Part 1
U660E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY
1. BEARING POSITION
2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat the lip of a new manual valve lever shaft oil seal with MP grease.
(b) Using SST and a hammer, install the manual valve lever shaft oil seal to the transaxle case.
SST : 09950-60010
09951-00230
SST : 09950-70010
09951-07100
Oil seal installation depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
3. INSTALL MANUAL VALVE LEVER SHAFT
(a) Install a new spacer to the parking lock lever sub-assembly.
(b) Install the parking lock lever sub-assembly to the manual valve lever shaft.
(c) Install a new spacer to the manual valve lever sub-assembly.
(d) Install the manual valve lever sub-assembly to the manual valve lever shaft.
(e) Install the manual valve lever shaft to the transaxle case.
NOTICE:
Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft to the transaxle case.
(f) Using a pin punch (3 mm) and hammer, install a new slotted spring pin to the parking lock lever sub-assembly.
(g) Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft.
(h) Using a pin punch, stake the spacer through the small hole.
(i) Check that the spacer does not turn.
(j) Using a pin punch (3 mm) and hammer, install a new slotted spring pin to the manual valve lever sub-assembly.
(k) Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft.
(l) Using a pin punch, stake the spacer through the small hole.
(m) Check that the spacer does not turn.
(n) Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case.
4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Align the dial with the notches on the parking lock lever sub-assembly and install the parking lock rod sub-assembly.
5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
(a) Install the manual detent spring sub-assembly and cover to the transaxle case with the bolt.
Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)
NOTICE:
Make sure to install the manual detent spring first and then the cover.
6. INSTALL COUNTER DRIVE GEAR BEARING
NOTICE:
Perform this procedure only when the counter drive gear bearing or transaxle case is replaced.
(a) Using SST and a press, install a new counter drive gear bearing and snap ring to the transaxle case.
SST : 09950-60020
09951-01030
SST : 09950-70010
09951-07100
7. INSTALL NO. 3 BRAKE PISTON
(a) Coat the contact surface of the transaxle case with ATF.
(b) Coat the lip seal of the No. 3 brake piston with ATF.
(c) Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts.
(d) Press the return spring installation surface to install the No. 3 brake piston to the transaxle case.
NOTICE:
* Make sure that the lip of the No. 3 brake piston is not twisted and does not get caught in the transaxle case.
* After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned.
(e) Install the return spring to the transaxle case.
(f) Remove the 2 bolts and pawl stopper plate from the transaxle case.
(g) Place SST on the brake piston return spring and compress the brake piston return spring with a press.
SST : 09387-00070
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.
(h) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.
NOTICE:
* Confirm that the snap ring is secured in the groove of the transaxle case.
* Be sure to align the opening ends of the snap ring with the protrusions on the brake piston return spring as shown in the illustration.
8. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, install the bearing inner race (front side) to the counter drive gear.
SST : 09387-00020
(b) Install the bearing inner race (rear side) and counter drive gear to the transaxle case.
SST : 09223-15030
SST : 09527-17011
SST : 09950-60020
09951-00810
SST : 09950-70010
09951-07100
NOTICE:
There should not be any clearance between the bearing inner race (front side) and counter drive gear.
9. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Using SST and a press, press in the planetary gear assembly to the transaxle case.
SST : 09223-15030
SST : 09527-17011
SST : 09951-01100
10. INSTALL NO. 2 BRAKE PISTON
(a) Coat 2 new O-rings with ATF and install them to the No. 2 brake piston.
NOTICE:
Ensure that the 2 O-rings are not twisted.
(b) Install the No. 2 brake piston to the transaxle case.
NOTICE:
Be careful not to damage the O-rings.
11. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the 1st and reverse brake return spring to the transaxle case.
(b) Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring with a press.
SST : 09387-00060
NOTICE:
Stop the press when the 1st and reverse brake return spring is flush with the snap ring groove. This prevents the 1st and reverse brake return spring from being deformed.
(c) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.
NOTICE:
* Confirm that the snap ring is secured in the groove of the transaxle case.
* Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case as shown in the illustration.
12. INSTALL NO. 2 BRAKE DISC
(a) Install the 5 brake discs, 5 brake plates, and brake flange to the transaxle case.
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 secured in the groove of the transaxle case.
* Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case as shown in the illustration.
13. INSPECT CLEARANCE OF NO. 2 BRAKE Transaxle Unit
14. INSTALL PLANETARY RING GEAR FLANGE
(a) Install the planetary ring gear flange to the planetary ring gear.
(b) Using a screwdriver, install the snap ring to the planetary ring gear.
NOTICE:
Confirm that the snap ring is secured in the groove of the planetary ring gear.
15. INSTALL PLANETARY RING GEAR
(a) Install the planetary ring gear to the one-way clutch assembly.
NOTICE:
Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration.
16. 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:
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.
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 secured in the groove of the transaxle case.
* Be sure to align the opening ends of the snap ring with the protrusions on the transaxle case.
17. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE
(a) Using SST and a hammer, install the 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.
18. INSTALL PARKING LOCK PAWL
(a) Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.
(b) Install the parking lock pawl pin to the transaxle case.
(c) Install the torsion spring to the parking lock pawl.
NOTICE:
Make sure that one end of the spring is fixed in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.
19. INSTALL PARKING LOCK SLEEVE
(a) Install the parking lock sleeve to the transaxle case.
20. 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)
21. 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)
22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install a new the 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 REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install a new the 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.
24. INSTALL COUNTER DRIVEN GEAR
(a) Install the counter driven gear sub-assembly to the transaxle case.
25. INSTALL COUNTER DRIVE GEAR NUT
(a) Turn the manual shaft lever 2 notches counterclockwise to set it in the P position as shown in the illustration.
(b) Using SST, install a new nut.
SST : 09387-00130
Torque : 120 Nm (1,223 kgf-cm, 88 ft-lbf)
(c) Turn the manual shaft lever 2 notches clockwise to set it in 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:
0.10 to 0.22 N*m (1.02 to 2.24 kgf*cm, 0.89 to 1.94 in.*lbf)
When 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 (1,835 kgf*cm, 132 ft.*lbf)
(e) Using SST and a hammer, stake the planetary gear assembly.
SST : 09930-00010
26. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the differential case sub-assembly to the transaxle case.
27. INSPECT DIFFERENTIAL SIDE GEAR Differential Case
28. INSTALL NO. 1 BRAKE PISTON
(a) Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.
NOTICE:
Ensure that the 2 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.
29. 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 straight through the protrusions on the oil pump assembly.
30. INSTALL NO. 1 BRAKE DISC
(a) Install the 4 brake discs, 4 brake plates, and brake flange to the oil pump assembly.
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 with 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 the snap ring is fixed in the groove of the oil pump assembly.
* Be sure to align the opening ends of the snap ring with the protrusions on the oil pump assembly as shown in the illustration.
(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 secured in the groove of the oil pump assembly.
* Be sure to align the opening ends of the snap ring with the protrusions on the oil pump assembly as shown in the illustration.
(f) Check that the brake snap ring stopper can be turned by hand.
NOTICE:
If the snap ring stopper cannot be turned by hand, the snap ring stopper may have been installed upside down, or the snap ring may have not been completely filled in the groove on the oil pump. Remove and install the snap ring and the brake snap ring stopper.