07 Automatic Transaxle

AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE SYSTEM AX1 . . . . . . .

COMPONENT PARTS AX3 . . . . . . . . . . . . . . . . . . . .
OIL PUMP AX51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECOND COAST BRAKE AX56 . . . . . . . . . . . . . . . . .
DIRECT CLUTCH AX60 . . . . . . . . . . . . . . . . . . . . . . . .
FORWARD CLUTCH AX66 . . . . . . . . . . . . . . . . . . . . .
FRONT PLANETARY GEAR AX72 . . . . . . . . . . . . . . .
SECOND BRAKE AX77 . . . . . . . . . . . . . . . . . . . . . . . .
REAR PLANETARY GEAR AX81 . . . . . . . . . . . . . . . .
FIRST AND REVERSE BRAKE AX85 . . . . . . . . . . . .
INTERMEDIATE SHAFT AX89 . . . . . . . . . . . . . . . . . .
COUNTER DRIVE GEAR AX92 . . . . . . . . . . . . . . . . .
COUNTER SHAFT AX95 . . . . . . . . . . . . . . . . . . . . . . .
UNDERDRIVE CLUTCH AX105 . . . . . . . . . . . . . . . . . .
UNDERDRIVE BRAKE AX114 . . . . . . . . . . . . . . . . . . . .
VALVE BODY AX120 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UPPER VALVE BODY AX126 . . . . . . . . . . . . . . . . . . . .
LOWER VALVE BODY AX130 . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE AX134 . . . . . . . . . . . . . . . . . . . .
F00484
C
1
C
2
C
3
B
1
B
2
Shift Lever
Range
Gear
No.2 OneWay Clutch (F
2
)
1st and Reverse Brake (B
3
)
U/D Brake (B
4
)
U/D OneWay Clutch (F
3
)
U/D Clutch (C
3
)
Direct Clutch (C
2
)
2nd Brake (B
2
)
Forward Clutch (C
1
)
2nd Coast Brake (B
1
)
B
4
B
3
Front Planetary Gear Unit
F
1
F
2
F
3
ON OFF
ON
ON
ON
ON
OFF
OFF ON
ON
ON
ON
ON
ON
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
F F F
F
F
F
F
F
F F
F
F
F
F
F
F
F
F
F
F
F F
F
F
F
F
F
F
F
F
F
F
F F
F F
F
F
F
F
F
F
F
F
F
F
F
F
F
2nd
Neutral
Reverse
Park
1st
O/D
3rd
2nd*
2nd
1st
3rd*
1st
P
R
N
D
2
L
F : Operating
*: Downshift only in the 3rd gear for the 2 range and 2nd gear for the L range no upshift
Rear Planetary Gear Unit
U/D Planetary Gear Unit
No.1 OneWay Clutch (F
1
)
No. 1 Solenoid
Valve
No. 2 Solenoid
Valve
AX06902
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SYSTEM
AX1
A245E AX (RM757E)
AUTOMATIC TRANSAXLE SYSTEM
OPERATION
AT2690
D02641
U/D Planetary Gear Unit
Rear Planetary Gear Unit Front Planetary Gear Unit
Front and Rear Sun Gear
Intermediate
Shaft
Input Shaft
Ring Gear
Counter Shaft
B
4 F
3
C
3
B
3 F
2
B
2
F
1
B
1
C
1
C
2
AX2
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SYSTEM
A245E AX (RM757E)
FUNCTION OF COMPONENTS
Component Function
C
1
Forward Clutch Connects input shaft and front planetary ring gear.
C
2
Direct Clutch Connects input shaft and front and rear planetary sun gear.
C
3
U/D Clutch Connects U/D sun gear and U/D planetary carrier.
B
1
2nd Coast Brake
Prevents front and rear planetary sun gear from turning either
clockwise or counterclockwise.
B
2
2nd Brake
Prevents outer race of F
1
from turning either clockwise or
counterclockwise, thus preventing the front and rear sun gear
turning counterclockwise.
B
3
1st and Reverse Brake
Prevents rear planetary carrier from turning either clockwise or
counterclockwise.
B
4
U/D Brake
Prevents U/D sun gear from turning either clockwise or coun-
terclockwise.
F
1
No.1 Oneway Clutch
When B
2
is operating, this clutch prevents the front and rear
planetary gear from turning counterclockwise.
F
2
No.2 Oneway Clutch Prevents rear planetary carrier from turning counterclockwise.
F
3
U/D Oneway Clutch Prevents U/D planetary sun gear from turning clockwise.
Planetary Gears
These gears change the route through which driving force is
transmitted, in accordance with the operation of each clutch
and brake, in order to increase or reduce the input and output
speed.
