Page 3609 of 5135
C68212
D25110
C68213
C67875
C67876
40±60
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
8. INSPECT DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
9. REMOVE DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Put a match±mark on the direct clutch drum at the same
position with the cutout of the intermediate shaft assy.
(b) Apply compressed air into the oil hole shown in the il-
lustration and remove the direct clutch drum from the in-
termediate shaft.
10. INSPECT INTERMEDIATE SHAFT SUB±ASSY
[ 35708G / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
11. REMOVE DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Using a screwdriver, remove the 2 O±rings.
12. REMOVE DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Using a screwdriver, remove the O±ring.
Page 3610 of 5135
C67876
C67875
D25111
C68200
C67871
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±61
U340E A/T REPAIR MANUAL (RM824E)
13. INSTALL DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Coat the O±ring with ATF, install it to the direct clutch
drum.
NOTICE:
Be careful not to damage the O±ring.
14. INSTALL DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Coat the 2 O±rings with ATF, install them to the direct
clutch piston.
NOTICE:
Be careful not to damage the O±ring.
15. INSTALL DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Coat the direct clutch drum with ATF.
(b) Aligning the cutout in the intermediate shaft assy with the
match±mark on the direct clutch drum, install the direct
clutch drum to the intermediate shaft assy.
NOTICE:
Be careful not to damage the O±ring and clutch drum's lip.
16. INSTALL DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Coat the direct clutch piston with ATF, install it to the inter-
mediate shaft.
NOTICE:
Do not damage the O±ring the direct clutch piston's.
17. INSTALL DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Install the direct clutch return spring on the direct clutch
piston.
(b) Place SST on the piston return spring and compress the
springs with a press.
SST 09387±00020
(c) Using a snap ring expander , install the snap ring from the
direct clutch drum.
Page 3611 of 5135
D25112
Disc
Flange
Plate
D25113
Disc
Flange
Plate
D25114
40±62
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
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, preventing the spring sheet from the deform-
ing.
Do not expand the snap ring excessively.
18. INSTALL DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Coat the 3 plates, 3 discs and flange with ATF, install them
to the intermediate shaft.
(b) Install the snap ring.
19. INSTALL FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Install the 2 plates, 2 discs and a flange.
(b) Install the snap ring.
20. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the forward and reverse clutch and thrust 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 kgfcm
2, 57 psi)
Pack clearance:
0.86 ± 1.26 mm (0.0339 ± 0.0496 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again.
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Flange Thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)
Page 3612 of 5135
D25115
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±63
U340E A/T REPAIR MANUAL (RM824E)
21. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct and reverse clutch and thrust needle roll-
er bearing on the transaxle rear cover.
(b) Using a dial indicator and measuring terminal (SST),
measure the forward clutch pack clearance while apply-
ing and releasing compressed air (392 kPa, 4.0 kgfcm
2,
57 psi)
SST 09350±36010 (09350±06110)
HINT:
The direct and reverse clutch will come out as you apply the
compressed air. Therefore, while the checking is being done,
press on the input shaft of the direct and reverse clutch using
stamping machine or alike so that the pressure is not applied
on the direct and reverse clutch.
Pack clearance:
0.62 ± 1.02 mm (0.0244 ± 0.0402 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again..
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Selected flange thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)
Page 3613 of 5135
9808Y±01
± COMPONENTS151350
98±11
4301/FRONT AXLE HOUSING & DIFFERENTIAL
(0008± )NZE121..ATM U340E
Page 3614 of 5135
0103N±01
± INTRODUCTIONSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL01±11
U241E A/T REPAIR MANUAL (RM840U)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltmmmmN´mkgf´cmft´lbfN´mkgf´cmft´lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.´lbf
9
19
35
55
836
14
29
53
84
±60
145
290
540
850
±52 in.´lbf
10
21
39
61
±
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.´lbf
12
24
43
67
1017.5
17.5
36
65
100
±75
175
360
670
1,050
±65 in.´lbf
13
26
48
76
±
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.´lbf
14
29
53
80
1279
21
44
80
125
±90
210
440
810
1,250
±78 in.´lbf
15
32
59
90
±
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
±120
290
590
1,050
1,700
±9
21
43
76
123
±
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130
Page 3615 of 5135
0103M±01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
01±10± INTRODUCTIONSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
U241E A/T REPAIR MANUAL (RM840U)
STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
HOW TO DETERMINE BOLT STRENGTH
Page 3616 of 5135
4006V±01
C83194
C83195
C83196
C83197
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±97
U241E A/T REPAIR MANUAL (RM840U)
TRANSMISSION VALVE BODY ASSY (U241E)
OVERHAUL
1. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the bolt and line pressure control solenoid assy.
2. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1.
3. REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL.
4. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2.