Page 123 of 969
D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-51
75 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the 1st & re-
verse brake hub correctly.
100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 in.)
HINT:
Piston stroke = Dimension A -Flange thickness
Page 124 of 969
D03815
D26396Second Brake Piston Assy
D08058
Snap Ring
C929771-W ay Clutch Sleeve Outer
40-52
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76 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 in.)
NOTICE:
Because the taper snap ring has the positioning
direction, check it when installing.
When the diameter does not meet the specified value,
replace the snap ring with new one.
After assembling, confirm that there is no clearance
between the second brake cylinder and the fitting sur-
face of the cylinder in the transaxle case.
103. INSTALL 1WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.
Page 126 of 969
D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40-54
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
78 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1 discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness - Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
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)8-
Page 128 of 969
D26470
D
D26390
D03923
D26391
Brake Apply
Tube
Clutch Apply Tube
40-56
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80 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using vernier calipers and a simple straightedge, mea-
sure the position shown in the illustration.
(f) Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value
and install it.
End play: 0.244 - 0.901 mm (0.0096 - 0.0355 in.)
NOTICE:
Make sure that the no colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
ThicknessInsideOutside
3.6 (0.1417)56.3 (2.217)75.7 (2.980)
3.8 (0.1496)56.3 (2.217)75.7 (2.980)
111. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the
transaxle case.
112. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before
installing the apply tube to the transaxle case. This pre-
vents the apply tube from being deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the transaxle
case.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.
Page 130 of 969
D26387AA
D26414
Flange
Plate Disc
D26466
Snap Ring
D08082
40-58
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82 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Apply liquid sealer to the ºAº bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A: 19.0 NVm (190 kgfVcm, 14 ftVlbf)
Other bolt: 25.0 NVm (250 kgfVcm, 18 ftVlbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle
case.
NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
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)--
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.
Page 135 of 969
D03573
D26450
Differential
Gear Assy
D25506
Thrust Bearing
Underdrive
Race No.2Underdrive Planetary
Gear Assy
Forward Clutch
Assy
Differential Gear Assy
Forward Clutch
Assy
D25505
Thrust
Needle
Roller Bearing
Differential Gear Assy
Underdrive Planetary
Gear Assy
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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87 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
126. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assy to the transaxle case.
128. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the un-
derdrive planetary gear assy.
129. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula
and values of Dimension E and F that ware measured
when installing cylindrical roller bearing and underdrive
planetary gear. Select an appropriate underdrive plane-
tary gear thrust bearing race No. 2 which satisfies the spe-
cified end play value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 in.)
HINT:
End play = Dimension F - Dimension E - thrust bearing thick-
ness 2.5 mm (0.0984 in.) - underdrive thrust bearing race No.
2 thickness.
Race thickness: mm (in.)
F - EThickness
Less than 7.72 (0.3039)3.5 (0.138)
7.72 (0.3039)3.8 (0.150)
Page 141 of 969
D03554
Check Ball
C83129
C83128
C83127
D03636AT F
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-69
93 Author: Date:
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 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.