AX06A02
D08571
Snap Ring
Oring
Cover
2nd Coast Brake Piston
Oil Seal Ring
Spring
30 (306, 22)
Union
z
z
Breather Hose
Plug
5.5 (56, 49 in.lbf)
Transmission Wire
z
5.3 (54, 49 in.lbf)
Spring
Check Ball Body
Neutral Start Switch
12.5 (127, 9)
Lock washer
Manual Shift
Lever
z
z
z
z
z
z
z
Spring
C
3
Accumulator
Piston
B
2
Accumulator Piston
C
2
Accumulator
Piston
Parking Lock Rod
Manual Valve Lever
Spring Pin
Manual Valve Shaft
Manual Valve
Spring Retainer
Plate Washer
Detent Spring
10 (102, 7)
Oil Seal
Spacer
5.2 (54, 47 in.lbf)
17.5 (178, 13)
Oil Pan
Magnet
Valve Body
Oil Strainer
10 (102, 7)
z Nonreusable part
Nm (kgfcm, ftlbf) : Specified torque
z
Oring z
z
z
Gasket z
Gasket z
Oring z
X2
X3
X17
10 (102, 7)
X18
z
C
1
Accumulator
Piston
Wire Retainer
5.3 (54, 49 in.lbf)
Apply Pipe
Apply Pipe Bracket
7.0 (71, 62 in.lbf)
6.4 (65, 56 in.lbf)
AUTOMATIC TRANSAXLE COMPONENT PARTS
AX3
A245E AX (RM757E)
COMPONENT PARTS
COMPONENTS
D08572
z Nonreusable part
Oil Pump
Oring
Direct Clutch
Forward Clutch
2nd Coast
Brake Band
Pin
Thrust Washer
Front Planetary
Gear
Race
Front Planetary
Ring Gear
Thrust Washer
Race
No. 1 OneWay Clutch
Rear Planetary
Gear
No. 2 OneWay
Clutch
Disc
Return Spring
Snap Ring
Snap Ring
Race
Thrust Washer
Disc
Flange
Flange
Snap Ring
2nd Brake
Drum
Plate
Snap Ring
Plate
Oil Seal Ring
2nd Brake Drum Seal
2nd Brake Apply Gasket
Transaxle Rear Cover
2nd Coast Brake
Band Guide
z
Front Bearing
Counter Drive
Gear Assembly
Spacer
Lock Nut
z
25 (255, 18)
z
5.4 (55, 48 in.lbf)
10 (102, 7)
X6
X13
Intermediate Shaft
Assembly
z
Thrust Washer
Planetary Sun Gear and
Sun Gear Input Drum
Assembled Bearing
and Race
Assembled Bearing
and Race
Assembled Bearing
and Race
Assembled Bearing
and Race
Assembled Bearing
and Race
AX4
A245E AX (RM757E)
D08615
Transaxle Housing
Bearing
Bearing Stopper
Oil Seal
Ring
Oil Pipe
Clamp
U/D Planetary Gear
Unit w/Counter Shaft
z Lock Nut
Pawl Shaft Clamp
Parking Lock Pawl
Thrust Needle Bearing
30 (306, 22)
17 (173, 13)
5.4 (55, 48 in.lbf)
180 (1,835, 133)
30 (306, 22)
5.4 (55, 48 in.lbf)
U/D Clutch and
U/DOneway Clutch
AntiRattle Clip
Counter
Driven Gear
Assembled Bearing
and Race
Bearing
z Lock Nut
5.4 (55, 48 in.lbf)
Parking Lock Pawl Shaft
Cam Guide
Bracket
Spring
Differential
Assembly
Apply Gasket
10 (102, 7)
Spring Guide
Parking Lock
Sleeve
13 (130, 9)
z Oring
Oil Gallery Cover
L Screw
10 (102, 7)
No. 3 Transmission
Case Plate
7.0 (71, 62 in.lbf)
10 (102, 7)
B
4
Accumulator
Piston
z Nonreusable part
L
L Precoated part
Clamp
Clamp
Parking Lock Pawl
Stopper Plate
13 (130, 10)
z Gasket
X14
X3
X3
X6
Torsion Spring
No. 1 TransmissionCase Plate
AX5
A245E AX (RM757E)
AX0PR01
D08573
D08574
D08575
Q02178
AX6
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE PLUG AND GASKET
3. REMOVE NEUTRAL START SWITCH
(a) Remove the nut, washer and manual shift lever.
(b) Pry off the lock washer and remove the manual valve
shaft nut.
(c) Remove the 2 bolts and pull out the neutral start switch.
4. REMOVE UNION
(a) Using an open end wrench, remove the 2 unions.
(b) Remove the 2 Orings from the unions.
5. REMOVE SOLENOID WIRE RETAINING BOLT
6. REMOVE PAN AND GASKET
(a) Remove the 18 bolts.
(b) Remove the pan by lifting the transaxle case.
NOTICE:
Do not turn the transaxle over as it will contaminate the
valve body with the foreign materials from the bottom of the
pan.
(c) Remove the gasket.
(d) Place the transaxle on wooden blocks to prevent damage
to the pipes.
AT0103
D08576
D08577
Q02182
Q02184
AX7
A245E AX (RM757E)
7. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips.
Carefully 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 (nonmagnetic).....bushing wear
8. TURN TRANSAXLE OVER
9. REMOVE OIL STRAINER
Remove the 3 bolts and oil strainer.
10. DISCONNECT SOLENOID CONNECTORS
(a) Disconnect solenoid connectors.
(b) Remove the bolt and wire retainer.
11. REMOVE MANUAL DETENT SPRING
12. REMOVE VALVE BODY
(a) Remove the transmission wire.
D08579
AT5616
Q02240
Q02187
Q02333
AX8
A245E AX (RM757E)
(b) Remove the 17 bolts.
(c) While disconnecting the manual valve connecting rod
from the manual valve lever, remove the valve body.
(d) Remove the manual valve from the valve body.
13. REMOVE CHECK BALL BODY
Remove the check ball body and spring.
14. REMOVE 2ND BRAKE APPLY GASKET
15. REMOVE 2ND BRAKE DRUM SEAL
Using needlenose pliers, pull out the 2nd brake drum seal.
Q02241
Q02242
Q02243
Q03875
Q02688
AX9
A245E AX (RM757E)
16. REMOVE B
2
ACCUMULATOR PISTON AND SPRING
(a) Using lowpressure compressed air (98 kPa, 1 kgf/cm
2
,
14 psi), pop out the B
2
piston into a rag and remove the
spring.
(b) Remove the 2 Orings from the piston.
17. REMOVE C
2
2,
14 psi), pop out the C
2
spring.
18. REMOVE C
1
2,
1
spring.
19. REMOVE C
3
2,
3
spring.
20. REMOVE 2ND COAST BRAKE BAND GUIDE
AT2905
AT2906
AT0547
AT0548
Q02291
AX10
A245E AX (RM757E)
21. REMOVE MANUAL VALVE SHAFT
(a) Using a screwdriver and hammer, unstake the spacer and
remove it.
(b) Using a punch and hammer, drive out the pin.
HINT:
Drive out the spring pin slowly so that it will not fall into the trans-
axle case.
(c) Remove the spring retainer.
(d) Slide out the manual valve shaft and remove the manual
valve lever and plate washer.
22. IF NECESSARY, REPLACE OIL SEAL OF MANUAL
SHAFT
(a) Using a screwdriver, remove the oil seal.
