Page 156 of 969
400H2-02
D26426
D26427
40-84
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
108 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
DIRECT CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft and needle roller bearing on
the transaxle rear cover .
(b) Using a dial indicator, measure the reverse clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
Page 157 of 969
D26419
Snap Ring
D26420
D26718
D26422
D26719
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40-85
109 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 3 discs,, 3 plates and cushion plate
from the intermediate shaft.
4. INSPECT DIRECT 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 a
part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at
least 15 minutes.
5. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the inter-
mediate shaft.
6. INSPECT OVERDRIVE DIRECT 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 a
part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at
least 15 minutes.
Page 158 of 969
D03677
SST
D26424
Clutch
Balancer
Direct Clutch
Drum
D26423
Direct Clutch
Drum
Overdrive
Clutch Return
Spring
D09211
Overdrive Clutch
Return Spring
40-86
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
11 0 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(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 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.
(c) Remove the clutch balancer from the direct clutch drum.
(d) Remove the overdrive clutch return spring from the direct
clutch drum.
8. INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)
Page 159 of 969
D26463
D26425
D26464
O-ring
D26464
O-ring
D26462
Intermediate
ShaftDirect Clutch
Drum
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40-87
111 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install intermediate shaft on the transaxle rear cover.
(b) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch piston.
10. REMOVE OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Holding the direct clutch drum by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
rear cover to remove the direct clutch drum.
11. REMOVE OVERDRIVE DIRECT CLUCH O-RING
(a) Using a screwdriver, remove the O-ring from the direct
clutch drum.
12. INSTALL OVERDRIVE DIRECT CLUCH O-RING
(a) Coat a O-ring with ATF, and install it to the direct clutch
drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
13. INSTALL OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Coat the direct clutch drum with ATF, and install it to the
intermediate shaft.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the direct
clutch drum.
Page 160 of 969
D26461
Overdrive Direct
Clutch Piston
D26423
Overdrive
Clutch Return
Spring
D26424
Clutch
BalancerDirect Clutch
Drum
D03677
SST
40-88
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
11 2 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
14. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Apply the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.
15. INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the piston return spring to the direct clutch drum.
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 direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct
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 pis-
ton return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to the di-
rect clutch drum.
(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
grove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
Page 161 of 969
D25588
Stopper
Stopper
D26417
Disc Flange
Plate
D26421
Snap Ring
D26416
Disc Flange
Plate
Cushion
Plate
D26419
Snap Ring
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40-89
11 3 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(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.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate
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.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.
NOTICE:
Install the cushion plate with the mark on the white
surface facing to plate.
Be careful about the order of discs, plates and flange
assembly.
(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.
Page 162 of 969
D26426
D26427
D26428
40-90
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
11 4 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)53.4 (0.134)
23.1 (0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)--
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
02.5 (0.098)42.9 (0.114)
12.6 (0.102)53.0 (0.118)
22.7 (0.106)63.1 (0.122)
32.8 (0.110)--
(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.
Page 163 of 969
4006I-03
D26703
SST
D26704
2nd Brake Piston
Return Spring
C89124
2nd Brake Piston
Return Spring
D26705
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40-91
11 5 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.
