Part 1

U760E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

1. BEARING POSITION

(a) Check bearing position and installation direction.

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 driven in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

(a) 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.

(b) 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 slot with the notches on the manual valve lever shaft 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 2 new O-rings with ATF and install them to the No. 3 brake piston.

NOTICE:
Ensure that the 2 O-rings are not twisted.

(b) Temporarily install the No. 3 brake piston to the transaxle case.

NOTICE:
After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned.

(d) Press the No. 3 brake piston into 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.

HINT
Use the installation surface of the return spring to press the piston into the transaxle case.

(e) Remove the 2 bolts and pawl stopper plate from the transaxle case.

(f) Install the brake piston return spring to the transaxle case.

NOTICE:
Install the brake piston return spring as shown in the illustration.

(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 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 brake piston return spring as shown in the illustration.

8. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, install a new bearing inner race (front side) to the counter drive gear.

SST : 09387-00020

(b) Using SST, install a new 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 a new front 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 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. 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 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.

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 correctly located in the groove of the planetary ring gear.

15. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the one-way clutch assembly.

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

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

(c) 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.

(d) 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.

(e) 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 FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE Reassembly

17. INSTALL TRANSAXLE CASE OIL SEAL Reassembly

18. 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

09951-00630

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.

19. 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 secured in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.

20. INSTALL PARKING LOCK SLEEVE

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

21. 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)

22. INSTALL NO. 1 TRANSMISSION CASE PLATE

(a) Install the No. 1 transmission case plate to the transaxle case with a new bolt.

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

HINT
Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case as shown in the illustration.

23. 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)

24. 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

09951-00490

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.

25. 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

09951-00400

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.

26. INSTALL COUNTER DRIVEN GEAR

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

27. INSTALL COUNTER DRIVE GEAR NUT

(a) Turn the manual valve lever shaft 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 : 150 Nm (1530 kgf-cm, 110 ft-lbf)

(c) Turn the manual valve lever shaft 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 0.8 N*m (1 to 8 kgf*cm, 1 to 7 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

28. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Differential Case

29. INSTALL FRONT DIFFERENTIAL CASE

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

30. 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 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.

31. 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.