remove the 2 O-rings from the 2nd coast and overdrive brake piston.
40. REMOVE CLUTCH DRUM OIL SEAL RING

(a) Remove the 3 oil seal rings from the rear transaxle cover.
41. REMOVE REAR TRANSAXLE COVER NEEDLE ROLLER BEARING

(a) Using SST, remove the bearing from the rear transaxle cover.
SST: 09387-00041
09387-01021
42. REMOVE TRANSAXLE CASE GASKET

(a) Remove the 4 transaxle case gaskets.
43. REMOVE REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING

(a) Using a magnetic pick-up tool, remove the rear clutch drum thrust needle roller bearing.
44. REMOVE INTERMEDIATE SHAFT ASSEMBLY

(a) Remove the intermediate shaft assembly from the transaxle case.
45. REMOVE REVERSE CLUTCH DISC

(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 3 discs and 3 plates.
46. REMOVE DIRECT CLUTCH DISC

(a) Using a screwdriver, remove the snap ring.
(b) Remove the direct clutch flange, 3 discs and 3 rear clutch flanges.
47. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using SST and a press.
SST: 09387-00020
(b) Using snap ring pliers, remove the snap ring.
(c) Remove the direct clutch return spring sub-assembly from the intermediate shaft.
48. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Install the intermediate shaft onto the rear transaxle cover.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole shown in the illustration and remove the direct clutch piston from the intermediate shaft.
NOTICE:
- Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

49. REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

(a) Install the intermediate shaft onto the rear transaxle cover.
(b) Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly.
(c) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole shown in the illustration and remove the direct clutch drum from the intermediate shaft.
NOTICE:
- Blowing air may cause the drum to jump out. When removing the drum, hold it by hand using a piece of cloth.
- Do not splash ATF with compressed air.

50. REMOVE DIRECT CLUTCH PISTON O-RING

(a) Using a screwdriver, remove the 2 piston O-rings from the direct clutch piston.
51. REMOVE DIRECT CLUTCH DRUM O-RING

(a) Using a screwdriver, remove the direct clutch drum O-ring from the direct clutch drum.
52. REMOVE 2ND COAST AND OVERDRIVE BRAKE DISC

(a) Remove the flange, 2 discs and 2 No. 2 flanges from the transaxle.
53. REMOVE THRUST NEEDLE ROLLER BEARING

(a) Using a magnetic pick-up tool, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the No. 3 thrust bearing race from the direct clutch hub.
54. REMOVE DIRECT CLUTCH HUB

(a) Remove the direct clutch hub from the transaxle case.
55. REMOVE REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING

(a) Using a magnetic pick-up tool, remove the rear No. 2 planetary sun gear thrust needle roller bearing from the rear planetary sun gear assembly.