Part 1

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Remove the nut, washer and control shaft lever.

(b) Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper.

2. REMOVE NO. 2 BREATHER PLUG

(a) Remove the No. 2 breather plug from the transaxle case.

(b) Remove the hose and O-ring from the No. 2 breather plug.

3. REMOVE OIL COOLER TUBE ELBOW (INLET OIL COOLER ELBOW)

(a) Remove the elbow.

(b) Remove the O-ring from the elbow.

4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Remove the union.

(b) Remove the O-ring from the union.

5. REMOVE TRANSMISSION REVOLUTION SENSOR

(a) Remove the 2 bolts and 2 speed sensors from the transaxle assembly.

(b) Remove the 2 O-rings from the 2 speed sensors.

6. REMOVE NO. 1 TRANSAXLE CASE PLUG

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

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

7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the transaxle assembly onto wooden blocks.

8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Remove the drain plug and drain plug gasket from the oil pan.

(b) Remove the 18 bolts, oil pan and gasket.

9. INSPECT TRANSMISSION OIL CLEANER MAGNET Transaxle Unit

10. DISCONNECT TRANSMISSION WIRE

(a) Disconnect the 7 connectors from the shift solenoid valves.

(b) Remove the bolt, lock plate, and ATF temperature sensor.

11. REMOVE TRANSMISSION WIRE

(a) Remove the bolt and transmission wire from the transaxle case.

12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Remove the 3 bolts and oil strainer.

(b) Remove the O-ring from the oil strainer.

13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Support the valve body assembly and remove the 17 bolts and valve body assembly.

14. REMOVE NO. 1 GOVERNOR APPLY GASKET

(a) Remove the No. 1 governor apply gasket from the transaxle case.

15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET

(a) Remove the transaxle case 2nd brake gasket from the transaxle case.

16. REMOVE BRAKE DRUM GASKET

(a) Remove the brake drum gasket from the transaxle case.

17. REMOVE CHECK BALL BODY

(a) Remove the check ball body and spring from the transaxle case.

18. REMOVE C-3 ACCUMULATOR PISTON

(a) Remove the spring from the C-3 accumulator piston.

(b) Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.

19. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the reverse accumulator piston and spring.

NOTICE:
* Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
* Do not splash ATF when applying compressed air.

(b) Remove the 2 O-rings from the reverse clutch accumulator piston.

20. REMOVE B-3 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.

21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, remove the manual valve lever shaft retainer spring.

22. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Remove the 2 bolts and manual detent spring sub-assembly.

23. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 2 bolts and parking lock pawl bracket.

24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Using a screwdriver, slide the spacer as shown in the illustration.

(b) Using a pin punch (dia3 mm) and a hammer, drive out the pin.

HINT
Slowly drive out the pin so that it will not fall into the transaxle case.

(c) Remove the manual valve lever shaft, manual valve lever and spacer.

25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

(a) Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.

HINT
Align the dial with the notches on the manual valve lever sub-assembly to remove the parking lock rod sub-assembly.

26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using a screwdriver, remove the oil seal from the transaxle case.

27. SECURE AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the transaxle case with the oil pump facing up.

28. INSPECT INPUT SHAFT END PLAY Transaxle Unit

29. REMOVE TRANSAXLE HOUSING

(a) Remove the 18 bolts.

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

NOTICE:
The differential may be accidentally removed when the transaxle housing is removed.

30. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 7 bolts and oil pump from the transaxle case.

31. REMOVE THRUST NEEDLE ROLLER BEARING

(a) Remove the thrust needle roller bearing from the underdrive planetary gear assembly.

32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Remove the No. 2 thrust bearing underdrive race from the underdrive planetary gear assembly.

33. REMOVE DIFFERENTIAL GEAR ASSEMBLY

(a) Remove the differential gear assembly from the transaxle case.

34. REMOVE OVERDRIVE BRAKE GASKET

(a) Remove the 2 overdrive brake gaskets from the transaxle case.

35. REMOVE FORWARD CLUTCH ASSEMBLY

(a) Remove the forward clutch assembly from the transaxle case.

(b) Remove the thrust needle roller bearing from the forward clutch assembly.

36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transaxle Unit

37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC

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

(b) Remove the flange, 5 discs and 5 plates from the input shaft.

38. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the spring retainer 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. This prevents the spring seat from being deformed.
* Do not expand the snap ring excessively.

(c) Remove the clutch balancer from the input shaft.

(d) Remove the forward clutch return spring from the input shaft.

39. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Place the input shaft drum onto the oil pump.

(b) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston.

HINT
If the piston is slanted and cannot be removed, either blow air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped.

40. REMOVE INPUT SHAFT OIL SEAL RING

(a) Remove the input shaft oil seal ring from the input shaft.

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.

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 : 09387-00050

SST : 09495-65040

SST : 09930-00010

09931-00010

09931-00020

(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.