01-6

INTRODUCTION

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

0103C-06

ABBREVIATIONS USED IN MANUAL

Abbreviations ASSY ATF B3 C2 C3 FIPG O/D SSM SST U/D w/ w/o 1st 2nd Assembly Automatic Transaxle Fluid U/D Brake Reverse Clutch U/D Clutch Formed In Place Gasket Overdrive Special Service Materials Special Service Tools Underdrive With Without First Second Meaning

U250E A/T REPAIR MANUAL (RM1123U)

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

FRONT DIFFERENTIAL ASSY (U250E)

401FR-01

COMPONENTS
Transaxle Housing S Transaxle Housing Oil Seal Front Differential Pinion Shaft Straight Pin Front Differential Pinion Thrust Washer Front Differential Pinion Shaft No.1 Front Differential Side Gear Front Differential Side Gear Thrust Washer No.1

Front Differential Pinion Front Differential Ring Gear

S FR Differential Case Front Tapered Roller Bearing Outer Race S FR Differential Case Front Tapered Roller Bearing
95.1 (970, 70)

x10

Front Differential Case S Differential Side Bearing Oil Seal

Front Differential Case Rear Shim

S FR Differential Case Rear Tapered Roller Bearing S FR Differential Case Rear Tapered Roller Bearing Outer Race Nm (kgfcm, ftlbf) : Specified torque S Non-reusable part MP grease

G35950

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40-98
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U250E)

TRANSMISSION VALVE BODY ASSY (U250E)

401FQ-01

COMPONENTS

Shift Solenoid Valve S4 Shift Solenoid Valve SR

10.8 (110, 8) 10.8 (110, 8)

Solenoid Lock Plate No.3

6.6 (67, 58 in.lbf)

Solenoid Lock Plate No.2

Line Pressure Control Solenoid Assy Shift Solenoid Valve SL2

Shift Solenoid Valve SL3

6.6 (67, 58 in.lbf)

10.8 (110, 8)

Solenoid Lock Plate

Shift Solenoid Valve DSL

Shift Solenoid Valve SL1 Manual Valve

Nm (kgfcm, ftlbf) : Specified torque

G35992

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40-91
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR ASSY (U250E)

UNDERDRIVE PLANETARY GEAR ASSY (U250E)

401FP-01

COMPONENTS

Parking Lock Gear Differential Drive Pinion Cylindrical Roller Bearing Race Inner

Front Planetary Gear Nut S 280 (2,855, 207)

SUnderdrive Angular Ball Bearing Inner Race (rear side) SUnderdrive Angular Ball Bearing (rear side)

Counter Driven Gear SUnderdrive Angular Ball Bearing (front side) SUnderdrive Angular Ball Bearing Inner Race (front side)

SCounter Drive Gear Hole Snap Ring SUnderdrive Angular Ball Bearing Outer Race Underdrive Planetary Gear Assy Underdrive Planetary Ring Hole Snap Ring Underdrive Planetary Ring Gear

Nm (kgfcm, ftlbf) : Specified torque S Non-reusable part

G35947

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40-84
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U250E)

UNDERDRIVE CLUTCH ASSY (U250E)

401FO-01

COMPONENTS

Underdrive Clutch Plate No.1 Underdrive Clutch Flange No.1

Underdrive Clutch Drum Sub-assy

Underdrive Clutch Piston Set Underdrive Clutch Disc No.1

Underdrive Clutch Flange No.2 Hole Snap Ring Clutch Balancer

S Underdrive Clutch Drum O-ring Underdrive Clutch Return Spring Sub-assy

Underdrive Return Spring Shaft Snap Ring

S Non-reusable part

G35949

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40-81
AUTOMATIC TRANSMISSION / TRANS SECOND BRAKE PISTON ASSY (U250E)

SECOND BRAKE PISTON ASSY (U250E)

401FN-01

COMPONENTS

2nd Brake Cylinder

2nd Brake Piston 2nd Brake Piston Return Spring Seat Shaft Snap Ring

S 2nd Brake Piston O-ring

2nd Brake Piston Return Spring Sub-assy

S Non-reusable part

D26702

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40-73
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U250E)

DIRECT CLUTCH ASSY (U250E)

401FM-01

COMPONENTS
Direct Multiple Disc Clutch Clutch Disc Direct Clutch Flange Direct Clutch Flange Hole Snap Ring Direct Multiple Disc Clutch Clutch Cushion Plate

Overdrive Clutch Plate Direct Multiple Disc Clutch Clutch Plate

Overdrive Direct Clutch Hole Snap Ring

Overdrive Direct Clutch Disc Overdrive Clutch Flange Overdrive Direct Clutch Piston S Overdrive Direct Clutch O-ring

Overdrive Direct Clutch Balancer

Intermediate Shaft Sub-assy Overdrive Direct Clutch Overdrive Direct Clutch Return Drum Sub-assy Spring Shaft Snap Ring Overdrive Clutch Return Spring Sub-assy S Non-reusable part
G35948

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40-67
AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U250E)

FORWARD CLUTCH ASSY (U250E)

401FL-01

COMPONENTS
Forward Clutch Return Spring Sub-assy Forward Clutch Piston Sub-assy Input Shaft Sub-assy SInput Shaft Oil Seal Ring Clutch Balancer No.1

Forward Clutch Piston Return Spring Shaft Snap Ring

Forward Clutch Flange Hole Snap Ring Forward Clutch Flange

Forward Clutch Flange

Forward Multiple Disc Clutch Clutch Disc

S Non-reusable part

C89127

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40-61
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U250E)

OIL PUMP ASSY (U250E)

401FK-01

COMPONENTS

Front Oil Pump Driven Gear FR Oil Pump & Gear Body Sub-assy S Front Oil Pump Body O-ring

9.8 (100, 87 in.lbf)

x11

Clutch Drum Oil Seal Ring Stator Shaft Assy Front Oil Pump Drive Gear S Front Oil Pump Oil Seal

Nm (kgfcm, ftlbf) : Specified torque S Non-reusable part MP grease

G35946

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40-1
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

AUTOMATIC TRANSAXLE ASSY (U250E)

401FI-02

COMPONENTS

8.8 (90, 78 in.lbf)

Hose Speed Sensor Speed Sensor

11 (110, 8)

Breather Plug No.2 (ATM) O-Ring

5.4 (55, 48 in.lbf)

Automatic Transaxle Case No.1 Plug Transmission Wire Oil Cooler Tube Union (Inlet Oil Cooler Union)
27 (275, 20) 7.4 (75, 65 in.lbf)

O-Ring O-Ring

Lock Plate O-Ring

6.6 (67, 58 in.lbf) 7.4 (75, 65 in.lbf)

O-Ring

Automatic Transaxle Case No.1 Plug O-Ring

O-Ring

Automatic Transaxle Case No.1 Plug

7.4 (75, 65 in.lbf)

Oil Cooler Tube Union (Outlet Oil Cooler Union)

27 (276, 20)

Drain Plug Gasket Drain Plug

49 (500, 36)

Nm (kgfcm, ftlbf) : Specified torque Non-reusable part S Precoated part

G35578

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40-2
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

Automatic Transaxle Case No.1 Plug

7.4 (75, 65 in.lbf)

Cylindrical Roller Bearing Transaxle Rear Cover Automatic Transaxle Bolt A: 19 (190, 14) Underdrive Output Case Sub-assy Other bolt: 25 (250, 18) Shaft Oil Seal Ring x 11 O-Ring

29 (295, 21)

x8 O-Ring

9.8 (100, 87 in.lbf)

Transaxle Apply Tube Clamp x3

29 (296, 21)

Automatic Transaxle Case No.1 Plug

7.4 (75, 65 in.lbf)

O-Ring x4

x5 S
22 (225, 16)

Governor Apply Gasket No.1 Transaxle Case Differential Gear 2nd Brake Gasket Lube Apply Tube Brake Drum Gasket Spacer Manual Valve Lever Shaft Retainer Spring Slotted Spring Pin Manual Valve Lever Shaft Manual Valve Lever Shaft Oil Seal Manual Valve Lever Sub-assy
5.4 (55, 48 in.lbf) 6.9 (70, 61 in.lbf)

Transaxle Housing Transmission Valve Body Assy

11 (110, 8)

x 17 O-Ring

Parking Lock Rod Sub-assy

Park/Neutral Position Switch

Control Shaft Lever

13 (130, 9)

Parking Lock Pawl Bracket Valve Body Oil Strainer Assy

11 (110, 8 )

Nut Stopper

Spring Check Ball Body

20 (205, 15)

Washer Compression Spring C-3 Accumulator Piston

Transmission Oil Cleaner Magnet Automatic Transaxle Oil Pan Gasket Manual Detent Spring Sub-assy

Compression Spring

20 (205, 15)

O-Ring
12 (120, 9)

O-Ring

Automatic Transaxle Oil Pan Sub-assy

x 18 S
7.8 (80, 69 in.lbf)

Reverse Clutch Accumulator Piston

Nm (kgfcm, ftlbf) : Specified torque Non-reusable part S Precoated part MP grease

U250E A/T REPAIR MANUAL (RM1123U)

O-Ring

O-Ring Compression Spring B-3 Accumulator Piston

G35579

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40-3
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

Thrust Needle Roller Bearing Oil Pump Assy

Thrust Needle Roller Bearing

Overdrive Brake Gasket

Forward Clutch Assy Counter Drive Gear Thrust Needle Roller Bearing Washer Counter Drive Angular Ball Bearing (Front Side) Flange

22 (225, 16)

x7 Multiple Disc Clutch Clutch Hub 1st & Reverse Brake Piston O-Ring Snap Ring

Nut Thrust Bearing Race No.1 Snap Ring Plate

185 (1,886, 136) to 350 (3,569, 258)

Front Planetary Gear Assy Brake Hub

1st & Reverse Brake Disc 1st & Reverse Brake Snap Ring Return Spring Plate Flange

Counter Drive Angular Ball Bearing (Rear Side) Second Brake Piston Assy

Rear Planetary Sun Gear Assy Front Planetary Ring Gear

Thrust Bearing Race

1-W ay Clutch Assy 2nd Brake Disc 1-W ay Clutch Snap Ring Sleeve Outer Thrust Bearing Race No.3 Rear Planetary Gear Assy Thrust Bearing Race No.2 1-W ay Clutch Input Sun Gear Inner Race Snap Ring Planetary Carrier Thrust Washer No.1 Thrust Needle Roller Bearing Thrust Bearing Direct Clutch Assy Thrust Bearing Race O/D Direct Clutch Hub Sub-assy Nm (kgfcm, ftlbf) : Specified torque Non-reusable part
U250E A/T REPAIR MANUAL (RM1123U)

Thrust Needle Roller Bearing Planetary Carrier Thrust Washer No.2 Transaxle Rear Cover

Thrust Needle Roller Bearing

Thrust Bearing

Needle Roller Bearing Rear Clutch Oil Seal Ring Outer

G35580

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40-4
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

Underdrive Clutch Assy

Underdrive 1-W ay Clutch Assy Underdrive Planetary Gear Assy Thrust Bearing Underdrive Race No.2 Snap Ring

Underdrive Underdrive Cluth Disc No.2 Brake Piston Flange

Needle Roller Bearing

Plate Snap Ring Outer Race Retainer Thrust Bearing Race Thrust Needle Roller Bearing Underdrive Clutch Drum Oil Seal Ring Snap Ring O-Ring Underdrive Clutch Return Spring Sub-assy

Thrust Needle Roller Bearing

Differential Gear Assy

Parking Lock Pawl

Clutch Apply Tube Brake Apply Tube

Parking Lock Pawl Shaft Tension Spring

9.8 (100, 87 in.lbf)

Parking Lock Pawl Pin Pawl Shaft Clamp

5.4 (55, 48 in.lbf)

Transaxle Apply Tube Clamp Nm (kgfcm, ftlbf) : Specified torque Non-reusable part
U250E A/T REPAIR MANUAL (RM1123U)

Governor Apply Gasket No.1

G35581

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INTRODUCTION

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

01-7
0103D-11

GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents.
SAE ABBREVIATIONS A/C ACL AIR AP B+ BARO CAC CARB CFI CKP CL CMP CPP CTOX CTP DFI DI DLC1 DLC2 DLC3 DTC DTM ECL ECM ECT EEPROM EFE EGR EI EM EPROM EVAP FC FEEPROM FEPROM FF FP GEN GND HO2S IAC IAT ICM IFI IFS Air Conditioning Air Cleaner Secondary Air Injection Accelerator Pedal Battery Positive Voltage Barometric Pressure Charge Air Cooler Carburetor Continuous Fuel Injection Crankshaft Position Closed Loop Camshaft position Clutch Pedal Position Continuous Trap Oxidizer Closed Throttle Potion Direct Fuel Injection (Diesel) Distributor Ignition Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 Diagnostic Trouble Code Diagnostic Test Mode Engine Control Level Engine Control Module Engine Control Temperature Electrically Erasable Programmable Read Only Memory Early Fuel Evaporation Exhaust Gas Recirculation Electronic Ignition Engine Modification Erasable Programmable Read Only Memory Evaporative Emission Fan Control Flash Electrically Erasable Programmable Read Only Memory Flash Erasable Programmable Read Only Memory Flexible Fuel Fuel Pump Generator Ground Heated Oxygen Sensor Idle Air Control Intake Air Temperature Ignition Control Module Indirect Fuel Injection Inertia Fuel-Shutoff SAE TERMS Air Conditioner Air Cleaner Air Injection (AI) +B, Battery Voltage Inter cooler Carburetor Crank Angle Closed Loop Cam Angle Direct Injection (DI) 1: Check Connector 2: Total Diagnosis Communication Link (TDCL) 3: OBD II Diagnostic Connector Diagnostic Code Engine ECU (Electronic Control Unit) Coolant Temperature, Water Temperature (THW) Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) Cold Mixture Heater (CMH), Heat Control Valve (HCV) Exhaust Gas Recirculation (EGR) Distributorless Ignition (DI) Engine Modification (EM) Programmable Read Only Memory (PROM) Evaporative Emission Control (EVAP) Fuel Pump Alternator Ground (GND) Heated Oxygen Sensor (HO2S) Idle Speed Control (ISC) Intake or Inlet Air Temperature Indirect Injection TOYOTA TERMS ( )--ABBREVIATIONS

U250E A/T REPAIR MANUAL (RM1123U)

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01-8

INTRODUCTION

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL Knock Sensor Air Flow Meter Manifold Pressure Intake Vacuum Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) Electronic Fuel Injection (EFI) Check Engine Light Oxygen Sensor, O2 Sensor (O2S) On-Board Diagnostic (OBD) Oxidation Catalyst Converter (OC), CC0 Open Loop Air Suction (AS) Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) Random Access Memory (RAM) Read Only Memory (ROM) Engine Speed Supercharger Electronic Fuel Injection (EFI), Sequential Injection Throttle Body Single Point Injection Central Fuel Injection (Ci) Turbocharger Torque Converter Transmission ECU (Electronic Control Unit) Throttle Position Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) Three-W ay Catalytic (TWC) CCRO CCR + CCO Air Flow Meter Voltage Regulator Vehicle Speed Sensor (Read Switch Type) Full Throttle

ISC KS MAF MAP

Idle Speed Control Knock Sensor Mass Air Flow Manifold Absolute Pressure

MC MDP MFI MIL MST MVZ NVRAM O2S OBD OC OP PAIR PCM PNP PROM PSP PTOX RAM RM ROM RPM SC SCB SFI SPL SRI SRT ST TB TBI TC TCC TCM TP TR TVV TWC TWC+OC VAF VR VSS WOT

Mixture Control Manifold Differential Pressure Multiport Fuel Injection Malfunction Indicator Lamp Manifold Surface Temperature Manifold Vacuum Zone Non-V olatile Random Access Memory Oxygen Sensor On-Board Diagnostic Oxidation Catalytic Converter Open Loop Pulsed Secondary Air Injection Powertrain Control Module Park/Neutral Position Programmable Read Only Memory Power Steering Pressure Periodic Trap Oxidizer Random Access Memory Relay Module Read Only Memory Engine Speed Supercharger Supercharger Bypass Sequential Multiport Fuel Injection Smoke Puff Limiter Service Reminder Indicator System Readiness Test Scan Tool Throttle Body Throttle Body Fuel Injection Turbocharger Torque Converter Clutch Transmission Control Module Throttle Position Transmission Range Thermal Vacuum Valve Three-W ay Catalytic Converter Three-W ay + Oxidation Catalytic Converter Volume Air Flow Voltage Regulator Vehicle Speed Sensor Wide Open Throttle

U250E A/T REPAIR MANUAL (RM1123U)

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INTRODUCTION

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL Manifold Converter -

01-9

WU-OC WU-TWC 3GR 4GR

Warm Up Oxidation Catalytic Converter Warm Up Three-Way Catalytic Converter Third Gear Fourth Gear

U250E A/T REPAIR MANUAL (RM1123U)

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SERVICE SPECIFICATIONS

STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

03-3
032HU-01

HOW TO DETERMINE NUT STRENGTH

Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Cutting Processed Nut Class

4N
No Mark

5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark

6N
6N

7N (5T) *

8N
8N

10N (7T)
10N

No Mark

11N
11N

12N
12N

*: Nut with 1 or more marks on one side surface of the nut.

HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more
U250E A/T REPAIR MANUAL (RM1123U)

B06432

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SERVICE SPECIFICATIONS

STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

03-1

STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

032HS-01

HOW TO DETERMINE BOLT STRENGTH

Mark Hexagon head bolt Bolt head No. 4567891011Class 4T 5T 6T 7T 8T 9T 10T 11T Hexagon flange bolt w/ washer hexagon bolt Hexagon flange bolt w/ washer hexagon bolt Hexagon flange bolt No mark 4T w/ washer hexagon bolt Hexagon flange bolt No mark w/ washer hexagon bolt Hexagon head bolt 2 Protruding lines 4T 4T Stud bolt Mark 4 Protruding lines Class

9T

5 Protruding lines

10T

6 Protruding lines No mark

11T

5T Grooved

Hexagon flange bolt w/ washer hexagon bolt Hexagon head bolt

2 Protruding lines

6T

6T

3 Protruding lines

7T

Welded bolt

Hexagon head bolt

4 Protruding lines

4T 8T

V06821

U250E A/T REPAIR MANUAL (RM1123U)

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INTRODUCTION

HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL

01-1

HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL

0103A-09

GENERAL INFORMATION
1. (a) (b) GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. Removal and Installation, Replacement, Disassembly, Installation and Check, and Adjustment 3. Final Inspection This manual explains Removal and Installation, Replacement, Disassembly, Installation and Check, and Adjustment, but Final inspection is omitted. The following essential operations are not written in this manual, however these operations must be done in the practical situation. (1) Operation with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check INDEX An alphabetical INDEX section is provided at the end of the book as a reference to help find the item to be repaired. PREPARATION Use of special service tools (SST) and special service materials (SSM) may be required, depending on the repairing condition. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. REPAIR PROCEDURES A component illustration is placed under the title where necessary. Illustrations of the parts catalog are placed as the disassembled parts drawing so that it enables you to understand the fitting condition of the components. Non-reusable parts, grease applied parts, precoated parts and tightening torque are specified in the component illustrations. Example:

(c) (d)

2. (a) 3. (a)

4. (a) (b) (c)

Stator Shaft Assy Oil Pump Drive Gear

Oil Seal Ring

S Oil Seal

x13

10 (100, 7)

Oil Pump Driven Gear S O-ring Nm (kgfcm, ftlbf) : Specified torque S Non-reusable part
U250E A/T REPAIR MANUAL (RM1123U)
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INTRODUCTION

HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL

(d)

Tightening torque, oil applying position, and non-reusable parts are described as important points in the procedure. NOTICE: There are cases where such information can only be indicated by an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (e) The installation procedures are the reverse order of the removal procedures. However, only installation procedures requiring additional information are included. (f) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (g) Illustrations of similar vehicle models are sometimes used. In these cases, specific details may be different from the actual vehicle. (h) The procedures are presented in a step-by-step format: (1) The illustration shows what to do and where to do. (2) The task heading tells what to do. (3) The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example:
Illustration: what to do and where
87.

Task heading: what to do

INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and a press, install the front differential case tapered roller bearing front inner race to the differential case. SST 09316-60011 (09316-00011) Detailed text: how to do task

(a)

Set part No.

Component part No.

D26831

HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary, and the text below provides detailed information. Important specifications and warnings always stand out in bold type. 5. SERVICE SPECIFICATIONS (a) Specifications are presented in bold type throughout the manual. The specifications are also found in the Service Specifications section for quick reference. 6. TERMS DEFINITION
Indicates the possibility of injury to you or other people. Indicates the possibility of damage to the components being repaired. Provides additional information to help you perform the repair efficiently. NOTICE HINT

CAUTION

U250E A/T REPAIR MANUAL (RM1123U)

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HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL

01-3

7. (a)

SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English system. Example: Torque: 30 Nm (310 kgfcm, 22 ftlbf)

U250E A/T REPAIR MANUAL (RM1123U)

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03-4
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE

AUTOMATIC TRANSMISSION / TRANSAXLE

031I7-03

SERVICE DATA
Oil pump Body clearance Tip clearance Side clearance Drive gear thickness STD Max. STD Max. STD Max. Mark A B C D E Mark A B C D E STD Max. STD Max. 0.10 to 0.17 mm (0.0039 to 0.0067 in.) 0.17 mm (0.0067 in.) 0.07 to 0.15 mm (0.0028 to 0.0059 in.) 0.15 mm (0.0059 in.) 0.02 to 0.05 mm (0.0008 to 0.0020 in.) 0.05 mm (0.0020 in.) 11.690 to 11.699 mm (0.4602 to 0.4606 in.) 11.700 to 11.709 mm (0.4606 to 0.4610 in.) 11.710 to 11.720 mm (0.4610 to 0.4614 in.) 11.721 to 11.730 mm (0.4615 to 0.4618 in.) 11.731 to 11.740 mm (0.4619 to 0.4622 in.) 11.690 to 11.699 mm (0.4602 to 0.4606 in.) 11.700 to 11.709 mm (0.4606 to 0.4610 in.) 11.710 to 11.720 mm (0.4610 to 0.4614 in.) 11.721 to 11.730 mm (0.4615 to 0.4618 in.) 11.731 to 11.740 mm (0.4619 to 0.4622 in.) 38.113 to 38.138 mm (1.50050 to 1.50149 in.) 38.188 mm (1.50346 in.) 21.500 to 21.526 mm (0.84646 to 0.84748 in.) 21.57 mm (0.8492 in.)

Driven gear thickness

Pump body bushing inside diameter Stator shaft bushing inside diameter

Multiple disc clutch clutch hub Inside diameter STD Max. 23.025 to 23.046 mm (0.9065 to 0.9073 in.) 23.09 mm (0.9091 in.)

Over direct clutch drum sub-assy Inside diameter STD Max. 23.025 to 23.046 mm (0.9065 to 0.9073 in.) 23.09 mm (0.9091 in.)

Forward clutch Pack clearance Return spring free length Flange thickness Mark 0 1 2 3 4 5 6 0.85 to 1.25 mm (0.0335 to 0.0492 in.) 26.74 mm (1.0528 in.) 2.85 mm (0.1122 in.) 3.00 mm (0.1181 in.) 3.15 mm (0.1240 in.) 3.30 mm (0.1299 in.) 3.45 mm (0.1358 in.) 3.60 mm (0.1417 in.) 3.75 mm (0.1476 in.)

Reverse clutch Pack clearance: Flange thickness Mark 0 1 2 3 4 5 6 7 0.60 to 0.82 mm (0.02362 to 0.03228 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) 3.6 mm (0.142 in.)

U250E A/T REPAIR MANUAL (RM1123U)

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03-5
SERVICE SPECIFICATIONS Direct clutch & O/D clutch Pack clearance Return spring free length Flange thickness Mark 0 1 2 3 4 5 6 0.52 mm (0.02047 in.) 25.91 mm (1.0201 in.) 2.5 mm (0.098 in.) 2.6 mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) AUTOMATIC TRANSMISSION / TRANSAXLE

2nd brake Pack clearance Return spring free length Flange thickness Mark 0 1 2 3 4 5 6 7 8 0.53 to 0.91 mm (0.0209 to 0.0358 in.) 16.61 mm (0.6539 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) 3.6 mm (0.142 in.) 3.7 mm (0.146 in.)

2nd brake piston Inside diameter U/D clutch Pack clearance U/D clutch drum bushing inside diameter Return spring free length Flange thickness Mark K A G B H C J U/D clutch No.2 Pack clearance Return spring free length Flange thickness Mark Y A B C D 1.645 to 2.20 mm (0.0648 to 0.0866 in.) 13.24 mm (0.5213 in.) 2.8 mm (0.110 in.) 3.0 mm (0.118 in.) 3.2 mm (0.126 in.) 3.4 mm (0.134 in.) 3.6 mm (0.142 in.) STD Max. 1.42 to 1.71 mm (0.0559 to 0.0673 in.) 32.56 to 32.58 mm (1.2818 to 1.2826 in.) 32.68 mm (1.2846 in.) 17.14 mm (0.6752 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) More than 167 mm (6.57in.)

U250E A/T REPAIR MANUAL (RM1123U)

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03-6
SERVICE SPECIFICATIONS 1st & reverse brake Pack clearance Return spring free length Flange thickness Mark 1 2 3 4 5 6 7 8 0.745 to 1.21 mm (0.0293 to 0.0476in.) 17.63 mm (0.6941 in.) 1.8 mm (0.071 in.) 1.9 mm (0.075 in.) 2.0 mm (0.079 in.) 2.1 mm (0.083 in.) 2.2 mm (0.087 in.) 2.3 mm (0.091 in.) 2.4 mm (0.094 in.) 2.5 mm (0.098 in.) AUTOMATIC TRANSMISSION / TRANSAXLE

U/D planetary gear Preload (at 60 rpm) Front planetary gear Turning torque (at 60 rpm) Input shaft End play Direct clutch to transaxle rear cover End play U/D planetary gear assy to U/D cylindrical roller bearing End play Race thickness Less than 7.339 mm (02890in.) 7.339 mm (0.2890in.) or more 0.198 to 0.693 mm (0.00780 to 0.02728 in.) 3.5 mm (0.138in.) 3.8 mm (0.150in.) 0.199 to 0.970 mm (0.0078 to 0.0382 in.) 0.262 to 1.249 mm (0.0103 to 0.0492 in.) 0.19 to 0.4 Nm (1.9 to 4.1 kgfcm, 1.7 to 3.5 in.lbf) 0.28 to 0.89 Nm (2.9 to 9.1 kgfcm, 2.478 to 7.877 in.lbf)

Transaxle rear cover Bearing press fit depth Transmission valve body Valve body installation bolt length A B C 25 mm (0.984 in.) 57 mm (2.244 in.) 41 mm (1.614 in.) 20.55 to 21.25 mm (0.8091 to 0.8366 in.)

Accumulator Spring B-3 Reverse clutch C-3 Manual valve lever shaft oil seal Oil seal drive depth Front differential Backlash Thrust washer thickness Mark 1 2 3 4 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 1.000 mm (0.0394 in.) 1.100 mm (0.0433 in.) 1.200 mm (0.0472 in.) 1.300 mm (0.0512 in.) -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) Inner Outer Free length/Outer diameter 62.00 (2.4409) / 15.50 (0.610) 74.23 (2.9224) / 21.70 (0.854) 60.96 (2.3999) / 14.10 (0.555) 72.20 (2.8425) / 19.0 (0.748) Color Purple Purple Yellow Colorless

U250E A/T REPAIR MANUAL (RM1123U)

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03-7
SERVICE SPECIFICATIONS Preload (at 60 rpm) Flange thickness AUTOMATIC TRANSMISSION / TRANSAXLE 0.20 to 1.0 Nm (2.0 to 10.2 kgfcm, 1.8 to 8.9 in.lbf) 0.10 to 0.35 Nm (1.0 to 3.6 kgfcm, 0.9 to 3.1 in.lbf) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.)

New bearing Used bearing Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F G H J

U250E A/T REPAIR MANUAL (RM1123U)

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03-2

SERVICE SPECIFICATIONS

STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

032HT-01

SPECIFIED TORQUE FOR STANDARD BOLTS

Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt Nm kgfcm kgfcm ftlbf Nm ftlbf in.lbf in.lbf

Class

in.lbf

in.lbf

in.lbf

in.lbf

V00079

U250E A/T REPAIR MANUAL (RM1123U)

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02-1
PREPARATION AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSMISSION / TRANS

0247U-01

PREPARATION
SST
09223-15030
Oil Seal & Bearing Replacer AUTOMATIC ASSY(U250E) TRANSAXLE

09308-00010

Oil Seal Puller

AUTOMATIC TRANSAXLE ASSY(U250E) OIL PUMP ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL TRANSAXLE

09316-12010

Transfer Bearing Replacer

AUTOMATIC ASSY(U250E)

09316-2001 1

Transfer Bearing Replacer

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09350-32014

TOYOTA Automatic Transmission Tool Set

OIL PUMP ASSY(U250E) UNDERDRIVE ASSY(U250E)

CLUTCH

(09351-32070)

No.2 Piston Spring Compressor

UNDERDRIVE ASSY(U250E)

CLUTCH

(09351-32140)

Oil Seal Replacer

OIL PUMP ASSY(U250E)

09387-00020

Direct Clutch Wrench

AUTOMATIC TRANSAXLE ASSY(U250E) FORWARD CLUTCH ASSY(U250E) DIRECT CLUTCH ASSY(U250E)

09387-00030

Counter Drive Gear Holding Tool

AUTOMATIC ASSY(U250E)

TRANSAXLE

09387-00041

Bearing Puller Assembly

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09387-01010)

Claw No.1

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09387-01021)

Claw No.2

AUTOMATIC ASSY(U250E)

TRANSAXLE

U250E A/T REPAIR MANUAL (RM1123U)

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02-2
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AUTOMATIC ASSY(U250E) TRANSAXLE

(09387-01030)

Pin

(09387-01040)

Bearing Puller Body

AUTOMATIC ASSY(U250E)

TRANSAXLE

09387-00050

Under Drive Gear Puller

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09387-00060

Second Brake Wrench

SECOND BRAKE ASSY(U250E)

PISTON

09387-00070

First & Reverse Brake Wrench

AUTOMATIC ASSY(U250E)

TRANSAXLE

09387-00080

Counter Drive Gear Nut Wrench

AUTOMATIC ASSY(U250E)

TRANSAXLE

09495-65040

Axle Hub Oil Seal Replacer

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09502-24010

Bearing Replacer

AUTOMATIC ASSY(U250E)

TRANSAXLE

09515-21010

Rear Axle Shaft Bearing Replacer

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09523-36010

Rear Axle Hub Guide Tool

AUTOMATIC ASSY(U250E)

TRANSAXLE

09527-1701 1

Rear Axle Shaft Bearing Remover

AUTOMATIC ASSY(U250E)

TRANSAXLE

09550-60010

Differential Side Bearing Replacer

FRONT ASSY(U250E)

DIFFERENTIAL

(09951-00480)

Replacer 48

FRONT ASSY(U250E)

DIFFERENTIAL

U250E A/T REPAIR MANUAL (RM1123U)

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02-3
PREPARATION AUTOMATIC TRANSMISSION / TRANS
FRONT ASSY(U250E) DIFFERENTIAL

09564-3201 1

Differential Preload Adaptor

09608-10010

Steering Knuckle Oil Seal Replacer

FRONT ASSY(U250E)

DIFFERENTIAL

09608-32010

Steering Knuckle Oil Seal Replacer

FRONT ASSY(U250E)

DIFFERENTIAL

09649-17010

Steering Knuckle Tool

AUTOMATIC ASSY(U250E)

TRANSAXLE

09710-04081

Base

FRONT ASSY(U250E)