Q02292
Q02189
AT0525
Q02204
D08612
AX11
A245E AX (RM757E)
(b) Using a 14 mm socket wrench and hammer, drive in a new
oil seal.
(c) Apply MP grease to the seal lip.
23. REMOVE TRANSAXLE HOUSING
Remove the 17 bolts and transaxle housing.
24. REMOVE DIFFERENTIAL ASSEMBLY
25. REMOVE NO. 1 TRANSMISSION CASE PLATE
Remove the bolt and No. 1 transmission case plate.
26. REMOVE APPLY GASKET
27. REMOVE OIL PUMP
(a) Remove the 6 bolts and holding the oil pump to the trans-
axle case.
D08613
AT8648
AT3035
Q02334
Q02335
AX12
A245E AX (RM757E)
(b) Pull out the oil pump from the transaxle case.
(c) Remove the race from the oil pump.
(d) Using a screwdriver, remove the Oring from the oil
pump.
28. REMOVE APPLY PIPE
(a) Remove the bolt and apply pipe bracket.
(b) Using a screwdriver, remove the apply pipe.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Be careful not to bend or damage the pipe.
Q02336
Q02337
SST
Q02295
SST
Q03874
Q02244
AX13
A245E AX (RM757E)
29. MEASURE PISTON STROKE OF 2ND COAST BRAKE
(a) Apply a small amount of paint to the piston rod at the point
where it meets the case.
(b) Using SST, measure the piston stroke while applying and
releasing compressed air (392 785 kPa, 4 8 kgf/cm
2
,
57 114 psi).
SST 0924000020
Piston stroke: 1.5 3.5 mm (0.059 0.138 in)
If the piston stroke exceeds the limit, inspect the brake band.
30. REMOVE 2ND COAST BRAKE PISTON
(a) Using SST, remove the snap ring.
SST 0935032014 (0935132050)
(b) Using lowpressure compressed air (98 kPa, 1 kgf/cm
2,
14 psi), pop out the cover into a rag.
(c) Remove the cover, piston and spring.
(d) Remove the 2 Orings from the cover.
(e) Remove the oil seal ring.
Q02338
AT8650
Q02245
Q02192
Q02246
AX14
A245E AX (RM757E)
31. REMOVE DIRECT CLUTCH WITH FORWARD CLUTCH
(a) Remove the direct clutch with the forward clutch from the
case.
(b) Remove the direct clutch from the forward clutch.
(c) Remove the thrust washer and 2 assembled bearings
and races from the forward clutch.
32. REMOVE 2ND COAST BRAKE BAND
(a) Pull out the pin.
(b) Remove the brake band.
33. REMOVE FRONT PLANETARY RING GEAR
(a) Remove the front planetary ring gear.
Q02193
Q02247
Q02194
Q02248
Q02249
AX15
A245E AX (RM757E)
(b) Remove the assembled bearing and race and race from
the ring gear.
34. REMOVE FRONT PLANETARY GEAR
(a) Remove the front planetary gear with the bearing and
race.
(b) Remove the assembled bearing and race and race from
the planetary gear.
35. REMOVE PLANETARY SUN GEAR WITH SUN GEAR
INPUT DRUM AND THRUST WASHER
36. REMOVE NO. 1 ONEWAY CLUTCH
AT8652
Q02250
Q02251
Q02339
Q02252
AX16
A245E AX (RM757E)
37. CONFIRM THAT 2ND BRAKE PISTON MOVES
Using compressed air, check that the 2nd brake piston moves
smoothly.
38. REMOVE 2ND BRAKE
(a) Using a screwdriver, remove the snap ring.
HINT:
(b) Remove the 2nd brake drum.
HINT:
If the brake drum is difficult to remove, lightly tap it with a wood-
en block.
(c) Remove the return spring.
(d) Remove the plates, discs and flange.
Q02296
Q02253
AT8653
Q02254
Q02390
AX17
A245E AX (RM757E)
39. REMOVE REAR PLANETARY GEAR
(a) Using 2 screwdrivers, remove the snap ring.
HINT:
(b) Remove the No. 2 oneway clutch and rear planetary
gear with the 2 thrust washers.
(c) Remove the 2 thrust washers from the rear planetary
gear.
(d) Remove the No. 2 oneway clutch from the rear planetary
gear.
(e) Remove the assembled bearing and race and race from
the planetary ring gear.
40. CHECK PACK CLEARANCE OF 1ST AND REVERSE
BRAKE
Using a feeler gauge, measure the 1st and reverse brake pack
clearance.
Pack clearance:
1.19 2.25 mm (0.0469 0.0886 in.)
If the pack clearance is nonstandard, check the disc.
Q02297
D08580
Q02195
Q02196
Q02340
AX18
A245E AX (RM757E)
41. REMOVE 1ST AND REVERSE BRAKE PACK
HINT:
(b) Remove the flange, plates and discs.
42. REMOVE TRANSAXLE REAR CASE
(b) Tap off the circumference of the cover with a plastic ham-
mer to remove the rear case from the transaxle case, and
remove the cover.
43. REMOVE INTERMEDIATE SHAFT
(a) Using a chisel and hammer, unstake the intermediate
shaft lock nut.
Q02197
SST
Q02255
Q02341
SST
Q02991
AT2895 AT2894 D02423
AX19
A245E AX (RM757E)
(b) Using SST, remove the lock nut.
SST 0933000021, 0935032014 (0935132032)
(c) Remove the intermediate shaft.
44. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear.
SST 0995060010 (0995100380), 0995070010
(0995107100)
(b) Remove the spacer from the counter drive gear assem-
bly.
45. REMOVE FRONT BEARING
46. REMOVE COUNTER DRIVEN GEAR
(a) Using a chisel and hammer, unstake the counter shaft
lock nut on both sides.
Q02198
SST
Q02343
SST
SST
Q02199
SST
D08614
AT2896
AX20
A245E AX (RM757E)
(b) Using SST to hold the counter shaft, remove the lock nut
on the driven gear side.
SST 0935032014 (0935132170)
(c) Using SST to hold the driven gear, remove the lock nut of
the other side.
