Part 3 of 3
U/D GEAR UNIT REMOVAL
1. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH
a. Set a dial indicator and measuring terminal (SST) together.
SST 09350-32014 (09351-32190)
b. While applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm, 57 - 114 psi), measure the underdrive clutch piston stroke.
Piston stroke:
A241E: 1.21 - 1.55 mm (0.0476 - 0.0610 inch)
A244E: 1.50 - 1.86 mm (0.0590 - 0.0732 inch)
If the piston stroke is non-standard, select another flange.
HINT: There are 3 (A241E) or 2 (A244E) different flange thicknesses.
Flange thickness:
A241E
2.30 mm (0.0906 inch)
2.50 mm (0.0984 inch)
2.70 mm (0.1063 inch)
A244E
2.04 mm (0.0803 inch)
2.40 mm (0.0945 inch)
2. REMOVE UNDERDRIVE CLUTCH DRUM AND ANTIRATTLE CLIP
3. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES
Using compressed air, confirm that the underdrive brake piston moves smoothly.
4. REMOVE OIL SEAL RINGS
Remove the 2 oil seal rings.
5. REMOVE FLANGE, PLATES AND DISCS
a. Using SST and press, press in the flange until the snap ring is free from the flange.
SST 09350-32014 (09351-32070)
b. Using a screwdriver, remove the snap ring.
c. Remove the flange, 3 plates and discs.
6. REMOVE RETURN SPRING
7. REMOVE UNDERDRIVE BRAKE PISTON
Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the brake piston into a rag.
8. REMOVE O-RINGS FROM PISTON
Remove the 2 O-rings from the piston.
9. REMOVE SNAP RING
a. Set SST and tighten the bolt gradually to compress the springs until the snap ring is free from the spring seat.
SST 09350-32014 (09351-32040)
b. Using a snap ring expander, remove the snap ring.
c. Remove SST.
10. REMOVE RETURN SPRING
Remove the return spring and snap ring.
11. REMOVE PISTON FROM TRANSMISSION CASE WITH COMPRESSED AIR
a. Apply compressed air into the oil passage of the case to remove the piston.
HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.
b. If the piston does not pop out with compressed air, use needle-nose pliers to remove it.
12. REMOVE O-RINGS FROM PISTON
Remove the 2 O-rings from the piston.
13. REMOVE PARKING LOCK PAWL STOPPER PLATE, TORSION SPRING AND SPRING GUIDE
14. REMOVE PAWL SHAFT CLAMP
Remove the bolt and pawl shaft clamp.
15. REMOVE PARKING LOCK PAWL SHAFT AND LOCKPAWL
16. REMOVE PARKING LOCK SLEEVE
17. REMOVE CAM GUIDE BRACKET
Remove the cam guide bracket, as shown.
18. REMOVE MANUAL VALVE SHAFT SPACER
Using a screwdriver and hammer, unstake the spacer and remove it.
19. REMOVE PIN
Using a punch and hammer, drive out the pin.
20. REMOVE MANUAL VALVE SHAFT AND LEVER
a. Remove the retaining spring.
b. Slide out the manual valve shaft and remove the manual valve lever and washer.
21. IF NECESSARY, REPLACE OIL SEAL OF MANUAL SHAFT
a. Using a screwdriver, remove the oil seal.
b. Using a 14 mm socket wrench and hammer, drive in a new oil seal.
c. Apply MP grease to the oil seal lip.
22. REMOVE OIL GALLERY COVER AND GASKET
a. Remove the 3 bolts.
b. Using a torx wrench, remove the 6 screws. Remove the gallery cover and gasket.
23. REMOVE 134ACCUMULATOR PISTON AND SPRING
24. REMOVE BEARING
Using SST, remove the bearing.
SST 09308-00010
25. REMOVE OIL TUBES
a. Remove the 4 tube clamps from transaxle housing.
b. Using a screwdriver, remove the 3 oil tubes.
26. REMOVE OIL TUBE APPLY COVER AND GASKET
Remove the 3 bolts, and remove the cover and gasket.
27. REMOVE BEARING
a. Remove the bolt and retainer.
b. Using SST, remove the bearing.
SST 09308-00010