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01-6 INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

0103C-05

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
ASSY Assembly
ATF Automatic Transaxle Fluid
B3 U/D Brake
C2 Reverse Clutch
C3 U/D Clutch
FIPG Formed In Place Gasket
O/D Overdrive
SSM Special Service Materials
SST Special Service Tools
U/D Underdrive
w/ With
w/o Without
1st First
2nd Second

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-1

TRANSAXLE (U151E/U151F)

AUTOMATIC TRANSMISSION / TRANSAXLE (U151E/U151F)

4010I-01

COMPONENTS
U151E:

Speed Sensor
Speed Sensor
11.3 (158, 8)

11.3 (158, 8) Automatic Transmission

Case Plug
7.4 (75, 65 in.⋅lbf)
5.4 (55, 48 in.⋅lbf)

Transmission Wire
O-Ring
 O-Ring

Union
25 (255, 18)
Automatic Transmission
 O-Ring
Case Plug
7.4 (75, 65 in.⋅lbf)  O-Ring

 O-Ring

 O-Ring Automatic Transmission

Elbow Case Plug
27 (276, 20) 7.4 (75, 65 in.⋅lbf)

 Drain Plug Gasket

Drain Plug
47 (479, 34)

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part C86320

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40-2 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

U151E: Transaxle Rear Cover

Automatic Transaxle
Case Sub-assy Bolt A: 18.6 (190, 14)
Transaxle Apply Tube Clamp Other bolt: 24.5 (250, 18)
Case Plug
9.8 (100, 87 in.⋅lbf)
7.4 (75, 65 in.⋅lbf) x 11

29 (295, 21)
 O-Ring

x8

x3

 O-Ring Governor Apply Gasket

Transaxle Case
33 (337, 24) Differential Gear 2nd Brake Gasket
Lube Apply Tube
x5 Brake Drum Gasket
 Spacer
 25 (255, 18)
Retainer Spring
Sloted Spring Pin
Transmission Valve Body Assy Manual Valve Lever Shaft
Manual Valve Lever Shaft Oil Seal
5.4 (55, 48 in.⋅lbf)

6.9 (70, 61 in.⋅lbf)

Parking Lock Park/ Neutral Control Shaft Lever

11 (110, 8)
Rod Sub-assy Position Switch
x 17
13 (130, 9)
 Oil Strainer Gasket
Nut Stopper
Oil Cleaner Parking Lock
Magnet Pawl Bracket
Valve Body Spring Washer
Oil Strainer Assy Compression Spring
Check Ball
11 (110, 8 )
Body
20 (205, 15)
C-3 Accumulator
 Automatic Transaxle Manual Detent Piston
Oil Pan Gasket Spring Sub-assy Compression Spring

20 (205, 15)

 O-Ring
11.8 (120, 9)

Reverse Clutch
Automatic Transaxle
x 18  O-Ring
Accumulator Piston Compression
Oil Pan Sub-assy
 7.8 (80, 69 in.⋅lbf) Spring
 O-Ring B-3 Accumulator
N·m (kgf·cm, ft·lbf) : Specified torque  O-Ring Piston
 Non-reusable part
 Precoated part
C89119

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-3

TRANSAXLE (U151E/U151F)

U151E: Thrust Needle Thrust Needle  O/D Brake gasket

Roller Bearing Roller Bearing

Forward Clutch Assy

Oil Pump Assy
Counter
Drive Gear
Counter Drive
Thrust Needle Gear Bearing
22 (226, 16)
Roller Bearing
x7  Washer

Multiple
Disc Clutch Nut Flange
Clutch Hub 210 (2,141, 155) - 350 (3,569, 258)

Thrust Bearing Plate Front Planetary

1st & Reverse Race No. 1 Gear Assy
Brake Piston
Snap Ring
O-Ring
Snap Ring
Brake Hub
Disc
Snap Ring
1st & Reverse Brake Flange
Rear Planetary
Counter Drive Return Spring Plate
Sun Gear Assy
Gear Bearing
Second Brake Piston Assy Front Planetary
Ring Gear Thrust Bearing Race

1-W ay Clutch Assy

Disc
Snap Ring 1-W ay Clutch Sleeve Outer
Rear Planetary
Gear Assy Thrust Needle
Thrust Bearing
Race No. 2 Roller Bearing
Thrust Needle 1-W ay Clutch
Planetary Carrier
Roller Bearing Inner Race
Thrust Washer No. 2
Snap Ring Planetary Carrier Thrust Needle
Thrust Needle Thrust Washer No. 1 Roller Bearing
Transaxle Rear Cover
Roller Bearing
Input Sun Gear
Thrust Bearing
Thrust Bearing

Direct Clutch Assy

Thrust Bearing Race

 Needle Roller Bearing
O/D Direct
Clutch Hub Sub-assy Outer Rear Clutch Oil Seal Ring

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part D26457

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-4 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

U151E:

Underdrive Clutch Assy Plate

Underdrive Brake Piston
Flange
Underdrive
Snap Ring
Planetary  Needle Roller
Gear Assy Bearing
Thrust Bearing
Underdrive Race No. 2

Disc
Underdrive 1-Way Underdrive Clutch
Clutch Assy Drum Oil Seal Ring
Bearing Race Snap Ring
 O-Ring
Thrust Bearing Underdrive Brake Return
Spring Sub-assy
Thrust Needle
Roller Bearing

Parking Lock Pawl

Parking Lock Pawl Shaft

Torsion
Spring
9.8 (100, 87 in.⋅lbf)

Parking Lock Pawl Pin

Pawl Shaft Clamp

Front Differential Assy

Clutch Apply Tube

Brake Apply Tube

5.4 (55, 48 in.⋅lbf)

Transaxle Apply
Tube Clamp
N·m (kgf·cm, ft·lbf) : Specified torque
 Governor Apply Gasket No. 1
 Non-reusable part D26594

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-5

TRANSAXLE (U151E/U151F)

U151F:

69 (704, 51)

Gascket
39 (387, 29)
X6 Speed Sensor

Speed Sensor 11.3 (158, 8)

Transmission Wire 11.3 (158, 8)

5.4 (55, 48 in.⋅lbf)

Automatic Transmission
Case Plug
7.4 (75, 65 in.⋅lbf)

O-Ring

 O-Ring
Union
27 (275, 20)

Automatic Transmission O-Ring

Case Plug
7.4 (75, 65 in.⋅lbf)
 O-Ring

Elbow  O-Ring
27 (276, 20)

 O-Ring
Automatic Transmission
Case Plug

 Drain Plug Gasket

Drain Plug
49 (500, 36)

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part C86315

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40-6 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

U151F: Transaxle Rear Cover

Automatic Transaxle
Case Sub-assy Bolt A: 18.6 (190, 14)
Transaxle Apply Tube Clamp Other bolt: 24.5 (250, 18)
Case Plug
9.8 (100, 87 in.⋅lbf)
7.4 (75, 65 in.⋅lbf) x 11

29.4 (300, 21.7)

 O-Ring

x8

 O-Ring Governor Apply Gasket

Transaxle Case
x3 Differential Gear
33 (337, 24) 2nd Brake Gasket
Lube Apply Tube
x5 Brake Drum Gasket
 Spacer
 25 (255, 18)
Retainer Spring
Sloted Spring Pin
Transmission Valve Body Assy Manual Valve Lever Shaft
Manual Valve Lever Shaft Oil Seal
5.4 (55, 48 in.⋅lbf)

6.9 (70, 61 in.⋅lbf)

Parking Lock Park/ Neutral Control Shaft Lever

11 (110, 8)
Rod Sub-assy Position Switch
x 17
13 (130, 9)
 Oil Strainer Gasket
Nut Stopper
Oil Cleaner Parking Lock
Magnet Pawl Bracket
Valve Body Washer
Spring
Oil Strainer Assy Compression Spring
Check Ball
11 (110, 8 ) Body
20.1 (205, 15)
C-3 Accumulator
 Automatic Transaxle Manual Detent Piston
Oil Pan Gasket Spring Sub-assy Compression Spring

20 (205, 15)

 O-Ring
12 (120, 9)

Reverse Clutch
Automatic Transaxle
x 18  O-Ring
Accumulator Piston Compression
Oil Pan Sub-assy
 7.8 (80, 69 in.⋅lbf) Spring
 O-Ring B-3 Accumulator
N·m (kgf·cm, ft·lbf) : Specified torque  O-Ring Piston
 Non-reusable part
 Precoated part
C89116

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-7

TRANSAXLE (U151E/U151F)

U151F: Thrust Needle Thrust Needle  O/D Brake gasket

Roller Bearing Roller Bearing

Forward Clutch Assy

Oil Pump Assy
Counter
Drive Gear
Counter Drive
Thrust Needle Gear Bearing
22 (226, 16)
Roller Bearing
x7  Washer

Multiple
Disc Clutch Nut Flange
Clutch Hub 210 (2,141, 155) - 350 (3,569, 258)

Thrust Bearing Plate Front Planetary

1st & Reverse Race No. 1 Gear Assy
Brake Piston
Snap Ring
O-Ring
Snap Ring
Brake Hub
Disc
Snap Ring
1st & Reverse Brake Flange
Rear Planetary
Counter Drive Return Spring Plate
Sun Gear Assy
Gear Bearing
Second Brake Piston Assy Front Planetary
Ring Gear Thrust Bearing Race

1-W ay Clutch Assy

Disc
Snap Ring 1-W ay Clutch Outer Sleeve
Rear Planetary
Gear Assy Thrust Needle
Thrust Bearing
Race No. 2 Roller Bearing
Thrust Needle 1-W ay Clutch Planetary Carrier
Roller Bearing Inner Race Thrust Washer No. 2
Snap Ring Planetary Carrier Thrust Needle
Thrust Needle Thrust Washer No. 1 Roller Bearing
Transaxle Rear Cover
Roller Bearing
Input Sun Gear
Thrust Bearing
Thrust Bearing

Direct Clutch Assy

Thrust Bearing Race

 Needle Roller Bearing
O/D Direct
Clutch Hub Sub-assy Outer Rear Clutch Oil Seal Ring

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part D26457

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-8 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

U151F: Underdrive Brake Piston

 Needle Roller
Underdrive Clutch Assy Plate Bearing
Flange
Underdrive Planetary Snap Ring
Gear Assy

Thrust Bearing
Underdrive Race No. 2
Disc

Underdrive 1-Way
Underdrive Clutch
Clutch Assy
Drum Oil Seal Ring
Thrust Bearing Race Snap Ring
 O-Ring
Needle Roller Bearing Underdrive Brake Return
Spring Sub-assy
Thrust Needle
Roller Bearing

Parking Lock Pawl

Parking Lock Pawl Shaft Torsion

Spring

9.8 (100, 87 in.⋅lbf)

Parking Lock Pawl Pin

Pawl Shaft Clamp

Clutch Apply Tube

Brake Apply Tube

Front Differential Assy

5.4 (55, 48 in.⋅lbf)

Transaxle Apply
Tube Clamp

N·m (kgf·cm, ft·lbf) : Specified torque

 Governor Apply Gasket No. 1
 Non-reusable part C89125

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-9

TRANSAXLE (U151E/U151F)

Stator Shaft Assy

9.8 (100, 87 in.⋅lbf)

Oil Pump Body Oil Pump Driven Gear

 O-ring
x11

Clutch Drum
Oil Seal Ring

Oil Pump Drive Gear

 Front Oil Pump Oil Seal

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part
Apply petroleum jelly
D03643

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-10 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

Disc Cushion Plate

Flange

Snap Ring

Plate

Plate

Disc

Flange
Snap Ring
Overdrive Direct
Overdrive Direct Clutch Piston
Clutch Balancer

 O-ring

Intermediate Shaft

Overdrive Direct Clutch

Overdrive Direct Clutch Drum Sub-assy
Snap Ring Return Spring Sub-assy

 Non-reusable part
D26471

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-1 1

TRANSAXLE (U151E/U151F)

Forward Clutch Return Spring Sub-assy

Forward Clutch Balancer

Forward Clutch Piston Sub-assy Snap Ring
Forward Clutch Drum

Input Shaft Oil Seal Ring

Snap Ring
Flange

Plate

Disc

 Non-reusable part
C89127

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-12 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

2nd Brake Cylinder

2nd Brake Piston

Snap Ring

 O-ring

2nd Brake Piston Return Spring Sub-assy

 Non-reusable part

D26702

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-13

TRANSAXLE (U151E/U151F)

Cylindrical
Roller Bearing
Inner Race

Parking Lock Gear

Underdrive Planetary
Lock Nut Differential Ring Gear
 280 (2,855, 207)
Drive Pinion

 Radial Ball Bearing FR

Snap Ring

Underdrive Planetary Gear

Counter Driven Gear

 Radial Ball Bearing RR

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part D03683

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-14 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

Plate

Flange

Snap Ring

Underdrive Clutch Drum

Disc Underdrive Clutch Piston Set

 O-ring

Underdrive Clutch Pis-

ton
Return Spring

Snap Ring

 Non-reusable part
D03697

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-15

TRANSAXLE (U151E/U151F)

Shift Solenoid Valve S4

Shift Solenoid Valve SR 10.8 (110, 8)

10.8 (110, 8)

6.6 (67, 58 in.⋅lbf)

Shift Solenoid Valve SL2

Line Pressure
Control Solenoid Assy

Shift Solenoid Valve SL3

6.6 (67, 58 in.⋅lbf) 10.8 (110, 8)

Shift Solenoid Valve DSL

Shift Solenoid Valve SL1

N·m (kgf·cm, ft·lbf) : Specified torque

C89117

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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40-16 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)

U151E: Differential Pinion Thrust Washer

Transaxle Housing
Differential Pinion Shaft

Pin Differential Side Gear

 Oil Seal
Differential Side Gear
Thrust Washer

Differential Pinion
Differential Ring Gear

 Tapered Roller Bearing FR

 Bearing Outer Race

Differential Case

95.1 (970, 70)

x14  Oil Seal

 Bearing Outer Race

Shim
 Tapered Roller Bearing RR

N·m (kgf·cm, ft·lbf) : Specified torque

 Non-reusable part D03761

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION / 40-17

TRANSAXLE (U151E/U151F)

U151F: Differential RH Case

Center Differential
Side Gear
Bearing Race Conical Spring

Center Differential
Side Gear Thrust
 Oil Seal Washer No.1
Tapered Roller
Bearing Front Differential
Pinion Shaft
Pin
Front Differential Front Differential
Side Gear Pinion Thrust Washer
Front Differential
Pinion Shaft Holder
Front Differential
95.1 (970, 70) Case No.2 Pinion Shaft
Spacer Snap
Center Differential Ring
Pinion Thrust Washer
x16 Front Differential
Pinion Shaft

Front Differential
Center Differential Front Differential
x15 Side Gear Thrust Pinion
Pinion Spider Washer
63 (642, 46)
Differential
Intermediate
Center Differential Pinion Case
 Oil Seal