SST 0933000021, 0935032014 (0935132032,
0935132170)
(d) Using SST, remove the driven gear.
SST 0935032014 (0935132061)
(e) Remove the thrust needle bearing.
47. REMOVE COUNTER SHAFT ASSEMBLY
(a) Pull out the counter shaft assembly.
AT0535
Q04379
AT0541
AT8663
AT8664
AX21
A245E AX (RM757E)
(b) Remove the thrust bearing with race from the counter
shaft assembly.
48. REMOVE U/D CLUTCH AND U/D ONEWAY CLUTCH
49. REMOVE ANTIRATTLE CLIP
50. REMOVE PARKING LOCK PAWL
(a) Remove the 2 bolts, parking lock pawl stopper plate, tor-
sion spring and spring guide.
(b) Remove the bolt and pawl shaft clamp.
(c) Remove the parking lock pawl shaft and lock pawl.
AT8665
AT8666
Q05207
AT2910
AT0555
SST
AX22
A245E AX (RM757E)
51. REMOVE PARKING LOCK SLEEVE
52. REMOVE CAM GUIDE BRACKET
Remove the cam guide bracket.
53. REMOVE B
4
(b) Using a torx wrench, remove the 6 screws.
Remove the oil gallery cover and gasket.
(c) Remove the B
4
accumulator piston and spring.
54. REMOVE NO. 3 TRANSMISSION CASE PLATE
Remove the bolt and No. 3 transmission case plate.
55. REMOVE BEARING
Using SST, remove the bearing.
SST 0930800010
Q02202
Q02203
Q04381
Q05196
SST
AX23
A245E AX (RM757E)
56. REMOVE OIL PIPE
(a) Remove the 3 bolts and oil pipe clamps.
(b) Using a screwdriver, remove the 2 oil pipes.
HINT:
NOTICE:
Be careful not to bend or damage the pipes.
57. REMOVE BEARING
(a) Remove the bolt and retainer.
(b) Using SST, remove the bearing.
SST 0930800010
AX0PS01
AX24
A245E AX (RM757E)
REASSEMBLY
NOTICE:
S The automatic transaxle is composed of highly precisionfinished parts, necessitating careful
inspection before reassembly because even a small nick could cause fluid leakage or affect
performance. The instructions here are organized so that you work on only one component
group at a time. This will help avoid confusion from similarlooking parts of different subas-
semblies being on your workbench at the same time. The component groups are inspected and
repaired from the converter housing side. As much as possible, complete the inspection, repair
and reassembly before proceeding to the next component group. If a defect is found in a certain
component group during reassembly, inspect and repair this group immediately. If a compo-
nent group cannot be assembled because parts are being ordered, be sure to keep all parts of
that group in a separate container while proceeding with disassembly, inspection, repair and
reassembly of other component groups.
Recommended ATF: DII or DEXRON III (DEXRON II)
S All disassembled parts should be washed clean and any fluid passages and holes should be
blown through with compressed air.
S Dry all parts with compressed airnever use shop rags.
S When using compressed air, always aim away from yourself to prevent accidentally spraying
ATF or kerosene on your face.
S The recommended automatic transaxle fluid or kerosene should be used for cleaning.
S After cleaning, the parts should be arranged in the correct order to allow efficient inspection,
repairs, and reassembly.
S When disassembling a valve body, be sure to keep each valve together with the corresponding
spring.
S New discs for the brakes and clutches that are to be used for replacement must be soaked in
ATF for at least 15 minutes before reassembly.
S All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
S All gaskets and rubber Orings should be replaced.
S Do not use adhesive cements on gaskets and similar parts.
S Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
S If a worn bushing is to be replaced, the subassembly containing that bushing must also be
replaced.
S Check thrust bearings and races for wear or damage. Replace if necessary.
S Use petroleum jelly to keep parts in place.
S When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gas-
ket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a nonresidue solvent.
Parts must be reassembled within 10 minutes often application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
Q02419
B
A
C
H
G
D
E
F
AX25
A245E AX (RM757E)
BEARING AND RACES INSTALLATION POSITION AND DIRECTION
AX26
A245E AX (RM757E)
Mark
Front Race Diameter
Inside / Outside mm (in.)
Thrust Bearing Diameter
Rear Race Diameter
A 30.0 (1.181) / 41.8 (1.646) 31.0 (1.220) / 43.9 (1.728)
B 31.0 (1.220) / 43.9 (1.728)
C 41.0 (1.614) / 58.0 (2.283)
D 30.7 (1.209) / 46.0 (1.811)
E 25.8 (1.016) / 42.0 (1.654) 26.0 (1.024) / 39.5 (1.555)
F 22.0 (0.866) / 38.0 (1.496) 19.0 (0.748) / 35.0 (1.378)
G 28.1 (1.106) / 45.0 (1.772)
H 24.1 (0.949) / 37.6 (1.480) 22.1 (0.870) / 37.6 (1.480)
Q02361
SST
Q02589
Q02362
Q02202
AT0593
SST
AX27
A245E AX (RM757E)
1. INSTALL BEARING TO TRANSAXLE HOUSING
(a) Using SST and a press, install the bearing into the trans-
axle housing.
SST 0935032014 (0935132140)
(b) Install the bearing stopper with the bolt.
Torque: 17 Nm (173 kgfcm, 13 ftlbf)
2. INSTALL OIL PIPE
(a) Using a plastic hammer, install the 2 oil pipes.
NOTICE:
Be careful not to bend or damage the pipes.
(b) Install the 3 pipe clamps with the 3 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
3. INSTALL BEARING TO TRANSAXLE CASE
Using SST and a press, install the bearing into the transaxle
case.
SST 0935032014 (0935132090)
4. INSTALL NO. 3 TRANSMISSION CASE PLATE
Install the No.3 transmission case plate with the bolt.
Torque:10 Nm (102 kgfcm, 7 ftlbf)
AT2910
Q05208
Q05207
AT0548
AT0547
AX28
A245E AX (RM757E)
5. INSTALL B
4
(a) Coat new Oring with ATF, and install them to the piston.
