Part 2

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

41. REMOVE MULTIPLE DISC CLUTCH HUB

(a) Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and No. 1 thrust bearing race from the transaxle case.





42. INSPECT MULTIPLE DISC CLUTCH HUB Transaxle Unit

43. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Remove the bolt and pawl shaft clamp from the transaxle case.





(b) Remove the parking lock pawl shaft from the transaxle case.





(c) Push the parking lock pawl.





HINT
Failure to do so will cause interference when the underdrive planetary gear is removed.

(d) Remove the underdrive planetary gear assembly from the transaxle case.





NOTICE:
Do not drop the underdrive planetary gear assembly.

44. REMOVE FRONT PLANETARY GEAR NUT

(a) Using SST and a hammer, loosen the staked part of the gear nut.





SST : 09930-00010

09931-00010

09931-00020

SST : 09387-00050

SST : 09495-65040

(b) Clamp the underdrive planetary gear in a soft jaw vise.





NOTICE:
Be careful not to damage the differential drive pinion.

(c) Using a socket wrench, remove the gear nut.





45. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER

(a) Using SST, remove the cylindrical roller bearing race inner.





SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00320

46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.





SST : 09387-00050

SST : 09495-65040

SST : 09950-60010

09951-00320

SST : 09950-70010

09951-07100

(b) Clamp the underdrive planetary gear in a soft jaw vise.





(c) Using SST, remove the rear angular ball bearing from the underdrive planetary gear.

SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00320

47. REMOVE UNDERDRIVE PLANETARY RING GEAR

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





(b) Remove the underdrive planetary ring gear from the counter driven gear.





48. REMOVE PARKING LOCK PAWL

(a) Remove the spring, pawl pin and parking lock pawl.





49. REMOVE UNDERDRIVE CLUTCH ASSEMBLY

(a) Remove the underdrive clutch assembly, thrust bearing, and bearing race from the transaxle case.





50. REMOVE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING

(a) Using a screwdriver, remove the No. 2 underdrive clutch flange hole snap ring.





51. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC

(a) Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum.





52. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(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:
* 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 underdrive clutch drum.





(d) Remove the return spring from the underdrive clutch drum.





53. REMOVE UNDERDRIVE CLUTCH PISTON SET

(a) Remove the underdrive clutch from the transaxle case.





NOTICE:
Be careful not to damage the oil seal ring.

(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.

54. REMOVE UNDERDRIVE CLUTCH DRUM O-RING

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





55. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

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





(b) Remove the underdrive one-way clutch from the transaxle case.





(c) Remove the outer race retainer from the one-way clutch.





56. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC

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





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





57. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC Transaxle Unit

58. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Remove the 11 bolts.





(b) Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.

59. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 4 No. 1 transaxle case plugs from the transaxle rear cover.





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

60. REMOVE REAR CLUTCH OIL SEAL RING

(a) Remove the 3 rear clutch oil seal rings from the transaxle rear cover.





61. REMOVE NEEDLE ROLLER BEARING

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





SST : 09387-00041

09387-01021

09387-01030

09387-01040

62. REMOVE NO. 1 GOVERNOR APPLY GASKET

(a) Using a screwdriver, remove the 3 apply gaskets.





63. REMOVE BRAKE APPLY TUBE

(a) Remove the bolt, clamp and brake apply tube.





(b) Remove the clutch apply tube.

(c) Remove the brake apply tube from the clamp.

64. REMOVE DIRECT CLUTCH ASSEMBLY

(a) Remove the thrust bearing and the direct clutch assembly from the transaxle case.





65. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transaxle Unit

66. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH Transaxle Unit

67. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC

(a) Using a screwdriver, remove the snap ring from the intermediate shaft.





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





68. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC Transaxle Unit

69. 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.

70. INSPECT OVERDRIVE DIRECT CLUTCH DISC Transaxle Unit

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.





(c) Remove the No. 2 planetary carrier thrust washer 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.