Part 1

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION
Check each bearing position and installation direction.

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTE: Make sure to insert the pipe to the stopper.

3. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install a new O-ring to each No. 1 transaxle case plugs.
(b) Install the 2 No. 1 transaxle case plugs to the transaxle rear housing.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Coat a new oil seal ring with ATF and install it to the transaxle housing.
5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical roller bearing.
SST: 09950-60020
SST: 09950-70010
09951-00780
09951-07100
NOTE: Do not apply excessive pressure to it.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

NOTICE:
- Do not expand the gap of the oil seal ring excessively.
- Securely engage the hooks. Confirm that the rings rotate smoothly.

7. INSTALL NEEDLE ROLLER BEARING

(a) Wrap vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.).
NOTE: Clean SST to remove deposited oil before wrapping the vinyl tape.

(b) Coat a new needle roller bearing with ATF.

(c) Using SST and a press, install the needle roller bearing to the transaxle case.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTE: When the wrapped vinyl tape contacts the transaxle case, stop the press.

8. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.

NOTICE:
- Install the O-rings carefully so that they are not twisted or pinched.
- Apply sufficient ATF to the O-rings prior to installation.

(b) Coat the underdrive brake piston with ATF.

(c) Install the underdrive brake piston to the transaxle case.
NOTE: Be careful not to damage the O-rings.

9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.
SST: 09387-00020
(b) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
- Do not expand the snap ring excessively.
- After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
- The snap ring should be securely engaged in the groove of the transaxle case.

10. INSTALL COUNTER DRIVE GEAR BEARING

(a) Install the snap ring to the transaxle case.

(b) Using SST and a press, install the bearing outer race (rear side) to the transaxle case.
SST: 09316-12010
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150

NOTICE:
- Ensure that the snap ring is securely installed.
- Do not apply excessive pressure to the bearing outer race.

(c) Using SST and a press, install the bearing outer race (front side) to the transaxle case.
SST: 09316-12010
SST: 09502-24010
SST: 09523-36010
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150

NOTICE:
- Do not apply excessive pressure to the bearing outer race.
- Install the bearing outer race with a press while holding the bearing outer race with SST (09502-24010, 09523-36010).

(d) Install the 2 angular balls to the transaxle case.
11. INSTALL COUNTER DRIVE GEAR
(a) Coat the counter drive gear with ATF.

(b) Using SST and a press, install the tapered roller bearing inner race (front side) to the counter drive gear.
SST: 09649-17010
SST: 09950-70010
09951-07150
NOTE: Do not apply excessive pressure to the bearing inner race.

(c) Using SST and a press, install the counter drive gear and bearing inner race (rear side) to the transaxle case.
SST: 09223-15030
SST: 09527-17011
SST: 09950-60020
09951-00720
SST: 09950-70010
09951-07150
NOTE: Do not apply excessive pressure to the counter drive gear and bearing inner race.

12. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st and reverse brake piston.
NOTICE:
- Install the O-rings carefully so that they are not twisted or pinched.
- Apply sufficient ATF to the O-rings prior to installation.

(c) Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
NOTE: Be careful not to damage the O-rings.

13. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the return spring.

(b) Place SST on the return spring and compress the return spring with a press.
SST: 09387-00070
(c) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
- Do not expand the snap ring excessively.
- After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
- The snap ring should be securely engaged in the groove of the cylinder.

14. INSTALL FRONT PLANETARY RING GEAR

(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.

15. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear assembly.
SST: 09950-60010
09951-00500
SST: 09950-70010
09951-07100

NOTICE:
- Do not apply excessive pressure to the front planetary gear assembly.
- Press the inner race of the counter drive angular ball bearing (front side), counter drive gear, and front planetary gear assembly to the position where no pre-load is applied to each tapered roller bearing (left and right).

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 185 Nm (1886 kgf-cm, 136 ft-lbf)

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range.
SST: 09387-00080
Torque: 350 Nm (3569 kgf-cm, 258 ft-lbf)
Bearing Turning Torque:
0.19 to 0.4 N*m (1.9 to 4.1 kgf*cm, 1.7 to 3.5 in.*lbf)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) to measure the turning torque.

(f) Using a chisel and hammer, stake the front lock washer.
16. INSTALL INPUT SUN GEAR

(a) Coat the 2 thrust bearings with ATF.
(b) Install the input sun gear, 2 thrust needle roller bearings, 2 No. 2 thrust bearing races, and No. 3 thrust bearings to the transaxle case.
NOTICE:Ensure that the parts are installed in the correct order and direction.

Thrust Bearing and Bearing Race Diameter

17. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear assembly to the brake hub.

(b) Using a screwdriver, install the snap ring.
NOTE: Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.

18. INSTALL 1ST AND REVERSE BRAKE DISC

(a) Coat the 5 discs with ATF.
(b) Install the 5 plates and 5 discs.
NOTE: Be sure to install the plates and disks in the correct order.

19. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE Transaxle Unit
20. INSTALL 2ND BRAKE PISTON

(a) Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder.
21. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the 2nd brake piston return spring sub-assembly.
NOTE: Ensure that all springs are fitted in the piston correctly.

