Part 1

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION
(a) Check each bearing position and installation direction.

Standard Bearing Position:

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the apply tube and 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 UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Install a new oil seal ring to the transaxle housing.
4. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Using SST and a press, press in the underdrive cylindrical roller bearing.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07100
NOTE: Do not apply excessive pressure.

5. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Install 2 new oil seal rings to the transaxle.
6. INSTALL UNDERDRIVE BRAKE PISTON

(a) Wrap vinyl tape around SST 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.)
SST: 09950-60010
09951-00320
NOTE: Clean SST to remove oil deposits before wrapping with vinyl tape.

(b) Using SST and a press, press in the needle-roller bearing to the transaxle until the wrapped vinyl tape contacts the transaxle case.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100

(d) Install the underdrive brake piston to the transaxle.

(e) Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
SST: 09387-00020
NOTE: Do not apply excessive pressure.

7. INSTALL NO. 2 BREATHER PLUG
8. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING

(a) Using a screwdriver, press in the snap ring to the transaxle.
9. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, press in the 2 bearing outer races to the transaxle.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150

(b) Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts the snap ring.
SST: 09649-17010
NOTE: Do not apply excessive pressure.

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle.
SST: 09950-70010
09951-07150
SST: 09950-60020
09951-00750
NOTE: Do not apply excessive pressure.

10. 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.

(c) Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
11. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

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

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. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.

12. INSTALL FRONT PLANETARY RING GEAR

(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
13. 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.
SST: 09950-60010
09951-00500
SST: 09950-70010
09951-07100
NOTE: Do not apply excessive pressure.

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 280 Nm (2855 kgf-cm, 206 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 value, gradually tighten the nut until it reaches the specified value.
SST: 09387-00080
Turning torque at 60 rpm - Torque: 0.5 to 1.0 Nm (5 to 10 kgf-cm, 4 to 9 in-lbf)
Turning torque at 60 rpm - Torque: 0.3 to 0.5 Nm (3 to 5 kgf-cm, 3 to 4 in-lbf)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

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

(a) Install the 2 thrust bearings, bearing race and input sun gear to the front planetary gear.
Standard Bearing and Race Diameter:

15. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Coat the bearing race with ATF, and install it to the rear planetary gear assembly.
Standard Race Diameter:

(b) Install the No. 1 washer.

(d) Using a screwdriver, install the snap ring.
16. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the pack clearance will meet the specified value.
0.75 to 1.21 mm (0.0295 to 0.0476 in.)
HINT: Pack clearance = Dimension A - Flange thickness

Flange Thickness:

(d) Install the flange.
17. INSTALL 2ND BRAKE PISTON O-RING

(a) Coat 2 new O-rings with ATF, and install them into the 2nd brake piston.
18. INSTALL 2ND BRAKE PISTON

(a) Press the 2nd brake piston into the 2nd brake cylinder by hand.
19. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the piston return spring.

(b) Place SST on the piston return spring, and compress the piston return spring with a press.
SST: 09387-00060
(c) Using a screwdriver, install the snap ring.
NOTE: Be sure that the end gap of the snap ring is not aligned with the piston return spring claw.

20. INSTALL 2ND BRAKE PISTON ASSEMBLY

(a) Install the 2nd brake piston to the transaxle.
(b) Install the snap ring and measure the inside diameter.
Standard inside diameter:
More than 167 mm (6.57 in.)
NOTICE:
- Check the direction of the tapered snap ring when installing it.
- If the diameter does not satisfy the specified value, replace the snap ring with a new one.

21. INSTALL ONE-WAY CLUTCH OUTER SLEEVE

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

22. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the inner race to the one-way clutch.
NOTE: Check the direction of the inner race.

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

(c) Install the one-way clutch and thrust bearing to the one-way clutch outer sleeve.
Standard Thrust Bearing Diameter:

NOTE: Install the thrust bearing properly so that un-colored race will be visible.

23. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 2 washer with petroleum jelly, and install it onto the rear planetary sun gear.

(b) Coat the thrust bearing with petroleum jelly, and install it onto the rear planetary sun gear.
Standard Thrust Bearing Diameter: