Page 3617 of 5135
C83198
C83198
C83197
C83196
40±98
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4.
6. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
7. INSTALL MANUAL VALVE
(a) Coat the manual valve with ATF, install it to the valve body assy.
8. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the bolt and shift solenoid valve S4.
9. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the bolt and shift solenoid valve SL2.
10. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the bolt and shift solenoid valve DSL.
Page 3618 of 5135
C83195
C83194
D03553
A C
B
C A
CA
B B
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±99
U241E A/T REPAIR MANUAL (RM840U)
11. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the bolt and shift solenoid valve SL1.
12. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the bolt and line pressure control solenoid assy.
13. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Align the groove of the manual valve with the pin of lever.
(b) Install the 17 bolts.
Torque: 11 Nm (110 kgfcm, 8 ftlbf)
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 41 mm (1.614 in.)
Bolt C: 45 mm (1.771 in.)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
Tighten those bolts marked by in the illustration
first temporarily because they are positioning bolts.
Page 3619 of 5135
4006U±01
D25594
SST
D03686
SST
D03687
D25609
SST 40±92
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
UNDERDRIVE PLANETARY GEAR ASSY (U241E)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST a torque wrench, measure the turning torque
of U/D planetary gear assy while rotating the torque
wrench at 60 rpm.
SST 09387±00050, 09564±16020
Turning torque at 60 rpm:
0.23 ± 5.01 Nm (2 ± 51 kgfcm, 2.0 ± 44.3 in.lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, loosen the staked part of the nut.
SST 09930±00010 (09931±00010, 09931±00020),
09387±00050
(b) Clamp the U/D planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(c) Using SST, remove lock nut.
SST 09564±16020
Page 3620 of 5135
D03689
SST
SST
D03690
SST
D03691
SST SST
D03826
D03827
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
40±93
U241E A/T REPAIR MANUAL (RM840U)
(d) Using SST, remove cylindrical roller bearing inner race.
SST 09950±00020, 09950±00030, 09950±60010
(09951±00340)
3. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Using SST and press, remove the differential drive pinion,
parking lock gear, counter driven gear with U/D planetary
ring gear and front tapered roller bearing.
SST 09387±00050
(b) Clamp the U/D planetary gear in soft jaw vise.
(c) Using SST, remove rear tapered roller bearing form the
U/D planetary gear.
SST 09950±00020, 09950±00030, 09950±60010
(09951±00320)
4. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.
(b) Remove the U/D planetary ring gear from the counter
driven gear.
Page 3621 of 5135
D08112
D08113
D08114
SST
SST
D03827
D03826
40±94
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the tapered roll-
er bearing.
(b) Using a piston ring compressor, squeeze the snap ring.
(c) Using SST a press, press in the outer race of the tapered
roller bearing.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07100)
(d) Install the underdrive planetary ring gear to the counter
driven gear.
(e) Using snap ring pliers, install the snap ring.
Page 3622 of 5135
D03692
D08117
D08118
SSTSST
D03694
D08120
SST
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
40±95
U241E A/T REPAIR MANUAL (RM840U)
6. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, install the tapered roller bearing.
(b) Install the counter driven gear with planetary ring gear to
the U/D planetary gear.
(c) Using SST and a press, press in the tapered roller bear-
ing.
SST 09316±60011 (09316±00011)
NOTICE:
Press in the counter driven gear while rotating it.
(d) Using a press, install the parking lock gear.
NOTICE:
Press in the counter driven gear while rotating it.
(e) Using SST and a press, install the differential drive pinion.
NOTICE:
Press in the counter driven gear while rotating it.
SST 09506±35010, 09950±60010 (09951±00250)
Page 3623 of 5135

D08121
SST
D25609
SST
D25594
SST
D03852
40±96
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(f) Using SST and a press, in the cylindrical roller bearing in-
ner race.
NOTICE:
Press in the counter driven gear while rotating it.
SST 09506±35010, 09950±60010 (09951±00250)
(g) Clamp the U/D planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(h) Using SST, install a new lock nut.
Torque: 280 Nm (2,855 kgfcm, 207 in.lbf)
SST 09564±16020
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
(i) Using SST and a torque wrench, measure the turning
torque of U/D planetary gear assy while rotating the
torque wrench at 60 rpm.
SST 09564±16020, 09387±00050
Turning torque at 60 rpm:
0.23 ± 5.01 Nm (2 ± 51 kgfcm, 2.0 ± 44.3 in.lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(j) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.
Page 3624 of 5135
4006T±01
D08123
D08124
D08125
D08126
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±87
U241E A/T REPAIR MANUAL (RM840U)
UNDERDRIVE CLUTCH ASSY (U241E)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Inspect the U/D 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 U/D clutch pack clearance while applying
and releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Pack clearance: 1.51 ± 1.90 mm (0.0594 ± 0.0748 in.)
If the pack clearance is non±standard, inspect the discs, plates
and flange.
2. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 3 discs and 3 plates from the U/D
clutch drum.