(b) Place SST on the piston return spring, and compress it with a press.
SST: 09387-00060
(c) Using a screwdriver, install the snap ring.
NOTE: Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.

22. INSTALL 2ND BRAKE PISTON ASSEMBLY

(a) Install the 2nd brake piston assembly to the transaxle case.

(b) Install the snap ring and measure the inside diameter.
Inside diameter:
More than 172 mm (6.77 in.)

NOTICE:
- Make sure to install the tapered snap ring in the correct direction.
- If the diameter does not meet the specified value, replace the snap ring with a new one.
- After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the contact surface of the cylinder in the transaxle case.

23. INSTALL ONE-WAY CLUTCH SLEEVE

(a) Install the one-way clutch sleeve to the 2nd brake cylinder assembly.
NOTE: Check the positioning direction of the outer sleeve.

24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER

(a) Coat the No. 1 planetary carrier thrust washer with ATF, and install it onto the planetary sun gear assembly.
NOTE: After installing the washer, confirm that the projections on the washer are securely fitted in the holes of the planetary sun gear assembly.

25. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the one-way clutch inner race to the one-way clutch.

NOTICE:
- Check the direction of the inner race.
- Confirm that the identification mark can be seen.

(b) Make sure that the one way clutch turns freely counterclockwise and locks when turned clockwise.

NOTE: Install the thrust bearing properly so that uncolored race will be visible.

26. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 2 planetary carrier thrust washer with ATF, and install it onto the rear planetary sun gear.

(b) Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

(c) Install the rear planetary sun gear assembly to the rear planetary gear.
NOTE: After installing the rear planetary sun gear assembly, confirm that the B1 discs engage.

27. INSTALL 2ND BRAKE CLUTCH DISC

(a) Coat the 3 discs with ATF.
(b) Install the 3 discs and 3 plates to the transaxle case.
(c) Install the snap ring.
28. INSPECT PACK CLEARANCE OF 2ND BRAKE Transaxle Unit
29. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY

(a) Install the direct clutch hub to the planetary gear assembly.
NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.

(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct clutch hub.
NOTE: When installing the bearing, hold the side of the overdrive clutch hub.

Bearing and Race Diameter

30. INSTALL OVERDRIVE DIRECT CLUTCH O-RING

(a) Coat a new O-ring with ATF, and install it to the direct clutch drum.
NOTE: Ensure that the O-ring is not twisted or pinched.

31. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

(a) Coat the direct clutch drum with ATF, and install it to the intermediate shaft.

NOTICE:
- Be careful not to damage the O-ring.
- Be careful not to damage the lip seal of the direct clutch drum.

32. INSTALL OVERDRIVE DIRECT CLUTCH PISTON

(a) Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum sub-assembly.
NOTE: Be careful not to damage the lip seal of the direct clutch piston.

33. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the overdrive clutch return spring sub-assembly to the overdrive direct clutch drum sub-assembly.
NOTE: When installing the spring sub-assembly, ensure that all springs are fitted in the piston correctly.

(b) Coat the clutch balancer with ATF.

(c) Install the clutch balancer to the overdrive direct clutch drum sub-assembly.

NOTICE:
- Be careful not to damage the lip seal of the direct clutch balancer.
- Ensure that the clutch balancer is not pinched and there are no other defects at the sealing lip.
- Apply enough ATF to the sealing lip prior to installation.

(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST: 09387-00020
(e) Using a snap ring expander, install the snap ring to the direct clutch drum.
NOTICE:
- Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.

(f) Position the end gap of the snap ring in the piston as shown in the illustration.
NOTE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

34. INSTALL OVERDRIVE DIRECT CLUTCH DISC

(a) Coat the 3 discs with ATF.
(b) Install the 3 plates, 3 discs and flange to the intermediate shaft.
NOTE: Be sure to install the plates, disks and flange in the correct order.

(c) Using a screwdriver, install the snap ring.
NOTE: The snap ring should be securely engaged in the groove of the drum.

35. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC

(a) Coat the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.
NOTICE:
- Install the cushion plate with the mark on the white surface facing the plate.
- Be sure to install the cushion plate, plates, disks and flange in the correct order.

(c) Using a screwdriver, install the snap ring.
NOTE: The snap ring should be securely engaged in the groove of the drum.

36. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transaxle Unit
37. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH Transaxle Unit
38. INSTALL DIRECT CLUTCH ASSEMBLY

(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
NOTE: The disc in the direct clutch should be completely matched with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

(c) Clean the contact surfaces of the transaxle case and the rear cover.
(d) As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension C).

(e) Using a vernier caliper and a simple straightedge, measure the dimension shown in the illustration.
(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the specified end play value and install it.
End play:
0.199 to 0.970 mm (0.00783 to 0.0382 in.)
NOTE: Make sure that the uncolored race side is facing the direct clutch assembly.
HINT: End play = Dimension D - Dimension C

Bearing Thickness and Diameter

39. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 3 new No. 1 governor apply gaskets to the transaxle case.
40. INSTALL BRAKE APPLY TUBE

(a) Install the clamp to the brake apply tube.
NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

(b) Install the clutch apply tube.

(c) Install the brake apply tube to the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: Each pipe should be securely inserted until it reaches the stopper.