Page 164 of 969
D26706
O-ring
O-ring
D26706
O-ring
O-ring
D26775
D26704
2nd Brake Piston
Return Spring
40-92
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
11 6 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE 2ND BRAKE PISTON O-RING
(a) Remove the 2 O-rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O-RING
(a) Apply the 2 new O-rings with ATF, install them in the 2nd
brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
6. INSTALL 2ND BRAKE PISTON
(a) Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.
NOTICE:
Be careful not to damage the O-ring.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Install the 2nd brake piston return spring.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
Page 165 of 969
D26703
SST
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40-93
11 7 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387-00060
(c) Using a screwdriver, install the snap ring.
(d) 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.
Page 166 of 969
400H3-02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40-94
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
11 8 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.
Page 167 of 969
D04077
D08129
D03703
SST
Snap Ring
C56359
Clutch
Balancer
Underdrive
Clutch Drum
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
40-95
11 9 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(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. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
underdrive clutch drum bushing.
Standard drum bushing:
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)
If the inside diameter is greater than the maximum, replace the
underdrive clutch drum.
6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(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 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 underdrive clutch
drum.
Page 168 of 969
C56360
D03824
D03705
D26465
O-ring
D26465
O-ring
40-96
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
120 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Apply the new O-ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
Page 169 of 969
D03860
C56360
Underdrive
Clutch
Return
Spring
Underdrive
Clutch Drum
C56359
Clutch
Balancer
Underdrive
Clutch Drum
D03703
SST
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
40-97
121 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, install it to the
underdrive clutch piston drum.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the piston.
12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the underdrive 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 underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to the un-
derdrive 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 170 of 969
D25592
StopperStopper
D26431
Disc
Flange
Plate
D03701
D26429
40-98
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
122 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the underdrive clutch
drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.
13. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive
clutch drum.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
14. INSTALL UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
15. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf/cm
2,
57 psi).
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)--
Page 171 of 969
4006K-03
D25593
SST Underdrive
Planetary Gear
D25594
SST
D03686
SST
D03687
Underdrive
Planetary Gear
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-99
123 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050
(b) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
