Part 1

U340E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY





1. REMOVE SPEEDOMETER SENSOR
(a) Remove the bolt and remove the speedometer sensor.





2. REMOVE SPEEDOMETER DRIVEN GEAR
(a) Remove the clip and speedometer driven gear from the speedometer sensor.
(b) Remove the O-ring from the speedometer sensor.
3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY





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





(b) Using a screwdriver, pry out the lock plate and remove the manual valve shaft nut.





(c) Remove the 2 bolts and pull out the park/neutral position switch assembly.





4. REMOVE TRANSMISSION REVOLUTION SENSOR
(a) Remove the bolt and remove the transmission revolution sensor.





5. REMOVE OIL COOLER TUBE UNION
(a) Remove the 2 oil cooler tube unions from the transaxle case.
(b) Remove the 2 O-rings from the 2 oil cooler tube unions.
6. REMOVE NO. 1 TRANSAXLE CASE PLUG





(a) Remove the 4 No. 1 transaxle case plugs from the transaxle housing and transaxle case.





(b) Remove the No. 1 transaxle case plug from the transaxle case.
(c) Remove the O-rings from the No. 1 transaxle case plugs.





7. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the transaxle case.
8. FIX AUTOMATIC TRANSAXLE ASSEMBLY
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY





(a) Remove the 19 bolts and remove the oil pan and oil pan gasket.





(b) Remove the 2 oil cleaner magnets from the oil pan.
(c) Examine the particles in the pan.
(1) Collect any steel chips with the removed magnets.
Carefully look at the foreign matter and particles in the pan and on the magnets to predict the type of wear which might be found in the transaxle.
Steel (magnetic): bearing, gear and clutch plate wear
Brass (non-magnetic): bearing wear
10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY





(a) Remove the 3 bolts and remove the oil strainer assembly.





(b) Remove the oil strainer gasket from the oil strainer.
11. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
(a) Disconnect the 5 solenoid connectors.





(b) Remove the bolt and lock plate and remove the ATF temperature sensor.





(c) Remove the 2 bolts and remove the detent spring cover and detent spring.





(d) Remove the 13 bolts and the valve body assembly from the transaxle case.
12. REMOVE TRANSMISSION WIRE





(a) Remove the bolt and the transmission wire from the transaxle case.





(b) Remove the O-ring from the transmission wire.





13. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the transaxle case.





14. REMOVE TRANSAXLE CASE GASKET
(a) Remove the transaxle case 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 case.
17. REMOVE B-2 ACCUMULATOR PISTON





(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-2 accumulator piston and spring.
NOTICE:
- Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.
- Do not splash ATF with the compressed air.





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





(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-3 accumulator piston and spring.
NOTICE:
- Blowing the air may cause the piston to jump out. When removing the piston, hold it with your hand using a shop rag or piece of cloth.
- Do not splash ATF with the compressed air.





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





(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-2 accumulator piston and the spring.
NOTICE:
- Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.
- Do not splash ATF with the compressed air.





(b) Remove the 2 O-rings from the C-2 accumulator piston.





20. REMOVE TRANSAXLE HOUSING
(a) Remove the 14 bolts.
(b) Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
NOTE: The differential gear assembly may be accidentally removed when the transaxle housing is removed.





21. INSPECT INPUT SHAFT END PLAY
(a) Measure the end play in the axial direction.
End play:
0.37 to 1.29 mm (0.0146 to 0.0508 in.)
If the end play is not as specified, select and replace the thrust needle roller bearing.





22. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and the oil pump assembly from the transaxle case.





23. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear assembly from the transaxle case.





24. REMOVE OVERDRIVE BRAKE GASKET
(a) Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.





25. REMOVE INPUT SHAFT ASSEMBLY
(a) Remove the input shaft assembly from the transaxle case.





26. REMOVE STATOR SHAFT THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the input shaft.





27. REMOVE FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the forward clutch hub.





28. INSPECT INTERMEDIATE SHAFT ASSEMBLY
(a) Using a dial indicator, measure the clearance of the intermediate shaft.
Standard clearance:
0.204 to 0.966 mm (0.008 to 0.038 in.)





29. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Remove the forward clutch hub from the transaxle case.





30. REMOVE REAR TRANSAXLE COVER ASSEMBLY
(a) Remove the 11 bolts.
(b) Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.





31. REMOVE TRANSAXLE CASE GASKET
(a) Remove the 4 transaxle case gaskets.





32. REMOVE REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
(a) Using a magnetic finger, remove the thrust needle roller bearing.





33. REMOVE INTERMEDIATE SHAFT ASSEMBLY
(a) Remove the intermediate shaft assembly from the transaxle case.





34. REMOVE 2ND COAST AND OVERDRIVE BRAKE DISC
(a) Remove the flange, 2 discs and 2 No. 2 flanges from the transaxle.





35. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Using a magnetic finger, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the thrust bearing race from the direct clutch hub.





36. REMOVE DIRECT CLUTCH HUB
(a) Remove the direct clutch hub from the transaxle case.





37. REMOVE REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
(a) Using a magnetic finger, remove the thrust bearing from the rear thrust needle bearing.