Transaxle Unit

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: INSPECTION

1. INSPECT MULTIPLE DISC CLUTCH HUB

(a) Using a dial indicator, measure the inside diameter of the multiple disc 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.)

(b) If the diameter is greater than the maximum, replace the multiple disc clutch hub with a new one.

NOTICE:
Check the contact surface of the bushing in the direct clutch shaft. If any scratches or discoloration is found, replace the direct clutch sub-assembly with a new one.

2. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC

(a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt.

(b) If necessary, replace them.

NOTICE:
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

(a) Using a dial indicator, measure the inside diameter of the overdrive direct clutch drum sub-assembly 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.)

(b) If the diameter is greater than the maximum, replace the overdrive direct clutch drum sub-assembly.

NOTICE:
Check the contact surface of the bushing in the direct clutch shaft. If any scratches or discoloration is found, replace the direct clutch sub-assembly with a new one.

4. INSPECT 2ND BRAKE DISC

(a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt.

(b) If necessary, replace them.

NOTICE:
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
5. INSPECT 1ST AND REVERSE BRAKE DISC

(a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt.

(b) If necessary, replace them.

NOTICE:
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
6. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

17.63 mm (0.6941 in.)

(b) If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

7. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

13.24 mm (0.5213 in.)

(b) If the free length is shorter than the standard free length, replace the underdrive brake return spring sub-assembly.

8. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

(a) Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).

(b) Select an appropriate flange so that the pack clearance will be within the specified range.

Pack clearance:

0.745 to 1.21 mm (0.0293 to 0.0476 in.)

HINT
Piston stroke = Dimension A - Flange thickness

Flange Thickness:

(c) Install the flange.

9. INSPECT PACK CLEARANCE OF 2ND BRAKE

(a) Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).

(b) Select an appropriate flange so that the pack clearance will be within the specified range.

Pack clearance:

0.53 to 0.91 mm (0.0209 to 0.0358 in.)

HINT
Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.0630 in.)

Flange Thickness:

(c) Install the flange.

10. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

(a) Using a dial indicator, measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

Pack clearance:

1.81 to 2.20 mm (0.0713 to 0.0866 in.)

(b) Select an appropriate flange from the table below so that the pack clearance will be within the specified range.

Flange Thickness:

(c) Temporarily remove the snap ring and attach the flange to the transaxle case.

(d) Reinstall the snap ring to the transaxle case.

11. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

(a) Install the underdrive clutch assembly to the one-way clutch.

(b) Make sure that the underdrive one-way clutch turns freely counterclockwise and locks when turned clockwise.

(c) Remove the underdrive clutch assembly from the one-way clutch.

12. INSPECT INPUT SHAFT END PLAY

(a) Using a dial indicator, measure the input shaft end play.

End play:

0.262 to 1.249 mm (0.0103 to 0.0492 in.)

13. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC

(a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt.

If necessary, replace them.

NOTICE:
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
14. INSPECT OVERDRIVE DIRECT CLUTCH DISC

(a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt. If necessary, replace them.

NOTICE:
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
15. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

25.91 mm (1.0201 in.)

(b) If the free length is shorter than the standard free length, replace the overdrive clutch return spring sub-assembly.

16. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) 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:

1.05 to 1.47 mm (0.04134 to 0.05787 in.)

(c) If the pack clearance is not as specified, inspect the discs, plates and flange.

17. 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:

0.61 to 0.83 mm (0.02402 to 0.03268 in.)

(b) If the pack clearance is not as specified, inspect the discs, plates and flange.

18. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

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

(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:

1.05 to 1.47 mm (0.04134 to 0.05787 in.)

(c) If the pack clearance is less than the minimum, the parts may have been assembled incorrectly, so check and reassemble them.

If the clearance is not as specified, select another flange.

HINT
There are 8 different thicknesses of flanges available.

Flange Thickness:

19. 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:

0.61 to 0.83 mm (0.02402 to 0.03268 in.)

(b) If the pack clearance is less than the minimum, the parts may have been assembled incorrectly, so check and reassemble them.

If the clearance is not as specified, select another flange.

HINT
There are 7 different thicknesses of flanges available.

Flange Thickness:

NOTICE:
Do not place the rear planetary sun gear in a vise.

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

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

16.61 mm (0.6539 in.)

(b) If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.

21. 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:

1.00 to 1.25 mm (0.0394 to 0.0492 in.)

(c) If the clearance is not within the standard, inspect the discs, plates and flange.

If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again.

HINT
* As the opening is large, cover it with a piece of cloth or shop rag to prevent the compressed air from being released.
* There are 7 different thicknesses of flanges available.

Flange Thickness:

22. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC

(a) Check if the sliding surfaces of the discs, plates, and flange are worn or burnt.

(b) If necessary, replace them.

HINT
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
23. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

26.74 mm (1.0528 in.)

(b) If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.

24. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC

(a) Check if the disc rotates when lightly rotating the forward clutch assembly after inserting the multiple disc clutch.

NOTICE:
Do not place the forward clutch assembly in a vise.

25. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD

(a) Using SST, fix the underdrive planetary gear assembly.

SST : 09387-00050

SST : 09495-65040

(b) Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while turning the torque wrench at 60 rpm.

SST : 09387-00050

SST : 09495-65040

Turning torque at 60 rpm:

0.28 to 0.89 N*m (2.9 to 9.1 kgf*cm, 2.5 to 7.9 in.*lbf)

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

26. 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:

1.51 to 1.71 mm (0.0594 to 0.0673 in.)

(d) If the pack clearance is not within the specified range, inspect the discs, plates, and flange.

27. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC

(a) Check if the sliding surfaces of the discs, plates and flange are worn or burnt.

If necessary, replace them.

HINT
* If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.
28. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY

(a) Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing.

Standard inside diameter:

32.56 to 32.58 mm (1.2818 to 1.2826 in.)

Maximum inside diameter:

32.63 mm (1.2846 in.)

(b) If the inside diameter is greater than the maximum, replace the underdrive clutch drum.

29. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

17.14 mm (0.6748 in.)

(b) If the free length is shorter than the standard free length, replace the underdrive clutch return spring sub-assembly.