Front Differential
Side Gear Thrust
Washer Differential Ring Gear

Center Differential
Side Gear Thrust
Washer No.2

Plate Washer

Bearing Race
Conical
Spring Differential
LH Case
Front Differential
Side Gear Tapered Roller Bearing
N·m (kgf·cm, ft·lbf) : Specified torque
 Non-reusable part D03707

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-7

MANUAL
0103D-09

GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE TOYOTA TERMS
SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure -
CAC Charge Air Cooler Inter cooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
CTP Closed Throttle Potion -
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition -
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Communication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode -
ECL Engine Control Level -
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Control Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only memory
Electrically Erasable Programmable Read Only
EEPROM (EEPROM),
memory
Erasable Programmable Read Only memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
Flash Electrically Erasable Programmable
FEEPROM -
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idol Air Control Idol Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module -
IFI Indirect Fuel Injection Indirect Injection
IFS Inertia Fuel-Shutoff -
U151E, U151F A/T REPAIR MANUAL (RM1021U)

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01-8 INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL

ISC Idle Speed Control -

KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure -
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface temperature -
MVZ Manifold Vacuum Zone -
NVRAM Non-V olatile Random Access Memory -
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD On-Board Diagnostic On-Board Diagnostic (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CC0
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module -
PNP Park/Neutral Position -
PROM Programmable Read Only Memory -
PSP Power Steering Pressure -
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module -
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass -
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter -
SRI Service Reminder Indicator -
SRT System Readiness Test -
ST Scan Tool -
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU (Electronic Control Unit)
TP Throttle Position Throttle Position
TR Transmission Range -
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three-W ay Catalytic (TWC)
TWC Three-W ay Catalytic Converter
CCRO
TWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCO
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type)
WOT Wide Open Throttle Full Throttle

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-9

MANUAL

WU-OC Warm Up Oxidation Catalytic Converter -

WU-TWC Warm Up Three-Way Catalytic Converter Manifold Converter
3GR Third Gear -
4GR Fourth Gear -

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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SERVICE SPECIFICATIONS - STANDARD BOLT FOR AUTOMATIC TRANSAXLE 03-3

REPAIR MANUAL
030JM-02

HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut

4N

No Mark

5N (4T)

No Mark (w/ Washer) No Mark (w/ Washer) No Mark

6N
6N

7N (5T)

8N
8N

10N (7T)
10N

No Mark

11N
11N

12N
12N

*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
U151E, U151F A/T REPAIR MANUAL (RM1021U)

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SERVICE SPECIFICATIONS - STANDARD BOLT FOR AUTOMATIC TRANSAXLE 03-1

REPAIR MANUAL

STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR

MANUAL
030JK-02

HOW TO DETERMINE BOLT STRENGTH

Mark Class Mark Class

Hexagon head 4- 4T Hexagon
bolt flange bolt 4
Bolt 5- 5T
Protruding 9T
head No. 6- 6T w/ washer lines
7- 7T hexagon bolt
8- 8T Hexagon
9- 9T flange bolt 5
10- 10T Protruding 10T
w/ washer lines
11- 11T
hexagon bolt
Hexagon
flange bolt 6
No mark 4T Protruding 11T
w/ washer lines
hexagon bolt
Hexagon Stud bolt No mark
flange bolt
No mark 4T
w/ washer
hexagon bolt 4T

Hexagon head
bolt 2
Protruding 5T
lines
Grooved
Hexagon
flange bolt 2
Protruding 6T 6T
w/ washer
lines
hexagon bolt
Hexagon head
bolt 3
Protruding 7T Welded bolt
lines

Hexagon head
4T
bolt 4
Protruding 8T
lines

V06821

U151E, U151F A/T REPAIR MANUAL (RM1021U)

Author
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INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-1

MANUAL

HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR

MANUAL
0103A-09

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removal and Installation, Replacement, Disassembly, Installation and Check, and Adjustment
3. Final Inspection
(c) This manual explains ”Removal and Installation, Replacement, Disassembly, Installation and Check,
and Adjustment”, but ”Final inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a reference to help find the item
to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) A component illustration is placed under the title where necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non-reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
component illustrations.
Example:

Stator Shaft Assy Oil Seal Ring

Oil Pump Drive Gear

Oil Seal
x13

10 (100, 7)

Oil Pump Driven Gear

O-ring
N·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part
U250E A/T REPAIR MANUAL (RM1123U) D25697

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MANUAL

(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In these cases, all
the information such as torque, oil, etc. are described in the illustration.
(e) The installation procedures are the reverse order of the removal procedures. However, only installation
procedures requiring additional information are included.
(f) Only items with key points are described in the text. What to do and other details are placed in illustra-
tions next to the text. Both the text and illustrations are accompanied by standard values and notices.
(g) Illustrations of similar vehicle models are sometimes used. In these cases, specific details may be dif-
ferent from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:

Illustration: Task heading: what to do

what to do and where
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING

(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Detailed text:
how to do task

Set part No. Component part No.

D26831

HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. The specifications are also found
in the Service Specifications section for quick reference.

6. TERMS DEFINITION
CAUTION Indicates the possibility of injury to you or other people.
NOTICE Indicates the possibility of damage to the components being repaired.
HINT Provides additional information to help you perform the repair efficiently.

U250E A/T REPAIR MANUAL (RM1123U)

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MANUAL

7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English system.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

U250E A/T REPAIR MANUAL (RM1123U)

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INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-1

MANUAL

HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR

MANUAL
0103A-07

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains” Removing and Installing, Replacing, Disassembling ,Instaling and Checking,
Adjusting” , but” Final inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the” disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non-reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:

Stator Shaft Assy Oil Seal Ring

Oil Pump Drive Gear

Oil Seal
x13

10 (100, 7)

Oil Pump Driven Gear

O-ring
N·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U) D25697

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01-2 INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL

(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc are described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:

Illustration: Task heading: what to do

what to do and where
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING

(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Detailed text:
how to do task

Set part No. Component part No.

D26831

HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.

6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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: Date
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INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-3

MANUAL

7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE

AUTOMATIC TRANSMISSION / TRANSAXLE

0305K-11

SERVICE DATA
Oil pump
Body clearance STD 0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Max. 0.17 mm (0.0067 in.)
Tip clearance STD 0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Max. 0.15 mm (0.0059 in.)
Side clearance STD 0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Max. 0.05 mm (0.0020 in.)
Drive gear thickness Mark
A 11.690 - 11.699 mm (0.4602 - 0.4606 in.)
B 11.700 - 11.709 mm (0.4606 - 0.4610 in.)
C 11.710 - 11.720 mm (0.4610 - 0.4614 in.)
D 11.721 - 11.730 mm (0.4615 - 0.4618 in.)
E 11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Driven gear thickness Mark
A 11.690 - 11.699 mm (0.4602 - 0.4606 in.)
B 11.700 - 11.709 mm (0.4606 - 0.4610 in.)
C 11.710 - 11.720 mm (0.4610 - 0.4614 in.)
D 11.721 - 11.730 mm (0.4615 - 0.4618 in.)
E 11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Pump body bushing inside diameter STD 38.113 - 38.138 mm (1.50050 - 1.50149 in.)
Max. 38.188 mm (1.50346 in.)
Stator shaft bushing inside diameter STD 21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Max. 21.57 mm (0.8492 in.)

Multiple disc clutch

Inside diameter STD 23.025 - 23.045 mm (0.9065 - 0.9073 in.)
Max. 23.09 mm (0.9091 in.)

Forward clutch
Pack clearance 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
Return spring free length 26.74 mm (1.0528 in.)
Flange thickness Mark
1 3.00 mm (0.1181 in.)
2 3.15 mm (0.1240 in.)
3 3.30 mm (0.1299 in.)
4 3.45 mm (0.1358 in.)
5 3.60 mm (0.1417 in.)

Reverse clutch
Pack clearance: 0.60 - 0.82 mm (0.02362 - 0.03228 in.)
Flange thickness Mark
1 3.0 mm (0.118 in.)
2 3.1 mm (0.122 in.)
3 3.2 mm (0.126 in.)
4 3.3 mm (0.130 in.)
5 3.4 mm (0.134 in.)
6 3.5 mm (0.138 in.)
7 3.6 mm (0.142 in.)

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SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE

Direct clutch & O/D clutch

Pack clearance 0.61 - 0.83 mm (0.02401 - 0.03268 in.)
Return spring free length 25.91 mm (1.0201 in.)
Flange thickness Mark
0 2.5 mm (0.098 in.)
1 2.6 mm (0.102 in.)
2 2.7 mm (0.106 in.)
3 2.8 mm (0.110 in.)
4 2.9 mm (0.114 in.)
5 3.0 mm (0.118 in.)
6 3.1 mm (0.122 in.)

2nd brake
Pack clearance 0.62 - 0.91 mm (0.0244 - 0.0358 in.)
Return spring free length 16.61 mm (0.6539 in.)

Flange thickness Mark

1 3.0 mm (0.118 in.)
2 3.1 mm (0.122 in.)
3 3.2 mm (0.126 in.)
4 3.3 mm (0.130 in.)
5 3.4 mm (0.134 in.)
6 3.5 mm (0.138 in.)
7 3.6 mm (0.142 in.)

U/D clutch
Pack clearance 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
U/D clutch drum bushing inside diameter STD 37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Max. 37.13 mm (1.4618 in.)
Return spring free length 17.14 mm (0.6752 in.)
Flange thickness Mark
1 3.0 mm (0.118 in.)
2 3.1 mm (0.122 in.)
3 3.2 mm (0.126 in.)
4 3.3 mm (0.130 in.)
5 3.4 mm (0.134 in.)

U/D brake
Pack clearance 1.81 - 2.20 mm (0.0713 - 0.0866 in.)
Return spring free length 14.04 mm (0.5528 in.)
Flange thickness Mark
1 3.0 mm (0.118 in.)
2 3.2 mm (0.126 in.)
3 3.4 mm (0.134 in.)

1st & reverse brake

Pack clearance 1.16 - 1.35 mm (0.0457 - 0.0531in.)
Return spring free length 15.53 mm (0.6114 in.)
Flange thickness Mark
1 1.8 mm (0.071 in.)
2 1.9 mm (0.075 in.)
3 2.0 mm (0.079 in.)
4 2.1 mm (0.083 in.)
5 2.2 mm (0.087 in.)
6 2.3 mm (0.091 in.)
7 2.4 mm (0.094 in.)
8 2.5 mm (0.098 in.)

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SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE

U/D planetary gear

Preload (at 60 rpm) 0.50 - 1.42 N⋅m (5.1 - 14.5 kgf⋅cm, 0.06 - 0.17 in.⋅lbf)

Front planetary gear

Turning torque (at 60 rpm) New Bearing 0.51 - 1.02 N⋅m (5.1 - 10.0 kgf⋅cm, 4.4 - 8.7 in.⋅lbf)
Used Bearing 0.26 - 0.51 N⋅m (2.7 - 5.2 kgf⋅cm, 2.3 - 4.5 in.⋅lbf)

Input shaft
End play 0.262 - 1.249 mm (0.0103 - 0.0492 in.)

Transaxle rear cover

Bearing press fit depth 20.55 - 21.25 mm (0.8091 - 0.8366 in.)

Transmission valve body

Valve body installation bolt length A 41 mm (1.614 in.)
B 57 mm (2.244 in.)
C 25 mm (0.984 in.)

Accumulator
Spring Free length/Outer diameter Color
B3 Inner 62.00 (2.4409) / 15.50 (0.610) Purple
Outer 74.23 (2.9224) / 16.50 (0.649) Purple
C2 60.96 (2.3999) / 14.10 (0.555) Yellow
C3 72.20 (2.8425) / 19.0 (0.748) Colorless

Front differential(U151E)
Backlash 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
- 1.625 mm (0.0640 in.)
- 1.725 mm (0.0679 in.)
- 1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing 0.20 - 0.69 N⋅m (2.0 - 7.0 kgf⋅cm, 1.8 - 6.1 in.⋅lbf)
Used bearing 0.10 - 0.35 N⋅m (1.0 - 3.6 kgf⋅cm, 0.9 - 3.1 in.⋅lbf)
Flange thickness Mark
0 2.00 mm (0.0787 in.)
1 2.05 mm (0.0807 in.)
2 2.10 mm (0.0827 in.)
3 2.15 mm (0.0846 in.)
4 2.20 mm (0.0866 in.)
5 2.25 mm (0.0886 in.)
6 2.30 mm (0.0906 in.)
7 2.35 mm (0.0925 in.)
8 2.40 mm (0.0945 in.)
9 2.45 mm (0.0965 in.)
A 2.50 mm (0.0984 in.)
B 2.55 mm (0.1004 in.)
C 2.60 mm (0.1024 in.)
D 2.65 mm (0.1043 in.)
E 2.70 mm (0.1063 in.)
F 2.75 mm (0.1083 in.)
G 2.80 mm (0.1102 in.)
H 2.85 mm (0.1122 in.)

Front differential (U151F)

Side gear backlash 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

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SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE

Thrust washer thickness

= Clearance - 0.162 - 0.265 mm (0.0064 - 0.0104 in.)
Mark
A 0.95 mm (0.0373 in.)
B 1.00 mm (0.0393 in.)
C 1.05 mm (0.0413 in.)
D 1.10 mm (0.0433 in.)
E 1.15 mm (0.0453 in.)
F 1.20 mm (0.0472 in.)
G 1.25 mm (0.0492 in.)
H 1.30 mm (0.0512 in.)
J 1.35 mm (0.0532 in.)
K 1.40 mm (0.0552 in.)
Pinion’s backlash 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
MA 0.80 mm (0.0313 in.)
MB 0.85 mm (0.0333 in.)
MC 0.90 mm (0.0353 in.)
MD 0.95 mm (0.0373 in.)
ME 1.00 mm (0.0393 in.)
MF 1.05 mm (0.0413 in.)
MG 1.10 mm (0.0433 in.)
MH 1.15 mm (0.0453 in.)
MJ 1.20 mm (0.0472 in.)
MK 1.25 mm (0.0492 in.)
ML 1.30 mm (0.0512 in.)
MM 1.35 mm (0.0532 in.)
MN 1.40 mm (0.0552 in.)
Praload (at 60 rpm) New bearing 0.20 - 0.69 N⋅m (2.0 - 7.0 kgf⋅cm, 1.8 - 6.1 in.⋅lbf)
Used bearing 0.10 - 0.35 N⋅m (1.0 - 3.6 kgf⋅cm, 0.9 - 3.1 in.⋅lbf)
Flange thickness Mark
0 2.00 mm (0.0787 in.)
1 2.05 mm (0.0807 in.)
2 2.10 mm (0.0827 in.)
3 2.15 mm (0.0846 in.)
4 2.20 mm (0.0866 in.)
5 2.25 mm (0.0886 in.)
6 2.30 mm (0.0906 in.)
7 2.35 mm (0.0925 in.)
8 2.40 mm (0.0945 in.)
9 2.45 mm (0.0965 in.)
A 2.50 mm (0.0984 in.)
B 2.55 mm (0.1004 in.)
C 2.60 mm (0.1024 in.)
D 2.65 mm (0.1043 in.)
E 2.70 mm (0.1063 in.)
F 2.75 mm (0.1083 in.)
G 2.80 mm (0.1102 in.)
H 2.85 mm (0.1122 in.)
Oil seal press in depth 5.5 - 6.5 mm (0.217 - 0.256 in.)