(b) Install the piston and spring to the case.
6. INSTALL OIL GALLERY COVER AND GASKET
(a) Clean the threads of the screws and case with white gaso-
line.
(b) Install a new gasket and oil gallery cover in place.
(c) Install and tighten the 3 bolts.
(d) Apply seal packing or equivalent to the 6 screws.
Seal packing:
Part No. 08833 00070, THREE BOND 1324 or equiva-
lent
(e) Using a torx wrench, install the 6 screws.
7. INSTALL MANUAL VALVE SHAFT AND LEVER
(a) Install the parking lock rod to the manual valve lever.
(b) Slide in the shaft and install the plate washer, a new
spacer and manual lever.
(c) Install the retaining spring retainer.
HINT:
Make sure there is a washer between the retaining spring and
case.
AT2959
AT8666
AT8665
AT0700
AT0701
AX29
A245E AX (RM757E)
(d) Using a punch and hammer, drive in the pin.
(e) Position the spacer and stake it.
8. INSTALL PARKING LOCK PAWL
(a) Install the cam guide bracket and then insert the parking
lock rod into the guide bracket.
(b) Install the parking lock sleeve with the protruding portion
facing up.
(c) Place the stopper plate on the protruding portion of the
lock sleeve.
(d) Install the guide sleeve and spring with the 2 bolts.
AT7931
AT7890
Clamp Groove
Q02991
Q02401
SST
Q02255
AX30
A245E AX (RM757E)
(e) Install the parking lock pawl.
(f) Install the parking lock pawl shaft and install the shaft
clamp with the 2 bolts.
9. INSTALL COUNTER DRIVE GEAR
(a) Install the front bearing and spacer.
(b) Using SST and a press, install the counter drive gear,
front bearing, and a new spacer.
SST 0935032014 (0935132130, 0935132150)
10. INSTALL INTERMEDIATE SHAFT
(a) Install the intermediate shaft.
Q02725
SST
Q02556
Q04377
AT2942
Thrust Washer
Q02595
AX31
A245E AX (RM757E)
(b) Using SST, install the lock nut.
SST 0996010010 (0996201000, 0996301000)
11. CHECK DRIVE GEAR PRELOAD
Using a torque wrench, measure the starting torque of the
counter drive gear.
Starting torque:
New bearing:
0.3 0.7 Nm (3.1 7.1 kgfcm, 2.6 6.1 in.lbf)
Reused bearing:
0.2 0.4 Nm (2.0 4.1 kgfcm, 1.7 3.5 in.lbf)
If the torque exceeds the limit, replace the spacer.
12. STAKE LOCK NUT
Using a pin punch and hammer, stake the lock nut.
13. REMOVE U/D ONEWAY CLUTCH FROM CLUTCH
DRUM
Remove the U/D oneway clutch and thrust washer from the
U/D clutch drum.
14. INSTALL U/D ONEWAY CLUTCH
AT1289
Q02596
Free
Lock
Q02597
Q02599
Q04376
AX32
A245E AX (RM757E)
15. INSTALL ANTIRATTLE CLIP
In the place shown in the illustration (the space between the
oneway clutch outer race and case), push the antirattle clip
in until you hear a click.
16. INSTALL U/D CLUTCH ASSEMBLY
(a) Coat the thrust washer with petroleum jelly and install it
onto the No. 3 oneway clutch.
(b) Align the flukes of discs in the U/D brake.
(c) Install the U/D clutch assembly.
(d) Turn the U/D clutch assembly. The clutch assembly
should turn freely counterclockwise and should lock
clockwise.
17. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the
inner race.
Height: 17.3 18.2 mm (0.681 0.717 in.)
18. INSTALL ASSEMBLED BEARING AND RACE
Install the assembled bearign and race, with the bearing facing
upward.
Assembled bearing and race:
Outer diameter Inner diameter
Assembled bearing
and race
43.9 mm (1.728 in.) 31.0 mm (1.220 in.)
19. REMOVE U/D PLANETARY SUN GEAR FROM COUNT-
ER SHAFT
(a) Remove the U/D planetary sun gear from the counter
shaft.
(b) Remove the thrust bearing and race.
Q02600
Q02601
Q02402
Q02200
AX33
A245E AX (RM757E)
20. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.
21. INSTALL COUNTER SHAFT ASSEMBLY
(a) Align the flukes of the discs in the U/D clutch.
(b) Install the thrust bearing with the race, with the bearing
facing upward.
Bearing and race:
Bearing 43.9 mm (1.728 in.) 31.0 mm (1.220 in.)
Race 41.8 mm (1.646 in.) 30.0 mm (1.181 in.)
(c) Install the counter shaft assembly.
22. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of
the counter shaft and bolt seat of the clutch support.
Height: 33.3 35.5 mm (1.311 1.398 in.)
23. INSTALL THRUST NEEDLE BEARING
Bearing:
Q02552
SST
Q02369
SST
AT0076
Q02403
Q02365
FIPG
AX34
A245E AX (RM757E)
24. INSTALL COUNTER DRIVEN GEAR
Using SST and a press, press in the driven gear.
SST 0935032014 (0935132100, 0935132140)
25. TIGHTEN NEW LOCK NUT
(a) Using SST to hold the driven gear, tighten a new lock nut.
SST 0935032014 (0935132032)
Torque: 180 Nm (1,835 kgfcm, 133 ftlbf)
(b) Remove the SST.
26. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter
shaft.
End play: 0.2 0.9 mm (0.008 0.035 in.)
27. STAKE LOCK NUT
Using a punch and hammer, stake the lock nut.
28. INSTALL TRANSAXLE REAR COVER
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
transaxle case.
(b) Apply FIPG sealant to the rear cover.
FIPG:
Part No. 08826 00090, THREE BOND 1281 or equiva-
lent
AT8039
A
B
A
A
Q02405
D08580
D08608
Q02408
AX35
A245E AX (RM757E)
(c) Install and tighten the 13 bolts.
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
Bolt A: 25 mm (0.98 in.)
Bolt B: 32 mm (1.26 in.)
