Part 1

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

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

(b) Using a screwdriver, unstake the lock plate.
(c) Remove the nut and lock plate.

(d) Remove the 2 bolts and pull out the switch.
2. REMOVE BREATHER PLUG HOSE
3. REMOVE OIL COOLER OUTLET TUBE UNION

(a) Remove the union.
(b) Remove the O-ring from the union.
4. REMOVE OIL COOLER INLET TUBE UNION

(a) Remove the union.
(b) Remove the O-ring from the union.
5. REMOVE SPEED SENSOR

(a) Remove the 2 bolts and 2 speed sensors from the transaxle.
(b) Remove the 2 O-rings from the sensors.
6. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 4 plugs from the transaxle case.
(b) Remove the 4 O-rings from the 4 plugs.
7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY

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

(a) Remove the 18 bolts.
(b) Remove the oil pan and 3 magnets.
(c) Remove the gasket from the oil pan.
9. INSPECT TRANSMISSION OIL CLEANER MAGNET Transaxle Unit
10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Remove the 3 bolts and oil strainer.

(b) Remove the O-ring from the oil strainer.
11. REMOVE TRANSMISSION WIRE

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

(d) Remove the O-ring from the transmission wire.
12. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Support the valve body and remove the 17 bolts and valve body.
13. REMOVE NO. 1 GOVERNOR APPLY GASKET

(a) Remove the governor apply gasket from the transaxle case.
14. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET

(a) Remove the 2nd brake 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.
17. REMOVE C-3 ACCUMULATOR PISTON

(a) Remove the spring from the C-3 accumulator piston.

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

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

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-1 accumulator piston and spring.

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

(b) Remove the 2 O-rings from the C-1 accumulator piston.
19. REMOVE B-3 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.

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

(b) Remove the O-ring from the B-3 accumulator piston.
20. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Remove the 2 bolts, manual detent spring and cover.
21. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 2 bolts and parking lock pawl bracket.
22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, remove the retainer spring.
23. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Using a chisel and hammer, unstake and remove the spacer.

(b) Using a pin punch and hammer, tap out the pin.
HINT: Slowly tap out the pin so that it will not fall into the transaxle.

(a) Remove the parking lock rod from the manual valve lever.
25. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using a screwdriver, pry out the oil seal from the transaxle.
26. SECURE AUTOMATIC TRANSAXLE ASSEMBLY
(a) Secure the automatic transaxle assembly with the oil pump side facing up.
27. INSPECT INPUT SHAFT END PLAY Transaxle Unit
28. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 2 plugs.
(b) Remove the 2 O-rings from the 2 plugs.
29. REMOVE TRANSAXLE HOUSING

(a) Remove the 18 bolts.
(b) Tap on the circumference of the transaxle housing with a plastic-faced hammer to remove the transaxle housing from the transaxle case.
NOTE: The differential may be accidentally removed when the transaxle housing is removed.

30. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 7 bolts and oil pump from the transaxle.
31. REMOVE THRUST NEEDLE ROLLER BEARING

(a) Remove the thrust needle roller bearing from the underdrive planetary gear.
32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Remove the thrust bearing underdrive race from the underdrive planetary gear.
33. REMOVE DIFFERENTIAL GEAR ASSEMBLY

(a) Remove the differential gear from the transaxle.
34. REMOVE OVERDRIVE BRAKE GASKET

(a) Remove the 2 overdrive brake gaskets from the transaxle.
35. REMOVE FORWARD CLUTCH ASSEMBLY

(a) Remove the forward clutch from the transaxle.

(b) Remove the thrust bearing from the forward clutch.
36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transaxle Unit
37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC

(a) Using a screwdriver, remove the snap ring.

(b) Remove the flange, 5 discs and 5 plates from the input shaft.
38. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Transaxle Unit
39. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the spring retainer and compress the return spring with a press.
SST: 09350-32014
09351-32070
(b) Using a snap ring expander, remove the snap ring.

(c) Remove the forward clutch return spring sub-assembly.
40. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Transaxle Unit
41. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Place the forward clutch drum 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 sub-assembly.
HINT: When the piston is slanted and cannot be removed, remove it by pushing down the protruding side and applying compressed air again, or using needlenose pliers (with its tips wrapped in tape).

42. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY Transaxle Unit
43. REMOVE INPUT SHAFT OIL SEAL RING

(a) Remove the input shaft oil seal ring from the forward clutch drum.
44. REMOVE MULTIPLE DISC CLUTCH HUB

(a) Remove the thrust needle roller bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle.
45. INSPECT MULTIPLE DISC CLUTCH HUB Transaxle Unit
46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Remove the bolt and parking pawl shaft clamp.

(b) Remove the parking lock pawl shaft.

(c) Push the parking lock pawl.
HINT: Failure to do so will cause interference when the underdrive planetary gear is removed.

(d) Remove the underdrive planetary gear from the transaxle.
NOTE: Be careful not to drop the underdrive planetary gear assembly.

(e) Remove the spring, pawl pin and parking lock pawl.
47. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Transaxle Unit
48. REMOVE UNDERDRIVE INPUT SHAFT NUT

(a) Using SST, secure the underdrive planetary gear.
SST: 09387-00050

(b) Using SST, loosen the staked part of the nut.
SST: 09930-00010
09931-00010
09931-00020

(c) Clamp the underdrive planetary gear in a soft jaw vise.
NOTE: Be careful not to damage the differential drive pinion.

(d) Using a socket wrench, remove the lock nut.
49. REMOVE CYLINDRICAL ROLLER BEARING INNER RACE

(a) Using SST, remove the cylindrical roller bearing inner race.
SST: 09950-00020
SST: 09950-00030
SST: 09950-60010
09951-00340
SST: 09950-40011
09957-04010
50. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.
SST: 09387-00050
(b) Clamp the underdrive planetary gear in a soft jaw vise.

(c) Using SST, remove the rear angular ball bearing from the underdrive planetary gear.
SST: 09950-00020
SST: 09950-00030
SST: 09950-60010
09951-00320
SST: 09950-40011
09957-04010
51. REMOVE UNDERDRIVE PLANETARY RING GEAR

(a) Using snap ring pliers, remove the snap ring.

(b) Remove the underdrive planetary ring gear from the counter driven gear.
52. REMOVE UNDERDRIVE CLUTCH ASSEMBLY

(a) Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle.
53. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH Transaxle Unit
54. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC

(a) Using a screwdriver, pry out the underdrive clutch flange snap ring.

(b) Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.