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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03-2 SERVICE SPECIFICATIONS - STANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
030JL-02

SPECIFIED TORQUE FOR STANDARD BOLTS

Diameter Pitch Specified torque

Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
in.·lbf in.·lbf

in.·lbf in.·lbf

in.·lbf in.·lbf

V00079

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSMISSION / TRANS

022FX-01

PREPARATION
SST
09214-7601 1 Crankshaft Pulley Replacer FRONT DIFFERENTIAL
ASSY(U151F)

09215-00013 Crankshaft Bearing Remover & FRONT DIFFERENTIAL

Replacer Set B ASSY(U151E)

(09215-00471) Camshaft Bearing Remover & FRONT DIFFERENTIAL

Replacer ASSY(U151E)

09223-15020 Oil Seal & Bearing Replacer FRONT DIFFERENTIAL

ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)

09223-15030 Oil Seal & Bearing Replacer AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09308-00010 Oil Seal Puller FRONT DIFFERENTIAL

ASSY(U151E)
OIL PUMP ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09316-12010 Transfer Bearing Replacer FRONT DIFFERENTIAL
ASSY(U151E)

09316-2001 1 Transfer Bearing Replacer UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09350-32014 TOYOTA Automatic Transmission OIL PUMP ASSY(U151E/U151F)

Tool Set UNDERDRIVE CLUTCH
ASSY(U151E/U151F)

(09351-32070) No.2 Piston Spring Compressor UNDERDRIVE CLUTCH

ASSY(U151E/U151F)

(09351-32140) Oil Seal Replacer OIL PUMP ASSY(U151E/U151F)

09387-00020 Direct Clutch Wrench AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

09387-00030 Counter Drive Gear Holding Tool AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09387-00041 Bearing Puller Assembly AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09387-01010) Claw No.1 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09387-01021) Claw No.2 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09387-01030) Pin AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09387-01040) Bearing Puller Body AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09387-00050 Under Drive Gear Puller UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

09387-00060 Second Brake Wrench SECOND BRAKE PISTON

ASSY(U151E/U151F)

09387-00070 First & Reverse Brake Wrench AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09387-00080 Counter Drive Gear Nut Wrench AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09502-12010 Differential Bearing Replacer UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

09506-35010 Differential Drive Pinion Rear UNDERDRIVE PLANETARY GEAR

Bearing Replacer ASSY(U151E/U151F)

09514-3501 1 Rear Wheel Bearing Puller AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

09527-1701 1 Rear Axle Shaft Bearing Remover AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09550-60010 Differential Side Bearing FRONT DIFFERENTIAL

Replacer ASSY(U151E)

(09951-00490) Replacer 49 FRONT DIFFERENTIAL

ASSY(U151E)

09564-3201 1 Differential Preload Adaptor FRONT DIFFERENTIAL

ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)

09608-10010 Steering Knuckle Oil Seal FRONT DIFFERENTIAL

Replacer ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)

09649-17010 Steering Knuckle Tool AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09710-30050 Suspension Arm Bushing Replacer FRONT DIFFERENTIAL

ASSY(U151E)

09726-40010 Lower Control Shaft Bearing UNDERDRIVE PLANETARY GEAR

Replacer ASSY(U151E/U151F)

09930-00010 Drive Shaft Nut Chisel UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

(09931-00010) Handle UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

(09931-00020) Nut Chisel UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

09950-00020 Bearing Remover FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

09950-00030 Bearing Remover Attachment FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09950-4001 1 Puller B Set FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)

(09957-04010) Attachment FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)

09950-60010 Replacer Set FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

(09951-00230) Replacer 23 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09951-00260) Replacer 26 UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

(09951-00320) Replacer 32 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)

(09951-00450) Replacer 45 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09951-00480) Replacer 48 FRONT DIFFERENTIAL

ASSY(U151F)

(09951-00490) Replacer 49 FRONT DIFFERENTIAL

ASSY(U151E)

(09951-00500) Replacer 50 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

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(09951-00590) Replacer 59 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09951-00600) Replacer 60 FRONT DIFFERENTIAL

ASSY(U151F)

(09952-06010) Adapter AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

09950-60020 Replacer Set No.2 FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

(09951-00730) Replacer 73 FRONT DIFFERENTIAL

ASSY(U151F)

(09951-00750) Replacer 75 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09951-00810) Replacer 81 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)

(09951-00890) Replacer 89 FRONT DIFFERENTIAL

ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

(09951-00910) Replacer 91 FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

(09951-01030) Replacer 103 AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09950-70010 Handle Set FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

(09951-07100) Handle 100 FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

(09951-07150) Handle 150 FRONT DIFFERENTIAL

ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

Recomended Tools
09031-00030 Pin Punch AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

09031-00040 Pin Punch . FRONT DIFFERENTIAL

ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)

09905-00012 Snap Ring No.1 Expander AUTOMATIC TRANSAXLE

ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

09905-00013 Snap Ring Pliers UNDERDRIVE PLANETARY GEAR

ASSY(U151E/U151F)

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PREPARATION - AUTOMATIC TRANSMISSION / TRANS

Equipment
Dial indicator with magnetic base
Feeler gauge
Vernier calipers
Torque wrench
Plastic hammer
Straight edge
Press
Seal packing 2403, THREE BOND 2403 or equivalent
Seal packing 2430, THREE BOND 2430 or equivalent

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Lubricant
item
U151E / U151F
Automatic transaxle fluid
ATF type T-IV
Dry fill 6.8 liter (7.2 USqts, 6.0 lmp.qts)
Drain and refill 2.9 liter (3.1 USqts, 2.6 lmp.qts)

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SSM (Special Service Materials)

08826-00090 Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)

08833-00080 Adhesive 1344

THREE BOND 1344
LOCTITE 242 or equivalent

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SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE
0305L-11

TORQUE SPECIFICATION
Part Tightened N⋅m kgf⋅cm ft⋅lbf
Differential gear lube apply tube x Transaxle housing 9.8 100 87 in.⋅lbf
Front planetary gear lock nut 210-350 2141-3569 155-258
Brake apply tube clamp x Transaxle case 5.4 55 48 in.⋅lbf
Transaxle case No. 1 plug x Transaxle rear cover 7.4 75 65 in.⋅lbf
Transaxle rear cover x Transaxle case Bolt A 19 190 14
Other bolt 25 250 18
Pawl shaft clamp x Transaxle case 9.8 100 87 in.⋅lbf
Oil pump assy x Transaxle case 22 226 16
Transaxle housing x Transaxle case Bolt A 25 255 18
Bolt B 33 337 24
Bolt C 29 295 21
Bolt D 22 226 16
Automatic transmission case plug x Transaxle housing 7.4 75 65 in.⋅lbf
Automatic transmission case plug x Transaxle case 7.4 75 65 in.⋅lbf
Parking lock pawl bracket x Transaxle case 20 205 15
Manual detent spring x Transaxle case Bolt A 20 205 15
Bolt B 12 120 9
Transmission wire x Transaxle housing 5.4 55 48 in.⋅lbf
Transmission valve body x Transaxle case 11 110 8
ATF temperature sensor clamp x Transmission valve body 6.6 67 58 in⋅lbf
Valve body oil strainer assy x Transmission valve body 11 110 8
Automatic transaxle oil pan sub-assy x Transaxle case 7.8 80 69 in.⋅lbf
Drain plug x Automatic transaxle oil pan sub-assy 49 500 36
Speed sensor x Transaxle case 11 115 8
Oil cooler tube union x Transaxle case Union 27 276 20
Elbow 27 276 20
Park/neutral start switch x nut 6.9 70 61 in.⋅lbf
Park/neutral start switch x Bolt 5.4 55 48 in.⋅lbf
Park/neutral start switch x Control shaft lever 13 130 9
Speedometer driven hole cover sub-assy x Transaxle case 6.9 70 61
Oil pump body x Stator shaft assy 9.8 100 87 in.⋅lbf
Line pressure control solenoid assy x Transmission valve body assy 6.6 67 58 in.⋅lbf
Shift solenoid valve SL1x Transmission valve body assy 6.6 67 58 in.⋅lbf
Shift solenoid valve SL2x Transmission valve body assy 10.8 110 8
Shift solenoid valve SL3x Transmission valve body assy 6.6 67 58 in.⋅lbf
Shift solenoid valve S4x Transmission valve body assy 10.8 110 8
Shift solenoid valve DSL x Transmission valve body assy 10.8 110 8
Front differential case x Front differential ring gear 95.1 970 70

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

FRONT DIFFERENTIAL ASSY (U151F)

4006N-02

OVERHAUL

1. REMOVE FRONT DIFFERENTIAL RING GEAR

Match-marks (a) Place the match-marks on the ring gear and differential
case.

Front Differential Ring Gear C50182

Front Differential
(b) Remove the 16 bolts.
Ring Gear

C50183

(c) Using a plastic hammer, tap on the ring gear to remove it

from the case.

Front Differential Ring Gear C50184

2. REMOVE FRONT DIFFERENTIAL SIDE GEAR

Differential (a) Remove the differential LH case from the differential case
Case Assy assy.

Differential
LH Case

C50187

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(b) Remove the differential case No.2 from the differential

Differential
case LH.
Case No.2 Differential
Case LH

C50188

Front (c) Remove the front differential side gear, front differential
Front
Differential side gear thrust washer, conical spring and center differ-
Differential
Side Gear ential side gear thrust washer No.2 from the differential
Side Gear
Thrust Washer case LH.
Conical Spring
Center
Differential
Differential
Side Gear
Case LH
Thrust Washer
No.2 C50189

(d) Using a snap ring expander, remove the pinion shaft

spacer snap ring.

D25610

(e) Using a pin punch and a hammer, remove 3 straight pins.

C50190

(f) Remove the center differential pinion shaft and 2 differen-

tial pinion shafts.

C50191

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(g) Remove 4 front differential pinions, 4 front differential pin-

ion thrust washers, front differential pinion shaft holder,
front differential planetary ring gear and differential side
gear thrust washer No. 1.

C50943

3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED

ROLLER BEARING
Hold Turn (a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
SST
(09951-00480)
SST

D25597

(b) Using SST, remove the front differential case rear tapered
SST roller bearing outer race and differential case washer.
SST 09308-00010

D25598

4. REMOVE CENTER DIFFERENTIAL PINION

(a) Using torx socket (T50), remove the 15 bolts.

C50193

(b) Place the matchmarks on the differential intermediate

Differential
case and differential case.
RH Case
(c) Remove the differential intermediate case from the differ-
ential case RH.

Differential
Intermediate Case C50230

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(d) Remove the center differential side gear, conical spring

Differential Case RH washer and center differential side gear thrust washer No.
1 RH from the differential case RH.

Center Differential
Side Gear
C50196

(e) Remove the differential spider, 5 center differential pin-

ions and 5 center differential pinion thrust washers from
the differential intermediate case.

C50194

5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED

Hold ROLLER BEARING
Turn
(a) Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
SST (09951-00600)
SST

D25611

(b) Using SST, remove the front differential case front ta-
SST pered roller bearing outer race and differential case wash-
er.
SST 09308-00010

D25596

6. REMOVE TRANSAXLE HOUSING OIL SEAL

(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09649-17010

SST

D25599

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
SST

D25600

8. INSTALL DIFFERENTIAL CASE SUB-ASSY NO.2

(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.

C50943

(b) Using a dial indicator, measure the backlash of one pinion

gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
C50216 If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
Mark Thickness Mark Thickness
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
E 1.15 (0.0453) K 1.40 (0.0552)

Differential (c) Engage the front differential side gear to the above men-
Case LH tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.

Differential
Case No.2

C50213

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(f) Using a straight edge and feeler gauge, measure the

clearance between the front differential case and the front
differential side gear.
t= Thrust washer thickness
L= Clearance
t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.)
If the clearance is not within the specified value, refer to the
table below and select a thrust washer which will ensure that the
C50214 clearance is within the specified value.
Thrust washer thickness: mm (in.)
Mark Thickness Mark Thickness
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
E 1.15 (0.0453) K 1.40 (0.0552)

If the clearance is not within the specified value, parts may have
been assembled incorrectly, so check and reassemble it.

(g) Using a pin punch and a hammer, install 3 straight pins.

C50217

(h) Using a snap ring expander, install the pinion shaft spacer
snap ring.

D25610

9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR

Differential Case RH ASSY
(a) Install the center differential side gear, conical spring
washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.
Center Differential
Side Gear C51252

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(b) Hold the differential case RH by vice. Install the center dif-
ferential pinion and pinion thrust washer to the differential
spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH by vise, be sure to
place an aluminum sheet between them and use a mini-
mum force.

C50950

(c) Pressing and holding the differential spider toward the dif-
ferential case RH, measure the pinion’s backlash with a
dial indicator as illustrated.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
C50205 Thrust washer thickness: mm (in.)
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -

(d) Temporarily install the differential side gear thrust washer

No.2 LH, center differential side gear conical spring wash-
er and differential case No.2 to the differential case LH.
HINT:
Ensure that the conical washers is installed correctly.

C50206

(e) Install the differential intermediate case to the above and

fix them with 4 bolts.

C50207

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(f) Remove the differential spider, 5 center differential pin-

ions and 5 center differential pinion thrust washers from
the differential case RH. Put them in the differential inter-
mediate case and fix the case.

C50208

(g) Pressing and holding the differential spider toward the dif-
ferential intermediate case, measure the pinion’s back-
lash with a dial indicator.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
C50209 Thrust washer thickness: mm (in.)
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -

(h) Remove the 4 bolts and disconnect the differential case

LH from the differential intermediate case.

C50210

(i) Remove the differential case No.2 from the differential

Differential
case LH.
Case No.2
Differential
Case LH

C51468

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(j) Install the selected differential side gear thrust washer

No. 2 LH and center differential planetary gear to the dif-
ferential case LH.

C51469

(k) Install the differential case No. 2 to the differential case LH

Differential
again.
Case No.2
Differential
Case LH

C50188

(l) Install the adjusted differential case RH to the intermedi-

ate case and tighten the 15 bolts using a torx socket
wrench (T50).
Torque: 63 N⋅m (642 kgf⋅cm, 46 ft⋅lbf)
NOTICE:
Align the matchmarks.

C50193

10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED

ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing FR to the differential case.
SST
SST 09950-70010 (09951-07100), 09649-17010
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
D25612

(b) Using SST, install the outer race of the tapered roller bear-
ing FR.
SST 09527-1701 1, 09950-60020 (09951-01030)
NOTICE:
Clearance is not allowed between the plate washer and
SST transaxle housing.