DIFFERENTIAL

09726-36010

Lower Control Arm Bushing Replacer

FRONT ASSY(U250E)

DIFFERENTIAL

09726-40010

Lower Control Shaft Bearing Replacer

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09820-00031

Alternator Rotor Rear Bearing Replacer

AUTOMATIC ASSY(U250E)

TRANSAXLE

09930-00010

Drive Shaft Nut Chisel

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

(09931-00010)

Handle

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

(09931-00020)

Nut Chisel

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09950-00020

Bearing Remover

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL

09950-00030

Bearing Remover Attachment

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL

U250E A/T REPAIR MANUAL (RM1123U)

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02-4
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL TRANSAXLE

09950-4001 1

Puller B Set

(09952-04010)

Slide Arm

AUTOMATIC ASSY(U250E)

(09954-04010)

Arm 25

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09955-04061)

Claw No. 6

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

TRANSAXLE DIFFERENTIAL

(09957-04010)

Attachment

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL DIFFERENTIAL

(09958-0401 1)

Holder

FRONT ASSY(U250E)

09950-50013

Puller C Set

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

TRANSAXLE DIFFERENTIAL

(09951-05010)

Hanger 150

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

TRANSAXLE DIFFERENTIAL

(09952-05010)

Slide Arm

FRONT ASSY(U250E)

DIFFERENTIAL

(09953-05020)

Center Bolt 150

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

TRANSAXLE DIFFERENTIAL

(09954-05021)

Claw No. 2

FRONT ASSY(U250E)

DIFFERENTIAL

(09955-05010)

Adapter No.1

FRONT ASSY(U250E)

DIFFERENTIAL

U250E A/T REPAIR MANUAL (RM1123U)

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02-5
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL TRANSAXLE

09950-60010

Replacer Set

(09951-00230)

Replacer 23

AUTOMATIC ASSY(U250E)

(09951-00260)

Replacer 26

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

(09951-00320)

Replacer 32

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E)

(09951-00360)

Replacer 36

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00450)

Replacer 45

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00480)

Replacer 48

FRONT ASSY(U250E)

DIFFERENTIAL

(09951-00500)

Replacer 50

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00590)

Replacer 59

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00630)

Replacer 63

FRONT ASSY(U250E)

DIFFERENTIAL

(09952-06010)

Adapter

AUTOMATIC ASSY(U250E)

TRANSAXLE

09950-60020

Replacer Set No. 2

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL TRANSAXLE

(09951-00720)

Replacer 72

AUTOMATIC ASSY(U250E)

U250E A/T REPAIR MANUAL (RM1123U)

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02-6
PREPARATION AUTOMATIC TRANSMISSION / TRANS
FRONT ASSY(U250E) DIFFERENTIAL

(09951-00750)

Replacer 75

(09951-00780)

Replacer 78

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00790)

Replacer 79

FRONT ASSY(U250E)

DIFFERENTIAL

(09951-00810)

Replacer 81

AUTOMATIC ASSY(U250E)

TRANSAXLE

(09951-00890)

Replacer 89

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09950-70010

Handle Set

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL

(09951-07100)

Handle 100

AUTOMATIC TRANSAXLE ASSY(U250E) UNDERDRIVE PLANETARY GEAR ASSY(U250E) FRONT ASSY(U250E) DIFFERENTIAL TRANSAXLE DIFFERENTIAL

(09951-07150)

Handle 150

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

(09951-07200)

Handle 200

AUTOMATIC ASSY(U250E) FRONT ASSY(U250E)

TRANSAXLE DIFFERENTIAL

U250E A/T REPAIR MANUAL (RM1123U)

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02-7
PREPARATION AUTOMATIC TRANSMISSION / TRANS

Recommended Tools
09031-00030
Pin Punch AUTOMATIC ASSY(U250E) TRANSAXLE

09042-00010

Torx Socket T30

OIL PUMP ASSY(U250E)

09905-00012

Snap Ring No. 1 Expander

AUTOMATIC TRANSAXLE ASSY(U250E) FORWARD CLUTCH ASSY(U250E) DIRECT CLUTCH ASSY(U250E)

09905-00013

Snap Ring Pliers

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

(09904-00090)

Claw Set

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

09924-1241 1

Deep Socket Wrench 41

UNDERDRIVE PLANETARY GEAR ASSY(U250E)

Equipment
Dial indicator with magnetic base Feeler gauge Vernier calipers Torque wrench Plastic hammer Straight edge Press

Lubricant
item U250E Automatic transaxle fluid Dry fill Drain and refill

8.0 liter (8.5 USqts, 7.0 lmp.qts) 3.5 liter (3.7 USqts, 3.1 lmp.qts)

ATF type T-IV

SSM (Special Service Materials)

08826-00090
Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG)

08833-00080

Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent

U250E A/T REPAIR MANUAL (RM1123U)

Author :

Date :

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03-8
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
031I8-03

TORQUE SPECIFICATION
Part Tightened Differential gear lube apply tube x Transaxle housing Front planetary gear lock nut Brake apply tube clamp x Transaxle case Transaxle case No. 1 plug x Transaxle rear cover Transaxle case No.1 plug x Transaxle housing Transaxle case No.1 plug x Transaxle case Transaxle rear cover x Transaxle case Pawl shaft clamp x Transaxle case Oil pump assy x Transaxle case Transaxle housing x Transaxle case Bolt A Bolt B Bolt C Bolt A Bolt B Bolt A Other bolt Nm 9.8 185-350 5.4 7.4 7.4 7.4 19 25 9.8 22 22 29 29 20 20 12 5.4 11 6.6 11 7.8 49 Bolt A Bolt B 8.8 11 27 6.9 5.4 13 9.8 6.6 6.6 10.8 6.6 10.8 10.8 95.1 280 kgfcm 100 1886-3569 55 75 75 75 190 250 100 225 225 296 296 205 205 120 55 110 67 110 80 500 90 115 276 70 55 130 100 67 67 110 67 110 110 970 2855 ftlbf 87 in.lbf 136-258 48 in.lbf 65 in.lbf 65 in.lbf 65 in.lbf 14 18 87 in.lbf 16 16 21 21 15 15 9 48 in.lbf 8 58 inlbf 8 69 in.lbf 36 79 in.lbf 8 20 61 in.lbf 48 in.lbf 9 87 in.lbf 58 in.lbf 58 in.lbf 8 58 in.lbf 8 8 70 207

Parking lock pawl bracket x Transaxle case Manual detent spring x Transaxle case Transmission wire x Transaxle housing Transmission valve body x Transaxle case ATF temperature sensor clamp x Transmission valve body Valve body oil strainer assy x Transmission valve body Automatic transaxle oil pan sub-assy x Transaxle case Drain plug x Automatic transaxle oil pan sub-assy Speed sensor x Transaxle case Oil cooler tube union x Transaxle case Park/neutral start switch x nut Park/neutral start switch x Bolt Park/neutral start switch x Control shaft lever Oil pump body x Stator shaft assy Line pressure control solenoid assy x Transmission valve body assy Shift solenoid valve SL1x Transmission valve body assy Shift solenoid valve SL2x Transmission valve body assy Shift solenoid valve SL3x Transmission valve body assy Shift solenoid valve S4x Transmission valve body assy Shift solenoid valve DSL x Transmission valve body assy Front differential case x Front differential ring gear Front planetary gear nut

U250E A/T REPAIR MANUAL (RM1123U)

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40-103
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)
4006M-04

OVERHAUL

Matchmarks

Front Differential Ring Gear

1. (a)

REMOVE FRONT DIFFERENTIAL RING GEAR Put the matchmarks on the front differential ring gear and differential case.

G35951

Front Differential Ring Gear

(b)

Remove the 10 bolts.

G35952

(c)

Using a plastic hammer, tap on the front differential ring gear to remove it from the case.

Front Differential Ring Gear

G35953

2.
Hold Turn

(a)

SST SST

REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST, remove the front differential case front differential tapered roller bearing from the differential case. SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00480), 09950-40011 (09957-04010)

G35954

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

(b)
SST

Using SST, remove the front differential case front tapered roller bearing outer race. SST 09308-00010

D25596

3.
Hold Turn SST

(a)

SST

G35955

(b)
SST

(c)

REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST, remove the front differential case rear tapered roller bearing from the differential case. SST 09950- 00020, 09950- 00030, 09950- 40011 (09955-04061, 09957-04010, 09958-04011), 09950- 50013 (09951- 05010, 09952- 05010, 09953- 05020, 09954- 05021, 09955- 05010), 09950- 60010 (09951- 00480), 09950- 70010 (09951-07100) Using SST, remove the front differential case rear tapered roller bearing outer race. SST 09308-00010 Remove the front differential case rear shim.

D25598

4.

REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, remove the straight pin. NOTICE: Before removing the straight pin, unstake it with a pin punch.

G35961

5.
Differential Case

(a)

REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1 Remove the front differential pinion shaft No.1 from the differential case.

Front Differential Pinion Shaft No.1

U250E A/T REPAIR MANUAL (RM1123U)

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

Front Differential Side Gear

6. (a)

REMOVE FRONT DIFFERENTIAL SIDE GEAR Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.

Front Differential Side Gear G35958

7. (a)

REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, remove the oil seal. SST 09950- 70010 (09951- 07200), 09950- 60010 (09951-00630)

SST
G35959

8. (a)
SST

REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, remove the oil seal. SST 09950-70010 (09951-07100), 09608-10010

G35960

Front Differential Side Gear

9. (a)

INSTALL FRONT DIFFERENTIAL SIDE GEAR Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.

Front Differential Side Gear

G35958

Differential Case

10. (a)

INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1 Coat the front differential pinion shaft No.1 with ATF, and install it to the differential case.

Front Differential Pinion Shaft No.1

U250E A/T REPAIR MANUAL (RM1123U)

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

11. (a)

INSPECT BACKLASH Using a dial indicator, inspect the backlash of the side gear. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Thrust washer thickness
Mark 1 2 3 4 Thickness 1.000 mm (0.0394 in.) 1.100 mm (0.0433 in.) 1.200 mm (0.0472 in.) 1.300 mm (0.0512 in.)

C50252

12.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, install the pinion shaft straight pin. NOTICE: Align the holes, and install the pinion shaft straight pin.

G35962

(b) Using a chisel and hammer, stake the differential case. NOTICE: Stake it after adjusting the backlash.

G35963

13.

SST

G35964

INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case. SST 09550- 60010 (09951- 00480), 09950- 70010 (09951-07100), 09710-04081 NOTICE: Do not damage the bearing cage during bearing inner race installation.

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

(b)

Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing. SST 09950-70010 (09951-07200), 09950-60020 (09951-00750)

C83736

14.

SST

G35965

INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case. SST 09710- 04081, 09550- 60010 (09951- 00480), 09950-70010 (09951-07100) NOTICE: Do not damage the bearing cage during bearing inner race installation. (b) (c) Install the front differential case rear shim. Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing. SST 09950- 70010 (09951- 07150), 09950- 60020 (09951-00790) NOTICE: Ensure that there is no clearance between the bearing and transaxle housing. 15. (a) ADJUST DIFFERENTIAL SIDE BEARING PRELOAD Install the differential assy to the transaxle case.

SST

D26449

G35993

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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U250E)

(b)
B

(c)
A C A

D33498

Clean the matching surfaces of the transaxle case and transaxle housing. Install the transaxle housing to the transaxle case with the 16 bolts. Torque: Bolt A: 22 Nm (224 kgfcm, 16 ftlbf) Bolt B: 29 Nm (296 kgfcm, 21 ftlbf) Bolt C: 29 Nm (296 kgfcm, 21 ftlbf) Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.)

(d)

(e)

Using SST, turn the differential assy right and left 2 or 3 times to settle the bearing. SST 09564-3201 1 Using SST and a torque wrench, measure the turning torque of the differential. SST 09564-3201 1 Turning torque at 60 rpm: New bearing 0.20 to 1.00 Nm (2.0 to 10.2 kgfcm, 1.8 to 8.9 in.lbf) Used bearing 0.10 to 0.35 Nm (1.0 to 3.6 kgfcm, 0.9 to 3.1 in.lbf)

SST

HINT: If the turning torque is not within the specified values, refer to the table below to select a shim which turning torque is within the specified values. Shim thickness: mm (in.)
Mark 0
D25604

Thickness 1.90 (0.0748) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925)

Mark A B C D E F G H J

Thickness 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024) 2.65 (0.1043) 2.70 (0.1063) 2.75 (0.1083) 2.80 (0.1102)

1 2 3 4 5 6 7 8 9

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(f)

Remove the 16 bolts and the transaxle housing.

D26384

Differential Assy

(g)

Remove the differential assy.

G35993

90 to 100SC (194 to 230SF)

16. (a)

INSTALL FRONT DIFFERENTIAL RING GEAR Using ATF and a heater, heat the front differential ring gear to 90 to 110SC (194.0 to 230.0SF). NOTICE: Do not heat the ring gear to more than 110SC (230.0SF). (b) Clean the contact surface of the front differential case.

D25215

Matchmarks

Front Differential Ring Gear

(c)

Align the matchmarks, and install the front differential ring gear case quickly. NOTICE: Do not install the bolts while the ring gear is hot.

G35951

(d)

Tighten the 10 bolts. Torque: 95.1 Nm (970 kgfcm, 70 ftlbf) NOTICE: Tighten the bolts a little at a time in diagonal order.

G35952

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17. (a) (b)

INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, install a new oil seal. Coat the lip of the oil seal with a little MP grease. Oil seal drive in depth: 0 " 0.5 mm (0 " 0.0197 in.) SST 09950-70010 (09951-07150), 09608-32010

SST
D26451

18. (a) (b)

SST

INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, install a new oil seal. Coat the lip of the oil seal with a little MP grease. Oil seal drive in depth: 0 " 0.5 mm (0 " 0.0197 in.) SST 09950-70010 (09951-07150), 09726-36010

G35967

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4010J-02

OVERHAUL

1. (a) 2. (a)

REMOVE SHIFT SOLENOID VALVE SL3 Remove the bolt, solenoid lock plate No.3 and shift solenoid valve SL3 from the valve body assy. REMOVE LINE PRESSURE CONTROL SOLENOID ASSY Remove the line pressure control solenoid from the valve body assy.

C89112

3. (a)

REMOVE SHIFT SOLENOID VALVE S4 Remove the bolt and shift solenoid valve S4 from the valve body assy.

D26442

4. (a)

REMOVE SHIFT SOLENOID VALVE SR Remove the shift solenoid valve SR from the valve body assy.

D26438

5. (a)

REMOVE SHIFT SOLENOID VALVE DSL Remove the bolt and shift solenoid valve DSL from the valve body assy.

D26443

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6. (a)

REMOVE SHIFT SOLENOID VALVE SL2 Remove the bolt, solenoid lock plate No.2 and shift solenoid valve SL2 from the valve body assy.

C89113

7. (a)

REMOVE SHIFT SOLENOID VALVE SL1 Remove the bolt, solenoid lock plate and shift solenoid valve SL1 from the valve body assy.

C89115

8. (a) 9. (a)

REMOVE MANUAL VALVE Remove the manual valve from the valve body assy. INSTALL MANUAL VALVE Install the manual valve to the valve body assy. 10. (a) INSTALL SHIFT SOLENOID VALVE SL1 Install the shift solenoid valve SL1 and solenoid lock plate to the valve body assy with the bolt. Torque: 6.6 Nm (67 kgfcm, 58 in.lbf)

C89115

11. (a) 12. (a)

INSTALL LINE PRESSURE CONTROL SOLENOID ASSY Install the line pressure control solenoid assy to the valve body assy. INSTALL SHIFT SOLENOID VALVE SL3 Install the shift solenoid valve SL3 and solenoid lock plate No.3 to the valve body assy with the bolt. Torque: 6.6 Nm (67 kgfcm, 58 in.lbf)

C89112

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13. (a)

INSTALL SHIFT SOLENOID VALVE SL2 Install the shift solenoid valve SL2 and solenoid lock plate No.2 to the valve body assy with the bolt. Torque: 10.8 Nm (110 kgfcm, 8 ftlbf)

C89113

14. (a)

INSTALL SHIFT SOLENOID VALVE DSL Install the shift solenoid valve DSL to the valve body assy with the bolt. Torque: 10.8 Nm (110 kgfcm, 8 ftlbf)

D26443

15. (a)

INSTALL SHIFT SOLENOID VALVE SR Install the shift solenoid valve SR to the valve body assy.

