Part 2
U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY - (Continued)
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.
(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 : 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.
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) Install the underdrive clutch into 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 to 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 overdrive 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 overdrive direct clutch drum.
