Page 148 of 969
D25586
O-ring
D03647
SST
D03648
D03653
D03654
SST
40-76
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
100 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE FRONT OIL PUMP BODY O-RING
(a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.
8. REMOVE FRONT OIL PUMP OIL SEAL
(a) Mount oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump body.
SST 09308-00010
9. INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Standard inside diameter:
38.113 - 38.138 mm (1.50051 - 1.50149 in.)
Maximum inside diameter: 38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body sub-assy.
10. INSPECT STATOR SHAFT ASSY
(a) Using a dial indicator, measure the inside diameter of the
stator shaft.
Standard inside diameter:
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the indicator diameter is greater than maximum, replace the
stator shaft.
11. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the oil
pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of the oil pump.
(b) Coat the lip of the oil seal with MP grease.
Page 149 of 969
C55817
O-ring
D09206
MarkOil Pump
Driven
Gear
D09206
Mark
Oil
Pump
Drive
Gear
D03651
D26627
Clutch Drum
Oil Seal Ring
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
40-77
101 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
12. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat the new O-ring with ATF, install it to the oil pump
body.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.
13. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, install it to
the oil pump body with the marked side up.
14. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, install it to the
oil pump body with the marked side up.
15. INSTALL STATOR SHAFT ASSY
(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
16. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new clutch drum oil seal rings with ATF.
(b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
Page 150 of 969
D09205
40-78
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
102 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
Page 151 of 969
400H1-02
D26715
D26753
Snap Ring
D26754
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-79
103 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.
Page 152 of 969
D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
40-80
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
104 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if
replace all discs.
Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(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 sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove,
preventing the spring sheet from deforming.
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.
Page 153 of 969
D09211
Forward Clutch Re-
turn Spring
D03664
C56374
D25587
A
D26707Forward Clutch Piston
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-81
105 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
5. INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 26.74 mm (1.0528 in.)
6. REMOVE FORWARD CLUTCH PISTON SUB-ASSY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the oil pump
to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
7. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring to the input shaft.
8. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the new input shaft oil seal ring from both sides
to reduce dimension A.
Dimension A: 5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input
shaft.
NOTICE:
Do not expand the gap of the oil seal ring too much. Fix the
hooks certainly.
9. INSTALL FORWARD CLUTCH PISTON SUB-ASSY
(a) Coat the forward clutch piston with ATF, and install it to the
input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.
Page 154 of 969
D26708
Forward Clutch
Return SpringInput Shaft
D26709
Clutch BalancerInput Shaft
D26418
SST
Snap Ring
D26788
Stopper
Stopper
40-82
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
106 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
10. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward
clutch balancer.
Install the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.
Apply enough ATF to the sealing lip prior to assem-
bling.
(d) Place SST on the clutch balancer, and compress the
clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
Page 155 of 969
D26415
Flange
Plate Disc
D26753
Snap Ring
D26715
D03672
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-83
107 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
12. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kgfVcm
2, 4.0 kPa, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.00 (0.1181)43.45 (0.1358)
23.15 (0.1240)53.60 (0.1417)
33.30 (0.1299)--
13. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.
