Transaxle Unit

U341E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: INSPECTION

INSPECTION

1. INSPECT TRANSMISSION OIL CLEANER MAGNET

(a) Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle.
Result:
Steel (magnetic)
bearing, gear, and plate wear
Brass (non-magnetic)
bushing wear
2. INSPECT FRONT CLUTCH DISC

(a) Check whether the contact surfaces of the discs, plates and flanges are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all the discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

3. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length:
21.69 mm (0.853 in.)
If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.
4. INSPECT OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length:
17.88 mm (0.703 in.)
If the free length is shorter than the standard free length, replace the overdrive brake return spring sub-assembly.
5. INSPECT REVERSE CLUTCH DISC

(a) Check whether the contact surfaces of the discs, plates and flanges are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all the discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

7. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length:
31.7 mm (1.248 in.)
If the free length is shorter than the standard free length, replace the direct clutch return spring sub-assembly.
8. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Shake the direct clutch pin and confirm that the check ball is not stuck.
(b) Apply low pressure compressed air to the check ball and confirm that there is no air leakage.
9. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY

(a) Shake the direct clutch pin and confirm that the check ball is not stuck.
(b) Apply low pressure compressed air to the check ball and confirm that there is no air leakage.
10. INSPECT 2ND COAST AND OVERDRIVE BRAKE DISC

(a) Check whether the contact surfaces of the discs, plates and flanges are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of any disc is peeled off or discolored or even if part of the groove is damaged, replace all the discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

12. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length:
14.65 mm (0.576 in.)
If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.
13. INSPECT 1ST AND REVERSE BRAKE DISC

(a) Check whether the contact surfaces of the discs, plates and flanges are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all the discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

14. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length:
13.96 mm (0.549 in.)
If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.
15. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD
(a) Coat the front differential case and bearing with ATF and install them to the transaxle case.

(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt B - Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)

If the preload is not within the specifications, remove the differential from the transaxle case.
Select a new transaxle case side adjusting shim in accordance with the following table:
Adjusting Shim Thickness:

16. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

(a) Using SST and a dial indicator, measure the 1st and reverse brake clearance while pressing the discs and plates from the rear side.
SST: 09350-36010
09350-06110
Pack clearance:
0.81 to 1.20 mm (0.0318 to 0.0472 in.)
NOTE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

(b) Check that the 1st and reverse brake piston moves when compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) is applied to the oil hole.
17. INSPECT NO. 2 ONE-WAY CLUTCH

(a) Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.
If the No. 2 one-way clutch assembly does not operate normally, replace it.
18. INSPECT PACK CLEARANCE OF 2ND BRAKE

(a) Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
Pack clearance:
0.85 to 1.24 mm (0.0334 to 0.0488 in.)
NOTE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

19. INSPECT ONE-WAY CLUTCH ASSEMBLY

(a) Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
If the one-way clutch assembly does not operate normally, replace it.
20. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the rear transaxle cover.
(b) Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:
0.62 to 1.16 mm (0.0244 to 0.0456 in.)
NOTE: If the clearance is not within the specified range, select a new clutch flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

21. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
(b) Using a dial indicator and measuring terminal (SST), measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST: 09350-36010
09350-06110
HINT: The direct and reverse clutch will both move as compressed air is applied.
Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

Pack clearance:
0.62 to 1.02 mm (0.0244 to 0.0402 in.)
NOTE: If the clearance is not within the specified range, select a new clutch flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

22. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE

(a) As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using a vernier caliper. (Dimension B)

(b) As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper. (Dimension C)
Calculate the piston stroke value using the following formula:
HINT: (Dimension A + Dimension B) - Dimension C

Pack clearance:
2.10 to 2.49 mm (0.0826 to 0.0980 in.)
NOTE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

23. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(b) 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.
HINT: There are 2 different thicknesses of thrust needle roller bearings available.

(a) Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:
1.41 to 1.80 mm (0.0555 to 0.0708 in.)
NOTE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

25. INSPECT INPUT SHAFT ASSEMBLY

(a) Make sure that the input shaft turns smoothly.
26. 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 forward clutch hub thrust needle roller bearing and the stator shaft thrust needle roller bearing.