D26438

16. (a)

INSTALL SHIFT SOLENOID VALVE S4 Install the shift solenoid valve S4 to the valve body assy with the bolt. Torque: 10.8 Nm (110 kgfcm, 8 ftlbf)

D26442

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4006K-04

OVERHAUL

Underdrive Planetary Gear

1. (a)

INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Using SST, fix the underdrive planetary gear assy. SST 09387-00050, 09495-65040

SST

G35975

(b)

SST
G35976

Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assy while rotating the torque wrench at 60 rpm. SST 09387-00050, 09495-65040 Turning torque at 60 rpm.: 0.28 to 0.89 Nm (2.9 to 9.1 kgfcm, 2.478 to 7.877 in.lbf)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.). 2. (a) REMOVE FRONT PLANETARY GEAR NUT Using SST, loosen the staked part of the gear nut. SST 09930- 00010 (09931- 00010, 09931- 00020), 09387-00050, 09495-65040

SST

D03686

Underdrive Planetary Gear

(b) Clamp the underdrive planetary gear in a soft jaw vise. NOTICE: Be careful not to damage the differential drive pinion.

G35977

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Underdrive Planetary Gear

(c)

Using a socket wrench, remove the gear nut.

G35978

3.
Hold Turn

(a)

SST

REMOVE CYLINDRICAL ROLLER BEARING RACE INNER Using SST, remove the cylindrical roller bearing race inner. SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00320), 09950-40011 (09957-04010)

D03689

4. (a)
SST

REMOVE UNDERDRIVE PLANETARY GEAR ASSY Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with the underdrive planetary ring gear and angular ball bearing inner race (front side). SST 09387- 00050, 09495- 65040, 09950- 60010 (09951-00320), 09950-70010 (09951-07100)

G35979

Turn Hold SST SST

G35980

(b) (c)

Clamp the underdrive planetary gear in a soft jaw vise. Using SST, remove the angular ball bearing inner race (rear side) from the underdrive planetary gear. SST 09950- 00020, 09950- 00030, 09950- 40011 (09957-04010), 09950-60010 (09951-00320)

5. (a)

REMOVE UNDERDRIVE PLANETARY RING GEAR Using snap ring pliers, remove the snap ring.

Snap Ring

G35981

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Underdrive Planetary Ring Gear

(b)

Remove the underdrive planetary ring gear from the counter driven gear.

Counter Driven Gear

G35982

6. (a)

INSTALL UNDERDRIVE PLANETARY RING GEAR Install a new snap ring to a new outer race of the angular ball bearing.

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

Snap Ring

D08112

(b)

Using a piston ring compressor, squeeze the snap ring.

D08113

(c)
SST SST

Using SST and a press, press in the outer race of the angular ball bearing. SST 09950- 60020 (09951- 00890), 09950- 70010 (09951-07100), NOTICE: Be sure not to damage the snap ring during outer race installation.
G35983

Underdrive Planetary Ring Gear

(d)

Install the underdrive planetary ring gear to the counter driven gear.

Counter Driven Gear

G35982

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(e)
Snap Ring

Using snap ring pliers, install the snap ring. SST 09950- 60020 (09951- 00890), 09950- 70010 (09951-07100), 99999-60012

G35984

SST

INSTALL UNDERDRIVE PLANETARY GEAR ASSY Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear. SST 09950- 60010 (09951- 00260), 09950- 70010 (09951-07100), 09726-40010 NOTICE: Press the bearing until it becomes flat at the bottom.
G35985

7. (a)

(b)

Install the counter driven gear with the planetary ring gear to the underdrive planetary gear.

G35986

(c)

SST

Using SST and a press, press in the angular ball bearing inner race (front side). SST 09950- 60010 (09951- 00260), 09950- 70010 (09951-07100), 09726-40010 NOTICE: Press the counter driven gear while rotating it.

G35987

SST

(d) Using a press, press in the parking lock gear. NOTICE: Press the counter driven gear while rotating it. SST 09950- 60010 (09951- 00260), 09950- 70010 (09951-07100), 09316-20011

G35988

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8. (a)
SST

INSTALL DIFFERENTIAL DRIVE PINION Using a press, press the differential drive pinion. SST 09726- 40010, 09950- 60010 (09951- 00260), 09950-70010 (09951-07100) NOTICE: Press the counter driven gear while rotating it.

Differential Drive Pinion

D26434

9.

SST

INSTALL CYLINDRICAL ROLLER BEARING RACE INNER (a) Using a press, press the cylindrical roller bearing race inner. NOTICE: Press the counter driven gear while rotating it. SST 09515- 21010, 09950- 60010 (09951- 00260), 09950-70010 (09951-07100)

G35989

Underdrive Planetary Gear

G35978

10. INSTALL FRONT PLANETARY GEAR 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 gear nut. Torque: 280 Nm (2,855 kgfcm, 207 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.). 11. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assy while rotating the torque wrench at 60 rpm. SST 09387-00050, 09495-65040 Turning torque at 60 rpm.: 0.28 to 0.89 Nm (2.9 to 9.1 kgfcm, 2.478 to 7.877 in.lbf)

Underdrive Planetary Gear

(a)

SST
G35976

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

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(b) Using a pin punch and hammer, stake the gear nut. NOTICE: Make sure that there are no cracks on the nut.

C56809

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400H3-03

OVERHAUL

1. INSPECT UNDERDRIVE PACK CLEARANCE (a) Install the underdrive clutch to the transaxle case. NOTICE: Be careful not to damage the oil seal rings. (b) Install a dial indicator as shown in the illustration. (c) Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/ cm2, 57 psi). Pack clearance: 1.42 to 1.71 mm (0.0559 to 0.0673 in.) If the pack clearance is not within specification, inspect the discs, plates and flange.

G35968

2.
Snap Ring

(a)

REMOVE UNDERDRIVE CLUTCH FLANGE NO.2 HOLE SNAP RING Using a screwdriver, remove the underdrive clutch flange No.2 hole snap ring.

D03701

3. (a)
Underdrive Clutch Drum

REMOVE UNDERDRIVE CLUTCH DISC NO.1 Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.

G35969

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4. (a) HINT:
S S
D04077

INSPECT UNDERDRIVE CLUTCH DISC NO.1 Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. If the lining of the discs comes off or discolors, or a groove is damaged, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.

5. (a)

INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing. Standard drum bushing: 32.56 to 32.58 mm (1.2818 to 1.2826 in.) Maximum drum bushing: 32.63 mm (1.2846 in.) If the inside diameter is greater than the maximum, replace the underdrive clutch drum.
D08129

6.
SST

Snap Ring
D03703

REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY (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: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.This prevents the spring sheet from being deformed. S Do not expand the snap ring excessively.

Clutch Balancer

(c)

Remove the clutch balancer from the underdrive clutch drum.

Underdrive Clutch Drum

C56359

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(d)

Remove the return spring from the underdrive clutch drum.

C56360

7. (a)

INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.14 mm (0.6748 in.)

D03824

8. REMOVE UNDERDRIVE CLUTCH PISTON SET (a) Install the underdrive clutch to the transaxle case. NOTICE: Be careful not to damage the oil seal rings. (b) 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.
D03705

9. (a)

REMOVE UNDERDRIVE CLUTCH DRUM O-RING Using a screwdriver, remove the O-ring from the underdrive clutch drum.

O-ring
D26465

10. (a)

INSTALL UNDERDRIVE CLUTCH DRUM O-RING Coat a new O-ring with ATF, and install it to the underdrive clutch drum. NOTICE: Ensure that the O-ring is not twisted or pinched.

O-ring
D26465

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11. (a)

INSTALL UNDERDRIVE CLUTCH PISTON SET Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum. NOTICE: S Be careful not to damage the O-ring. S Be careful not to damage the lip seal of the piston.

D03860

12. (a)
Underdrive Clutch Return Spring

INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Install the return spring to the underdrive clutch drum.

Underdrive Clutch Drum

C56360

Clutch Balancer

Underdrive Clutch Drum

C56359

(b) Coat the clutch balancer with ATF. (c) Install the clutch balancer to the underdrive clutch drum. NOTICE: S Be careful not to damage the lip seal of the clutch balancer. S When installing the return spring, ensure that all springs are fit in the clutch balancer correctly.

SST

(d)

D03703

Place SST on the clutch balancer and compress the piston return spring with a press. SST 09350-32014 (09351-32070) (e) Using a snap ring expander, install the snap ring to the underdrive clutch drum. NOTICE: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring grove.This prevents the spring sheet from being deformed. S Do not expand the snap ring excessively.

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(f)
Stopper Stopper

Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration. NOTICE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

Snap Ring
D25592

Disc Flange Plate

13. (a) (b)

INSTALL UNDERDRIVE CLUTCH DISC NO.1 Coat the 3 discs with ATF. Install the 3 plates, 3 discs and flange to the underdrive clutch drum. NOTICE: Be careful about the order of the discs, plates and flange.

G35970

14.
Snap Ring

Drum
D03701

INSTALL UNDERDRIVE CLUTCH FLANGE NO.2 HOLE SNAP RING (a) Using a screwdriver, install the underdrive clutch flange No.2 hole snap ring. NOTICE: The snap ring should be securely fixed in the groove of the drum.

15. INSPECT UNDERDRIVE PACK CLEARANCE (a) Install the underdrive clutch to the transaxle case. NOTICE: Be careful not to damage the oil seal ring. (b) Set a dial indicator as shown in the illustration. (c) Measure the underdrive clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Park clearance: 1.42 to 1.71 mm (0.0559 to 0.0673 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble. If the pack clearance is not within specification, select another flange.

G35968

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HINT: There are 7 types of flanges of different thickness. Flange thickness: mm (in.)
Mark K A B C Thickness 2.9 (0.114) 3.0 (0.118) 3.2 (0.126) 3.4 (0.134) Mark G H J Thickness 3.1 (0.122) 3.3 (0.130) 3.5 (0.138) -

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AUTOMATIC TRANSMISSION / TRANS SECOND BRAKE PISTON ASSY (U250E)
4006I-04

OVERHAUL

1.
SST

(a)

(b)

REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSY Place SST on the return spring and compress it with a press. SST 09387-00060 Using a screwdriver, remove the snap ring.

D26703

2nd Brake Piston Return Spring Sub-assy

(c)

Remove the 2nd brake piston return spring sub-assy.

D26704

2nd Brake Piston R eturn Spring

2. (a)

INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 16.61 mm (0.6539 in.)

C89124

3. (a)

REMOVE 2ND BRAKE PISTON 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.

D26705

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4. (a)

REMOVE 2ND BRAKE PISTON O-RING Remove the 2 O-rings from the 2nd brake piston.

O-ring

O-ring
D26706

5. (a)

O-ring

INSTALL 2ND BRAKE PISTON O-RING Coat 2 new O-rings with ATF, and install them in the 2nd brake piston. NOTICE: Ensure that the O-ring is not twisted or pinched.

O-ring
D26706

6. (a)

INSTALL 2ND BRAKE PISTON Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder. NOTICE: Be careful not to damage the O-rings.

D26775

2nd Brake Piston Return Spring Sub-assy

7.

INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSY (a) Install the 2nd brake piston return spring sub-assy. NOTICE: Ensure that all springs are fit in the piston correctly.

D26704

(b)
SST

D26703

Place SST on the piston return spring, and compress it with a press. SST 09387-00060 (c) Using a screwdriver, install the snap ring. NOTICE: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.This prevents the spring sheet from being deformed.

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AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U250E)
400H2-03

OVERHAUL

INSPECT PACK CLEARANCE OF DIRECT CLUTCH Install the intermediate shaft and needle roller bearing on the transaxle rear cover . NOTICE: Be careful not to damage the oil seal ring outers. (b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.) If the pack clearance is not within specification, inspect the discs, plates and flange.

1. (a)

G36009

2.

INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (a) Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.52 to 0.83 mm (0.02047 to 0.03268 in.) If the pack clearance is not within specification, inspect the discs, plates and flange.

G35971

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AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U250E)

3. (a)

REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC Using a screwdriver, remove the snap ring from the intermediate shaft.

Snap Ring

D26419

(b)

Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.

D26420

G35972

INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC (a) Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes. 5. REMOVE OVERDRIVE DIRECT CLUTCH DISC (a) Using a screwdriver, remove the snap ring from the intermediate shaft. (b) Remove the flange, 3 discs and 3 plates from the intermediate shaft.

4.

G35973

6. (a)

D26719

INSPECT OVERDRIVE DIRECT CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes.

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7.

SST

D03677

REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY (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: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.This prevents the spring sheet from being deformed. S Do not expand the snap ring excessively.

(c)
Overdrive Direct Clutch Drum Clutch Balancer

Remove the clutch balancer from the overdrive direct clutch drum.

D26424

Overdrive Direct Clutch Drum

Overdrive Clutch Return Spring Sub-assy

(d)

Remove the overdrive clutch return spring from the overdrive direct clutch drum.

D26423

8. (a)

INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 25.91 mm (1.0201 in.)

Overdrive Clutch Return Spring Sub-assy

D09211

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9. (a) (b)

REMOVE OVERDRIVE DIRECT CLUTCH PISTON Install the intermediate shaft on the transaxle rear cover. 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.

D26463

10. (a)

REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle rear cover to remove the direct clutch drum.

D26425

O-ring

11. (a)

REMOVE OVERDRIVE DIRECT CLUTCH O-RING Using a screwdriver, remove the O-ring from the direct clutch drum.

D26464

O-ring

12. (a)

INSTALL OVERDRIVE DIRECT CLUTCH O-RING Coat a new O-ring with ATF, and install it to the direct clutch drum. NOTICE: Ensure that the O-ring is not twisted or pinched.

D26464

Intermediate Shaft Sub-assy

Overdrive Direct Clutch Drum Sub-assy

13.

INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY (a) Coat the direct clutch drum with ATF, and install it to the intermediate shaft. NOTICE: S Be careful not to damage the O-ring. S Be careful not to damage the lip seal of the direct clutch drum.

D26462

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Overdrive Direct Clutch Piston

14. (a)

INSTALL OVERDRIVE DIRECT CLUTCH PISTON Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum sub-assy. NOTICE: Be careful not to damage the lip seal of the direct clutch piston.

D26461

Overdrive Clutch Return Spring Sub-assy

15.

INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY (a) Install the overdrive clutch return spring sub-assy to the overdrive direct clutch drum sub-assy. NOTICE: When installing the spring sub-assembly, ensure that all springs are fit in the piston correctly. (b) Coat the clutch balancer with ATF.
D26423

(c)
Overdrive Direct Clutch Drum Sub-assy Clutch Balancer

D26424

Install the clutch balancer to the overdrive direct clutch drum sub-assy. NOTICE: S Be careful not to damage the lip seal of the direct clutch balancer. S Ensure that the clutch balancer is not pinched and there are no other defects at the sealing lip. S Apply enough ATF to the sealing lip prior to installation. (d) Place SST on the clutch balancer and compress the piston return spring with a press. SST 09387-00020 (e) Using a snap ring expander, install the snap ring to the direct clutch drum. NOTICE: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring grove.This prevents the spring sheet from being deformed. S Do not expand the snap ring excessively.

SST

D03677

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Stopper

Stopper

(f)

Set the end gap of the snap ring in the piston shown in the illustration. NOTICE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

D25588

Flange Plate

16. (a) (b)

Disc

INSTALL OVERDRIVE DIRECT CLUTCH DISC Coat the 3 discs with ATF. Install the 3 plates, 3 discs and flange to the intermediate shaft. NOTICE: Be careful about the order of the discs, plates and flange.

