Page 1953 of 3000

AX–248U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress a 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 end gap of the oil seal ring
too much. Fix the hooks firmly.
2. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Coat the forward clutch piston with ATF, and install it
to the input shaft.
NOTICE:
Be careful not to damage the lip of the forward
clutch piston.
3. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub-assembly, check that
all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the input shaft.
NOTICE:
• Be careful not to damage the lip of the
forward clutch balancer.
• Make sure that the clutch balancer is not
pinched and that there are no other defects at
the lip.
• Apply sufficient ATF to the sealing lip before
installation.
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U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–249
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(d) Place SST on the clutch balancer, and compress
the clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure that the end gap of the snap ring is not
aligned with the spring retainer claw.
NOTICE:
• Stop the press when the spring seat is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
• This prevents the spring seat from being
deformed.
• Do not expand the snap ring excessively.
(g) Set the end gap of the snap ring in the piston as
shown in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
4. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Make sure that the plates, discs, and flange are
installed as shown in the illustration.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
5. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
HINT:
(See page AX-247)
6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
HINT:
(See page AX-247)
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Page 1955 of 3000
AX–272U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
DISASSEMBLY
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the ring gear and
differential case.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential
case assembly.
(b) Remove the differential case No.2 from the
differential case LH.
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U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–273
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(c) Remove the front differential side gear, front
differential side gear thrust washer, conical spring
and center differential side gear thrust washer No.2
from the differential case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and hammer, remove 3 straight
pins.
(f) Remove the center differential pinion shaft and 2
differential pinion shafts.
(g) Remove 4 front differential pinions, 4 front
differential pinion thrust washers, front differential
pinion shaft holder, front differential planetary ring
and differential side gear thrust washer No.1.
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AX–274U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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3. REMOVE FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case rear
tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-60010
(09951-00480)
(b) Using SST, remove the front differential case rear
tapered roller bearing outer race and differential
case washer.
SST 09308-00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the 15 bolts.
(b) Place the matchmarks on the differential
intermediate case and differential case.
(c) Remove the differential intermediate case from the
differential case RH.
(d) Remove the center differential side gear, conical
spring washer and center differential side gear
thrust washer No.1 RH from the differential case
RH.
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U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–275
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(e) Remove the differential spider, 5 center differential
pinions and 5 center differential pinion thrust
washers from the differential intermediate case.
5. REMOVE FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front
tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030
SST 09950-60010 (09951-00600)
(b) Using SST, remove the front differential case front
tapered roller bearing outer race and differential
case washer.
SST 09308-00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100)
SST 09649-17010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
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AX–246U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCH
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(d) Remove the forward clutch return spring from the
input shaft.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply
compressed 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,
blow air again with the protruding side pushed, or
remove the piston using the needle nose pliers with
vinyl tape on the tip.
5. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring from the input
shaft.
INSPECTION
1. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil
pump.
(b) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the clearance is not as specified, inspect the
discs, plates and flange.
HINT:
If the opening is large, cover it with a shop rug or a
piece of cloth to prevent the compressed air from
being released.
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U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–247
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2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check 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 if
a part of the groove is worn, replace all discs.
• Before installing new discs, immerse them in ATF
for at least 15 minutes.
3. INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(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.)
4. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kgf/cm
2, 4.0 kPa, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the piston stroke is less than the minimum, parts
may be assembled incorrectly. Check and
reassemble the parts again.
If the clearance is not as specified, select another
flange.
HINT:
There are 5 different thicknesses of flanges
available.
Flange thickness: mm (in.)
5. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the
forward clutch assembly after inserting the multiple
disc clutch into it.
NOTICE:
Do not place the forward clutch assembly in a
vise.
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No. Thickness No. Thickness
1 3.00 (0.1181) 4 3.45 (0.1358)
2 3.15 (0.1240) 5 3.60 (0.1417)
3 3.30 (0.1299) - -
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