D25603

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11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing RR to the differential case.
SST
SST 09316-2001 1, 09214-76011
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
D25613 (b) Install the front differential case shim RR to the transaxle
case.
If the bearing is new, check to select a front differential case
shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case
shim RR starting from the same thickness as one installed be-
fore disassembly.
(c) Using SST, install the outer race of the front differential
case tapered roller bearing RR.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
SST NOTICE:
Clearance is not allowed between the differential case
shim and transaxle case.

D25601

12. ADJUST TAPERED POLLER BEARING PRELOAD

(a) Install the intermediate case to the differential case LH
and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.

C50224

C (c) Clean the matching surfaces of the transaxle case and

B transaxle housing.
C (d) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
A Bolt A: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
Bolt B 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf)
A
Bolt C 29 N⋅m (295 kgf⋅cm, 21 ft⋅lbf)
C
C D03568 Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

(e) Using SST, turn the differential assy right and left 2or 3
times to allow the bearing settle.
SST 09564-3201 1
(f) Using SST and a torque wrench, measure the turning
torque of the differential case assy.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 N⋅m (2.0 - 7.0 kgf⋅cm, 1.8 - 6.1 in.⋅lbf)
Used bearing
0.10 - 0.35 N⋅m (1.0 - 3.6 kgf⋅cm, 0.9 - 3.1 in.⋅lbf)
SST
HINT:
If the turning torque is not within the specified value, refer to the
table below and select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
Mark Thickness Mark Thickness
0 2.00 (0.0787) 9 2.45 (0.0965)
C50227 1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)

(g) Remove the 16 bolts and the transaxle housing.

D25614

(h) Remove the differential assy.

C50224

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151F)

90 - 100
C (194 - 230
F)

13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110
C. (194.0 - 230.0
F)
NOTICE:
Do not overheat the ring gear to 110
C (230.0
F) or more.
(b) Clean the contact surface of the front differential case.

D25215

(c) Set the match-marks, install the front differential ring gear
Match-marks case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

C50186

(d) Temporarily install the 8 bolts as shown in the illustration.

C50232

(e) Remove the 4 bolts shown in the illustration.

(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1 N⋅m (970 kgf⋅cm, 70 ft⋅lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.

C50233

14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223-15020, 09950-70010 (09951-07100)
SST (b) Coat the rip of oil seal with a little MP grease.

D25605

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Vinyl Tape 15. INSTALL TRANSAXLE HOUSING OIL SEAL

(a) Wind a vinyl tape around SST at the place 6.0 mm (0.236
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
SST 09950-60020 (09951-00730)
NOTICE:
Remove foreign matter such as grease on the SST before
SST
winding the tape.
D03809 (b) Coat the rip of oil seal with a little MP grease.

(c) Using SST, install a new oil seal.

SST 09950- 60020 (09951- 00730), 09950- 70010
(09951-07150)
Standard press in depth:
5.5 - 6.5 mm (0.217 - 0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is contact with the
transaxle housing.
D25615

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

FRONT DIFFERENTIAL ASSY (U151E)

4006M-03

OVERHAUL

Front 1. REMOVE FRONT DIFFERENTIAL RING GEAR

Mark Differential (a) Place the match-marks on the front differential ring gear
Ring Gear and differential case.

D26445

(b) Remove the 14 bolts.

Front
Differential
Ring Gear

D26446

(c) Using a plastic hammer, tap on the front differential ring

gear to remove it from the case.

Front Differential Ring Gear C50237

2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED

Turn
ROLLER BEARING
Hold (a) Using SST, remove the front differential case front differ-
ential tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
SST (09951-00490), 09950-40011 (09957-04010)
SST

D25595

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

(b) Using SST, remove the front differential case front ta-
SST pered roller bearing outer race.
SST 09308-00010

D25596

3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED

ROLLER BEARING
Hold Turn
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
SST (09951-00490), 09950-40011 (09957-04010)
SST

D25597

(b) Using SST, remove the front differential case rear tapered
roller bearing outer race.
SST SST 09308-00010

D25598

4. REMOVE FRONT DIFFERENTIAL PINION SHAFT

STRAIGHT PIN
(a) Using a pin punch and hammer, install the straight pin.
NOTICE:
Before removing the straight pin, unstake it with a pin
punch.

C50240

5. REMOVE FRONT DIFFERENTIAL PINION SHAFT

Differential Case NO.1
(a) Remove the front differential pinion shaft No.1 from the
differential case.

Front Differential Pinion Shaft No.1 C50241

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Front 6. REMOVE FRONT DIFFERENTIAL SIDE GEAR

Differential (a) Remove the 2 front differential pinions, 2 pinion thrust
Side Gear washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.

Front Differential
Side Gear C50242

7. REMOVE TRANSAXLE HOUSING OIL SEAL

(a) Using SST, remove the oil seal.
SST 09950- 70010 (09951- 07100), 09215- 00013
(09215-00471)

SST
D25599

8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
SST

D25600

Front 9. INSTALL FRONT DIFFERENTIAL SIDE GEAR

Differential (a) Apply the 2 front differential side gears, 2 side gear thrust
Side Gear washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.

Front Differential
Side Gear C50242

10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1

Differential Case (a) Apply the front differential pinion shaft No.1 with ATF,
install it to the differential case.

Front Differential Pinion Shaft No.1 C50241

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11. INSPECT BACKLASH

(a) Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness
Mark Thickness
- 1.625 mm (0.0640 in.)
C50252 - 1.725 mm (0.0679 in.)
- 1.825 mm (0.0719 in.)

12. INSTALL FRONT DIFFERENTIAL PINION SHAFT

STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft
straight pin.

C50253

(b) Using a chisel and hammer, stake the differential case.

NOTICE:
Stake it after adjusting the backlash.

C50254

13. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED

ROLLER BEARING
(a) Using SST and a press, install the front differential case
rear tapered roller bearing to the differential case.
SST SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
D26447 ing inner race installation.

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

(b) Using SST and a hammer, install the front differential

case tapered roller bearing front outer race to the trans-
axle housing.
SST 09550- 60010 (09951- 00490), 09950- 60020
(09951-00910)

C83736

14. INSTALL FR DIFFERENTIAL CASE REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing to the differential case.
SST SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
D26448 ing inner race installation.

(b) Using SST and a hammer, install the front differential

case tapered roller bearing front outer race to the trans-
SST axle housing.
SST 09950- 70010 (09951- 07150), 09950- 60020
(09951-00890)
NOTICE:
Clearance is not allowed between the bearing and trans-
axle housing.
D26449

15. ADJUST DIFFERENTIAL SIDE BEARING RRELOAD

Differential Assy (a) Install the differential assy to the transaxle case.

D26450

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

C (b) Clean the matching surfaces of the transaxle case and

B transaxle housing.
C (c) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
A
Bolt A: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
C Bolt B: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf)
Bolt C: 29 N⋅m (295 kgf⋅cm, 21 ft⋅lbf)
C A D26384 Bolt D: 22 N⋅m (226 kgf⋅cm, 16.0 ft⋅lbf)
HINT:
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.

(d) Using SST, turn the differential assy right and left 2 or 3
times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 N⋅m (2.0 - 7.0 kgf⋅cm, 1.8 - 6.1 in.⋅lbf)
Used bearing
0.10 - 0.35 N⋅m (1.0 - 3.6 kgf⋅cm, 0.9 - 3.1 in.⋅lbf)
HINT:
SST If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
Mark Thickness Mark Thickness
0 2.00 (0.0787) 9 2.45 (0.0965)
D25604 1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

Mark Thickness Mark Thickness

7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)

(f) Remove the 16 bolts and the transaxle housing.

D26384

(g) Remove the differential assy.

Differential Assy

D26450

90 - 100
C (194 - 230
F) 16. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110
C (194.0 - 230.0
F).
NOTICE:
Do not overheat the ring gear to 110
C (230.0
F) or more.
(b) Clean the contact surface of the front differential case.

D25215

(c) Align the match-marks, install the front differential ring

Mark gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

D26445

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL ASSY (U151E)

(d) Tighten the 14 bolts.

Torque: 95.0 N⋅m (970 kgf⋅cm, 70 ft⋅lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.

D26446

17. INSTALL TRANSAXLE HOUSING OIL SEAL

(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)

SST
D26451

18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
SST (b) Apply the lip of the oil seal with a little MP grease.
SST 09710-30050, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)

D25606

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ASSY (U151E/U151F)

UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)

4006K-03

OVERHAUL

Underdrive 1. INSPECT UNDERDRIVE PLANETARY GEAR

Planetary Gear PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050

SST

D25593

(b) Using SST and a torque wrench, measure the turning

torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 N⋅m (5.1 - 14.5 kgf⋅cm, 0.06 - 0.17 in.⋅lbf)
SST HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
D25594

2. REMOVE FRONT PLANETARY GEAR NUT

(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050

SST

D03686

Underdrive (b) Clamp the underdrive planetary gear in soft jaw vise.
Planetary Gear NOTICE:
Be careful not to damage the differential drive pinion.

D03687

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ASSY (U151E/U151F)

(c) Using a socket wrench, remove the lock nut.

Underdrive
Planetary Gear

D25609

3. REMOVE CYLINDRICAL ROLLER BEARING RACE

Turn
INNER
Hold
(a) Using SST, remove the cylindrical roller bearing race in-
ner.
SST 09950- 00020, 09950- 00030, 09950- 60010
SST
(09951-00320), 09950-40011 (09957-04010)

D03689

4. REMOVE UNDERDRIVE PLANETARY GEAR ASSY

(a) Using SST and a press, remove the differential drive pin-
ion, parking lock gear, counter driven gear with under-
SST drive planetary ring gear and front tapered roller bearing.
SST 09950-60010 (09951-00320), 09387-00050

D26437

(b) Clamp the underdrive planetary gear in soft jaw vise.

Turn (c) Using SST, remove the rear tapered roller bearing form
the underdrive planetary gear.
Hold SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
SST
SST

D03691

5. REMOVE UNDERDRIVE PLANETARY RING GEAR

(a) Using a snap ring pliers, remove the snap ring.

Snap Ring

D03826

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ASSY (U151E/U151F)

Underdrive (b) Remove the underdrive planetary ring gear from the
Planetary Ring Gear counter driven gear.

Counter Driven Gear

D03827

6. INSTALL UNDERDRIVE PLANETARY RING GEAR

(a) Install a new snap ring to the outer race of the tapered roll-
er bearing.
HINT:
When replacing the bearing, also replace the counter driven
gear with a new one.

Snap Ring
D08112

(b) Using a piston ring compressor, squeeze the snap ring.

D08113

(c) Using SST and a press, press in the outer race of the ta-
SST pered roller bearing.
SST SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Be sure not to damage on the snap ring during the outer
race installation.

D08114

Underdrive (d) Install the underdrive planetary ring gear to the counter
Planetary Ring Gear driven gear.

Counter Driven Gear

D03827

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ASSY (U151E/U151F)

(e) Using a snap ring pliers, install the snap ring.

Snap Ring

D08115

7. INSTALL UNDERDRIVE PLANETARY GEAR ASSY

(a) Using a press, press the rear tapered roller bearing to the
underdrive planetary gear.
SST 09502- 12010, 09950- 60010 (09951- 00260),
SST
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the bearing until it becomes flat at the bottom.

D26435

(b) Install the counter driven gear with planetary ring gear to
the underdrive planetary gear.

D08117

(c) Using SST and a press, press in the front tapered roller
bearing.
SST 09502- 12010, 09950- 60010 (09951- 00260),
SST 09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the counter driven gear while rotating it.

D26436

(d) Using a press, press in the parking lock gear.

SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
SST
NOTICE:
Press the counter driven gear while rotating it.

D26433

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ASSY (U151E/U151F)

8. INSTALL DIFFERENTIAL DRIVE PINION

(a) Using a press, press the differential drive pinion.
SST 09726- 40010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
SST
NOTICE:
Press the counter driven gear while rotating it.
Differential
Drive Pinion
D26434

9. INSTALL CYLINDRICAL ROLLER BEARING RACE

INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST
SST 09506- 35010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
D26432

Underdrive 10. INSTALL FRONT PLANETARY GEAR NUT

Planetary Gear (a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 N⋅m (2,855 kgf⋅cm, 207 in.⋅lbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
D25609 in.).

11. INSPECT UNDERDRIVE PLANETARY GEAR

Underdrive PRELOAD
Planetary Gear (a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
SST Turning torque at 60 rpm.:
0.5 - 1.42 N⋅m (5.1 - 14.5 kgf⋅cm, 0.06 - 0.17 in.⋅lbf)
D25594 HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.

C56809

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

TRANSMISSION VALVE BODY ASSY (U151E/U151F)

4010J-01

OVERHAUL

1. REMOVE SHIFT SOLENOID VALVE SL3

(a) Remove the bolt and shift solenoid valve SL3 from the
valve body assy.
2. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the shift solenoid valve SLT from the valve body
assy.

C89112

3. REMOVE SHIFT SOLENOID VALVE S4

(a) Remove the bolt and shift solenoid valve S4 from the
valve body assy.

D26442

4. REMOVE SHIFT SOLENOID VALVE SR

(a) Remove the shift solenoid valve SR from the valve body
assy.

D26438

5. REMOVE SHIFT SOLENOID VALVE DSL

(a) Remove the bolt and shift solenoid valve DSL from the
valve body assy.

D26443

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6. REMOVE SHIFT SOLENOID VALVE SL2

(a) Remove the bolt and shift solenoid valve SL2 from the
valve body assy.

C89113

7. REMOVE SHIFT SOLENOID VALVE SL1

(a) Remove the bolt and shift solenoid valve SL1 from the
valve body assy.

C89115

8. REMOVE MANUAL VALVE

(a) Remove the manual valve from the valve body assy.
9. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body assy.

10. INSTALL SHIFT SOLENOID VALVE SL1

(a) Install the shift solenoid valve SL1 to the valve body assy
with the bolt.
Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)

C89115

11. INSTALL LINE PRESSURE CONTROL SOLENOID

ASSY
(a) Install the shift solenoid valve SLT to the valve body assy
with the bolt.
Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)
12. INSTALL SHIFT SOLENOID VALVE SL3
(a) Install the shift solenoid valve SL3 to the valve body assy
with the bolt.
C89112 Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

13. INSTALL SHIFT SOLENOID VALVE SL2

(a) Install the shift solenoid valve SL2 to the valve body assy
with the bolt.
Torque: 10.8 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)

C89113

14. INSTALL SHIFT SOLENOID VALVE DSL

(a) Install the shift solenoid valve DSL to the valve body assy
with the bolt.
Torque: 10.8 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)

D26443

15. INSTALL SHIFT SOLENOID VALVE SR

(a) Install the shift solenoid valve SR to the valve body assy.

D26438

16. INSTALL SHIFT SOLENOID VALVE S4

(a) Install the shift solenoid valve S4 to the valve body assy
with the bolt.
Torque: 10.8 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)

D26442

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

DIRECT CLUTCH ASSY (U151E/U151F)

400H2-02

OVERHAUL

1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft and 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 kgf/cm2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.

D26426

2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &

OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.

D26427

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH

DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.