G35974

(c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely fixed in the groove of the drum.
Snap Ring Drum
D26421

Flange Plate Cushion Plate

D26416

Disc

INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC (a) Coat the 3 discs with ATF. (b) Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft. NOTICE: S Install the cushion plate with the mark on the white surface facing the plate. S Be careful about the order of discs, plates and flange installation. (c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely fixed in the groove of the drum.

17.

Snap Ring Drum

D26419

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INSPECT PACK CLEARANCE OF DIRECT CLUTCH Install the intermediate shaft on the transaxle rear cover. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble. If the stroke is not within specification, select another flange. HINT: There are 8 types of flanges of different thickness. Flange thickness: mm (in.)
No. 0 1 2 3
G36009

18. (a) (b)

Thickness 2.9 (0.114) 3.0 (0.118) 3.1 (0.122) 3.2 (0.126)

No. 4 5 6 7

Thickness 3.3 (0.130) 3.4 (0.134) 3.5 (0.138) 3.6 (0.142)

INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH (a) Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.52 to 0.83 mm (0.02047 to 0.03268 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble. If the stroke is not within standard, select another flange. HINT: There are 7 types of flanges of different thickness. Flange thickness: mm (in.)
No. 0 1 2 3
G35971

19.

Thickness 2.5 (0.098) 2.6 (0.102) 2.7 (0.106) 2.8 (0.110)

No. 4 5 6 -

Thickness 2.9 (0.114) 3.0 (0.118) 3.1 (0.122) -

(b)

Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear. NOTICE: Do not place the rear planetary sun gear in a vise.

D26428

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AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U250E)
400H1-03

OVERHAUL

1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (a) Install the forward clutch on the oil pump. NOTICE: Be careful not to damage the oil seal ring of the oil pump. (b) Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 0.85 to 1.25 mm (0.0335 to 0.0492 in.) If the clearance is not within specification, inspect the discs, plates and flange. HINT: As the opening is large, cover it with a shop rag to prevent the compressed air from being released.

D26715

2. (a)

REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Using a screwdriver, remove the snap ring.

Snap Ring
D26753

(b)

Remove the flange, 5 discs and 5 plates from the input shaft assy.

D26754

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D09189

SST Snap Ring

D26418

INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC (a) Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes. 4. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSY (a) Place SST on the spring retainer and compress the return spring with a press. SST 09387-00020 (b) Using a snap ring expander, remove the snap ring. NOTICE: S Stop the press when the spring sheet is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deformed. S Do not expand the snap ring excessively.

3.

(c)
Clutch Balancer

Remove the clutch balancer from the input shaft.

Input Shaft

D26709

(d)

Remove the forward clutch return spring sub-assy from the input shaft sub-assy.

Forward Clutch Return Spring Sub-assy

Input Shaft Sub-assy

D26708

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5. (a)

INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.0528 in.)

Forward Clutch Return Spring Sub-assy

D09211

6. (a) (b)

REMOVE FORWARD CLUTCH PISTON SUB-ASSY Place the forward clutch drum onto the oil pump. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.

D03664

HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed down or remove the piston using needle nose pliers with the tip wrapped with vinyl tape. 7. REMOVE INPUT SHAFT OIL SEAL RING (a) Remove the input shaft oil seal ring from the input shaft.

C56374

8. (a)

D25587

INSTALL INPUT SHAFT OIL SEAL RING Compress a new input shaft oil seal ring from both sides to adjust dimension A. Dimension A: 5 mm (0.197 in.) (b) Coat the oil seal ring with ATF and install it to the input shaft. NOTICE: Do not expand the gap of the oil seal ring too much. Securely engage the hooks. 9. (a) INSTALL FORWARD CLUTCH PISTON SUB-ASSY Coat the forward clutch piston with ATF, and install it to the input shaft. NOTICE: Be careful not to damage the lip seal of the forward clutch piston.

Forward Clutch Piston

D26707

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10. (a)
Input Shaft Sub-assy

Forward Clutch Return Spring Sub-assy

(b)

INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSY Install the return spring sub-assy to the input shaft subassy. Coat the clutch balancer with ATF.

D26708

Clutch Balancer

Input Shaft Sub-assy

D26709

SST Snap Ring

D26418

(c) Install the clutch balancer to the input shaft. NOTICE: S Be careful not to damage the lip seal of the forward clutch balancer. S Ensure that the clutch balancer is not pinched and there are no other defects on it. S Apply enough ATF to the sealing lip prior to installation. S When installing the spring sub-assembly, ensure that all springs are fit in the clutch balancer correctly. (d) Place SST on the clutch balancer, and compress the clutch balancer with a press. SST 09387-00020 (e) Install the snap ring with a snap ring expander. (f) Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTICE: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.This prevents the spring sheet from being deformed. S Do not expand the snap ring excessively.

Stopper

Stopper

(g)

Set the end gap of the snap ring in the piston as shown in the illustration. NOTICE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

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AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U250E)

11.
Flange Disc Plate

INSTALL FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC (a) Coat the 5 discs with ATF. (b) Install the 5 plates, 5 discs and flange to the input shaft. NOTICE: Be careful about the order of the discs, plates and flange.

D26415

Drum

(c) (d)

Snap Ring

Using a screwdriver, install the snap ring. Check that the end gap of the snap ring is not aligned with any of the cutouts. NOTICE: The snap ring should be securely fixed in the groove of the drum.

D26753

INSPECT PACK CLEARANCE OF FORWARD CLUTCH Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgfcm2, 57 psi). Pack clearance: 0.85 to 1.25 mm (0.0335 to 0.0492 in.) If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble again. If the clearance is not within specification, select another flange. HINT: There are 7 types of flanges of different thickness. Flange thickness: mm (in.)
No. 0 1 2 3 Thickness 2.85 (0.1122) 3.00 (0.1181) 3.15 (0.1240) 3.30 (0.1299) No. 4 5 6 Thickness 3.45 (0.1358) 3.60 (0.1417) 3.75 (0.1476) -

12. (a)

D26715

13.

D03672

INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC (a) Temporarily install the multiple disc clutch clutch hub into the forward clutch. (b) Check if the discs rotate smoothly when rotating the forward clutch assy after inserting the multiple disc clutch into the multiple disc clutch clutch hub. NOTICE: Do not place the forward clutch assy in a vise.

U250E A/T REPAIR MANUAL (RM1123U)

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AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U250E)
4006F-04

OVERHAUL

1. (a)

INSPECT OIL PUMP ASSY Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip.

G35990

Clutch Drum Oil Seal Ring

2. (a)

REMOVE CLUTCH DRUM OIL SEAL RING Remove the 2 clutch drum oil seal rings.

D03650

3. (a) (b)

REMOVE STATOR SHAFT ASSY Using a torx socket (T30), remove the 11 bolts and stator shaft. Keep the gears in the order of installation.

D03651

Oil Pump Drive Gear

Oil Pump Driven Gear

4. (a) (b)

D09207

INSPECT CLEARANCE OF OIL PUMP ASSEMBLY Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: 0.10 to 0.17 mm (0.0039 to 0.0067 in.) Side clearance: 0.02 to 0.05 mm (0.001 to 0.002 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance is greater than the maximum, replace the oil pump body sub-assy.

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(c)

Using a feeler gauge, measure the tip clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.07 to 0.15 mm (0.0028 to 0.0059 in.) Maximum tip clearance: 0.15 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the oil pump body sub-assy.
D09208

(d)

Using a straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 to 0.05 mm (0.0008 to 0.0020 in.) Maximum side clearance: 0.05 mm (0.0020 in.) Drive gear thickness: mm (in.)
Mark A
D09209

Thickness 11.690 to 11.699 (0.4602 to 0.4606) 11.700 to 11.709 (0.4606 to 0.4610) 11.710 to 11.720 (0.4610 to 0.4614) 11.721 to 11.730 (0.4615 to 0.4618) 11.731 to 11.740 (0.4619 to 0.4622)

B C D E

Driven gear thickness: mm (in.)

Mark A B C D E Thickness 11.690 to 11.699 (0.4602 to 0.4606) 11.700 to 11.709 (0.4606 to 0.4610) 11.710 to 11.720 (0.4610 to 0.4614) 11.721 to 11.730 (0.4615 to 0.4618) 11.731 to 11.740 (0.4619 to 0.4622)

5. (a)

REMOVE FRONT OIL PUMP DRIVE GEAR Remove the front oil pump drive gear.

D09206

6. (a)

REMOVE FRONT OIL PUMP DRIVEN GEAR Remove the front oil pump driven gear.

G35991

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AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U250E)

O-ring

7. REMOVE FRONT OIL PUMP BODY O-RING (a) Using a screwdriver, remove the O-ring. HINT: Tape the screwdriver before use.

D25586

SST

8. (a) (b)

REMOVE FRONT OIL PUMP OIL SEAL Mount the oil pump in a soft jaw vise. Using SST, remove the oil seal from the oil pump body. SST 09308-00010

D03647

9. (a)

INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 38.113 to 38.138 mm (1.50051 to 1.50149 in.) Maximum inside diameter: 38.188 mm (1.50346 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assy.
D03648

10. (a)

INSPECT STATOR SHAFT ASSY Using a dial indicator, measure the inside diameter of the stator shaft. Standard inside diameter: 21.500 to 21.526 mm (0.84646 to 0.84748 in.) Maximum inside diameter: 21.57 mm (0.8492 in.) If the indicator diameter is greater than the maximum, replace the stator shaft.
D03653

11. (a)

INSTALL FRONT OIL PUMP OIL SEAL Using SST and a hammer, install a new oil seal to the oil pump body. SST 09350-32014 (09351-32140)

SST

HINT: The seal end should be level with the outer edge of the oil pump. (b) Coat the lip of the oil seal with MP grease.
D03654

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O-ring

12. (a)

INSTALL FRONT OIL PUMP BODY O-RING Coat a new O-ring with ATF, and install it to the oil pump body. NOTICE: Ensure that the O-ring is not twisted or pinched.

C55817

Oil Pump Driven Gear

Mark

13. (a)

INSTALL FRONT OIL PUMP DRIVEN GEAR Coat the front oil pump driven gear with ATF, and install it to the oil pump body with the marked side up.

G35991

Mark Oil Pump Drive Gear

14. (a)

INSTALL FRONT OIL PUMP DRIVE GEAR Coat the front oil pump drive gear with ATF, install it to the oil pump body with the marked side up.

D09206

15. (a) (b)

INSTALL STATOR SHAFT ASSY Set the stator shaft aligned with each bolt hole. Using a torx socket (T30), install the 11 bolts. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)

D03651

Clutch Drum Oil Seal Ring

16. INSTALL CLUTCH DRUM OIL SEAL RING (a) Coat the 2 new clutch drum oil seal rings with ATF. (b) Install the 2 new clutch drum oil seal rings. NOTICE: Do not expand the ring ends excessively.

D26627

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17. (a)

INSPECT OIL PUMP ASSY Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip.

G35990

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AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)
401FJ-01

OVERHAUL

1. (a)

REMOVE PARK/NEUTRAL POSITION SWITCH ASSY Remove the nut, washer and control shaft lever.

Control Shaft Lever

D09644

(b)

Using a screwdriver, unstake the nut stopper, and remove the lock nut and nut stopper.

Lock Nut Nut Stopper

D09643

Park/Neutral Position Switch Assy

(c)

Remove the 2 bolts and pull out the park/neutral position switch assy.

D09639

2. (a)

REMOVE BREATHER PLUG NO.2 (ATM) Remove the breather plug No.2 (ATM) from the transaxle case.

G35583

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AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

(b)
Hose Breather Plug No.2 (ATM) O-ring
G35584

Remove the hose and O-ring from the breather plug No.2 (ATM).

Oil Cooler Tube Union (Inlet Oil Cooler Union)

3. (a) (b)

O-ring

REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Remove the oil cooler tube union (inlet oil cooler union). Remove the O-ring from the oil cooler tube union (inlet oil cooler union).

C83143

Oil Cooler Tube Union (Outlet Oil Cooler Union)

4. (a) (b)

REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Remove the oil cooler tube union (outlet oil cooler union). Remove the O-ring from the oil cooler tube union (outlet oil cooler union).

O-ring
C83144

5. (a)
Speed Sensor

REMOVE SPEED SENSOR Remove the 2 bolts and the 2 speed sensors from the transaxle assy.

D03900

D30672

6. (a) (b)

REMOVE TRANSAXLE CASE NO.1 PLUG Remove the 4 transaxle case No.1 plugs from the transaxle case. Remove the 4 O-rings from the 4 transaxle case No.1 plugs.

G35585

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7. (a)

FIX AUTOMATIC TRANSAXLE ASSY Fix the transaxle assy.

G35586

8. (a) (b)

REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Remove the drain plug and drain plug gasket from the automatic transaxle oil pan sub-assy. Remove the 18 bolts, automatic transaxle oil pan subassy and gasket.

C91925

(c)
Magnet

Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assy.

G35609

Magnet

9. (a)

INSPECT TRANSMISSION OIL CLEANER MAGNET Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle: Steel (magnetic).... bearing, gear and plate wear Brass (non-magnetic).... bushing wear

AT0103

10. (a) (b)

DISCONNECT TRANSMISSION WIRE Disconnect the 7 connectors from the shift solenoid valves. Remove the bolt, lock plate and ATF temperature sensor.

Temperature Sensor
G35587

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Transmission Wire

11. (a)

REMOVE TRANSMISSION WIRE Remove the bolt and transmission wire from the transaxle case.

D03547

12. (a)

REMOVE VALVE BODY OIL STRAINER ASSY Remove the 3 bolts and valve body oil strainer assy.

G35588

(b)

Remove the O-ring from the valve body oil strainer assy.

O-ring

C91932

13. (a)

REMOVE TRANSMISSION VALVE BODY ASSY Support the valve body assy and remove the 17 bolts and transmission valve body assy.

C91933

14. (a)

REMOVE GOVERNOR APPLY GASKET NO.1 Remove the governor apply gasket No.1 from the transaxle case.

C83127

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15. (a)

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

C83128

16. (a)

REMOVE BRAKE DRUM GASKET Remove the brake drum gasket from the transaxle case.

C83129

17. (a)

REMOVE CHECK BALL BODY Remove the check ball body and spring from the transaxle case.

Check Ball
D03554

18. (a)

REMOVE C-3 ACCUMULATOR PISTON Remove the spring from the C-3 accumulator piston.

D03555

(b)

Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.

G35589

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(c)
O-ring C-3 Accumulator Piston

Remove the O-ring from the C-3 accumulator piston.

G35590

D26401

REMOVE REVERSE CLUTCH ACCUMULATOR PISTON (a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the reverse accumulator piston and spring. NOTICE: S Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a waste . S Take care not to splash ATF when air-blowing. (b) Remove the 2 O-rings from the reverse clutch accumulator piston.

19.

Reverse Clutch Accumulator Piston

O-ring O-ring
D26402

REMOVE B-3 ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs. NOTICE: S Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a waste . S Take care not to splash ATF when air-blowing.
D03558

20. (a)

(b)
O-ring

Remove the O-ring from the B-3 accumulator piston.

B-3 Accumulator Piston

D03904

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21. (a)

REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING Using needle-nose pliers, remove the manual valve lever shaft retainer spring.

D03559

22. (a)

REMOVE MANUAL DETENT SPRING SUB-ASSY Remove the 2 bolts and manual detent spring sub-assy.

D03560

23. (a)

REMOVE PARKING LOCK PAWL BRACKET Remove the 2 bolts and parking lock pawl bracket.

C56727

24. (a)

REMOVE MANUAL VALVE LEVER SUB-ASSY Using a screwdriver, slide the spacer.

Spacer
G35591

(b)

Using a pin punch (35 mm) and hammer, drive out the pin.

HINT: Slowly drive out the pin so that it will not fall into the transaxle case.

G35592

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AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U250E)

(c)

Remove the manual valve lever shaft, manual valve lever and spacer.