29. CHECK INTERMEDIATE SHAFT
Make sure that the intermediate shaft turns smoothly.
30. INSTALL 1ST AND REVERSE BRAKE PACK
(a) Install the discs and plates in order.
Install in order: D = Disc P = Plate
P D P D P D P D P D
(b) Install the outer flange with the flat side facing downward.
(c) Using a screwdriver, install the snap ring.
HINT:
Be sure the snap ring end gap is not aligned with one of the cut-
outs.
Q02390
Q02254
AT0323
Thrust Washer
AT0614
Q04398
Rear
Planetary
Gear
Flange
A
AX36
A245E AX (RM757E)
31. CHECK PACK CLEARANCE OF 1ST AND REVERSE
BRAKE
Using a feeler gauge, measure the 1st and reverse brake pack
clearance.
Pack clearance:
1.19 2.25 mm (0.0469 0.0886 in.)
If the pack clearance is nonstandard, parts have been misas-
sembled. Check them.
32. INSTALL BEARING AND RACE TO REAR PLAN-
ETARY RING GEAR
Coat the races and bearing with petroleum jelly, and install them
onto the ring gear.
Bearing and races:
Race 37.6 mm (1.480 in.) 24.1 mm (0.949 in.)
33. INSTALL REAR PLANETARY GEAR
onto the planetary gear.
HINT:
Make sure that the different lug shapes match the correspond-
ing openings on the gear.
(b) Align the spline of the planetary gear with the flukes of the
discs and install the planetary gear into the 1st and re-
verse brake discs.
(c) Check the part A of the rear planetary gear is below the
upper surface of the flange.
AT2965
Lock
Free
SST
AT2966
Thrust Washer
AT7989
Q02602
Q02603
AX37
A245E AX (RM757E)
34. INSTALL NO. 2 ONEWAY CLUTCH
(a) Place the oneway clutch into the case, with the shiny
side facing upward.
(b) Install the oneway clutch onto the inner race while turn-
ing the planetary gear clockwise with SST.
SST 0935032014 (0935132050)
(c) Check that the planetary gear turns freely clockwise and
locks if turned counterclockwise.
(d) Coat the thrust washer with petroleum jelly and install it
onto the planetary gear.
(e) Be sure the end gap of the snap ring is not aligned with
one of the cutouts.
35. INSTALL 2ND BRAKE INTO CASE
(a) Install the flange with the flat side facing upward.
(b) Install the discs and plates in order.
Install in order: D = Disc P = Plate
D P D P D P
AT0620
Q02689
AT0621
AT0622
AT8696
AX38
A245E AX (RM757E)
(c) Install each of the springs over the protrusions in the
case.
(d) Install the 2nd coast brake band guide so that its tip
touches the case.
(e) Install the bolt.
(f) Align the groove of the drum with the bolt and place the
drum into the case.
(g) Place both ends of the snap ring in the groove, and then
set the snap ring into the case.
(h) While compressing the piston return springs over the
drum with hammer handles, install the snap ring.
HINT:
Be sure the end gap of the snap ring is not aligned with one of
the cutouts.
36. INSTALL 2ND BRAKE DRUM GASKET
Install a new drum gasket until it makes contact with the 2nd
brake drum.
AT7891
AT0626
AT8697
AT8088
AT8056
AX39
A245E AX (RM757E)
37. CONFIRM THAT 2ND BRAKE PISTON MOVES
Using compressed air, check that the 2nd brake piston moves
smoothly.
38. INSTALL 2ND BRAKE HUB AND NO. 1 ONEWAY
CLUTCH
(a) Using a screwdriver, align the flukes of the discs in the 2nd
brake.
(b) Align the spline of the hub with the flukes of the discs and
install the hub to the 2nd brake discs.
39. CHECK 2ND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the 2nd brake hub
and rear planetary gear.
Distance: Approx. 5 mm (0.20 in.)
40. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
on the sun gear input drum.
AT0628
Q02366
AT0631
AT2968
AT2023
AX40
A245E AX (RM757E)
(b) By turning the sun gear clockwise, install it into the No. 1
oneway clutch.
41. INSTALL FRONT PLANETARY GEAR
(a) Coat the race and bearing with petroleum jelly and install
them onto the planetary gear.
Bearing:
(b) Install the planetary gear.
42. INSTALL FRONT PLANETARY RING GEAR
(a) Coat the races and bearing with petroleum jelly and install
them onto the planetary ring gear.
Bearing and races:
Race 35.0 mm (1.378 in.) 19.0 mm (0.748 in.)
(b) Install the ring gear.
HINT:
If the planetary ring gear and the other parts are installed cor-
rectly into the case, the end of the bushing with the ring gear
flange will be flush with or under the shoulder of the intermedi-
ate shaft.
Q02410
Q02192
Q02411
AT0349
AT0350
AX41
A245E AX (RM757E)
(c) Coat the races and bearing with petroleum jelly and install
them onto the tip of ring gear flange.
Bearing and races:
Race 39.5 mm (1.555 in.) 26.0 mm (1.024 in.)
43. INSTALL 2ND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin.
44. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
(a) Coat the assembled bearing and race with petroleum jel-
ly, and install it onto the forward clutch drum.
Assembled bearing and race:
Assembled bearing
and race
46.0 mm (1.811 in.) 30.7 mm (1.209 in.)
(b) Coat the clutch drum thrust washer with petroleum jelly,
and install it onto the direct clutch drum with the oil groove
facing upward.
(c) Using a screwdriver, align the flukes of the discs in the di-
rect clutch.
Q04382
AT2971
Q02693
AT2870
Oring
Q02244
AX42
A245E AX (RM757E)
(d) Mesh the hub with the flukes of the direct clutch while turn-
ing the clutch drum or forward clutch.
HINT:
If the flukes of the discs are meshed correctly, the end of the
bushing with the direct clutch will be flush with the surfaces of
the forward clutch.
(e) Place the direct clutch and forward clutch into the case.
(f) While rotating the forward clutch to mesh the front plane-
tary ring gear and discs, install them.
(g) Check the distance between A and B.
Distance: Approx. 3 mm (0.118 in.)
