Part 1

U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

1. BEARING POSITION

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.

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

NOTICE:
Make sure to insert the pipe to the stopper.

3. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 No. 1 transaxle case plugs.

(b) Install the 2 No. 1 transaxle case plugs to the transaxle rear cover.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Coat a new oil seal ring with ATF and install it to the transaxle housing.

5. 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.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07100

NOTICE:
Do not apply excessive pressure to the bearing.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Coat 2 new oil seal rings with ATF and install them to the transaxle rear cover.

NOTICE:
* Do not expand the end gap of the oil seal ring too much.
* Secure the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
7. INSTALL NEEDLE ROLLER BEARING

(a) Wrap vinyl tape around SST 4.0 mm (0.157 in.) from the bottom of SST until the thickness of the tape is approximately 5.0 mm (0.197 in.).

SST : 09950-60010

09951-00320

SST : 09950-70010

09951-07100

NOTICE:
Clean SST to remove deposited oil before wrapping vinyl tape.

(b) Coat the needle roller bearing with ATF.

(c) Using SST and a press, install the needle-roller bearing to the transaxle case.

SST : 09950-60010

09951-00320

SST : 09950-70010

09951-07100

NOTICE:
When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.

8. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the underdrive brake piston.

NOTICE:
* Make sure that the O-rings are not twisted or pinched when they are installed.
* Apply sufficient ATF to the O-ring before installing.
(b) Coat the underdrive brake piston with ATF.

(c) Install the underdrive brake piston to the transaxle case.

NOTICE:
Be careful not to damage the O-ring.

9. INSTALL 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, install the snap ring to the transaxle case.

NOTICE:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.
* Install the spring sub-assembly and check that all of the springs are fully engaged in the piston correctly.
* The snap ring should be fully engaged in the groove of the transaxle case.
10. INSTALL NO. 2 BREATHER PLUG

11. INSTALL COUNTER DRIVE GEAR BEARING

(a) Coat the counter drive gear bearing with ATF.

(b) Using SST and a press, install the bearing outer race.

SST : 09950-60020

09951-01030

SST : 09950-70010

09951-07150

SST : 09649-17010

NOTICE:
* Do not apply excessive pressure to the bearing.
* Press-fit the bearing outer race until it contacts the transaxle case.
(c) Using a snap ring expander, install the snap ring.

NOTICE:
The surface with a white mark of the snap ring should face upward.

12. INSTALL COUNTER DRIVE GEAR

(a) Coat the counter drive gear with ATF.

(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.

SST : 09950-70010

09951-07150

SST : 09649-17010

NOTICE:
Do not apply excessive pressure to the bearing.

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case.

SST : 09950-70010

09951-07150

SST : 09223-15030

SST : 09527-17011

SST : 09950-60020

09951-00750

NOTICE:
Do not apply excessive pressure to the counter drive gear.

13. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.

(b) Install the 2 O-rings to the 1st and reverse brake piston.

NOTICE:
* Make sure that the O-rings are not twisted or pinched when they are installed.
* Apply sufficient ATF to the O-rings before assembling them.
(c) Coat the 1st and reverse brake piston with ATF and install it to the transaxle case.

NOTICE:
Be careful not to damage the O-ring.

14. INSTALL 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, install the snap ring to the transaxle case.

NOTICE:
* Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.
* Install the spring sub-assembly and check that all of the springs are fit in the piston correctly.
* The snap ring should be fully engaged in the groove of the cylinder.
* Fix the snap ring to the inside of the claw of the spring seat firmly.
15. INSTALL FRONT PLANETARY RING GEAR

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

NOTICE:
Confirm that the snap ring is engaged in the groove of the brake hub correctly.

16. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear assembly.

SST : 09950-60010

09951-00500

SST : 09950-70010

09951-07100

NOTICE:
* Do not apply excessive pressure to the planetary gear assembly.
* Press the inner race of the LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no pre-load should be applied to one pair of the tapered roller bearings (left and right).
(c) Install a new washer as shown in the illustration.

(d) Using SST, install the nut.

SST : 09387-00030

SST : 09387-00080

Torque : 280 Nm (2854 kgf-cm, 207 ft-lbf)

NOTICE:
Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.

(e) 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 as specified, gradually tighten the nut until it reaches the specified value.

SST : 09387-00080

Standard:

Turning torque at 60 rpm

Bearing:

New Bearing
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf)

Used Bearing
0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf)

HINT
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

(f) Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.

Torque : 350 Nm (3569 kgf-cm, 258 ft-lbf)

(g) Using a chisel and hammer, stake the front lock washer.

17. INSTALL INPUT SUN GEAR

(a) Coat the 2 thrust bearings with ATF.

(b) Install the 2 thrust bearings, the 3 bearing races, and the input sun gear to the transaxle case.

NOTICE:
* Install the bearing race on the side of the front planetary carrier. Make sure that the race is installed in the correct direction.
* When installing the thrust bearing and front sun gears, make sure that they are installed in the correct direction.
* Install the bearing race on the side of the front sun gear. Make sure that the race is installed in the correct direction.
* Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

18. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear assembly to the rear planetary ring gear.

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

NOTICE:
Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.

19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Coat the 6 discs with ATF.

(b) Install the 6 plates and 6 discs.

NOTICE:
Make sure that the plates, discs, and flange are installed as shown in the illustration.

20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

(a) Using vernier calipers, 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:

1.16 to 1.35 mm (0.0457 to 0.0531 in.)

HINT
Piston stroke = Dimension A - Flange thickness

21. INSTALL 2ND BRAKE PISTON ASSEMBLY

(a) Install the 2nd brake piston assembly to the transaxle case.

(b) Install the snap ring and measure the inside diameter.

Inside diameter:

Greater than 167 mm (6.57 in.)

NOTICE:
* Make sure that the tapered snap ring is installed in the correct direction.
* When the diameter is not as specified, replace the snap ring with a new one.
* After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
22. INSTALL ONE-WAY CLUTCH SLEEVE OUTER

(a) Install the one-way clutch sleeve outer to the 2nd brake cylinder assembly.

NOTICE:
Make sure that the outer sleeve is installed in the correct direction.

23. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the one-way clutch inner race to the one-way clutch.

NOTICE:
* Make sure that the inner race is installed in the correct direction.
* Confirm that the discrimination mark can be seen.
(b) Check the rotating direction of one-way clutch for the lock or free operation as shown in the illustration.

NOTICE:
Install the thrust bearing properly so that no-colored race can be seen.

24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER

(a) Coat the No. 1 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear assembly.

NOTICE:
After installing, confirm that the projection should be firmly engaged in the hole of the planetary sun gear assembly.

25. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 2 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.

(b) Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

NOTICE:
After installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.