Part 3

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY (Continued)

71. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(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:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
* Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the overdrive direct clutch drum.

(d) Remove the overdrive clutch return spring from the overdrive direct clutch drum.

72. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Transaxle Unit

73. REMOVE OVERDRIVE DIRECT CLUTCH PISTON

(a) Install the intermediate shaft on the transaxle rear cover.

(b) 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.

74. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

(a) 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.

75. REMOVE OVERDRIVE DIRECT CLUTCH O-RING

(a) Using a screwdriver, remove the O-ring from the direct clutch drum.

76. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY

(a) Remove the thrust bearing race, thrust bearing, and overdrive direct clutch hub from the planetary gear assembly.

77. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

(a) Remove the rear planetary sun gear assembly from the transaxle case.

(b) Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.

78. REMOVE ONE-WAY CLUTCH ASSEMBLY

(a) Remove the one-way clutch assembly and the thrust needle roller bearing from the transaxle case.

(b) Remove the one-way clutch inner race from the one-way clutch assembly.

79. REMOVE ONE-WAY CLUTCH SLEEVE

(a) Remove the one-way clutch sleeve from the transaxle case.

80. REMOVE NO. 1 PLANETARY CARRIER THRUST WASHER

(a) Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly.

81. REMOVE 2ND BRAKE DISC

(a) Using a screwdriver, remove the snap ring.

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

82. INSPECT 2ND BRAKE DISC Transaxle Unit

83. REMOVE 2ND BRAKE PISTON ASSEMBLY

(a) Using a screwdriver, remove the snap ring.

(b) Remove the 2nd brake piston assembly from the transaxle case.

84. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

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

SST : 09387-00060

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

(c) Remove the 2nd brake piston return spring sub-assembly.

85. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Transaxle Unit

86. REMOVE 2ND BRAKE PISTON

(a) 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.

87. REMOVE 2ND BRAKE PISTON O-RING

(a) Remove the 2 O-rings from the 2nd brake piston.

88. REMOVE REAR PLANETARY GEAR ASSEMBLY

(a) Using a screwdriver, remove the snap ring.

(b) Remove the rear planetary gear assembly from the transaxle case.

89. REMOVE INPUT SUN GEAR

(a) Remove the 2 thrust needle roller bearings, No. 2 thrust bearing races, No. 3 thrust bearing race, and input sun gear from the transaxle case.

90. REMOVE 1ST AND REVERSE BRAKE DISC

(a) Remove the flange, 5 discs and 5 plates from the transaxle case.

91. INSPECT 1ST AND REVERSE BRAKE DISC Transaxle Unit

92. REMOVE FRONT PLANETARY GEAR ASSEMBLY

(a) Using a chisel and hammer, unstake the lock washer.

NOTICE:
Push down all claws of the washer. If the claws are not pushed down, SST cannot be fully pressed against the nut, and the nut cannot be loosened.

(b) Using SST, remove the nut and washer.

SST : 09387-00030

SST : 09387-00080

SST : 09950-60010

09951-00450

SST : 09950-70010

09951-07100

(d) Remove the front planetary gear assembly from the brake hub.

93. REMOVE FRONT PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.

94. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(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:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.
(c) Remove the return spring.

95. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Transaxle Unit

96. REMOVE 1ST AND REVERSE BRAKE PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the 1st and reverse brake piston.

NOTICE:
* Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
* Take care not to splash ATF when applying compressed air.
(b) Remove the 2 O-rings from the 1st and reverse brake piston.

97. REMOVE COUNTER DRIVE GEAR BEARING

(a) Using SST and a press, remove the counter drive gear from the transaxle case.

SST : 09950-60010

09951-00590

SST : 09950-70010

09951-07100

(b) Tighten the 2 bolts evenly and make a clearance of approximately. 20.0 mm (0.797 in.) between the counter drive gear and the inner race.

SST : 09950-00020

SST : 09950-00030

SST : 09950-60010

09951-00590

98. REMOVE COUNTER DRIVE ANGULAR BALL BEARING

(a) Remove the bearing inner race (rear side) and angular ball (rear side).

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

SST : 09308-00010

(c) Remove the angular ball (front side).

(d) Using SST and a press, remove the bearing outer race (front side) from the transaxle case.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07200

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

99. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(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:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.
(c) Remove the return spring.

100. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Transaxle Unit

101. REMOVE UNDERDRIVE BRAKE PISTON

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

(b) Remove the 2 O-rings from the underdrive brake piston.

102. REMOVE NEEDLE ROLLER BEARING

(a) Using SST, remove the needle roller bearing from the transaxle case.

SST : 09387-00041

09387-01010

09387-01030

09387-01040

103. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Remove the 2 oil seal rings from the transaxle case.

104. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 2 No. 1 transaxle case plugs.

(b) Remove the O-ring from each No. 1 transaxle case plug.

105. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.

SST : 09820-00031

SST : 09950-40011

09952-04010

09954-04010

09955-04061

09957-04010

SST : 09950-50013

09951-05010

09953-05020

106. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Remove the oil seal ring from the transaxle housing.

107. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.