45. INSTALL 2ND COAST BRAKE PISTON
(a) Install 2 new Orings to the cover.
HINT:
Coat the Orings with ATF before the installation.
(b) Install the spring, piston and cover into the bore.
Q02295
SST
Q02336
Q02337
SST
Q02204
AT0525
AX43
A245E AX (RM757E)
(c) Using SST, install the snap ring.
SST 0935032014 (0935132050)
46. MEASURE PISTON STROKE OF 2ND COAST BRAKE
(a) Apply a small amount of paint to the piston rod at the point
where it meets the case.
(b) Using SST, measure the piston stroke while applying and
releasing compressed air (392 785 kPa, 4 8 kgf/cm
2
,
57 114 psi).
SST 0924000020
Piston stroke: 1.5 3.5 mm (0.059 0.138 in.)
If the piston stroke exceeds the limit, select a new piston rod.
47. INSTALL NEW APPLY GASKET
48. INSTALL NO. 1 TRANSMISSION CASE PLATE
Install the No.1 transmission case plate with the bolt.
49. INSTALL DIFFERENTIAL
Q02413
Q02334
Q02360
FIPG
Q04360
A
B
A
A
A
A
AX44
A245E AX (RM757E)
50. INSTALL APPLY PIPE
(a) Using a plastic hammer, install the apply pipe.
NOTICE:
Be careful not to bend or damage the pipe.
(b) Install the apply pipe bracket with the bolt.
51. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle housing or
transaxle case.
(b) Apply FIPG to the transaxle housing.
FIPG:
Part No.08826 00090, THREE BOND 1281 or equiva-
lent
(c) Apply sealant to the bolt B threads.
Sealant:
Part No.08833 00090, adhesive 1131, or equivalent
(d) Install the bolts.
HINT:
Bolt length:
Bolt A: 30 mm (1.18 in.)
Bolt B: 35 mm (1.38 in.)
52. CHECK PRELOAD OF DIFFERENTIAL SIDE BEARING
AT2972
Q05182
Q05181
Q05180
AX45
A245E AX (RM757E)
53. INSTALL OIL PUMP INTO CASE
(a) Coat a new Oring with ATF, and install it to the pump
body.
(b) Place the oil pump through the input shaft, and align the
bolt holes of the pump body with those of the transaxle
case.
(c) Hold the input shaft, and lightly press the oil pump body
to slide the oil seal rings on the stator shaft through the
direct clutch drum.
NOTICE:
Do not push on the oil pump strongly, or the oil seal ring will
stick to the direct clutch drum.
(d) Install the 6 bolts.
54. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play in the axial direction.
Thrust play: 0.3 0.9 mm (0.012 0.035 in.)
If the play is not as specified, select and replace the race for the
end of the stator shaft.
HINT:
There are 2 different thickness for races, if necessary, select
one of them.
Race thickness: mm (in.)
thickness thickness
0.8 (0.031) 1.4 (0.055)
Q05178
D02851
C
3
B
2
C
2
C
1
(1) (3) (4) (5)
(2)
(6)
C
3
B
2 C
2
C
1
Q02187
Q02240
AX46
A245E AX (RM757E)
55. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
56. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Coat new Orings with ATF, and install them to the pis-
tons.
(b) Install the pistons and springs to the case.
Spring Free length Color
(1) C
3
(Outer) 71.5 mm (2.815 in.) White
(2) C
3
(Inner)
(3) B
2
68.2 mm (2.685 in.) Yellow
(4) C
2
64.7 mm (2.547 in.) Green
(5) C
1
(Outer) 70.6 mm (2.780 in.) Red
(6) C
1
(Inner) 36.5 mm (1.437 in.) Red
57. INSTALL NEW 2ND BRAKE APPLY GASKET
58. INSTALL CHECK BALL BODY
Install the check ball body and spring.
Q02184
AT8707
D08581
AT8709
D08579
B
A
C
A
C
A
B
B
A
AX47
A245E AX (RM757E)
59. INSTALL TRANSMISSION WIRE
60. INSTALL VALVE BODY
(a) Install the connecting rod to the manual valve.
(b) Using needlepliers, install the Ering to the connecting
rod.
(c) Install the manual valve to the valve body.
(d) Connect the connecting rod to the manual valve lever.
(e) Install the 17 bolts.
HINT:
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 25 mm (0.98 in.)
Bolt C: 50 mm (1.97 in.)
D08577
Q02182
D08576
A
B
D08582
Q02527
AX48
A245E AX (RM757E)
(f) Install the wire retainer with the bolts.
(g) Connect 4 solenoid connectors.
61. INSTALL MANUAL DETENT SPRING
62. INSTALL OIL STRAINER
Install the oil strainer with the 3 bolts.
HINT:
Bolt length:
Bolt A: 12 mm (0.47 in.)
Bolt B: 20 mm (0.79 in.)
63. INSTALL 2 MAGNETS IN OIL PAN
64. INSTALL OIL PAN
(a) Install a new gasket to the oil pan and install them to the
transaxle.
(b) Tighten the 18 bolts.
D08575
D08574
D08573
D08583 N R
P
D08584
Neutral
Basic
Line
Groove
AX49
A245E AX (RM757E)
65. INSTALL TRANSMISSION WIRE RETAINING BOLT
66. INSTALL UNION
(a) Install new Orings to each union.
(b) Install the unions to the transaxle case.
67. INSTALL NEUTRAL START SWITCH
(a) Install the neutral start switch to the manual valve shaft.
(b) Place a new lock washer and tighten the nut.
(c) Temporarily install the 2 bolts.
(d) Temporarily install the manual shift lever.
(e) Turn the lever counterclockwise until it stops, then turn it
clockwise 2 notches.
(f) Remove the manual shift lever.
(g) Align the groove with neutral basic line.
(h) Install and tighten the 2 bolts.
Torque: 5.3 Nm (54 kgfcm, 49 ftlbf)
D08585
AX50
A245E AX (RM757E)
(i) Using a screwdriver, stake the nut with the lock washer.