Snap Ring

D26419

(b) Remove the flange, 3 discs,, 3 plates and cushion plate

from the intermediate shaft.

D26420

4. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH

DISC
(a) Check to see 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 even if a
part of the groove is defaced, replace all discs.
D26718
Before assembling new discs, soak them in ATF for at
least 15 minutes.
5. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the inter-
mediate shaft.

D26422

6. INSPECT OVERDRIVE DIRECT CLUTCH DISC

(a) Check to see 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 even if a
part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for at
D26719 least 15 minutes.

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

7. REMOVE OVERDRIVE CLUTCH RETURN SPRING

SUB-ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST SST 09387-00020
(b) Using a snap ring expander, remove the snap ring from
the direct clutch drum.
NOTICE:
D03677
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.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

(c) Remove the clutch balancer from the direct clutch drum.
Clutch
Balancer

Direct Clutch
Drum

D26424

(d) Remove the overdrive clutch return spring from the direct
Overdrive
Clutch Return clutch drum.
Spring
Direct Clutch
Drum

D26423

8. INSPECT OVERDRIVE CLUTCH RETURN SPRING

SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)

Overdrive Clutch
Return Spring D09211

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

9. REMOVE OVERDRIVE DIRECT CLUTCH PISTON

(a) Install intermediate shaft on the transaxle rear cover.
(b) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
transaxle rear cover to remove the direct clutch piston.

D26463

10. REMOVE OVERDRIVE DIRECT CLUTCH DRUM

SUB-ASSY
(a) Holding the direct clutch drum by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle
rear cover to remove the direct clutch drum.

D26425

11. REMOVE OVERDRIVE DIRECT CLUCH O-RING

O-ring (a) Using a screwdriver, remove the O-ring from the direct
clutch drum.

D26464

12. INSTALL OVERDRIVE DIRECT CLUCH O-RING

O-ring (a) Coat a O-ring with ATF, and install it to the direct clutch
drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.

D26464

13. INSTALL OVERDRIVE DIRECT CLUTCH DRUM

Direct Clutch SUB-ASSY
Intermediate Drum
(a) Coat the direct clutch drum with ATF, and install it to the
Shaft
intermediate shaft.
NOTICE:

Be careful not to damage the O-ring.

Be careful not to damage the lip seal of the direct
clutch drum.
D26462

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

Overdrive Direct
14. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
Clutch Piston (a) Apply the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.

D26461

15. INSTALL OVERDRIVE CLUTCH RETURN SPRING

Overdrive
SUB-ASSY
Clutch Return
(a) Install the piston return spring to the direct clutch drum.
Spring
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.

D26423

(c) Install the clutch balancer to the direct clutch drum.

Clutch NOTICE:
Direct Clutch
Be careful not to damage the lip seal of the direct
Balancer
Drum clutch balancer.

Install the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.

Apply enough ATF to the sealing lip prior to assem-
bling.
D26424

(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to the di-
SST rect clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
D03677
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

(g) Set the end gap of the snap ring in the piston shown in the
Stopper Stopper
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.

D25588

16. INSTALL OVERDRIVE DIRECT CLUTCH DISC

(a) Coat the 4 discs with ATF.
Flange (b) Install the 4 plates, 4 discs and flange to the intermediate
Disc
shaft.
Plate NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.

D26417

(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 fixed certainly in the groove of the
Snap Ring drum.

D26421

17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH

DISC
(a) Apply the 3 discs with ATF.
Flange
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
Disc intermediate shaft.
Plate NOTICE:
Cushion
Install the cushion plate with the mark on the white
Plate surface facing to plate.
D26416
Be careful about the order of discs, plates and flange
assembly.
(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 fixed certainly in the groove of the
Snap Ring drum.

D26419

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AUTOMATIC TRANSMISSION / TRANS - DIRECT CLUTCH ASSY (U151E/U151F)

18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No. Thickness No. Thickness
1 3.0 (0.118) 5 3.4 (0.134)
2 3.1 (0.122) 6 3.5 (0.138)
3 3.2 (0.126) 7 3.6 (0.142)
4 3.3 (0.130) - -

D26426

19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &

OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No. Thickness No. Thickness
0 2.5 (0.098) 4 2.9 (0.114)
1 2.6 (0.102) 5 3.0 (0.118)
2 2.7 (0.106) 6 3.1 (0.122)
3 2.8 (0.110) - -

D26427

(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

D26428

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AUTOMATIC TRANSMISSION / TRANS - SECOND BRAKE PISTON ASSY (U151E/U151F)

SECOND BRAKE PISTON ASSY (U151E/U151F)

4006I-03

OVERHAUL

1. REMOVE 2ND BRAKE PISTON RETURN SPRING

SST
SUB-ASSY
(a) Place SST on the return spring and compress.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.

D26703

(c) Remove the 2nd brake piston return spring.

2nd Brake Piston
Return Spring

D26704

2. INSPECT 2ND BRAKE PISTON RETURN SPRING

2nd Brake Piston
SUB-ASSY
Return Spring
(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.)

C89124

3. REMOVE 2ND BRAKE PISTON

(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.

D26705

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AUTOMATIC TRANSMISSION / TRANS - SECOND BRAKE PISTON ASSY (U151E/U151F)

4. REMOVE 2ND BRAKE PISTON O-RING

(a) Remove the 2 O-rings from the 2nd brake piston.

O-ring

O-ring
D26706

5. INSTALL 2ND BRAKE PISTON O-RING

(a) Apply the 2 new O-rings with ATF, install them in the 2nd
brake piston.
NOTICE:
O-ring Assemble the O-ring carefully not to have a twist and a
pinching.

O-ring
D26706

6. INSTALL 2ND BRAKE PISTON

(a) Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.
NOTICE:
Be careful not to damage the O-ring.

D26775

7. INSTALL 2ND BRAKE PISTON RETURN SPRING

2nd Brake Piston
SUB-ASSY
Return Spring
(a) Install the 2nd brake piston return spring.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.

D26704

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AUTOMATIC TRANSMISSION / TRANS - SECOND BRAKE PISTON ASSY (U151E/U151F)

(b) Place SST on the piston return spring, and compress the
SST piston return spring with a press.
SST 09387-00060
(c) Using a screwdriver, install the snap ring.
(d) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:

Stop the press when the spring sheet is lowered to the
D26703 place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

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AUTOMATIC TRANSMISSION / TRANS - UNDERDRIVE CLUTCH ASSY (U151E/U151F)

UNDERDRIVE CLUTCH ASSY (U151E/U151F)

400H3-02

OVERHAUL

1. INSPECT UNDERDRIVE PACK CLEARANCE

(a) Install the underdrive 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 underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm2, 57 psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.

D26429

2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2

HOLE SNAP RING
Snap Ring (a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.

D03701

3. REMOVE UNDERDRIVE CLUTCH DISC NO.1

(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.
Underdrive
Clutch Drum

D26430

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AUTOMATIC TRANSMISSION / TRANS - UNDERDRIVE CLUTCH ASSY (U151E/U151F)

4. INSPECT UNDERDRIVE CLUTCH DISC NO.1

(a) Check to see 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 even if a
part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for at
least 15 minutes.
D04077

5. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY

(a) Using a dial indicator, measure the inside diameter of the
underdrive clutch drum bushing.
Standard drum bushing:
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)
If the inside diameter is greater than the maximum, replace the
underdrive clutch drum.
D08129

6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING

SST SUB-ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350-32014 (09351-32070)
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Snap Ring
Stop the press when the spring sheet is lowered to the
D03703 place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

(c) Remove the clutch balancer from the underdrive clutch

Clutch
Balancer
drum.

Underdrive
Clutch Drum

C56359

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AUTOMATIC TRANSMISSION / TRANS - UNDERDRIVE CLUTCH ASSY (U151E/U151F)

(d) Remove the return spring from the underdrive clutch

drum.

C56360

7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING

SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)

D03824

8. REMOVE UNDERDRIVE CLUTCH PISTON SET

(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.

D03705

9. REMOVE UNDERDRIVE CLUTCH DRUM O-RING

(a) Using a screwdriver, remove the O-ring from the under-
drive clutch drum.

O-ring
D26465

10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING

(a) Apply the new O-ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.

O-ring
D26465
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AUTOMATIC TRANSMISSION / TRANS - UNDERDRIVE CLUTCH ASSY (U151E/U151F)

11. INSTALL UNDERDRIVE CLUTCH PISTON SET

(a) Coat the underdrive clutch piston with ATF, install it to the
underdrive clutch piston drum.
NOTICE:

Be careful not to damage the O-ring.

Be careful not to damage the lip seal of the piston.

D03860

12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING

SUB-ASSY
(a) Install the return spring to the underdrive clutch drum.
Underdrive NOTICE:
Clutch Installing the spring sub- assembly, check all of the
Return Underdrive springs are fit in the piston correctly.
Spring Clutch Drum (b) Coat the clutch balancer with ATF.

C56360

(c) Install the clutch balancer to the underdrive clutch drum.

Clutch NOTICE:
Balancer Be careful not to damage the lip seal of the clutch balancer.

Underdrive
Clutch Drum

C56359

(d) Place SST on the clutch balancer and compress the pis-
SST
ton return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to the un-
derdrive clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
D03703
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

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AUTOMATIC TRANSMISSION / TRANS - UNDERDRIVE CLUTCH ASSY (U151E/U151F)

(g) Set the end gap of the snap ring in the underdrive clutch
Stopper Stopper drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.

D25592

13. INSTALL UNDERDRIVE CLUTCH DISC NO.1

Disc (a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive
Flange
clutch drum.
Plate NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.

D26431

14. INSTALL UNDERDRIVE CLUTCH FLANGE NO.2

HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
D03701 drum.

15. INSPECT UNDERDRIVE PACK CLEARANCE

(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf/cm2,
57 psi).
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
Mark Thickness Mark Thickness
1 3.0 (0.118) 4 3.1 (0.122)
D26429 2 3.2 (0.126) 5 3.3 (0.130)
3 3.4 (0.134) - -
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AUTOMATIC TRANSMISSION / TRANS - FORWARD CLUTCH ASSY (U151E/U151F)

FORWARD CLUTCH ASSY (U151E/U151F)

400H1-02

OVERHAUL

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/cm2, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.

D26715

2. REMOVE FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.

Snap Ring

D26753

(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D26754

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AUTOMATIC TRANSMISSION / TRANS - FORWARD CLUTCH ASSY (U151E/U151F)

3. INSPECT FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
(a) Check to see 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 even if
replace all discs.
D09189
Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the spring retainer and compress the return
SST
spring with a press.
Snap Ring SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:

Stop the press when the spring sheet is lowered 1 -
D26418 2 mm (0.039 - 0.078 in.) from the snap ring groove,
preventing the spring sheet from deforming.

Do not expand the snap ring excessively.

(c) Remove the clutch balancer from the input shaft.

Clutch
Balancer

Input Shaft

D26709

(d) Remove the forward clutch return spring from the input
shaft.

Forward Clutch
Return Spring Input Shaft

D26708

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AUTOMATIC TRANSMISSION / TRANS - FORWARD CLUTCH ASSY (U151E/U151F)

5. INSPECT FORWARD CLUTCH RETURN SPRING

SUB-ASSY
(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.)

Forward Clutch Re-

turn Spring D09211

6. REMOVE FORWARD CLUTCH PISTON SUB-ASSY

(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump
to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
D03664 ton using the needle nose plier with vinyl tape on the tip.

7. REMOVE INPUT SHAFT OIL SEAL RING

(a) Remove the input shaft oil seal ring to the input shaft.

C56374

A 8. INSTALL INPUT SHAFT OIL SEAL RING

(a) Compress the 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 gap of the oil seal ring too much. Fix the
D25587 hooks certainly.

9. INSTALL FORWARD CLUTCH PISTON SUB-ASSY

(a) Coat the forward clutch piston with ATF, and install it to the
input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.

Forward Clutch Piston

D26707

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AUTOMATIC TRANSMISSION / TRANS - FORWARD CLUTCH ASSY (U151E/U151F)

10. INSTALL FORWARD CLUTCH RETURN SPRING

SUB-ASSY
(a) Install the return spring to the input shaft.
Forward Clutch NOTICE:
Return Spring Input Shaft Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.

D26708

(c) Install the clutch balancer to the input shaft.

NOTICE:

Be careful not to damage the lip seal of the forward
Input Shaft clutch balancer.
Clutch Balancer

Install the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.

Apply enough ATF to the sealing lip prior to assem-
bling.
D26709

(d) Place SST on the clutch balancer, and compress the

clutch balancer with a press.
SST SST 09387-00020
(e) Install the snap ring with a snap ring expander.
Snap Ring (f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:

Stop the press when the spring sheet is lowered to the
D26418 place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

(g) Set the end gap of the snap ring in the piston shown in the
Stopper Stopper
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.

D26788

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AUTOMATIC TRANSMISSION / TRANS - FORWARD CLUTCH ASSY (U151E/U151F)

11. INSTALL FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
Flange (a) Coat the 5 discs with ATF.
Disc (b) Install the 5 plates, 5 discs and flange input shaft.
Plate
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.

D26415

(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 fixed certainly in the groove of the
drum.
Snap Ring

D26753

12. 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⋅cm2, 4.0 kPa, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
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) - -

D26715

13. INSPECT FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.

D03672

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AUTOMATIC TRANSMISSION / TRANS - OIL PUMP ASSY (U151E/U151F)

OIL PUMP ASSY (U151E/U151F)

4006F-03

OVERHAUL

1. INSPECT OIL PUMP ASSY

(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.

D09205

2. REMOVE CLUTCH DRUM OIL SEAL RING

Clutch (a) Remove the 2 clutch drum oil seal rings.
Drum Oil
Seal Ring

D03650

3. REMOVE STATOR SHAFT ASSY

(a) Using a torx socket (T30), remove the 11 bolts and stator
shaft.
(b) Keep the gears in assembling order.

D03651

4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY

Oil Pump Drive Gear Oil Pump
Driven Gear
(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Side clearance: 0.02 - 0.05 mm (0.001 - 0.02 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum, replace the
D09207 oil pump body sub-assy.

U151E, U151F A/T REPAIR MANUAL (RM1021U)

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(c) Using a feeler gauge measure the tip clearance between

the driven gear teeth and drive gear teeth.
Standard tip clearance:
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)
If the tip clearance is greater than the maximum, replace the oil
pump body sub-assy.

D09208

(d) Using a straight edge and feeler gauge, measure the side
clearance of both gears.
Standard side clearance:
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Maximum side clearance: 0.05 mm (0.0020 in.)
Drive gear thickness: mm (in.)
Mark Thickness
A 11.690 - 11.699 (0.4602 - 0.4606)
D09209 B 11.700 - 11.709 (0.4606 - 0.4610)
C 11.710 - 11.720 (0.4610 - 0.4614)
D 11.721 - 11.730 (0.4615 - 0.4618)
E 11.731 - 11.740 (0.4619 - 0.4622)
Driven gear thickness: mm (in.)
Mark Thickness
A 11.690 - 11.699 (0.4602 - 0.4606)
B 11.700 - 11.709 (0.4606 - 0.4610)
C 11.710 - 11.720 (0.4610 - 0.4614)
D 11.721 - 11.730 (0.4615 - 0.4618)
E 11.731 - 11.740 (0.4619 - 0.4622)

5. REMOVE FRONT OIL PUMP DRIVE GEAR

(a) Remove the front oil pump drive gear.

