Page 141 of 969
D03554
Check Ball
C83129
C83128
C83127
D03636AT F
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40-69
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
143. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Regarding the installation of the spring for the check ball
body, be sure to place the spring in the hole in the ball body.
Be careful about the parts orientation.
144. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
146. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
147. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, install it to the transmission
wire.
NOTICE:
Be careful about the O-ring not to have a twist, a protrusion
and a pinching during installing the wire transmission to
the transaxle case. Moreover, apply enough ATF to the O-
ring prior to assembling.
Page 142 of 969
D03547
Transmission Wire
C91927
GFE
A
B
C
D
C91933
A
CB
B
A
C
C91932
O-ring
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the transmission wire retaining bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
148. CONNECT TRANSMISSION WIRE
(a) Coat a O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor, with the lock plate and
bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
Connect the connector to A, B, C, D, E, F, G, from
shorter one.
Apply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
Bolt length:
Bolt A: 41 mm (1.614 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
When installing the valve body to the transaxle case,
do not hold the solenoids.
Tighten temporarily those bolts marked by in the il-
lustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF, install it to the oil strainer.
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.
Page 143 of 969
C91931
Valve Body Oil
Strainer Assy.
C86316
Magnet
C91925
D26716
D03900D30672
Speed Sensor
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
NOTICE:
Apply ATF to the bolts.
151. I N S TA L L A U TO M AT I C T R A N S A X L E O I L PA N
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
NOTICE:
Because the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within 10 min-
utes after application.
Remove any oil or grease from the contacting surface
of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat the 4 new O-rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque: 11.0 NVm (115 kgfVcm, 8 ftVlbf)
Page 144 of 969
C83144
Elbow
O-ring
C83143
Union
O-ring
D09639
D09640Control Shaft Lever
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 NVm (276 kgfVcm, 20 ftVlbf)
155. INS TALL OIL CO O LE R TUBE UNIO N (INLE T OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 NVm (70 kgfVcm, 61 in.Vlbf)
(c) Temporarily install control shaft lever.
Page 145 of 969
D09641
D09642
D09643
D09644
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 NVm (70 kgfVcm, 61 ftVlbf)
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
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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 152 of 969
D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
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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
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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.
