Part 4

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - (Continued)

40. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC

(a) Install the 3 plates, 3 discs and flange to the underdrive clutch drum.





Install in order:

P - D - P - D - P - D - F

HINT
P = Plate

D = Disc

F = Flange

(b) Using a screwdriver, install the underdrive clutch flange hole snap ring.





(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.

41. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH Transaxle Unit

42. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.





Standard Bearing and Race Diameter:





(b) Install the underdrive clutch to the transaxle.

43. INSTALL UNDERDRIVE PLANETARY RING GEAR

(a) Install a new snap ring to the outer race of the angular ball bearing.





HINT
If replacing the bearing, also replace the counter driven gear with a new one.

(b) Using a piston ring compressor, squeeze the snap ring.





(c) Using SST and a press, press in the outer race of the angular ball bearing.





SST : 09950-60020

09951-00890

SST : 09950-70010

09951-07100

NOTICE:
Do not damage the snap ring during installation of the outer race.

(d) Install the underdrive planetary ring gear to the counter driven gear.





(e) Using snap ring pliers, install the snap ring.





44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.





SST : 09726-40010

SST : 09950-60010

09951-00260

SST : 09950-70010

09951-07100

(b) Install the counter driven gear with planetary ring gear to the underdrive planetary gear.





(c) Using SST and a press, press in the angular ball bearing inner race (front side).





SST : 09726-40010

SST : 09950-60010

09951-00260

SST : 09950-70010

09951-07100

NOTICE:
Rotate the counter driven gear while pressing.

(d) Using SST and a press, press in the parking lock gear.





SST : 09316-20011

SST : 09950-60010

09951-00260

SST : 09950-70010

09951-07100

NOTICE:
Rotate the counter driven gear while pressing.

(e) Using SST and a press, press in the differential drive pinion.





SST : 09726-40010

SST : 09950-60010

09951-00260

SST : 09950-70010

09951-07100

NOTICE:
Rotate the counter driven gear while pressing.

45. INSTALL CYLINDRICAL ROLLER BEARING INNER RACE

(a) Using SST and a press, press in the cylindrical roller bearing inner race.





SST : 09515-21010

SST : 09950-60010

09951-00260

SST : 09950-70010

09951-07100

NOTICE:
Rotate the counter driven gear while pressing.

46. INSTALL UNDERDRIVE INPUT SHAFT NUT

(a) Clamp the underdrive planetary gear in a soft jaw vise.





NOTICE:
Be careful not to damage the differential drive pinion.

(b) Using a socket wrench, install a new lock nut.

Torque : 280 Nm (2855 kgf-cm, 207 ft-lbf)

HINT
Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)

47. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Transaxle Unit

48. INSTALL UNDERDRIVE INPUT SHAFT NUT

(a) Using a pin punch and a hammer, stake the lock nut.





NOTICE:
Make sure that there are no cracks on the nut.

49. INSTALL UNDERDRIVE PLANETARY GEAR

(a) Install the pawl pin and spring to the parking lock pawl.





(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.





(c) Install the underdrive planetary gear to the transaxle.





NOTICE:
Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly.

(d) Install the parking lock pawl shaft.





(e) Install the pawl shaft clamp with the bolt.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(f) Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).





NOTICE:
Make a note of dimension D as it is necessary for the following process.

(g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate dimension E using the following formula:





NOTICE:
Make a note of dimension E as it is necessary for the following process.

HINT
Dimension E = Dimension (1) - Dimension (2)

50. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Install the bearing race to the transaxle while checking its direction.





Standard Bearing Race Diameter:





(b) Coat the thrust bearing with petroleum jelly, and install them onto the multiple disc clutch hub.





Standard Thrust Bearing Diameter:





(c) Install the bearing to the multiple disc clutch hub.





Standard Bearing Diameter:





(d) Install the multiple disc clutch hub to the transaxle.

51. INSTALL INPUT SHAFT OIL SEAL RING

(a) Compress the oil seal ring from both sides to reduce dimension A.





Standard dimension A:

5 mm (0.197 in.)

(b) Coat the oil seal ring with ATF and install it to the input shaft.

52. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Coat 2 new O-rings with ATF, and install them to the forward clutch piston.





(b) Install the forward clutch piston to the forward clutch drum.





53. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Place the return spring onto the piston.





(b) Place SST on the return spring, and compress the return spring with a press.





SST : 09350-32014

(c) Install the snap ring using a snap ring expander. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.

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.
(d) Set the end gap of the snap ring in the piston shown in the illustration.





NOTICE:
Do not align the end gap of the snap ring with any of the stoppers.

54. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

(a) Install the 5 plates, 5 discs and flange.





Install in order:

P - D - P - D - P - D - P - D - P - D - F

HINT
P = Plate

D = Disc

F = Flange

(b) Using a screwdriver, install the snap ring.





(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.

55. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transaxle Unit

56. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Transaxle Unit

57. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Install the thrust bearing to the forward clutch.





Standard Thrust Bearing Diameter:





NOTICE:
Install the thrust bearing properly so that the race "B" will be visible.

(b) Install the forward clutch to the multiple clutch hub.





NOTICE:
Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.

58. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets.





59. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear to the transaxle.





60. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the thrust bearing underdrive race to the underdrive planetary gear.





61. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select and install the appropriate bearing race to satisfy the specified end play value.





HINT
End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - bearing race thickness.

End play:

0.50 to 0.99 mm (0.0196 to 0.0389 in.)

Standard Race Thickness:





Standard Bearing and Bearing Race Diameter:





62. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle with the 7 bolts.





Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(b) Coat the O-ring of the oil pump with ATF.