D09206

6. REMOVE FRONT OIL PUMP DRIVEN GEAR

(a) Remove the front oil pump driven gear.

D09206

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7. REMOVE FRONT OIL PUMP BODY O-RING

O-ring (a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.

D25586

8. REMOVE FRONT OIL PUMP OIL SEAL

SST (a) Mount oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump body.
SST 09308-00010

D03647

9. INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY

(a) Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Standard inside diameter:
38.113 - 38.138 mm (1.50051 - 1.50149 in.)
Maximum inside diameter: 38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body sub-assy.
D03648

10. INSPECT STATOR SHAFT ASSY

(a) Using a dial indicator, measure the inside diameter of the
stator shaft.
Standard inside diameter:
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the indicator diameter is greater than maximum, replace the
stator shaft.
D03653

11. INSTALL FRONT OIL PUMP OIL SEAL

(a) Using SST and a hammer, install a new oil seal to the oil
pump body.
SST 09350-32014 (09351-32140)
HINT:
SST The seal end should be flat with the outer edge of the oil pump.
(b) Coat the lip of the oil seal with MP grease.

D03654

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12. INSTALL FRONT OIL PUMP BODY O-RING

(a) Coat the new O-ring with ATF, install it to the oil pump
O-ring
body.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.

C55817

13. INSTALL FRONT OIL PUMP DRIVEN GEAR

Oil Pump Mark (a) Coat the front oil pump driven gear with ATF, install it to
Driven
the oil pump body with the marked side up.
Gear

D09206

14. INSTALL FRONT OIL PUMP DRIVE GEAR

Mark (a) Coat the front oil pump drive gear with ATF, install it to the
oil pump body with the marked side up.
Oil
Pump
Drive
Gear

D09206

15. INSTALL STATOR SHAFT ASSY

(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

D03651

16. INSTALL CLUTCH DRUM OIL SEAL RING

Clutch Drum (a) Coat the 2 new clutch drum oil seal rings with ATF.
Oil Seal Ring (b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.

D26627

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17. INSPECT OIL PUMP ASSY

(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.

D09205

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AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

4010K-01

OVERHAUL
1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Remove the bolt and speedometer driven hole cover sub-assy from the transaxle assy.
(b) Remove the O-ring from the speedometer driven hole cover.

2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY

(a) Remove the nut, washer and control shaft lever.

Control Shaft Lever

D09644

(b) Using a screwdriver, unstake the nut stopper, and re-

move the lock nut and nut stopper.

Lock Nut
Nut Stopper
D09643

(c) Remove the 2 bolts and pull out the park/neutral position
Park/neutral Position Switch switch.

D09639

3. REMOVE BREATHER PLUG HOSE

(a) Remove the breather plug hose from the transaxle case.

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4. REMOVE OIL COOLER TUBE UNION (INLET OIL

COOLER UNION)
(a) Remove the union.
Union (b) Remove the O-ring from the union.
O-ring

C83143

5. REMOVE OIL COOLER TUBE UNION (OUTLET OIL

COOLER UNION)
(a) Remove the elbow.
Elbow
(b) Remove the O-ring from the elbow.

O-ring

C83144

6. REMOVE SPEED SENSOR

(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
Speed Sensor

D03900 D30672

7. REMOVE TRANSAXLE CASE NO.1 PLUG

(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.

D26716

8. FIX AUTOMATIC TRANSAXLE ASSY

(a) Fix the transaxle assy.

D09176

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9. REMOVE AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.

C91925

(b) Remove the 2 magnets from the oil pan.

Magnet

C86316

10. INSPECT TRANSMISSION OIL CLEANER MAGNET

Magnet (a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non-magnetic).... bushing wear

AT0103

11. DISCONNECT TRANSMISSION WIRE

(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.

Temperature
Sensor C91927

12. REMOVE TRANSMISSION WIRE

Transmission Wire (a) Remove the bolt and transmission wire from the transaxle
case.

D03547

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13. REMOVE VALVE BODY OIL STRAINER ASSY

(a) Remove the 3 bolts and oil strainer.

Valve Body Oil

Strainer Assy

C91931

(b) Remove the O-ring from the oil strainer.

O-ring

C91932

14. REMOVE TRANSMISSION VALVE BODY ASSY

(a) Support the valve body assy and remove the 17 bolts and
valve body assy.

C91933

15. REMOVE GOVERNOR APPLY GASKET NO.1

(a) Remove the governor apply gasket No.1 from the trans-
axle case.

C83127

16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET

(a) Remove the transaxle case 2nd brake gasket from the
transaxle case.

C83128

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17. REMOVE BRAKE DRUM GASKET

(a) Remove the brake drum gasket from the transaxle case.

C83129

18. REMOVE CHECK BALL BODY

(a) Remove the check ball body and spring from the trans-
axle case.

Check Ball
D03554

19. REMOVE C-3 ACCUMULATOR PISTON

(a) Remove the spring from the C-3 accumulator piston.

D03555

(b) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the C-3 accumulator piston.
NOTICE:

Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.

Take care not to splash ATF when air-blowing.

D03556

(c) Remove the O-ring from the C-3 accumulator piston.

O-ring

C-3 Accumulator Piston

D03902

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20. REMOVE REVERSE CLUTCH ACCUMULATOR

PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the reverse accumulator piston and
spring.
NOTICE:

Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
D26401 a waste cloth.

Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the reverse clutch accumula-
Reverse clutch Accumulator Piston tor piston.

O-ring

O-ring

D26402

21. REMOVE B-3 ACCUMULATOR PISTON

(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the B-3 accumulator piston and 2
springs.
NOTICE:

Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
D03558
Take care not to splash ATF when air-blowing.

(b) Remove the O-ring from the B-3 accumulator piston.

O-ring

B-3 Accumulator Piston

D03904

22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER

SPRING
(a) Using a needle-nose pliers, remove the manual valve le-
ver shaft retainer spring.

D03559

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23. REMOVE MANUAL DETENT SPRING SUB-ASSY

(a) Remove the 2 bolts, the manual detent spring sub-assy
and cover.

D03560

24. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 2 bolts and parking lock pawl bracket.

C56727

25. REMOVE MANUAL VALVE LEVER SUB-ASSY

(a) Using a chisel and hammer, cut off and remove the
spacer.

D03563

(b) Using a pin punch (φ35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.

D03564

(c) Remove the manual valve lever shaft and manual valve
lever.

D03565

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26. REMOVE PARKING LOCK ROD SUB-ASSY

Parking Lock Rod Sub-assy (a) Remove the parking lock rod from the manual valve lever.

D26382

27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using a screwdriver, remove the oil seal from the trans-
axle case.

D03566

28. FIX AUTOMATIC TRANSAXLE ASSY

(a) Fix the transaxle case with the oil pump side facing up.

29. INSPECT INPUT SHAFT ENDPLAY

(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262 - 1.244 mm (0.01 - 0.049 in.)

Oil Pump Assy

D08046

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30. REMOVE TRANSAXLE HOUSING

U151E: (a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.

U151F:

D25608

31. REMOVE OIL PUMP ASSY

(a) Remove the 7 bolts and oil pump from the transaxle case.
Oil Pump Assy

D03569

32. REMOVE THRUST NEEDLE ROLLER BEARING

Thrust Needle
Roller Bearing (a) Remove the thrust needle roller bearing from the under-
Differential Gear Assy Forward Clutch Assy
drive planetary gear assy.

D25505

Thrust Bearing Underdrive Race No.2 33. REMOVE THRUST BEARING UNDERDRIVE RACE
NO.2
Differential
(a) Remove the thrust bearing underdrive race No. 2 from the
Gear Assy Forward Clutch Assy
underdrive planetary gear assy.

Underdrive Planetary Gear Assy D25506

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34. REMOVE DIFFERENTIAL GEAR ASSEMBLY

Differential
(a) Remove the differential gear assy from the transaxle
Gear Assy
case.

D26450

35. REMOVE OVERDRIVE BRAKE GASKET

(a) Remove the 2 overdrive brake gaskets from the transaxle
case.

D03573

Forward Clutch 36. REMOVE FORWARD CLUTCH ASSY

Assy (a) Remove the forward clutch assy from the transaxle case.

D03574

(b) Remove the thrust needle roller bearing from the forward
Thrust Needle
Roller Bearing
clutch.

D03906

Thrust Needle 37. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB

Multiple Disc Roller Bearing (a) Remove the thrust needle roller bearing, multiple disc
Clutch Clutch clutch clutch hub, thrust needle roller bearing and thrust
Thrust Needle
Hub bearing race No.1 from the transaxle case.
Roller Bearing
Thrust
Bearing
Race
No.1
D26787

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38. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB

Dial Indicator (a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
Forward Clutch Hub 23.025 - 23.046 mm (0.9065 - 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:

When the diameter is over the maximum, replace the
D03829 multiple disc clutch hub with new one.

Check the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub-assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.

39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY

Pawl Shaft Clamp (a) Remove the bolt and pawl shaft clamp.

D03576

(b) Remove the parking lock pawl shaft.

D09652

(c) Push the parking lock pawl.

HINT:
Failure to do so will cause interference when the underdrive
planetary gear is removed.

D09689

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Underdrive (d) Remove the underdrive planetary gear assy from the
Planetary transaxle case.
Gear Assy NOTICE:
Be careful so that the underdrive planetary gear assy will
not fall out.

D03579

40. REMOVE PARKING LOCK PAWL

(a) Remove the spring, pawl pin and parking lock pawl.

D26386

41. REMOVE UNDERDRIVE CLUTCH ASSY

(a) Remove the underdrive clutch assy, thrust bearing and
bearing race from the transaxle case.
Thrust Bearing
Bearing Race

D03580

42. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY

(a) Using a screwdriver, remove the snap ring from the trans-
axle case.

Snap Ring D03581

(b) Remove the underdrive 1-way clutch from the transaxle

case.

Underdrive
1-W ay
Clutch
D03627

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(c) Remove the outer race retainer from the 1-way clutch.

Outer Race
Retainer
D03907

43. REMOVE UNDERDRIVE CLUTCH DISC NO.2

Snap
Ring
(a) Using a screwdriver, remove the snap ring.

D26466

(b) Remove the flange, 4 discs and 4 plates from the trans-
Flange axle case.

D26385

44. INSPECT UNDERDRIVE CLUTCH DISC NO.2

(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for
D09196 at least 15 minutes.

45. REMOVE TRANSAXLE REAR COVER SUB-ASSY

(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.

D26387

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46. REMOVE TRANSAXLE CASE NO.1 PLUG

(a) Remove the 4 transaxle case No.1 plugs from the trans-
axle rear cover.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.

D26388

Rear Clutch
47. REMOVE REAR CLUTCH OIL SEAL RING OUTER
Oil Seal (a) Remove the 3 rear clutch oil seal rings from the transaxle
Ring Outer rear cover.

D26389

48. REMOVE NEEDLE ROLLER BEARING

(a) Using SST, remove the needle-roller bearing from the
transaxle rear cover.
SST 09387- 00041 (09387- 01021, 09387- 01030,
SST 09387-01040)

D26472

49. REMOVE GOVERNOR APPLY GASKET NO.1

(a) Using a screwdriver, remove the 3 apply gaskets.

D26390

50. REMOVE BRAKE APPLY TUBE

(a) Remove the bolt, clamp and brake apply tube.
Brake Apply Tube
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.
Clutch Apply Tube

D26391

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51. REMOVE DIRECT CLUTCH ASSY

Thrust Bearing
(a) Remove the thrust bearing and the direct clutch assy from
the transaxle case.

Direct Clutch Assy D26403

Overdrive Direct Clutch Hub 52. REMOVE OVERDREVE DIRECT CLUTCH HUB
SUB-ASSY
Thrust Bearing
(a) Remove the thrust bearing race, thrust bearing and over-
drive direct clutch hub from the planetary gear assy.

Thrust Bearing Race

D26392

53. INSPECT OVERDRIVE DIRECT CLUTCH DRUM

Dial Indicator SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
Overdrive
forward clutch hub bushing.
Direct Clutch Standard inside diameter:
Drum Sub-assy 23.025 - 23.046 mm (0.9065 - 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:
D03829
When the diameter is over the maximum, replace the
multiple disc clutch hub with new one.

Check the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub-assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.
54. REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the trans-
axle case.

Rear Planetary Sun Gear Assy D26714

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Thrust Needle Roller Bearing (b) Remove the thrust needle roller bearing and thrust bear-
ing race from the rear planetary sun gear assy.

Thrust Bearing Race D26404

(c) Remove the planetary carrier thrust washer No.2 from the
Planetary
rear planetary sun gear assy.
Carrier
Thrust
Washer
No.2 Rear
Planetary
Sun Gear

D26393

Thrust Needle
55. REMOVE 1 WAY CLUTCH ASSY
Roller Bearing (a) Remove the 1-way clutch assy and the thrust needle roll-
er bearing from the transaxle case.

1-W ay Clutch Assy

D26598

(b) Remove the 1-way clutch inner race from the 1-way
1-W ay
clutch assy.
Clutch
Inner Race

D03909

1-W ay Clutch 56. REMOVE 1WAY CLUTCH SLEEVE OUTER

Sleeve Outer (a) Remove the 1-way clutch sleeve outer from the transaxle
case.

D03589

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Planetary Carrier
57. REMOVE PLANETARY CARRIER THRUST WASHER
Thrust Washer No.1 NO.1
(a) Remove the planetary carrier thrust washer No.1 from the
planetary gear assy.

D26394

58. REMOVE 2ND BRAKE CLUTCH DISC

(a) Using a screwdriver, remove the snap ring.
Snap Ring
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.

D26395

59. INSPECT 2ND BRAKE CLUTCH DISC

(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for
D26717 at least 15 minutes.

60. REMOVE SECOND BRAKE PISTON ASSY

(a) Using a screwdriver, remove the snap ring.

Snap Ring

D08058

(b) Remove the second brake piston assy from the transaxle
case.

Second Brake
Piston Assy D26396

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61. REMOVE REAR PLANETARY GEAR ASSY

(a) Using a screwdriver, remove the snap ring.

Snap Ring

D03616

(b) Remove the rear planetary gear assy from the transaxle
Rear Planetary
case.
Gear Assy

D26591

Input 62. REMOVE INPUT SUN GEAR

Thrust Bearing
Sun (a) Remove the 2 thrust needle roller bearings, thrust bearing
Race No.2
Gear race No.2 and input sun gear from the transaxle case.

Thrust Needle Roller Bearing D03873

63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC

(a) Remove the flange, 6 discs and 6 plates from the trans-
axle case.

