Page 3665 of 5135
D03917
D03596
SST
D03918
SST
D08074
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±43
U241E A/T REPAIR MANUAL (RM840U)
(c) Install the front planetary gear washer, as shown in the il-
lustration.
(d) Using SST, install the nut.
SST 09387±00030, 09387±00080
Torque: 268 Nm (2,728 kgfcm, 197 ftlbf)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09950±60010 (09951±00400), 09950±70010
(09951±07100), 09387±00030, 09387±00080
Turning torque at 60 rpm:
New Bearing
0.5 ± 1.0 Nm (5.1 ± 10.0 kgfcm, 4.4 ± 8.7 in.lbf)
Used Bearing
0.3 ± 0.5 Nm (3.1 ± 5.1 kgfcm, 2.7 ± 4.4 in.lbf)
(f) Using a chesel and hammer, stake the front planetary
gear washer.
Page 3666 of 5135
D03873
D03593
D03910
D08062
D03616
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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
83. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
Bearing and race diameter: mm (in.)
insideoutside
Bearing34.6 (1.362)52.2 (2.055)
Race40.3 (1.587)58.0 (2.283)
Bearing38.6 (1.520)60.0 (2.362)
84. INSTALL REAR PLANETARY GEAR ASSY
(a) Coat a bearing race with ATF, install it to the rear planetary
gear assy.
Bearing race diameter: mm (in.)
insideoutside
Race38.6 (1.520)58.0 (2.283)
(b) Install the planetary carrier thrust washer No. 2 to the
planetary gear assy.
(c) Install the rear planetary gear to the rear planetary ring
gear.
(d) Using a screwdriver, install the snap ring to the brake hub.
Page 3667 of 5135

D09190
D03618
A
D03815
D03619
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U241E A/T REPAIR MANUAL (RM840U)
85. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
86. 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 piston stroke will
meet the specified value.
Pack clearance:
1.02 ± 1.21 mm (0.0402 ± 0.0476 in.)
HINT:
Piston stroke = Dimension A ±Flange thickness
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.
87. INSTALL 2ND BRAKE CYLINDER
(a) Install the 2nd 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 satisfy the specified val-
ue, replace the snap ring with new one.
Page 3668 of 5135
D08078
D03909
D09638
Groove
Free
D03588
D03908
40±46
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
88. INSTALL 1WAY CLUTCH SLEEVE OUTER
(a) Install the 1±way clutch outer sleeve to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.
89. INSTALL 1 WAY CLUTCH ASSY
(a) Install the inner race to the 1±way clutch.
NOTICE:
Check the direction of the inner race.
(b) Check the rotating direction of 1±way clutch for the lock
or free operation, as shown in illustration.
(c) Install the 1±way clutch and bearing to the 1±way clutch
outer race sleeve.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.6 (2.740)
NOTICE:
Install the thrust bearing properly so that no±colored race
will be visible.
90. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 1 with petro-
leum jelly, install it onto the rear planetary sun gear.
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D03791
D03587
D09162
D09163
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
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U241E A/T REPAIR MANUAL (RM840U)
(b) Coat the bearing with petroleum jelly, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Bearing33.8 (1.331)48.2 (1.898)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
91. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle case.
(b) Temporarily install the snap ring.
92. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and snap ring surface.
(b) Select an appropriate flange so that the piston stroke will
meet the specified value.
Pack clearance: 0.62 ± 0.91 mm (0.0244 ± 0.0358 in.)
HINT:
Piston stroke = Clearance ± Flange thickness ± Snap ring thick-
ness 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±
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D03623
D03802
D03586
D03624
B
D03922
Dimension (1) Dimension (2) 40±48
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(c) Temporarily remove the snap ring, attach the selected
flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.
93. INSTALL DIRECT CLUTCH ASSY
(a) Install the bearing race to the direct clutch.
Bearing race diameter : mm (in.)
InsideOutside
Bearing race30.3 (1.193)46.0 (1.811)
(b) Install direct clutch assy and thrust needle roller bearing
to the rear planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely mate with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and rear
cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between the
the transaxle case and the straight edge using vernier cal-
ipers. (Dimension B)
(e) Measure the 2 places of the rear cover as shown in the
illustration and calculate a dimension C using the follow-
ing formula.
HINT:
Dimension C = Dimension (1) ± Dimension (2)
(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: 0.198 ± 0.936 mm (0.00800 ± 0.03685 in.)
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D03591
D03923
D03923
D25510
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
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U241E A/T REPAIR MANUAL (RM840U)
NOTICE:
Make sure that the colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension C ± Dimension B
Bearing thickness and diameter : mm (in.)
ThicknessInsideOutside
3.55 (0.1397)53.6 (2.110)69.6 (2.740)
3.85 (0.1515)53.6 (2.110)70.18 (2.763)
94. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install 2 new apply gaskets to the transaxle case.
95. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe before
installing the apply pipe to the transaxle case. This pre-
vents the apply pipe from being deformed or damaged.
96. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe before
installing the apply pipe to the transaxle case. This pre-
vents the apply pipe from being deformed or damaged.
(b) Install the 2 apply tubes and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.
Page 3672 of 5135
C83141
D09193
C83140
D09194
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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
97. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install 2 transaxle case No. 1 plugs to the transaxle rear
cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
98. INSTALL TRANSAXLE REAR COVER SUB±ASSY
(a) Using SST and a press, install the bearing.
SST 09950±60010 (09951±00230, 09951±00350)
Press fit depth: 12.05 ± 12.75 mm (0.4744 ± 0.5020 in.)
NOTICE:
Face the inscribed mark side of the bearing race up.
Repeat the press fit until the specified value is ob-
tained.
(b) Apply liquid sealer to the 2 screws.
Sealant:
Part No. 08833±00080, THREE BOND 2430 or equiva-
lent.
(c) Using a torx socket wrench T30, install the transaxle rear
cover plate with the 2 screws.
Torque: 7.5 Nm (76 kgfcm, 66 in.lbf)
(d) Coat 2 new oil seal rings with ATF, install them to the
transaxle rear cover.