G35593

25. (a)

REMOVE PARKING LOCK ROD SUB-ASSY Remove the parking lock rod sub-assy from the manual valve lever sub-assy.

HINT: Align the dial with the notches on the manual valve lever subassy to remove the parking lock rod sub-assy.

Parking Lock Rod Sub-assy

G35594

26. (a)

REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case.

D03566

27. (a)

FIX AUTOMATIC TRANSAXLE ASSY Fix the transaxle case with the oil pump side facing up.

28. (a)

INSPECT INPUT SHAFT ENDPLAY Using a dial indicator, measure the input shaft end play. End play: 0.262 to 1.249 mm (0.0103 to 0.0492 in.)

Oil Pump Assy

D08046

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29. (a) (b)

REMOVE TRANSAXLE HOUSING Remove the 16 bolts. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. NOTICE: The differential may be accidentally removed when the transaxle housing is removed.
D33498

Oil Pump Assy

30. (a)

REMOVE OIL PUMP ASSY Remove the 7 bolts and oil pump assy from the transaxle case.

D03569

Thrust Needle Roller Bearing Differential Gear Assy Forward Clutch Assy

31. (a)

REMOVE THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing from the underdrive planetary gear assy.

Underdrive Planetary Gear Assy

D25505

Thrust Bearing Underdrive Race No.2 Differential Gear Assy Forward Clutch Assy

32. (a)

REMOVE THRUST BEARING UNDERDRIVE RACE NO.2 Remove the thrust bearing underdrive race No.2 from the underdrive planetary gear assy.

Underdrive Planetary Gear Assy

D25506

Differential Gear Assy

33. (a)

REMOVE DIFFERENTIAL GEAR ASSY Remove the differential gear assy from the transaxle case.

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34. (a)

REMOVE OVERDRIVE BRAKE GASKET Remove the 2 overdrive brake gaskets from the transaxle case.

D03573

Forward Clutch Assy

35. (a)

REMOVE FORWARD CLUTCH ASSY Remove the forward clutch assy from the transaxle case.

D03574

Thrust Needle Roller Bearing

(b)

Remove the thrust needle roller bearing from the forward clutch.

D03906

Multiple Disc Clutch Clutch Hub Thrust Bearing Race No.1

Thrust Needle Roller Bearing Thrust Needle Roller Bearing

36. (a)

REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB Remove the thrust needle roller bearing, multiple disc clutch clutch hub, thrust needle roller bearing and thrust bearing race No.1 from the transaxle case.

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Dial Indicator

37. (a)

Multiple Disc Clutch Clutch Hub

D03829

INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB Using a dial indicator, measure the inside diameter of the multiple disc clutch clutch hub bushing. Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) NOTICE: S If the inside diameter is greater than the maximum, replace the multiple disc clutch clutch hub with a new one. S Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolortion is identified, replace the direct clutch sub-assy with a new one. 38. (a) REMOVE UNDERDRIVE PLANETARY GEAR ASSY Remove the bolt and pawl shaft clamp from the transaxle case.

Pawl Shaft Clamp

D03576

(b)

Remove the parking lock pawl shaft from the transaxle case.

D09652

(c) Push the parking lock pawl. HINT: Failure to do so will cause interference when the underdrive planetary gear is removed.

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Underdrive Planetary Gear Assy

(d)

Remove the underdrive planetary gear assy from the transaxle case. NOTICE: Be careful so that the underdrive planetary gear assy will not fall out.

D03579

39. (a)

REMOVE PARKING LOCK PAWL Remove the spring, pawl pin and parking lock pawl.

D26386

40. (a)
Thrust Needle Roller Bearing Thrust Bearing Race

REMOVE UNDERDRIVE CLUTCH ASSY Remove the underdrive clutch assy, thrust needle roller bearing and thrust bearing race from the transaxle case.

D33499

41. (a)

REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY Using a screwdriver, remove the snap ring from the transaxle case.

Snap Ring

D03581

(b)

Remove the underdrive 1-way clutch assy from the transaxle case.

Underdrive 1-W ay Clutch Assy

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(c)

Remove the outer race retainer from the 1-way clutch assy.

Outer Race Retainer

D03907

Snap Ring

42. (a)

REMOVE UNDERDRIVE CLUTCH DISC NO.2 Using a screwdriver, remove the snap ring.

D26466

(b)
Flange

Remove the flange, 3 discs and 3 plates from the transaxle case.

D33500

43. (a)

D09196

INSPECT UNDERDRIVE CLUTCH DISC NO.2 Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes. 44. (a) (b) REMOVE TRANSAXLE REAR COVER SUB-ASSY Remove the 11 bolts. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover sub-assy from the transaxle case.

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45. (a) (b)

REMOVE TRANSAXLE CASE NO.1 PLUG Remove the 4 transaxle case No.1 plugs from the transaxle rear cover. Remove the 4 O-rings from the 4 transaxle case No.1 plugs.

G35596

Rear Clutch Oil Seal Ring Outer

46. (a)

REMOVE REAR CLUTCH OIL SEAL RING OUTER Remove the 3 rear clutch oil seal ring outers from the transaxle rear cover.

G38041

47. (a)

SST

REMOVE NEEDLE ROLLER BEARING Using SST, remove the needle-roller bearing from the transaxle rear cover. SST 09387- 00041 (09387- 01021, 09387- 01030, 09387-01040)

D26472

48. (a)

REMOVE GOVERNOR APPLY GASKET NO.1 Using a screwdriver, remove the 3 apply gaskets.

D26390

Brake Apply Tube

49. (a) (b) (c)

REMOVE BRAKE APPLY TUBE Remove the bolt and clamp. Remove the clutch apply tube. Remove the brake apply tube.

Clutch Apply Tube

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Thrust Bearing

50. (a)

REMOVE DIRECT CLUTCH ASSY Remove the thrust bearing and the direct clutch assy from the transaxle case.

Direct Clutch Assy

D26403

Overdrive Direct Clutch Hub Sub-Assy Thrust Bearing

51. (a)

REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub sub-assy from the rear planetary sun gear assy.

Thrust Bearing Race

D26392

52.
Dial Indicator

Overdrive Direct Clutch Drum Sub-assy

D03829

INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY (a) Using a dial indicator, measure the inside diameter of the overdrive direct clutch drum sub-assy bushing. Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) NOTICE: S If the inside diameter is greater than the maximum, replace the overdrive direct clutch drum sub-assy with a new one. S Check the contact surface of the bush in the direct clutch shaft. If any scratch or discoloration is identified, replace the overdrive direct clutch drum subassy with a new one. 53. REMOVE REAR PLANETARY SUN GEAR ASSY (a) Remove the rear planetary sun gear assy from the transaxle case.

Rear Planetary Sun Gear Assy

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Thrust Needle Roller Bearing

(b)

Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assy.

D26404

Thrust Bearing Race

G37997

Planetary Carrier Thrust Washer No.2

(c)

Remove the planetary carrier thrust washer No.2 from the rear planetary sun gear assy.

Rear Planetary Sun Gear Assy

D26393

Thrust Needle Roller Bearing

54. (a)

REMOVE 1 WAY CLUTCH ASSY Remove the 1-way clutch assy and the thrust needle roller bearing from the transaxle case.

1-W ay Clutch Assy

D26598

1-W ay Clutch Inner Race

(b)

Remove the 1-way clutch inner race from the 1-way clutch assy.

D03909

1-W ay Clutch Sleeve Outer

55. (a)

REMOVE 1WAY CLUTCH SLEEVE OUTER Remove the 1-way clutch sleeve outer from the transaxle case.

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Planetary Carrier Thrust Washer No.1

56. (a)

REMOVE PLANETARY CARRIER THRUST WASHER NO.1 Remove the planetary carrier thrust washer No.1 from the planetary gear assy.

G38042

Snap Ring

57. (a) (b)

REMOVE 2ND BRAKE DISC Using a screwdriver, remove the snap ring. Remove the flange, 3 discs and 3 plates from the transaxle case.

D33501

58. (a)

D26717

INSPECT 2ND BRAKE DISC Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes. 59. (a) REMOVE SECOND BRAKE PISTON ASSY Using a screwdriver, remove the snap ring.

Snap Ring
D08058

(b)

Remove the second brake piston assy from the transaxle case.

Second Brake Piston Assy

U250E A/T REPAIR MANUAL (RM1123U)

D26396

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60. (a)
Snap Ring

REMOVE REAR PLANETARY GEAR ASSY Using a screwdriver, remove the snap ring.

D03616

Rear Planetary Gear Assy

(b)

Remove the rear planetary gear assy from the transaxle case.

D26591

Thrust Bearing Race No.2

Input Sun Gear

61. (a)

REMOVE INPUT SUN GEAR Remove the input sun gear, 2 thrust needle roller bearings, 2 thrust bearing race No.2 and thrust bearing race No.3 from the transaxle case.

Thrust Needle Roller Bearing Thrust Bearing Race No.3

G35597

62. (a)

REMOVE 1ST & REVERSE BRAKE DISC Remove the flange, 5 discs and 5 plates from the transaxle case.

D33502

63. (a)

D09189

INSPECT 1ST & REVERSE BRAKE DISC Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. NOTICE: S If the lining of a disc comes off or discolors, or a groove is damaged, replace all discs. S Before assembling new discs, soak them in ATF for at least 15 minutes.

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Lock Washer

64. REMOVE FRONT PLANETARY GEAR ASSY (a) Using a chisel and hammer, unstake the lock washer. NOTICE: Bend down all claws of the washer. Otherwise SST cannot be fully pressed against the nut to loosen it.

D03595

(b)
SST

Using SST, remove the nut and lock washer. SST 09387-00030, 09387-00080

D03596

(c)

SST

Using SST and a press, remove the front planetary gear assy from the counter drive gear. SST 09950- 60010 (09951- 00450), 09950- 70010 (09951-07100)

D26398

(d)

Remove the front planetary gear assy from the brake hub.

Front Planetary Gear Assy Brake Hub

D26763

Front Planetary Ring Gear Snap Ring

65. (a)

REMOVE FRONT PLANETARY RING GEAR Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.

Brake Hub
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66.
SST

D03600

REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY (a) Place SST on the return spring, and compress the return spring with a press. SST 09387-00070 (b) Using a snap ring expander, remove the snap ring. NOTICE: S Stop the press when the spring sheet is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring sheet from being deformed. S Do not expand the snap ring excessively.

1st & Reverse Brake Return Spring

67. (a)

INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.63 mm (0.6941 in.)

17.63 mm (0.6941 in.)

G37999

1st & Reverse Brake Piston

REMOVE 1ST & REVERSE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the 1st & reverse brake piston. NOTICE: S Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a waste . S Take care not to splash ATF when air-blowing.
D26405

68. (a)

(b)

Remove the 2 O-rings from the 1st & reverse brake piston.

O-ring

O-ring

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SST SST

69. (a)

REMOVE COUNTER DRIVE GEAR Using SST and a press, remove the counter drive gear from the transaxle case.

G35601

(b)

As shown in the illustration, tighten the 2 bolts evenly and leave a clearance of approx. 20.0 mm (0.797 in.) between the counter drive gear and the inner race.

D03602

(c)

Using SST, remove the bearing inner race (front side). SST 09950- 60010 (09951- 00590), 09950- 00020, 09950-00030

SST

G35602

70. (a)

REMOVE COUNTER DRIVE ANGULAR BALL BEARING Remove the bearing inner race (rear side) and angular ball (rear side).

G35603

(b)
SST

Using SST, remove the bearing outer race (rear side) from the transaxle case. SST 09308-00010

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(c)

Remove the angular ball (front side).

G35605

(d)
SST SST

Using SST and a press, remove the bearing outer race (front side) from the transaxle case. SST 09950- 70010 (09951- 07200), 09950- 60020 (09951-00810)

G35606

(e)

Using a screwdriver, remove the snap ring from the transaxle case.

G35607

71.

SST

Snap Ring
D26407

REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY (a) Place SST on the return spring, and compress the return spring with a press. SST 09387-00020 (b) Using a snap ring expander, remove the snap ring. NOTICE: S Stop the press when the spring sheet is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring sheet from being deformed. S Do not expand the snap ring excessively.

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72. (a)

INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 13.24 mm (0.5213 in.)

Underdrive Brake Return Spring 13.24 mm (0.5213 in.)

G38000

Underdrive Brake Piston

73. (a)

REMOVE UNDERDRIVE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive brake piston.

D26406

(b)

Remove the 2 O-rings from the underdrive brake piston.

O-ring

O-ring

D03794

Hold

SST

74. (a)

REMOVE NEEDLE ROLLER BEARING Using SST, remove the needle-roller bearing from the transaxle case. SST 09387- 00041 (09387- 01010, 09387- 01030, 09387-01040)

Turn

D03605

75. (a)
Underdrive Clutch Drum Oil Seal Ring

REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING Remove the 2 oil seal rings from the transaxle case.

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76. (a) (b)

REMOVE TRANSAXLE CASE NO.1 PLUG Remove the 2 transaxle case No.1 plugs. Remove the 2 O-rings from the 2 transaxle case No.1 plugs.

G35608

77.
Hold Turn

(a)

REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING Using SST, remove the underdrive cylindrical roller bearing from the transaxle case. SST 09950- 50013 (09951- 05010, 09953- 05020), 09950- 40011 (09952- 04010, 09954- 04010, 09955-04061, 09957-04010), 09820-00031

SST

G35711

Underdrive Output Shaft Oil Seal Ring

78. (a)

REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Remove the underdrive output shaft oil seal ring from the transaxle housing.

D03915

Transaxle Apply Tube Clamp

Differential Gear Lube Apply Tube

79. (a)

REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.

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80.

BEARING POSITION
B

E D

I H
G35582

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40-30
AUTOMATIC TRANSMISSION / TRANS Front Race Diameter Inside / Outside mm (in.) 34.5 (1.3583) / 56.82 (2.2370) 40.3 (1.5866) / 58.0 (2.2835) 33.1 (1.3031) / 45.4 (1.7874) AUTOMATIC TRANSAXLE ASSY (U250E) Rear Race Diameter Inside / Outside mm (in.) 52.1 (2.0512) / 75.5 (2.9724) 29.9 (1.1772) / 55.5 (2.1850) 34.5 (1.3583) / 48.5 (1.9094) 38.6 (1.5197) / 58.0 (2.2835) 23.6 (0.9291) / 36.6 (1.4409) -

Mark

Thrust Bearing Diameter Inside / Outside mm (in.) 53.0 (2.0866) / 78.2 (3.0787) 37.73 (1.4854) / 58.0 (2.2835) 33.85 (1.3327) / 52.2 (2.0551) 23.5 (0.9252) / 44.0 (1.7323) 36.3 (1.4291) / 52.2 (2.0551) 32.4 (1.2756) / 56.62 (2.2291) 38.6 (1.5197) / 60.0 (2.3622) 53.6 (2.1102) / 69.6 (2.7402) 31.85 (1.2539) / 45.2 (1.7795) 25.0 (0.9843) / 39.5 (1.5551) 55.9 (2.2008) / 76 (2.9921) or 76.6 (3.0157)

A B C D E F G H I J K

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Transaxle Apply Tube Clamp

Stopper

INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE Install the differential gear lube apply tube and transaxle apply tube clamp with the bolt to the transaxle housing. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf) NOTICE: Make sure to insert the pipe to the stopper.

81. (a)

Differential Gear Lube Apply Tube

G36619

82. (a) (b)

INSTALL TRANSAXLE CASE NO.1 PLUG Install 2 new O-rings to the 2 transaxle case No.1 plugs. Install the 2 transaxle case No.1 plugs to the transaxle housing. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)

D26383

ATF

83. (a)
Underdrive Output Shaft Oil Seal Ring

INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Coat a new oil seal ring with ATF and install it to the transaxle housing.