D26397

64. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC

(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for
D09189 at least 15 minutes.

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65. REMOVE FRONT PLANETARY GEAR ASSY

(a) Using a chisel and hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST cannot
Lock Washer
be fully pressed against the nut, and cannot loosen the nut.

D03595

(b) Using SST, remove the nut.

SST 09387-00030, 09387-00080
SST

D03596

(c) Using SST and a press, remove the front planetary gear
assy from the counter drive gear.
SST 09950- 60010 (09951- 00450), 09950- 70010
SST (09951-07100)

D26398

(d) Remove the front planetary gear assy from the brake hub.

Front Planetary
Gear Assy
Brake Hub

D26763

Front Planetary Ring Gear 66. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front plan-
Snap Ring etary ring gear from the brake hub.

Brake Hub
D03615

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67. REMOVE 1ST & REVERSE BRAKE RETURN SPRING

SST SUB-ASSY
(a) Place SST on the return spring, and compress the return
spring with a press.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:

Stop the press when the spring sheet is lowered 1 -
D03600 2 mm (0.039 - 0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.

Do not expand the snap ring excessively.

68. INSPECT 1ST & REVERSE BRAKE RETURN SPRING

SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.61 mm (0.6933 in.)

C89128

1st & Reverse Brake Piston 69. REMOVE 1ST & REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
transaxle case to remove 1st & reverse brake piston.
NOTICE:

Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.

Take care not to splash ATF when air-blowing.
D26405

(b) Remove the 2 O-rings from the 1st & reverse brake pis-
ton.

O-ring
O-ring

D26713

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70. REMOVE COUNTER DRIVE GEAR

SST (a) Using SST and a press, remove the counter drive gear
SST from the transaxle case.
SST 09950- 60010 (09951- 00590), 09950- 70010
(09951-07100)

C89120

(b) As shown in the illustration, tighten 2 bolts evenly and

make clearance of approx. 20.0 mm (0.797 in.) between
the counter drive gear and the inner race.

D03602

(c) Using SST, remove the tapered roller bearing.

SST 09950- 60010 (09951- 00590), 09950- 70010
Turn
(09951-07100), 09950-00020, 09950-00030,
09950-4001 1 (09957-04010)
SST

Hold

D03603

71. REMOVE COUNTER DRIVE GEAR BEARING

Snap Ring
(a) Using a snap ring expander, remove the snap ring.

D26467

(b) Using SST and a press, remove the bearing outer race.
SST 09950- 60020 (09951- 00910), 09950- 70010
(09951-07100)
SST

C89121

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72. REMOVE BREATHER PLUG NO.2 (ATM)

73. REMOVE UNDERDRIVE BRAKE RETURN SPRING

SUB-ASSY
(a) Place SST on the return spring, and compress the return
SST spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Snap Ring
Stop the press when the spring sheet is lowered 1 -
D26407 2 mm (0.039 - 0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.

Do not expand the snap ring excessively.

74. INSPECT UNDERDRIVE BRAKE RETURN SPRING

SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 13.24 mm (0.5213 in.)
Underdrive
Brake Return
Spring
D03806 D30852

75. REMOVE UNDERDRIVE BRAKE PISTON

Underdrive Brake Piston
(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
transaxle case to remove the underdrive brake piston.

D26406

(b) Remove the 2 O-rings from the underdrive brake piston.

O-ring O-ring

D03794

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

76. REMOVE NEEDLE ROLLER BEARING

Hold
(a) Using SST, remove the needle-roller bearing from the
SST
transaxle case.
SST 09387- 00041 (09387- 01010, 09387- 01030,
09387-01040)
Turn

D03605

77. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL

RING
(a) Remove the 2 oil seal rings from the transaxle case.
Underdrive
Clutch Drum
Oil Seal Ring

D03914

78. REMOVE TRANSAXLE CASE NO.1 PLUG

(a) Remove the 2 transaxle case No. 1 plugs.
(b) Remove the 2 O-rings from the 2 transaxle case No. 1
plugs.

D26383

79. REMOVE UNDERDRIVE CYLINDRICAL ROLLER

Turn BEARING
(a) Using SST, remove the underdrive cylindrical roller bear-
Hold ing from the transaxle case.
SST 09514-3501 1
SST

D03606

Underdrive 80. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL

Output RING
Shaft Oil (a) Remove the oil seal ring from the transaxle housing.
Seal Ring

D03915

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Transaxle Apply Differential 81. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
Tube Clamp Gear Lube (a) Remove the bolt, transaxle apply tube clamp and differen-
Apply Tube tial gear lube apply tube from the transaxle housing.

D26400

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

82. BEARING POSITION

D
C

F G

J K

H
C89118

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

Front Race Diameter Thrust Bearing Diameter Rear Race Diameter

Mark
Inside / Outside mm (in.) Inside / Outside mm (in.) Inside / Outside mm (in.)
A - 57.2 (2.252) / 84.96 (3.3449) 56.4 (2.220) / 83.0 (3.268)
B - 37.73 (1.4854) / 58.0 (2.283) -
C - 33.85 (1.3327) / 52.2 (2.055) -
D 24.94 (0.982) 23.5 (0.925) / 44.0(1.732) -
E - 36.3 (1.429) / 51.93 (2.044) 34.5 (1.358) / 48.35 (1.904)
F 34.35 (1.352) / 56.57 (2.227) 32.45 (1.278) / 56.48 (2.223) -
G 40.15 (1.581) / 59.25 (2.333) 38.65 (1.522) / 59.79 (2.354) 38.65 (1.522) / 59.25 (2.332)
H - 53.6 (2.110) / 69.6 (2.740) -
I 33.02 (1.3) / 45.8 (1.803) 31.85 (1.254) / 57.3 (2.256) -
J - 24.79 (0.976) / 39.5 (1.555) 23.6 (0.929) / 37.95 (1.494)
K - 56.3 (2.216) / 75.96 (2.991) -

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Transaxle Apply 83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

Tube Clamp (a) Install the differential gear lube apply tube and transaxle
apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
NOTICE:
Make sure to insert the pipe to the stopper.

Differential Gear Lube Apply Tube D26400

84. INSTALL TRANSAXLE CASE NO.1 PLUG

(a) Install the 2 new O-rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle
rear cover.
Torque: 7.4 N⋅m (75 kgf⋅cm, 65 in.⋅lbf)

D26383

ATF 85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL

RING
(a) Coat the new oil seal ring with ATF and install it to the
Underdrive transaxle housing.
Output Shaft
Oil Seal Ring

D03915

86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER

BEARING
SST (a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical
roller bearing.
SST 09950- 60020 (09951- 00810), 09950- 70010
(09951-07100)
NOTICE:
D03807 Do not apply excessive pressure to it.

87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL

RING
ATF (a) Coat the 2 new oil seal rings with ATF, install them to the
transaxle rear cover.
NOTICE:

Do not expand the gap of the oil seal ring too much.
Underdrive
Clutch Drum
Fix the hooks certainly. Confirm the smooth rotation.
Oil Seal Ring
D03914

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

Vinyl Tape 88. INSTALL NEEDLE ROLLER BEARING

(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
NOTICE:
Clean SST to remove deposited oil, before winding a vinyl
tape.
SST
(b) Coat the needle roller bearing with ATF.
D03809

(c) Using SST and a press, install the needle-roller bearing

to the transaxle case.
SST 09950- 60010 (09951- 00320), 09950- 70010
SST
(09951-07100)
NOTICE:
When the wound vinyl tape contacts the transaxle case,
stop press-fitting.

D03810

89. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat the 2 new O-rings with ATF, install them to the un-
derdrive brake piston.
NOTICE:
O-ring O-ring

Assemble the O-ring carefully not to have a twist and
a pinching.

Apply enough ATF to the O-ring prior to assembling.
(b) Coat the underdrive brake piston with ATF.
D03794

(c) Install the underdrive brake piston to the transaxle case.

NOTICE:
Be careful not to damage the O-ring.
Underdrive
Brake Piston

D26764

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SST
90.
INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387-00020
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
NOTICE:
Snap Ring D26407
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.

Do not expand the snap ring excessively.

Installing the spring sub-assembly, check all of the
springs are fit in the piston correctly.

The snap ring should be fixed surely in the groove of
the transaxle case.
91. INSTALL BREATHER PLUG NO.2 (ATM)

92. INSTALL COUNTER DRIVE GEAR BEARING

(a) Coat the counterdrive gear bearing with ATF.
SST (b) Using SST and a press, install the bearing outer race.
SST 09950- 60020 (09951- 01030), 09950- 70010
(09951-07150), 09649-17010
NOTICE:

Do not apply excessive pressure to it.

Press-fit the bearing outer race until it contacts the
C89126 transaxle case.

(c) Using a snap ring expander, install the snap ring.

NOTICE:
Face the white mark side of the snap ring up.
Snap Ring

D26467

93. INSTALL COUNTER DRIVE GEAR

(a) Coat the couterdrive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing
SST to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to it.

D26410

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(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09223- 15030, 09527- 17011, 09950- 60020
(09951-00750), 09950-70010 (09951-07150)
NOTICE:
SST Do not apply excessive pressure to it.
Counter Drive Bearing
Gear

SST

C89122

94. INSTALL 1ST & REVERSE BRAKE PISTON

(a) Coat the 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st & reverse brake piston.
O-ring NOTICE:
O-ring

Assemble the O-ring carefully not to have a twist and
a pinching.

Apply enough ATF to the O-ring prior to assembling.

D26713

(c) Coat a 1st & reverse brake piston with ATF, install it to the
1st & Reverse transaxle case.
Brake Piston NOTICE:
Be careful not to damage the O-ring.

D26593

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95. INSTALL 1ST & REVERSE BRAKE RETURN SPRING

SUB-ASSY
SST
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387-00070
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
NOTICE:
D03600
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 being de-
formed.

Do not expand the snap ring excessively.

Installing the spring sub-assembly, check all of the
springs are fit in the piston correctly.

The snap ring should be fixed surely in the groove of
the cylinder.

Fix the snap ring to the inside of the claw of the spring
seat surely.

96. INSTALL FRONT PLANETARY RING GEAR

Front Planetary Ring Gear
(a) Using a screwdriver, install the front planetary ring gear
and snap ring to the brake hub.
NOTICE:
Confirm the snap ring is fixed in the groove of the brake hub
correctly.

Brake Hub
Snap Ring D03615

97. INSTALL FRONT PLANETARY GEAR ASSY

(a) Install the front planetary gear assy to the brake hub.

Front Planetary
Gear Assy

Brake Hub

D26763

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(b) Using SST and a press, press-fit the front planetary gear
assy.
SST
SST 09950- 60010 (09951- 00500), 09950- 70010
(09951-07100)
NOTICE:

Do not apply excessive pressure to it.

Press the inner race of LH tapered roller bearing,
counter gear and front planetary gear assembly to the
position where no pre-load should be applied to one
pair of tapered roller bearings (left and right).
2nd Brake Hub
w/ Front Planetary
Gear Assy
SST

Transaxle
Case
Counter Drive
Gear D03916

(c) Install the new washer, as shown in the illustration.

D03917

(d) Using SST, install the nut.

SST SST 09387-00030, 09387-00080
Torque: 210 - 350 N⋅m
(2,141 kgf⋅cm, 155 ft⋅lbf - 3,569 kgf⋅cm, 258 ft⋅lbf)
NOTICE:
Assemble the washer after pressing each part, then tighten
the nut to minimum tightening torque.

D03596

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

(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 09387-00080
SST Turning torque at 60 rpm:
New Bearing
D03918 0.51 - 1.02 N⋅m (5.1 - 10.0 kgf⋅cm, 4.4 - 8.7 in.⋅lbf)
Used Bearing
0.26 - 0.51 N⋅m (2.7 - 5.2 kgf⋅cm, 2.3 - 4.5 in.⋅lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 N⋅m (3,569 kgf⋅cm, 258 ft⋅lbf) (a limit)

(g) Using a chisel and hammer, stake the front lock washer.

Lock Washer

D08074

98. INSTALL INPUT SUN GEAR

D C (a) Coat the 2 thrust bearings with ATF.
B A
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:

Install the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
Input Sun Gear race.
C89123
Installing thrust bearing and front sun gears, be care-
ful about the orientation of the parts.

Install the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.

Install the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

Thrust bearing and bearing race diameter: mm (in.)

inside outside
Thrust Bearing, A 32.5 (1.28) 56.5 (2.224)
Bearing Race, B 40.2 (1.583) 59.3 (2.335)
Thrust Bearing, C 38.6 (1.520) 59.7 (2.35)
Bearing Race, D 38.6 (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.

Rear Planetary Gear Assy D26591

(b) Using a screwdriver, install the snap ring.

NOTICE:
Confirm the snap ring is fixed in the groove of the 1st & re-
Snap Ring verse brake hub correctly.

D03616

100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC

(a) Coat the 6 discs with ATF.
Disc Plate (b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.

D26413

101. INSPECT PACK CLEARANCE OF FIRST & REVERSE

BRAKE
(a) Using vernier calipers, measure the distance between the
A 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.)
D26452 HINT:
Piston stroke = Dimension A -Flange thickness

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Flange thickness: mm (in.)

Mark Thickness Mark Thickness
1 1.8 (0.071) 5 2.2 (0.087)
2 1.9 (0.075) 6 2.3 (0.091)
3 2.0 (0.079) 7 2.4 (0.094)
4 2.1 (0.083) 8 2.5 (0.098)

(c) Install the flange.

D03815

102. INSTALL SECOND BRAKE PISTON ASSY

(a) Install the second brake piston assy to the transaxle case.

Second Brake Piston Assy D26396

(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.
Snap Ring
After assembling, confirm that there is no clearance
D08058 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.

1-W ay Clutch Sleeve Outer C92977

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104. INSTALL 1 WAY CLUTCH ASSY

(a) Install the 1-way clutch inner race to the 1-way clutch.
NOTICE:
1-W ay Clutch

Check the direction of the inner race.
Inner Race

Confirm that the discrimination mark can be seen by
the worker.

D03909

(b) Check the rotating direction of 1-way clutch for the lock
or free operation, as shown in the illustration.

Free

D09638

(c) Install the 1-way clutch and thrust needle roller bearing
Thrust Needle
to the 1-way clutch sleeve outer.
Roller Bearing
Bearing diameter: mm (in.)
Inside Outside
Bearing 53.6 (2.110) 69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no-colored race
will be visible.
1-W ay Clutch Assy D03588

Planetary Carrier 105. INSTALL PLANETARY CARRIER THRUST WASHER

Thrust Washer No.1 NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.

D26394

Planetary Carrier Thrust Washer No.2 106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.

Rear Planetary Sun Gear D26393

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(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
A
B Inside Outside
Race, A 33.0 (1.299) 45.4 (1.787)
Bearing, B 31.85 (1.254) 45.2 (1.78)

D26404

(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.

