Part 2

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY (Continued)

55. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC Transaxle Unit
56. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY Transaxle Unit
57. REMOVE UNDERDRIVE CLUTCH DRUM O-RING





(a) Remove the underdrive clutch drum O-ring from the underdrive clutch drum.
58. REMOVE UNDERDRIVE CLUTCH PISTON SET





(a) Place SST on the clutch balancer and compress the spring with a press.
SST: 09350-32014
09351-32070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.





(c) Remove the clutch balancer from the underdrive clutch drum.





(d) Remove the piston return spring from the underdrive clutch drum.





(e) Install the underdrive clutch to the transaxle.
NOTE: Be careful not to damage the oil seal rings.

(f) Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive clutch piston.
59. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Transaxle Unit
60. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY





(a) Using a screwdriver, pry out the snap ring from the transaxle.





(b) Remove the one-way clutch from the transaxle.





(c) Remove the outer race retainer from the one-way clutch.
61. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC





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





(b) Remove the flange, 3 discs and 3 plates from the transaxle.
62. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC Transaxle Unit
63. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY





(a) Using SST, a snap ring expander and press, remove the snap ring and underdrive brake return spring.
SST: 09387-00020
64. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Transaxle Unit
65. REMOVE NO. 1 TRANSAXLE CASE PLUG





(a) Remove the 2 plugs from the transaxle rear cover.
(b) Remove the 2 O-rings from the 2 plugs.
66. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY





(a) Remove the 11 bolts.





(b) Tap in the circumference of the rear cover with a plastic-faced hammer to remove the transaxle rear cover from the transaxle.
(c) Remove the 2 oil seal rings from the transaxle rear cover.





(d) Using a T30 ''TORX'' socket wrench, remove the 2 screws and transaxle rear cover plate.





(e) Using SST, remove the needle-roller bearing from the transaxle rear cover.
SST: 09387-00041
09387-01040
09387-01010
09387-01030
67. REMOVE BRAKE APPLY TUBE





(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the brake apply tube from the clamp.
68. REMOVE FRONT CLUTCH APPLY TUBE
(a) Remove the front clutch apply tube from the clamp.
69. REMOVE NO. 1 GOVERNOR APPLY GASKET





(a) Using a screwdriver, remove the 2 apply gaskets.
70. REMOVE DIRECT CLUTCH ASSEMBLY





(a) Remove the thrust bearing and direct clutch from the transaxle.





(b) Remove the bearing race from the direct clutch.
71. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transaxle Unit
72. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC





(a) Using a screwdriver, pry out the snap ring from the direct clutch drum.





(b) Remove the flange, 3 discs and 3 plates from the direct clutch drum.
73. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC Transaxle Unit
74. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY





(a) Place SST on the clutch balancer and compress the spring with a press.
SST: 09387-00020
(b) Using a snap ring expander, remove the snap ring from the direct clutch drum.
NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.





(c) Remove the clutch balancer from the direct clutch drum.





(d) Remove the return spring from the direct clutch drum.





(e) Install the direct clutch drum on the transaxle rear cover.
(f) Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf*cm2, 57 psi) to the transaxle rear cover to remove the direct clutch piston.
75. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY Transaxle Unit
76. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY





(a) Remove the rear planetary sun gear from the transaxle.





(b) Remove the thrust bearing from the rear planetary sun gear.





(c) Remove the No. 2 washer from the rear planetary sun gear.
77. REMOVE ONE-WAY CLUTCH ASSEMBLY





(a) Remove the one-way clutch and thrust bearing from the transaxle.





(b) Remove the inner race from the one-way clutch.





78. REMOVE ONE-WAY CLUTCH OUTER SLEEVE
79. REMOVE 2ND BRAKE CLUTCH DISC





(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 3 discs and 3 plates from the transaxle.
80. INSPECT 2ND BRAKE CLUTCH DISC Transaxle Unit
81. REMOVE 2ND BRAKE PISTON ASSEMBLY





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





(b) Remove the 2nd brake piston from the transaxle.
82. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





(a) Using SST and a press, remove the snap ring from the 2nd brake piston.
SST: 09387-00060
(b) Using a screwdriver, pry out the snap ring.





(c) Remove the piston return spring.
83. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Transaxle Unit
84. REMOVE 2ND BRAKE PISTON





(a) Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
85. REMOVE 2ND BRAKE PISTON O-RING





(a) Remove the 2 O-rings from the 2nd brake piston.
86. REMOVE REAR PLANETARY GEAR ASSEMBLY





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





(b) Remove the rear planetary gear from the transaxle.





(c) Remove the No. 1 washer from the rear planetary gear.





(d) Remove the bearing race from the rear planetary gear.
87. REMOVE INPUT SUN GEAR





(a) Remove the 2 thrust bearings, bearing race and input sun gear from the transaxle.
88. REMOVE FRONT PLANETARY GEAR ASSEMBLY





(a) Using a chisel and a hammer, unstake the lock washer.
NOTE: Push down all of the washer claws. Otherwise SST cannot be fully pressed against and loosen the nut.





(b) Using SST, remove the nut.
SST: 09387-00030
SST: 09387-00080





(c) Using SST and a press, remove the front planetary gear from the counter drive gear.
SST: 09950-60010
09951-00450





(d) Remove the front planetary gear from the brake hub.
89. REMOVE FRONT PLANETARY RING GEAR





(a) Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
90. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC





(a) Remove the flange, 5 discs and 5 plates from the transaxle case.
91. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC Transaxle Unit
92. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY





(a) Using SST, a press and snap ring expander, remove the snap ring and 1st and reverse brake return spring sub-assembly.
SST: 09387-00070

NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.

93. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Transaxle Unit
94. REMOVE 1ST AND REVERSE BRAKE PISTON





(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the 1st and reverse brake 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.





(b) Remove the 2 O-rings from the 1st and reverse brake piston.
95. REMOVE COUNTER DRIVE GEAR





(a) Using SST and a press, remove the counter drive gear from the transaxle case.
SST: 09950-60010
09951-00580
SST: 09950-70010
09951-07100





(b) As shown in the illustration, tighten 2 service bolts evenly and make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and the inner race.





(c) Using SST, remove the tapered roller bearing.
SST: 09950-60010
09951-00580
SST: 09950-00020
SST: 09950-00030





(d) Using a brass bar and a hammer, tap out the 2 bearing outer races.
96. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING





(a) Using a screwdriver, pry out the snap ring from the transaxle.
97. REMOVE NO. 2 BREATHER PLUG
98. REMOVE UNDERDRIVE BRAKE PISTON





(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive brake 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.





(b) Remove the 2 O-rings from the underdrive brake piston.





(c) Using SST, remove the needle-roller bearing from the transaxle.
SST: 09387-00041
09387-01010
09387-01030
09387-01040
99. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING





(a) Remove the 2 oil seal rings from the transaxle.
100. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING





(a) Using SST, remove the cylindrical roller bearing from the transaxle.
SST: 09514-35011
101. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING





(a) Remove the oil seal ring from the transaxle housing.
102. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE





(a) Remove the bolt, clamp and apply tube from the transaxle.