D03915

84.
SST

D03807

INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING (a) Coat the underdrive cylindrical roller bearing with ATF. (b) Using SST and a press, install the underdrive cylindrical roller bearing. NOTICE: Do not apply excessive pressure to the bearing. SST 09950- 60020 (09951- 00780), 09950- 70010 (09951-07100) 85. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING (a) Coat 2 new underdrive clutch drum oil seal rings with ATF, and install them to the transaxle rear cover. NOTICE: S Do not overly expand the gap of the oil seal ring. S Engage the hooks securely. Confirm the smooth rotation.

ATF Hook Underdrive Clutch Drum Oil Seal Ring

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5.0 mm (0.197 in.)

Vinyl Tape

86. (a)

SST 4.0 mm (0.157 in.)

D03809

INSTALL NEEDLE ROLLER BEARING Wind vinyl tape around SST at the point 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape becomes about 5.0 mm (0.197 in.). NOTICE: Clean SST to remove oil before winding vinyl tape. (b) Coat a new needle roller bearing with ATF.

(c)
SST

Vinyl Tape

Using SST and a press, install the needle roller bearing to the transaxle case. SST 09950- 60010 (09951- 00320), 09950- 70010 (09951-07100) NOTICE: When the wound vinyl tape come into contact with the transaxle case, stop press-fitting.
D03810

87. (a)
O-ring

O-ring

INSTALL UNDERDRIVE BRAKE PISTON Coat 2 new O-rings with ATF, and install them to the underdrive brake piston. NOTICE: S Ensure that the O-rings are not twisted or pinched. S Apply enough ATF to the O-rings prior to installation. (b) Coat the underdrive brake piston with ATF.

D03794

Underdrive Brake Piston

(c) Install the underdrive brake piston to the transaxle case. NOTICE: Be careful not to damage the O-rings.

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SST

88.

Snap Ring

D26407

INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY (a) Place SST on the underdrive clutch return spring subassy and compress the underdrive clutch return spring sub-assy with a press. SST 09387-00020 (b) Using a snap ring expander, install the snap ring to the transaxle case. NOTICE: S Stop the press when the spring sheet is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring sheet from being deformed. S Do not expand the snap ring excessively. S When installing the spring sub-assembly, ensure that all springs are fit in the piston correctly. S The snap ring should be securely fixed in the groove of the transaxle case.

89. (a)

INSTALL COUNTER DRIVE ANGULAR BALL BEARING Install the snap ring to the transaxle case.

G35712

(b)

SST

Using SST and a press, install the bearing outer race (rear side) to the transaxle case. SST 09316- 12010, 09950- 60020 (09951- 00810), 09950-70010 (09951-07150) NOTICE: S Ensure that the snap ring is securely installed. S Do not apply excessive pressure to the bearing outer race.

G35713

SST

(c)

Using SST and press, install the bearing outer race (front side) to the transaxle case. SST 09316- 12010, 09950- 60020 (09951- 00810), 09950- 70010 (09951- 07150), 09523- 36010, 09502-24010

SST
G35714

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NOTICE: S Do not apply excessive pressure to the bearing outer race. S Install the bearing outer race with a press while holding the bearing outer race with SST (09502-24010, 09523-36010). (d) Install the 2 angular balls to the transaxle case.

90. (a) (b)

SST

INSTALL COUNTER DRIVE GEAR Coat the counter drive gear with ATF. Using SST and a press, install the bearing inner race (front side) to the counter drive gear. SST 09950-70010 (09951-07150), 09649-17010 NOTICE: Do not apply excessive pressure to the bearing inner race.
G35715

(c)

SST Counter Drive Gear Bearing

Using SST and a press, install the counter drive gear and bearing inner race (rear side) to the transaxle case. NOTICE: Do not apply excessive pressure to them. SST 09223- 15030, 09527- 17011, 09950- 60020 (09951-00720), 09950-70010 (09951-07150)

SST

G35717

O-ring O-ring

91. INSTALL 1ST & REVERSE BRAKE PISTON (a) Coat 2 new O-rings with ATF. (b) Install the 2 O-rings to the 1st & reverse brake piston. NOTICE: S Ensure that the O-rings are not twisted or pinched. S Apply enough ATF to the O-rings prior to installation.

D26713

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(c)
1st & Reverse Brake Piston

Coat the 1st & reverse brake piston with ATF, and install it to the transaxle case. NOTICE: Be careful not to damage the O-rings.

D26593

SST

D03600

Front Planetary Ring Gear

INSTALL 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY (a) Place SST on the 1st & reverse brake return spring subassy and compress the 1st & reverse brake return spring sub-assy with a press. SST 09387-00070 (b) Using a snap ring expander, install the snap ring to the transaxle case. NOTICE: S Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deformed. S Do not expand the snap ring excessively. S When installing the spring sub-assembly, ensure that all springs are fit in the piston correctly. S The snap ring should be securely fixed in the groove of the cylinder. S Fix the snap ring to the inside of the spring seat claw securely. 93. INSTALL FRONT PLANETARY RING GEAR (a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. NOTICE: Confirm the snap ring is fixed in the groove of the brake hub correctly.

92.

Brake Hub Snap Ring

D03615

94. (a)
Front Planetary Gear Assy Brake Hub

INSTALL FRONT PLANETARY GEAR ASSY Install the front planetary gear assy to the brake hub.

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(b)
SST

SST

Brake Hub w/ Front Planetary Gear Assy

Using SST and a press, press-fit the front planetary gear assy. SST 09950- 60010 (09951- 00500), 09950- 70010 (09951-07100) NOTICE: S Do not apply excessive pressure to the front planetary gear assy. S Press the front planetary gear assembly until it just comes into contact with the angular ball bearings (front and rear sides).

Counter Drive Gear

Transaxle Case
G36065

Washer

(c)

Install a new washer, as shown in the illustration.

D03917

(d)
SST

Using SST, install the nut. SST 09387-00030, 09387-00080 Torque: 185 Nm (1,886 kgfcm, 136 ftlbf) NOTICE: Install the washer after pressing each part, then tighten the nut to the minimum tightening torque.

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(e)

SST

D03918

Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified range, gradually tighten the nut until it falls within the specified range. SST 09387-00080 Torque: 350 Nm (3,569 kgfcm, 258 ftlbf) (a limit) Turning torque at 60 rpm: 0.19 to 0.4 Nm (1.9 to 4.1 kgfcm, 1.7 to 3.5 in.lbf)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.) to measure the turning torque.

(f)

Using a chisel and hammer, stake the washer.

G36573

E D

B A

Input Sun Gear

G35597

INSTALL INPUT SUN GEAR Coat the 2 thrust bearings with ATF. Install the input sun gear, thrust needle roller bearings, 2 thrust bearing race No.2 and thrust bearing race No.3 to the transaxle case. NOTICE: S Ensure that the parts are installed in the correct order and direction. Thrust bearing and bearing race diameter: mm (in.)
inside Bearing Race, A Thrust Bearing, B Bearing Race, C Thrust Bearing, D Bearing Race, E 34.5 (1.3583) 32.4 (1.2756) 40.3 (1.5866) 38.6 (1.5197) 38.6 (1.5197) outside 56.82 (2.2370) 56.62 (2.2291) 58.0 (2.2835) 60.0 (2.3622) 58.0 (2.2835)

95. (a) (b)

96. (a)

INSTALL REAR PLANETARY GEAR ASSY Install the rear planetary gear assy to the brake hub.

Rear Planetary Gear Assy

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Snap Ring

(b) Using a screwdriver, install the snap ring. NOTICE: Confirm the snap ring is fixed in the groove of the brake hub correctly.

D03616

Disc

Plate

97. INSTALL 1ST & REVERSE BRAKE DISC (a) Coat the 5 discs with ATF. (b) Install the 5 plates and 5 discs. NOTICE: Be careful about the order of the discs, and plates.

G35716

98. (a)
A

(b)

D33503

INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE Using vernier calipers, measure the distance between the disc surface and the contact surface of the second brake cylinder and transaxle case (Dimension A). Select an appropriate flange so that the pack clearance will meet the specified values. Pack clearance: 0.745 to 1.21 mm (0.0293 to 0.0476 in.)

HINT: Pack clearance = Dimension A - Flange thickness Flange thickness: mm (in.)

Mark 1 2 3 4 Thickness 1.8 (0.071) 1.9 (0.075) 2.0 (0.079) 2.1 (0.083) Mark 5 6 7 8 Thickness 2.2 (0.087) 2.3 (0.091) 2.4 (0.094) 2.5 (0.098)

(c)

Install the flange.

D03815

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99. (a)

INSTALL SECOND BRAKE PISTON ASSY Install the second brake piston assy to the transaxle case.

Second Brake Piston Assy

D26396

Snap Ring
D08058

Install the snap ring and measure the snap ring inside diameter. Inside diameter: More than 167 mm (6.57 in.) NOTICE: S Install the tapered snap ring in the correct direction. S When the diameter does not meet the specified values, replace the snap ring with a new one. S After assembling, confirm that there is no clearance between the second brake cylinder and the fitting surface of the cylinder in the transaxle case. 100. INSTALL 1WAY CLUTCH SLEEVE OUTER (a) Install the 1-way clutch sleeve outer to the second brake cylinder assy. NOTICE: Check the direction of the sleeve outer.

(b)

1-W ay Clutch Sleeve Outer Planetary Carrier Thrust Washer No.1

C92977

101. INSTALL PLANETARY CARRIER THRUST WASHER NO.1 (a) Coat the planetary carrier thrust washer No.1 with ATF, and install it onto the rear planetary gear assy. NOTICE: After installation, confirm that the projection is securely fitted in the hole of the rear planetary gear assembly.
G38042

1-W ay Clutch Inner Race

102. INSTALL 1 WAY CLUTCH ASSY (a) Install the 1-way clutch inner race to the 1-way clutch. NOTICE: S Check the direction of the inner race. S Confirm that the identification mark can be seen.

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(b)

Check the rotating direction of the 1-way clutch inner race for lock or free operation, as shown in the illustration.

Free

Lock

G36572

Thrust Needle Roller Bearing

(c)

Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer. Bearing diameter: mm (in.)
Inside Bearing 53.6 (2.1102) Outside 69.6 (2.7402)

NOTICE: Install the thrust bearing properly so that no colored race will be visible.
1-W ay Clutch Assy Planetary Carrier Thrust Washer No.2
D03588

103. INSTALL REAR PLANETARY SUN GEAR ASSY (a) Coat the planetary carrier thrust washer No.2 with ATF, and install it onto the rear planetary sun gear assy.

Rear Planetary Sun Gear Assy

D26393

(b)
A

Coat the thrust needle roller bearing with ATF. Install the thrust bearing race and needle roller bearing onto the rear planetary sun gear. Bearing diameter: mm (in.)
Inside Race, A Bearing, B 33.1 (1.3031) 31.85 (1.2539) Outside 45.4 (1.7874) 45.2 (1.7795)

D26404

G37997

(c)

Install the rear planetary sun gear assy to the rear planetary gear. NOTICE: When installing the rear planetary sun gear assembly, confirm that the discs engage.

Rear Planetary Sun Gear Assy

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104. (a) (b) (c)

Disc Plate

INSTALL 2ND BRAKE DISC Coat the 3 discs with ATF. Install the 3 discs and 3 plates to the transaxle case. Temporarily install the snap ring.

G35719

G35720

105. INSPECT PACK CLEARANCE OF SECOND BRAKE (a) Using vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B). (b) Select an appropriate flange so that the pack clearance will meet the specified values. Pack clearance: 0.53 to 0.91 mm (0.0209 to 0.0358 in.) HINT: Pack clearance = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.) Flange thickness: mm (in.)
Mark 0 1 2 3 4 Thickness 2.9 (0.114) 3.0 (0.118) 3.1 (0.122) 3.2 (0.126) 3.3 (0.130) Mark 5 6 7 8 Thickness 3.4 (0.134) 3.5 (0.138) 3.6 (0.142) 3.7 (0.146) -

Snap Ring

(c)

Remove the snap ring, attach the selected flange and reinstall the snap ring. NOTICE: Install the snap ring so that its gap is visible through the groove of the transaxle case.

D03623

Overdrive Direct Clutch Hub Sub-Assy

U250E A/T REPAIR MANUAL (RM1123U)

G38043

106. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY (a) Install the overdrive direct clutch hub sub-assy to the planetary gear assy. NOTICE: Be careful not to damage the bush inside the overdrive clutch hub while installing. (b) Coat the thrust bearing with ATF. (c) Install the bearing race and the thrust bearing to the direct clutch hub.
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NOTICE: When installing the bearing, hold the overdrive clutch hub side. Bearing and race diameter: mm (in.)
Inside Bearing, A Race, B 25.0 (0.9843) 23.6 (0.9291) Outside 39.5 (1.5551) 36.6 (1.4409)

Thrust Bearing

107. INSTALL DIRECT CLUTCH ASSY (a) Coat the thrust bearing with ATF. (b) Install the direct clutch assy and thrust bearing to the rear planetary sun gear assy. NOTICE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
D26403

Direct Clutch Assy

(c)
C

(d)

Clean the connecting part of the transaxle case and the rear cover. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers (Dimension C).

G35721

(e)
D

D26470

Using vernier calipers and a simple straight edge, measure the distance shown in the illustration. (f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it. End play: 0.199 to 0.970 mm (0.0078 to 0.0382 in.) NOTICE: Make sure that the no colored race side is facing the direct clutch assy. HINT: End play = Dimension D - Dimension C Bearing thickness and diameter : mm (in.)
Thickness 3.6 (0.1417) 3.9 (0.1535) Inside 55.9 (2.2008) 55.9 (2.2008) Outside 76 (2.9921) 76.6 (3.0157)

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108. INSTALL GOVERNOR APPLY GASKET NO.1 (a) Install 3 new governor apply gasket No.1 to the transaxle case.

D26390

109. INSTALL BRAKE APPLY TUBE (a) Install the clamp to the brake apply tube. NOTICE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

D03923

Clutch Apply Tube

Stopper

(b) (c)

Stopper Brake Apply Tube

D26391

Install the clutch apply tube. Install the brake apply tube to the transaxle case with the bolt. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) NOTICE: Each pipe should be securely inserted until it reaches the stopper.

20.55 to 21.25 mm (0.8091 to 0.8366 in.) SST

D26766

110. INSTALL NEEDLE ROLLER BEARING (a) Using SST and a press, install a new needle roller bearing to the transaxle rear cover. SST 09950- 60010 (09951- 00230, 09952- 06010, 09951-00360) Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) NOTICE: S Face the inscribed mark side of the bearing race up. S Press-fit until the specified value is obtained. (b) Coat a needle roller bearing with ATF.

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Rear Clutch Oil Seal Ring Outer

111. INSTALL REAR CLUTCH OIL SEAL RING OUTER (a) Coat 3 new rear clutch oil seal ring outers with ATF, and install them to the transaxle rear cover. NOTICE: The snap ring should be securely fixed in the groove of the transaxle rear cover.

D26389

112. INSTALL TRANSAXLE CASE NO.1 PLUG (a) Install 4 new O-rings to the 4 transaxle case No.1 plugs. (b) Install the 4 transaxle case No.1 plugs to the transaxle rear cover. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)

D26388

FIPG

D26454

113. INSTALL TRANSAXLE REAR COVER SUB-ASSY (a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover sub-assy and the transaxle case. (b) Apply FIPG to the cover. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent. NOTICE: Apply FIPG in a continuous line (width 1.2mm (0.047in.)) along the sealing surface.

(c)

(d)

A A A
G35595

Apply liquid sealer to the A bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Install the 11 bolts. Torque: Bolt A: 19 Nm (190 kgfcm, 14 ftlbf) Other bolts: 25 Nm (250 kgfcm, 18 ftlbf)

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Disc

Flange Plate

114. INSTALL UNDERDRIVE CLUTCH DISC NO.2 (a) Coat the 3 discs with ATF. (b) Install the 3 discs, 3 plates and flange to the transaxle case. NOTICE: Be careful about the order of the discs, plates and flange.

G35718

Snap Ring

(c) Using a screwdriver, install the snap ring. NOTICE: The snap ring should be securely fixed in the groove of the drum.