Rear Planetary Sun Gear Assy D26714

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.
Disc
Plate

D26412

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 (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
D26453 thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
Mark Thickness Mark Thickness
1 3.0 (0.118) 5 3.4 (0.134)
2 3.1 (0.122) 6 3.5 (0.138)
3 3.2 (0.126) 7 3.6 (0.142)
4 3.3 (0.130) 8 -

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

(c) Temporarily remove the snap ring, attach the selected

Snap Ring
flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.

D03623

109. INSTALL OVERDREVE DIRECT CLUTCH HUB

SUB-ASSY
A (a) Install the direct clutch hub to the planetary gear assy.
B
NOTICE:
Be careful not to damage the bush inside of the overdrive
clutch hub during instaling.
(b) Coat the thrust bearing with ATF.
Overdrive Direct (c) Install the bearing race and the thrust bearing to the direct
Clutch Hub D26392 clutch hub.
NOTICE:
Installing the bearing, hold the part on the side of the over-
drive clutch hub.
Bearing and race diameter: mm (in.)
Inside Outside
Bearing, A 24.7 (0.972) 39.5 (1.555)
Race, B 23.6 (0.929) 38.0 (1.496)

110. INSTALL DIRECT CLUTCH ASSY

Thrust Bearing (a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assy and thrust bearing to the rear
planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely match with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
Direct Clutch Assy D26403

(c) Clean the connecter part of the transaxle case and the
C
rear cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between
transaxle case and the straight edge using vernier cali-
pers (Dimension C).

D26469

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(e) Using vernier calipers and a simple straightedge, mea-

D 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
D26470 clutch assy.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
Thickness Inside Outside
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.

D26390

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.

D03923

Clutch Apply Tube (c) Install the brake apply tube and a bolt to the transaxle
case.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.
Brake Apply
Tube
D26391

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113. INSTALL NEEDLE ROLLER BEARING

(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
SST Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 in.)
NOTICE:

Face the inscribed mark side of the bearing race up.

Repeat the press fit until the specified value is ob-
D26766 tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
Rear Clutch
Oil Seal them to the transaxle rear cover.
Ring Outer NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.

D26389

115. INSTALL TRANSAXLE CASE NO.1 PLUG

(a) Install the 4 new O-ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 N⋅m (75 kgf⋅cm, 65 in.⋅lbf)

D26388

116. INSTALL TRANSAXLE REAR COVER SUB-ASSY

(a) Remove any packing material and be careful not to get oil
FIPG
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent.
D26454 NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter: φ1.2)

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(c) Apply liquid sealer to the ”A” bolt threads.

Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A: 19.0 N⋅m (190 kgf⋅cm, 14 ft⋅lbf)
Other bolt: 25.0 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
A A D26387

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
Flange case.
Disc Plate NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.

D26414

(c) Using a screwdriver, install the snap ring.

NOTICE:
Snap Ring
The snap ring should be fixed certainly in the groove of the
drum.

D26466

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/cm2, 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
D08082 meet the specified value.
Flange thickness: mm (in.)
Mark Thickness Mark Thickness
1 3.0 (0.118) 4 3.1 (0.122)
2 3.2 (0.126) 5 3.3 (0.130)
3 3.4 (0.134) - -
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.

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119. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY

Free
(a) Install the underdrive clutch assy to the 1-way clutch.
(b) Rotate the underdrive clutch assy to check the rotating
direction for the lock or free operation.
Free

D03925

120. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY

(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth of the one
way clutch surely.

Outer Race
Retainer
D03907

(b) Install the 1-way clutch to the transaxle case.

Mark
NOTICE:
Mark
Make sure that the mark on the 1-way clutch outer race is
visible.

D03627

(c) Using a screwdriver, install the snap ring to the transaxle

case.
NOTICE:
The snap ring should be fixed certainly in the groove of the
transaxle case as the gap exists except in the lock of teeth.

Snap Ring D03581

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121. INSTALL UNDERDRIVE CLUTCH ASSY

(a) Coat the bearing and bearing race with petroleum jelly,
install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
Inside Outside
Bearing 37.73 (1.4854) 58.0 (2.2835)
Race 29.9 (1.1772) 55.5 (2.185)

(b) Install the underdrive clutch assy to the transaxle case.

D03580 NOTICE:
Installing the underdrive clutch drum sub-assy, be sure
not to damage the oil seal ring.

122. INSTALL PARKING LOCK PAWL

Parking Lock Pawl
(a) Install the pawl pin and spring to the parking lock pawl.

Spring
Pawl Pin

D09691

(b) Temporarily install the parking lock pawl, shaft and spring
to the transaxle case, as shown in the illustration.

D26386

Underdrive 123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY

Planetary (a) Install the underdrive planetary gear assy to the transaxle
Gear Assy case.
NOTICE:
Engage all the discs of underdrive clutch and hub splines
of the underdrive planetary gear assy firmly and assemble
them securely.

D03579

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(b) Install the parking lock pawl shaft.

D09693

(c) Install the pawl shaft clamp with the bolt.

Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

Pawl Shaft Clamp

D03576

(d) Using a straight edge and vernier calipers as shown in the

illustration, measure the gap between the top of the differ-
E ential drive pinion in the underdrive planetary gear and
contact surface of the transaxle case and housing (Di-
mension E).
NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.
D03875

(e) As shown in the illustration, measure the 2 places of the

transaxle housing, calculate the dimension F using the
Dimension (1) Dimension (2) formula.
NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1) - Dimension (2)
D25511

124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB

Thrust Bearing Race No.1
(a) Install the thrust bearing race No.1 to the transaxle case
while checking its direction.
Bearing race diameter: mm (in.)
Inside Outside
Bearing race 39.5 (1.555) 45.8 (1.803)

D08087

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(b) Coat the thrust needle roller bearing and race with yellow
Thrust Needle Multiple Disc petrolatum, install them onto the multiple disc clutch hub.
Roller Bearing Clutch Clutch Thrust bearing and race diameter: mm (in.)
Hub
Inside Outside
Thrust Bearing 36.4 (1.433) 52.2 (2.055)

(c) Coat the needle roller bearing with ATF.

D26710

(d) Install the needle roller bearing to the multiple clutch hub.
Thrust Needle Multiple Disc Bearing diameter: mm (in.)
Roller Bearing Clutch Clutch
Inside Outside
Hub
Bearing 23.6 (0.929) 44 (1.732)

(e) Install the multiple clutch hub to the transaxle case.

D26711

125. INSTALL FORWARD CLUTCH ASSY

Thrust Needle (a) Coat the thrust needle roller bearing with ATF.
Roller Bearing (b) Install the thrust needle roller bearing to the forward
clutch.
Thrust bearing diameter: mm (in.)
Inside Outside
Thrust Bearing 33.58 (1.3220) 51.9 (2.043)

NOTICE:
D03820 Install the thrust bearing properly so that the no colored
race or blue ink jet race will be visible.

Forward Clutch Assy (c) Install the forward clutch to the forward clutch assy.
NOTICE:

Align the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them se-
curely.

Be careful not to damage the bush inside of the for-
ward clutch hub during installing.

D03574

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126. INSTALL OVERDRIVE BRAKE GASKET

(a) Install the 2 new overdrive brake gaskets.

D03573

127. INSTALL DIFFERENTIAL GEAR ASSEMBLY

Differential
Gear Assy
(a) Install the differential gear assy to the transaxle case.

D26450

Thrust Bearing Underdrive Planetary 128. INSTALL THRUST BEARING UNDERDRIVE RACE
Underdrive Gear Assy NO.2
Race No.2 Forward Clutch (a) Install the thrust bearing underdrive race No.2 to the un-
Assy derdrive planetary gear assy.

Differential Gear Assy D25506

Underdrive Planetary 129. INSTALL THRUST NEEDLE ROLLER BEARING

Thrust
Gear Assy (a) Coat the thrust needle roller bearing with ATF.
Needle
Roller Bearing Forward Clutch (b) Calculate the end play value using the following formula
Assy 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.
Differential Gear Assy D25505 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-E Thickness
Less than 7.72 (0.3039) 3.5 (0.138)
7.72 (0.3039) 3.8 (0.150)

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Bearing and bearing race diameter: mm (in.)

Inside Outside
Bearing 57.2 (2.252) 84.96 (3.345)
Bearing race 56.4 (2.22) 83 (3.268)

130. INSTALL OIL PUMP ASSY

(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 N⋅m (226 kgf⋅cm, 16 ft⋅lbf)

D03569

(b) Coat the O-ring of oil pump with ATF.

NOTICE:
Confirm the input shaft rotates smoothly with the manual
operation after assembling the oil pump.

O-ring

D03629

131. INSTALL TRANSAXLE HOUSING

(a) Remove any parking material and be careful not to get oil
FIPG
on the contacting surface of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
Seal Bend Width 1.2 mm (0.047 in.)
D03630

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B (c) Install the transaxle housing and 16 bolts to the transaxle

2WD: C
case.
Torque:
B
Bolt A: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
Bolt B: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf)
Bolt C: 29 N⋅m (295 kgf⋅cm, 21 ft⋅lbf)
C D
Bolt D: 22 N⋅m (226 kgf⋅cm, 16.0 ft⋅lbf)
HINT:
A Apply seal packing or equivalent to the bolt A and D.
C B Seal packing:
4WD:
C THREE BOND 2403 or equivalent
Bolt length:
C Bolt A: 50 mm (1.969 in.)
B Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
A NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
C C A D25608 new bolts and tighten them within 10 minutes after applica-
tion.
132. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0100 - 0.0494 in.)

D08091

133. FIX AUTOMATIC TRANSAXLE ASSY

(a) Fix the transaxle assy.

D03631

134. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

SST (a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950- 60010 (09951- 00230), 09950- 70010
(09951-07100)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)

D26468

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135. INSTALL PARKING LOCK ROD SUB-ASSY

Parking Lock Rod Sub-assy (a) Install the parking lock rod to the manual valve lever.

D26382

136. INSTALL MANUAL VALVE LEVER SUB-ASSY

(a) Install a new spacer and manual valve lever shaft to the
transaxle case.
NOTICE:
Spacer
Do not damage on the oil seal during assembling the shaft
to the transaxle case.

D03565

(b) Using a pin punch and hammer, drive in a new pin.

D03564

(c) Turn the spacer and the lever shaft to align the small hole
for locating the staking position in the spacer with the
staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.

D26765

137. INSTALL MANUAL VALVE LEVER SHAFT RETAINER

SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft certainly.

D03559

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138. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N⋅m (205 kgf⋅cm, 15 ft⋅lbf)
Bolt length: 25 mm (0.984 in.)
NOTICE:
Be sure the parking rod is placed between the parking pawl
and the guide of the parking bracket when the parking
bracket is assembled.
D03561

139. INSTALL MANUAL DETENT SPRING SUB-ASSY

(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
B
this order.
HINT:
A
Tighten them in the order, A and B.
Torque:
D03560 Bolt A: 20 N⋅m (205 kgf⋅cm, 15 ft⋅lbf)
Bolt B: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B: 16 mm (0.630 in.)

140. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, install it to the B-3 accumula-
tor piston.
O-ring
NOTICE:
Install the O-ring to the accumulator piston and the accu-
B-3 Accumulator Piston mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
D03904

(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Color
Outer diameter mm (in.)
ATF
Inner 62.00 (2.4409) /
Purple
15.50 (0.610)
D25512
Outer 74.23 (2.9224) /
Purple
21.70 (0.854)

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141. INSTALL REVERSE CLUTCH ACCUMULATOR

Reverse clutch Accumulator Piston PISTON
(a) Coat the 2 new O-rings with ATF, install them to the re-
verse accumulator piston.
O-ring NOTICE:
Install the O-ring to the accumulator piston and the accu-
O-ring mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
D26402 installed position.

(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ATF ing of the identification color or each spring.
Accumulator spring:
Free length
Color
Outer diameter mm (in.)
60.96 (2.3999) /
Yellow
14.10 (0.555)
C92978

142. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, install it to the C-3 accumu-
O-ring lator piston.
NOTICE:
Install the O-ring to the accumulator piston and the accu-
C-3 Accumulator Piston
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
D03902

(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Color
Outer diameter mm (in.)
72.20 (2.8425) /
Colorless
19.0 (0.748)
C83146

(c) Install the spring from the C-3 accumulator piston.

NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.

D03555

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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.
Check Ball

D03554

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.
C83129

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.
C83128

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.
C83127

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.
ATF D03636

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(b) Install the transmission wire retaining bolt.

Transmission Wire Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)

D03547

G F E 148. CONNECT TRANSMISSION WIRE

(a) Coat a O-ring of the ATF temperature sensor with ATF.
D (b) Install the ATF temperature sensor, with the lock plate and
bolt.
Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)
C (c) Connect the 7 solenoid connectors.
B NOTICE:

Connect the connector to A, B, C, D, E, F, G, from
A C91927 shorter one.

Apply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
B
valve body with 17 bolts to the transaxle case.
A
Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)
B C Bolt length:
A Bolt A: 25 mm (0.984 in.)

Bolt B: 57 mm (2.244 in.)
C Bolt C: 41 mm (1.614 in.)
C91933 NOTICE:

Push the valve body against the accumulator piston
spring and the check ball body to install it.

When installing the valve body to the transaxle case,
do not hold the solenoids.

Tighten temporarily those bolts marked by
in the il-
lustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF, install it to the oil strainer.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.

O-ring

C91932

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(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)
NOTICE:
Valve Body Oil Apply ATF to the bolts.
Strainer Assy.

C91931

151. INSTALL AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
Magnet (a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent

C86316

(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
NOTICE:

Because the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within 10 min-
utes after application.

Remove any oil or grease from the contacting surface
C91925 of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat the 4 new O-rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 N⋅m (75 kgf⋅cm, 65 in.⋅lbf)

D26716

153. INSTALL SPEED SENSOR

(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Speed Sensor
Torque: 11.0 N⋅m (115 kgf⋅cm, 8 ft⋅lbf)

D03900 D30672

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: Date
: 98
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154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL

COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the elbow.
Elbow
(b) Install the elbow to the transaxle case.
Torque: 27 N⋅m (276 kgf⋅cm, 20 ft⋅lbf)

O-ring

C83144

155. INSTALL OIL COOLER TUBE UNION (INLET OIL

COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the union.
Union (b) Install the union to the transaxle case.
O-ring Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)

C83143

156. INSTALL BREATHER PLUG HOSE

(a) Install the breather plug hose into the transaxle case certainly.

157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY

(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 N⋅m (70 kgf⋅cm, 61 in.⋅lbf)

D09639

(c) Temporarily install control shaft lever.

Control Shaft Lever

D09640

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: Date
: 99
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(d) Turn the lever counterclockwise until it stops, and then

turn it clockwise 2 notches.
(e) Remove the control shaft lever.

D09641

(f) Align the groove with neutral basic line.

(g) Tighten the 2 bolts.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)

D09642

(h) Using a screwdriver, stake the nut with the nut stopper.

D09643

(i) Install the control shaft lever, washer and nut.

Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)

D09644

158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY

(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 N⋅m (70 kgf⋅cm, 61 ft⋅lbf)

Author
: Date
: 100