Part 1

U340E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT (for Hatchback): DISASSEMBLY

1. REMOVE TRANSMISSION CONTROL SHAFT LEVER

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





2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Using a screwdriver, pry out the lock plate and remove the nut, lock plate and washer.





(b) Remove the 2 bolts and pull out the park/neutral position switch assembly.





3. REMOVE TRANSMISSION REVOLUTION SENSOR





(a) Remove the bolt and the transmission revolution sensor.

(b) Remove the O-ring from the transmission revolution sensor.

4. REMOVE OIL COOLER TUBE UNION





(a) Remove the 2 oil cooler tube unions from the transaxle case.

(b) Remove the 2 O-rings from the 2 oil cooler tube unions.

5. REMOVE NO. 1 TRANSAXLE CASE PLUG





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

(b) Remove the No. 1 transaxle case plug from the transaxle case.





(c) Remove the 5 O-rings from each No. 1 transaxle case plugs.

6. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY





(a) Remove the transmission breather hose sub-assembly from the breather plug.

7. REMOVE BREATHER PLUG

(a) Remove the breather plug from the transaxle case.

(b) Remove the O-ring from the breather plug.

8. FIX AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the transaxle on wooden blocks.





Text in Illustration





9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Remove the drain plug and gasket from the automatic transaxle oil pan sub-assembly.

(b) Remove the 19 bolts, automatic transaxle oil pan sub-assembly and the automatic transaxle oil pan gasket.





(c) Remove the 2 oil cleaner magnets from the automatic transaxle oil pan sub-assembly.





(d) Examine the particles in the automatic transaxle oil pan gasket.

(1) Collect any steel chips with the removed magnets.

Carefully look at the foreign matter and particles in the automatic transaxle oil pan gasket and on the magnets to predict the type of wear which might be found in the transaxle.

Steel (magnetic): bearing, gear and clutch plate wear

Brass (non-magnetic): bearing wear

10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY





(a) Remove the 3 bolts and the valve body oil strainer assembly.

(b) Remove the oil strainer gasket from the valve body oil strainer assembly.





11. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Disconnect the 5 connectors from the transmission valve body assembly.





(b) Remove the bolt and the lock plate, and separate the transmission wire.

(c) Remove the 2 bolts, manual detent spring cover and the manual detent spring.





Text in Illustration





(d) Remove the 13 bolts and the transmission valve body assembly from the transaxle case.





12. REMOVE TRANSMISSION WIRE





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

(b) Remove the O-ring from the transmission wire.





13. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET





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

14. REMOVE TRANSAXLE CASE GASKET





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

15. REMOVE BRAKE DRUM GASKET





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

16. REMOVE CHECK BALL BODY





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

17. REMOVE B-2 ACCUMULATOR PISTON





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

NOTICE:
* Blowing the 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 with the compressed air.

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





18. REMOVE C-3 ACCUMULATOR PISTON





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

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

(b) Remove the 2 C-3 accumulator piston O-rings from the C-3 accumulator piston.





19. REMOVE C-2 ACCUMULATOR PISTON





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

NOTICE:
* Blowing the 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 with the compressed air.

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





20. REMOVE TRANSAXLE HOUSING





(a) Remove the 14 bolts.

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

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

21. INSPECT INPUT SHAFT END PLAY





(a) Measure the end play in the axial direction.

End play:

0.37 to 1.29 mm (0.0146 to 0.0508 in.)

If the end play is not as specified, select and replace the thrust needle roller bearing.

22. REMOVE OIL PUMP ASSEMBLY





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

23. REMOVE DIFFERENTIAL GEAR ASSEMBLY





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

24. REMOVE OVERDRIVE BRAKE GASKET





(a) Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.

25. REMOVE INPUT SHAFT ASSEMBLY





(a) Remove the input shaft assembly from the transaxle case.

26. REMOVE STATOR SHAFT THRUST NEEDLE ROLLER BEARING





(a) Remove the stator shaft thrust needle roller bearing from the input shaft assembly.

27. REMOVE FRONT CLUTCH CLUTCH DISC

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





(b) Remove the forward clutch flange, 4 front clutch clutch discs and the 4 No. 1 clutch plates from the input shaft sub-assembly.

28. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using SST on the No. 1 clutch balancer, compress the forward clutch return spring sub-assembly with a press.





SST : 09320-89010

NOTICE:
Do not compress the return spring excessively.

(b) Using a snap ring expander, remove the snap ring.

(c) Remove the No. 1 clutch balancer and the forward clutch return spring sub-assembly.





29. REMOVE FORWARD CLUTCH PISTON

(a) Place the input shaft 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
When the piston cannot be removed due to being slanted, either blow the air again with the protruding side pushed or remove the piston using needle-nose pliers with their tips wrapped in protective tape.

30. REMOVE FORWARD CLUTCH PISTON O-RING

(a) Using a screwdriver, remove the forward clutch piston O-ring from the forward clutch piston.





31. REMOVE INPUT SHAFT OIL SEAL RING

(a) Using a screwdriver, remove the input shaft oil seal ring from the input shaft sub-assembly.





32. REMOVE FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING





(a) Remove the forward clutch hub thrust needle roller bearing from the forward clutch hub sub-assembly.

33. INSPECT INTERMEDIATE SHAFT ASSEMBLY





(a) Using a dial indicator, measure the clearance of the intermediate shaft assembly.

Standard clearance:

0.204 to 0.966 mm (0.00803 to 0.03803 in.)

If the clearance is outside the specification, replace the rear clutch drum thrust needle roller bearing.

34. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY





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