D26466

D08082

115. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH NO.2 (a) Using a dial indicator, measure the underdrive clutch No.2 pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi). Pack clearance: 1.645 to 2.20 mm (0.0648 to 0.0866 in.) HINT: Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.)
Mark Y A B Thickness 2.8 (0.110) 3.0 (0.118) 3.2 (0.126) Mark C D Thickness 3.4 (0.134) 3.6 (0.142) -

Free

Free

116. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY (a) Temporarily install the underdrive 1-way clutch assy to the underdrive clutch. (b) Rotate the underdrive clutch assy to check the rotating direction for lock or free operation. (c) Remove the underdrive 1-way clutch assy.

D03925

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117. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY (a) Install the outer race retainer to the underdrive 1-way clutch. NOTICE: Fix the outer race retainer to the external tooth of the 1-way clutch securely.
Outer Race Retainer
D03907

(b) Install the 1-way clutch to the transaxle case. NOTICE: Ensure that the outer race retainer and the mark on the transaxle case are aligned.

Outer Race Retainer

Mark

G35723

(c)

Using a screwdriver, install the snap ring to the transaxle case. NOTICE: The snap ring should be securely fixed in the groove of the transaxle case.

Snap Ring

D03581

118. INSTALL UNDERDRIVE CLUTCH ASSY (a) Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch assy. Bearing and bearing race diameter: mm (in.)
Inside Bearing Race 37.73 (1.4854) 29.9 (1.1772) Outside 58.0 (2.2835) 55.5 (2.1850)

(b)
D33499

Install the underdrive clutch assy to the transaxle case.

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NOTICE: When installing the underdrive clutch drum assy, be sure not to damage the oil seal rings.

Parking Lock Pawl

119. INSTALL PARKING LOCK PAWL (a) Install the pawl pin and spring to the parking lock pawl.

Spring Pawl Pin

D09691

(b)

Temporarily install the parking lock pawl, pin and spring to the transaxle case, as shown in the illustration.

D26386

Underdrive Planetary Gear Assy

120. INSTALL UNDERDRIVE PLANETARY GEAR ASSY (a) Install the underdrive planetary gear assy to the transaxle case. NOTICE: Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assy firmly and assemble them securely.

D03579

(b)

Install the parking lock pawl shaft.

D09693

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(c)

Install the pawl shaft clamp with the bolt. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)

Pawl Shaft Clamp

D03576

(d)
E

Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E). NOTICE: Note down the dimension E as it is necessary for the following process.
D03875

(e)
Dimension (1) Dimension (2)

As shown in the illustration, measure the 2 places of the transaxle housing, and calculate the dimension F using the following formula. NOTICE: Note down the dimension F as it is necessary for the following process. HINT: Dimension F = Dimension (1) - Dimension (2)

D25511

Thrust Bearing Race No.1

121. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB (a) Install the thrust bearing race No.1 to the transaxle case in the correct direction. Bearing race diameter: mm (in.)
Inside Bearing race 34.5 (1.3583) Outside 48.5 (1.9094)

D08087

(b)
Thrust Needle Roller Bearing Multiple Disc Clutch Clutch Hub

Coat the thrust needle roller bearing with ATF, and install it onto the multiple disc clutch clutch hub. Thrust bearing and race diameter: mm (in.)
Inside Thrust Bearing 36.3 (1.4291) Outside 52.2 (2.0551)

(c)

Coat the needle roller bearing with ATF.

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(d)
Thrust Needle Roller Bearing Multiple Disc Clutch Clutch Hub

Install the needle roller bearing to the multiple disc clutch clutch hub. Bearing diameter: mm (in.)
Inside Bearing 23.5 (0.9252) Outside 44.0 (1.7323)

(e)

Install the multiple disc clutch clutch hub to the transaxle case.

D26711

Thrust Needle Roller Bearing

122. INSTALL FORWARD CLUTCH ASSY (a) Coat the thrust needle roller bearing with ATF. (b) Install the thrust needle roller bearing to the forward clutch assy. Thrust bearing diameter: mm (in.)
Inside Thrust Bearing 33.85 (1.3327) Outside 52.2 (2.0551)

D03820

NOTICE: Install the thrust bearing properly so that temper colored race will be visible.

Forward Clutch Assy

(c) Install the forward clutch assy to the transaxle case. NOTICE: S Align the splines of all discs in the forward clutch assy with those of the multiple clutch clutch hub to assemble them securely. S Be careful not to damage the bush inside the forward clutch assy while installing.

D03574

123. INSTALL OVERDRIVE BRAKE GASKET (a) Install 2 new overdrive brake gaskets.

D03573

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Differential Gear Assy

124. INSTALL DIFFERENTIAL GEAR ASSY (a) Install the differential gear assy to the transaxle case.

D26450

Thrust Bearing Underdrive Race No.2

Underdrive Planetary Gear Assy Forward Clutch Assy

125. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2 (a) Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assy.

Differential Gear Assy

D25506

Thrust Needle Roller Bearing

Underdrive Planetary Gear Assy Forward Clutch Assy

Differential Gear Assy

D25505

126. INSTALL THRUST NEEDLE ROLLER BEARING (a) Coat the thrust needle roller bearing with ATF. (b) Calculate the end play value using the following formula. (Dimensions E and F were measured when installing the needle roller bearing and underdrive planetary gear.) Select an appropriate underdrive planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install it. End play: 0.198 to 0.693 mm (0.00780 to 0.02728 in.) HINT: End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 in.) - Underdrive thrust bearing race No.2 thickness. Race thickness: mm (in.)
F-E Less than 7.339 (0.2890) 7.339 (0.2890) or more Thickness 3.5 (0.138) 3.8 (0.150)

Bearing and bearing race diameter: mm (in.)

Inside Bearing Bearing race 53.0 (2.0866) 52.1 (2.0512) Outside 78.2 (3.0787) 75.5 (2.9724)

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127. INSTALL OIL PUMP ASSY (a) Install the oil pump assy to the transaxle case with the 7 bolts. Torque: 22 Nm (225 kgfcm, 16 ftlbf)

D03569

(b) Coat the O-ring of the oil pump assy with ATF. NOTICE: Confirm the input shaft rotates smoothly with manual operation after assembling the oil pump assy.

O-ring
D03629

FIPG

Sealing Application Width 1.2 mm (0.047 in.)

D03630

128. INSTALL TRANSAXLE HOUSING (a) Remove any packing material and be careful not to get oil on the contacting surface of the transaxle case or transaxle housing. (b) Apply FIPG to the transaxle case. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

B B

(c)

Install the transaxle housing to the transaxle case with the 16 bolts. Torque: Bolt A: 22 Nm (225 kgfcm, 16 ftlbf) Bolt B: 29 Nm (296 kgfcm, 21 ftlbf) Bolt C: 29 Nm (296 kgfcm, 21 ftlbf)

D33498

HINT: Apply seal packing or equivalent to the bolts A. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) NOTICE: Because the bolts A are seal bolts, apply seal packing to them and tighten within 10 minutes of application.

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129. INSPECT INPUT SHAFT ENDPLAY (a) Using a dial indicator, measure the input shaft end play. End play: 0.262 to 1.249 mm (0.0100 to 0.0494 in.)

D08091

130. FIX AUTOMATIC TRANSAXLE ASSY (a) Fix the transaxle assy.

D03631

SST

131. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL (a) Coat a new oil seal with MP grease. (b) Install the oil seal to the transaxle case. SST 09950- 60010 (09951- 00230), 09950- 70010 (09951-07100) Oil seal drive in depth: -0.5 to 0.5 (- 0.0197 to 0.0197in.)
D26468

132. INSTALL PARKING LOCK ROD SUB-ASSY (a) Install the parking lock rod to the manual valve lever. HINT: Align the dial with the notches on the manual valve lever and turn the dial 90 to install the parking lock rod.

Parking Lock Rod Sub-assy

G36062

133. INSTALL MANUAL VALVE LEVER SUB-ASSY (a) Install a new spacer and the manual valve lever shaft to the transaxle case. NOTICE: Do not damage the oil seal while installing the shaft to the transaxle case.

G36434

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(b)

Using a pin punch and hammer, drive in a new pin.

D03564

(c)
Pin Pin Punch

(d) (e)

Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft. Using a pin punch, stake the spacer through the smaller hole. Check that the spacer does not turn.

D26765

134. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING (a) Using needle-nose pliers, install the retainer spring. NOTICE: Hang the spring on the shaft securely.

D03559

135. INSTALL PARKING LOCK PAWL BRACKET (a) Install the parking lock pawl bracket with the 2 bolts. Torque: 20 Nm (205 kgfcm, 15 ftlbf) Bolt length: 25 mm (0.984 in.) NOTICE: Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
D03561

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B A

D03560

136. INSTALL MANUAL DETENT SPRING SUB-ASSY (a) Install the manual detent spring sub-assy with the 2 bolts. NOTICE: Make sure to install the manual detent spring first and then the cover. HINT: First tighten bolt A then bolt B. Torque: Bolt A: 20 Nm (205 kgfcm, 15 ftlbf) Bolt B: 12 Nm (120 kgfcm, 9 ftlbf) Bolt length: Bolt A: 27 mm (1.063 in.) Bolt B: 16 mm (0.630 in.)

O-ring

137. INSTALL B-3 ACCUMULATOR PISTON (a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston. NOTICE: Ensure that the O-ring is not twisted.

B-3 Accumulator Piston

D03904

(b) Coat the piston with ATF. (c) Install the 2 compression springs and piston. NOTICE: Install the correct springs to the B-3 accumulator piston by checking the color or dimension of the springs. Accumulator spring:
ATF
D25512

Free length Outer diameter mm (in.) Inner 62.00 (2.4409) / 15.50 (0.610) Outer 74.23 (2.9224) / 21.70 (0.854)

Color Purple Purple

Reverse Clutch Accumulator Piston

O-ring O-ring
D26402

138. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON (a) Coat 2 new O-rings with ATF, and install them to the reverse accumulator piston. NOTICE: Ensure that the O-rings are not twisted.

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(b)

ATF

Coat the piston with ATF, and install the spring and piston to the transaxle case. NOTICE: Install the correct spring to the reverse accumulator piston by checking the color or dimension of the spring. Accumulator spring:
Free length Outer diameter mm (in.)
C92978

Color Yellow

60.96 (2.3999) / 14.10 (0.555)

O-ring C-3 Accumulator Piston

139. INSTALL C-3 ACCUMULATOR PISTON (a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston. NOTICE: Ensure that the O-ring is not twisted.

G35590

(b)

Coat the piston with ATF, and install it to the transaxle case.

C83146

(c) Install the spring to the C-3 accumulator piston. NOTICE: Install the correct spring to the C-3 accumulator piston by checking the color or dimension of the spring. Accumulator spring:
Free length Outer diameter mm (in.) 72.20 (2.8425) / 19.0 (0.748)
D03555

Color Colorless

Check Ball
D03554

140. INSTALL CHECK BALL BODY (a) Coat the check ball body with ATF. (b) Install the check ball body and spring. NOTICE: Regarding the installation of the spring for the check ball body, be sure to place the spring in the hole in the ball body. Be careful about the direction of the parts.

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141. INSTALL BRAKE DRUM GASKET (a) Coat a new brake drum gasket with ATF, and install it to the transaxle case. NOTICE: Be sure not to damage the lip of the brake drum gasket when inserting it to the case. Be careful about the direction of the gasket.
C83129

142. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET (a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case. NOTICE: Be sure not to damage the lip of the 2nd brake gasket when inserting it to the case.

C83128

143. INSTALL GOVERNOR APPLY GASKET NO.1 (a) Coat a new governor apply gasket No.1 with ATF, and install it to the transaxle case. NOTICE: Be sure not to damage the lip of the governor apply gasket No.1 when inserting it to the case.

C83127

B B A A C

S
C
C91933

144. INSTALL TRANSMISSION VALVE BODY ASSY (a) Confirm the manual valve lever position, and install the valve body with the 17 bolts to the transaxle case. Torque: 11 Nm (110 kgfcm, 8 ftlbf) Bolt length: Bolt A: 25 mm (0.984 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 41 mm (1.614 in.) NOTICE: S Push the valve body against the accumulator piston spring and the check ball body to install it. S When installing the valve body to the transaxle case, do not hold the solenoids. S First, temporarily tighten the bolts marked by S in the illustration because they are positioning bolts.

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145. INSTALL VALVE BODY OIL STRAINER ASSY (a) Coat a new O-ring with ATF, and install it to the oil strainer. NOTICE: Ensure that the O-ring is not twisted or pinched.

O-ring
C91932

(b)

Install the oil strainer to the valve body with the 3 bolts. Torque: 11 Nm (110 kgfcm, 8 ftlbf) NOTICE: Apply ATF to the bolts.

G35588

146. INSTALL TRANSMISSION WIRE (a) Coat the O-ring of the transmission wire with ATF.

ATF

D03636

(b)
Transmission Wire

Install the transmission wire with the bolt. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)

D03547

A B

C D

E F

147. CONNECT TRANSMISSION WIRE (a) Coat the O-ring of the ATF temperature sensor with ATF. (b) Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 Nm (67 kgfcm, 58 in.lbf) NOTICE: Apply ATF to the bolt. (c) Connect the 7 solenoid connectors.
G35587

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NOTICE: Connect the connectors in the following order: A, B, C, D, E, F, G

Magnet

148. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY (a) Install the 2 magnets in the oil pan. (b) Apply seal packing or equivalent to the 18 bolts. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.

G35609

C91925

Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) NOTICE: S Because the bolts should be seal bolts, apply seal packing to them and tighten within 10 minutes of application. S Completely remove any oil or grease from the contacting surface of the transaxle case and the oil pan with the gasket before installation. (d) Install the drain plug and a new drain plug gasket to the automatic transaxle oil pan sub-assy. Torque: 49 Nm (500 kgfcm, 36 ftlbf)

(c)

149. INSTALL TRANSAXLE CASE NO.1 PLUG (a) Coat 4 new O-rings with ATF, and install them to the 4 transaxle case No.1 plugs. (b) Install the 4 transaxle case No.1 plugs to the transaxle case. Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)

G35585

A Speed Sensor

D03900

D30672

150. INSTALL SPEED SENSOR (a) Apply liquid sealer to the A bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. (b) Install the 2 sensors to the transaxle case with the 2 bolts. Torque: Bolt A: 8.8 Nm (90 kgfcm, 79 in.lbf) Bolt B: 11 Nm (110 kgfcm, 8 ftlbf)

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Oil Cooler Tube Union (Outlet Oil Cooler Union)

O-ring
C83144

151. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) (a) Coat a new O-ring with ATF, and install it to the oil cooler tube union (outlet oil cooler union). (b) Install the oil cooler tube union (outlet oil cooler union) to the transaxle case. Torque: 27 Nm (276 kgfcm, 20 ftlbf)

O-ring

152. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) (a) Coat a new O-ring with ATF, and install it to the oil cooler tube union (inlet oil cooler union). (b) Install the oil cooler tube union (inlet oil cooler union) to the transaxle case. Torque: 27 Nm (275 kgfcm, 20 ftlbf)
C83143

Oil Cooler Tube Union (Inlet Oil Cooler Union)

Hose Breather Plug No.2

153. INSTALL BREATHER PLUG NO.2 (ATM) (a) Install the hose and a new O-ring to the breather plug No.2 (ATM).

O-ring
G35584

(b)

Install the breather plug No.2 (ATM) to the transaxle case.

G35583

154. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY (a) Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. (b) Install a new nut stopper and the nut. Torque: 6.9 Nm (70 kgfcm, 61 in.lbf)

D09639

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(c)

Temporarily install the control shaft lever.

Control Shaft Lever

D09640

(d) (e)

Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches. Remove the control shaft lever.

D09641

(f) (g)

Align the groove with the neutral basic line. Tighten the 2 bolts. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)

D09642

(h)

Using a screwdriver, stake the nut stopper.

D09643

(i)

Install the control shaft lever, washer and nut. Torque: 13 Nm (130 kgfcm, 9 ftlbf)

D09644

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