Part 2

U660F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

11. INSTALL NO. 2 BRAKE DISC

(a) Install the 5 brake discs, 5 brake plates and brake flange to the transaxle case.

Text in Illustration

NOTICE:
Make sure that the discs, plates and flange are installed in the correct order.

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

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

12. INSPECT CLEARANCE OF NO. 2 BRAKE Transaxle Unit

13. INSTALL PLANETARY RING GEAR FLANGE

(a) Install the planetary ring gear flange to the planetary ring gear.

Text in Illustration

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

Text in Illustration

NOTICE:
Confirm that the snap ring is correctly located in the groove of the planetary ring gear.

14. INSTALL PLANETARY RING GEAR

(a) Install the planetary ring gear to the one-way clutch assembly.

Text in Illustration

NOTICE:
Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration.

15. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF, and install it onto the planetary gear assembly.

Bearing Diameter: mm (in.)

NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(b) Install the one-way clutch assembly to the transaxle case.

Text in Illustration

NOTICE:
Make sure that there is no clearance between the retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer will be deformed.

(c) Using a screwdriver, install the snap ring to the transaxle case.

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

16. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE

(a) Using SST and a hammer, install a new counter driven gear rear tapered roller bearing outer race to the transaxle case.

SST : 09950-60010

09951-00650

SST : 09950-70010

09951-07100

NOTICE:
Be sure to install the counter driven gear rear tapered roller bearing outer race so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

17. INSTALL PARKING LOCK PAWL

(a) Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.

Text in Illustration

(b) Install the parking lock pawl pin to the transaxle case.

Text in Illustration

NOTICE:
Make sure that one end of the spring is set in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.

18. INSTALL PARKING LOCK SLEEVE

(a) Install the parking lock sleeve to the transaxle case.

19. INSTALL PAWL STOPPER PLATE

(a) Install the pawl stopper plate to the transaxle case with the 2 bolts.

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

20. INSTALL PAWL SHAFT CLAMP

(a) Install the pawl shaft clamp to the transaxle case with the bolt.

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

21. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

(a) Using SST and a press, install a new counter driven gear rear tapered roller bearing to the counter driven gear sub-assembly.

SST : 09950-60010

09951-00420

NOTICE:
Be sure to install the counter driven gear rear tapered roller bearing and the differential drive pinion so that there is no clearance between each of them and the counter driven gear.

22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install a new counter driven gear front tapered roller bearing to the counter driven gear sub-assembly.

SST : 09950-60010

09951-00530

NOTICE:
Be sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

23. INSTALL COUNTER DRIVEN GEAR

(a) Install the counter driven gear sub-assembly to the transaxle case.

24. INSTALL COUNTER DRIVE GEAR NUT

(a) Turn the manual valve lever 2 notches counterclockwise to set it to the P position as shown in the illustration.

(b) Using SST, install a new counter drive gear nut.

SST : 09387-00130

Torque : 120 Nm (1223 kgf-cm, 88 ft-lbf)

(c) Turn the manual valve lever 2 notches clockwise to set it to the N position as shown in the illustration.

(d) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm.

SST : 09387-00130

Turning torque:

0.1 to 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.9 in.*lbf)

If the measured value is not within the specified range, gradually tighten the nut until the turning toque falls within the specified range.

Maximum torque:

180 N*m (1835 kgf*cm, 132 ft.*lbf)

(e) Using SST and a hammer, stake the planetary gear assembly.

SST : 09930-00010

25. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Differential Case

26. INSTALL FRONT DIFFERENTIAL CASE

(a) Install the front differential case to the transaxle case.

27. INSTALL NO. 1 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

Text in Illustration

NOTICE:
Ensure that the O-rings are not twisted.

(b) Install the No. 1 brake piston to the oil pump assembly.

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

28. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the 3 2nd brake piston return springs to the oil pump assembly.

NOTICE:
Make sure that the 3 2nd brake piston return springs are installed onto the protrusions on the oil pump assembly.

29. INSTALL NO. 1 BRAKE DISC

(a) Install the 4 No. 1 brake discs, 4 No. 1 brake plates and No. 1 brake flange to the oil pump assembly.

Text in Illustration

NOTICE:
* Make sure that the discs, plates, and flange are installed in the correct order.
* Be sure to install the flange in the correct direction.

(b) Place SST on the flange and compress the flange using a press.

SST : 09387-00070

SST : 09495-65040

NOTICE:
Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

(c) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#1).

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the oil pump.
* Make sure to align the protruding part of the snap ring with the indented part (#1) of the front oil pump assembly shown in the illustration to install the snap ring.

(d) Install the brake snap ring stopper to the oil pump assembly.

NOTICE:
Be sure to install the brake snap ring stopper in the correct direction.

(e) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#2).

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the oil pump.
* Make sure to align the protruding part of the snap ring with the indented part (#2) of the front oil pump assembly shown in the illustration to install the snap ring.

(f) Check that the brake snap ring stopper can be turned by hand.

NOTICE:
If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the oil pump. Remove and reinstall the snap ring and the brake snap ring stopper.