40–52

AUTOMATIC TRANSMISSION / TRANS – INPUT SHAFT ASSY (U34#E Series)

INPUT SHAFT ASSY (U34#E Series)

4002I–01

OVERHAUL

1. REMOVE FRONT CLUTCH CLUTCH DISC

[ 35633 / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates.

C67851

2. INSPECT FRONT CLUTCH CLUTCH DISC

[ 35633 / 3507 ]
(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 is peeling off or discolored, or
even if a part of the printed number is defaced, re-
C67852 place all discs.

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

3. REMOVE FORWARD CLUTCH RETURN SPRING

SUB–ASSY
SST [ 35603A / 3507 ]
(a) Using SST on the clutch balancer, and compress the re-
turn spring with a press.
SST 09320–89010
NOTICE:
Do not compress the return spring excessively.
D08368 (b) Using a snap ring expander, remove the snap ring.

(c) Remove the clutch balancer and piston return spring.

D08369

U340E A/T REPAIR MANUAL (RM824E)

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AUTOMATIC TRANSMISSION / TRANS – INPUT SHAFT ASSY (U34#E Series)

4. INSPECT FORWARD CLUTCH RETURN SPRING

SUB–ASSY
[ 35603A / 3507 ]
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 21.69 mm (0.8540 in.)

C67855

5. REMOVE FORWARD CLUTCH PISTON

[ 35612B / 3507 ]
(a) Place the input shaft onto the oil pump.
(b) Holding the forward clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf
cm2, 57 psi) to the oil
pump to remove the forward clutch piston.
HINT:
When the piston can not be removed as it is slanted, either blow
C67856 the air again with the protruding side pushed or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
6. REMOVE FORWARD CLUTCH PISTON O–RING
[ 35612C / 3507 ]
(a) Using a screwdriver, remove the O–ring.

C67857

7. REMOVE INPUT SHAFT OIL SEAL RING

[ 35712A / 3507 ]
(a) Using a screwdriver, remove the oil seal ring from the in-
put shaft.

C67858

8. INSTALL INPUT SHAFT OIL SEAL RING

[ 35712A / 3507 ]
(a) Coat a new oil seal ring with ATF, and install it to the input
shaft.

C67858

U340E A/T REPAIR MANUAL (RM824E)

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AUTOMATIC TRANSMISSION / TRANS – INPUT SHAFT ASSY (U34#E Series)

9. INSTALL FORWARD CLUTCH PISTON O–RING

[ 35612C / 3507 ]
(a) Coat a new O–ring with ATF, and install it to the forward
clutch piston.

C67857

10. INSTALL FORWARD CLUTCH PISTON

[ 35612B / 3507 ]
(a) Install the forward clutch piston to the input shaft.
NOTICE:
Be careful not to damage the O–ring.

C68199

11. INSTALL FORWARD CLUTCH RETURN SPRING

SUB–ASSY
[ 35603A / 3507 ]
(a) Install the clutch balancer and return spring to the input
shaft.

C67854

(b) Using SST, a press and a snap ring plier, install the snap
ring to the forward clutch return spring.
SST
SST 09320–89010

D08368

Flange 12. INSTALL FRONT CLUTCH CLUTCH DISC

Disc
[ 35633 / 3507 ]
(a) Install the 4 plates, 4 discs and flange.
Plate (b) Using a screwdriver, install the snap ring.

D25109

U340E A/T REPAIR MANUAL (RM824E)

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AUTOMATIC TRANSMISSION / TRANS – INPUT SHAFT ASSY (U34#E Series)

13. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

(a) Using a dial indicator, measure the pack clearance while
applying and releasing compressed air (392 kPa, 4.0
kgf
cm2, 57 psi).
Pack clearance:
1.406 – 1.806 mm (0.05535 – 0.07110 in.)
If the piston stroke is less than the limit, parts may have been
assembled incorrectly, check and reassemble again.
C67860 If the clearance is non–standard, select another flange.
HINT:
There are 4 different flanges in thickness.
Flange thickness: mm (in.)
No. Thickness No. Thickness
– 3.00 (0.1181) 2 3.40 (0.1339)
1 3.20 (0.1260) 3 3.60 (0.1417)

U340E A/T REPAIR MANUAL (RM824E)