68. INSTALL MANUAL SHIFT LEVER
Torque: 12.5 Nm (127 kgfcm, 9 ftlbf)
69. INSTALL BREATHER HOSE
70. INSTALL NEW GASKET AND PLUG
AX06D02
AT8669
z Oil Seal
z Oring
Pump Body
Driven Gear
Drive Gear
Stator Shaft
Thrust Washer
Oil Seal Ring
10 (100, 7)
z Nonreusable part
x11
AUTOMATIC TRANSAXLE OIL PUMP
AX51
A245E AX (RM757E)
OIL PUMP
COMPONENTS
AX06E02
AT0150
AT8670
AT3611
AT2732
AX52
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE OIL SEAL RING
Remove the 2 oil seal rings from the stator shaft back side.
2. REMOVE THRUST WASHER FROM STATOR SHAFT
BACK SIDE
3. REMOVE STATOR SHAFT
Remove the 11 bolts and stator shaft. Keep the gears in the as-
sembled order.
4. REMOVE FRONT OIL SEAL
Using a svrewdriver, pry off the oil seal.
AX06F02
AT0153
AT0154
AT0155
AT7708
AT8090
Rear
Front
AX53
A245E AX (RM757E)
INSPECTION
1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body. Using a feeler
gauge, measure the clearance.
Standard body clearance:
0.075 0.150 mm (0.00295 0.00591 in.)
Maximum body clearance: 0.3 mm (0.012 in.)
If the body clearance is greater than the maximum, replace the
oil pump body subassembly.
2. CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure the tip clearanse between the driven gear teeth and
crescentshaped part of the pump body.
Standard tip clearance:
0.004 0.248 mm (0.00016 0.00976 in.)
Maximum tip clearance: 0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, replace the oil
pump body subassembly.
3. CHECK SIDE CLEARANCE OF BOTH GEAR
Using a steel 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: 0.1 mm (0.004 in.)
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of the oil
pump body bushing.
Maximum inside diameter: 38.18 mm (1.5031 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body subassembly.
5. CHECK STATOR SHAFT BUSHING
Using a dial indicator, measure the inside diameter of the stator
shaft bushings.
Maximum inside diameter:
Front side 21.57 mm (0.8492 in.)
Rear side 27.07 mm (1.0657 in.)
stator shaft.
AX06G02
AT0156
SST
AT0157
AT3611
AT8670
AT0160
AX54
A245E AX (RM757E)
REASSEMBLY
1. INSTALL FRONT OIL SEAL
Using SST and a hammer, install a new oil seal. The seal end
should be flush with the outer edge of the pump body.
SST 0935032014 (0935132140)
2. INSTALL DRIVEN GEAR AND DRIVE GEAR
Make sure the top of the gears are facing upward.
3. INSTALL STATOR SHAFT TO PUMP BODY
(a) Align the bolt holes of the stator shaft with those of the
pump body.
(b) Torque the 11 bolts.
4. INSTALL THRUST WASHER
(a) Coat the thrust washer with petroleum jelly.
(b) Align the tab of the washer with the hollow of the pump
body.
5. INSTALL OIL SEAL RING
Install the 2 oil seal rings to the stator shaft back side.
NOTICE:
Do not spread the ring ends more than necessary.
HINT:
After installing the oil seal rings, check that they move smoothly.
AT0161
AX55
A245E AX (RM757E)
6. CHECK PUMP DRIVE GEAR ROTATION
Turn the drive gear with 2 screwdrivers and make sure it rotates
smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
AX06H02
Q02378
2nd Coast Brake Band
z Nonreusable part
Outer Spring
Piston Rod
Inner Spring
Oil Seal Ring
Snap Ring
Pin
Cover
z Oring
Ering
Piston
Plate Washer
AX56
AUTOMATIC TRANSAXLE SECOND COAST BRAKE
A245E AX (RM757E)
SECOND COAST BRAKE
COMPONENTS
AX06I02
AT5418
AT5260
AT5206
Piston Rod
Plate Wsher
Spring
Piston
AX57
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE OIL RING
Remove the oil seal ring from the piston.
2. REMOVE PISTON ROD
(a) Remove the Ering with needlenose pliers while push-
ing the piston.
(b) Remove the spring, plate washer and piston rod.
AX06J01
AT5205
Printed
Number
AX58
A245E AX (RM757E)
INSPECTION
INSPECT BRAKE BAND
If the lining of the brake band is peeling off or discolored, or even
if a part of the printed numbers are defaced, replace the brake
band.
AX06K02
AT7705
AT5206
Piston
Spring
Plate Washer
Piston Rod
AT5260
AT5419
AX59
A245E AX (RM757E)
REASSEMBLY
1. SELECT PISTON ROD
Even though the band is in good condition, if the piston stroke
is not within the standard value, select a new piston rod.
There are 2 lengths of piston rod.
Piston rod length: mm (in.)
72.9 (2.870) 71.4 (2.811)
2. INSTALL PISTON ROD
(a) Install the plate washer and spring to the piston rod.
(b) Install an Ering with needlenose pliers while pushing
the piston.
(a) Apply ATF to the oil seal ring.
(b) Install the oil seal ring to the piston.
NOTICE:
AX06L02
Q02393
Clutch Drum
z Oring
Piston
Snap Ring
z Nonreusable part
Disc
Flange
Plate
Piston Return Spring
Snap Ring
AX60
AUTOMATIC TRANSAXLE DIRECT CLUTCH
A245E AX (RM757E)
DIRECT CLUTCH
COMPONENTS
AX06M02
Q02344
SST
AT0163
AT2733
SST
AT2734
AX61
A245E AX (RM757E)
DISASSEMBLY
1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, and measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392 785 kPa, 4
8 kgf/cm
2
, 57 114 psi).
SST 09350 32014 (09351 32190)
Piston stroke:
1.12 1.52 mm (0.0441 0.0578 in.)
If the piston stroke is greater than the maximum, inspect each
component.
2. REMOVE SNAP RING FROM CLUTCH DRUM
Using a screwdriver, remove the snap ring from the clutch drum.
3. REMOVE FLANGE, DISCS AND PLATES
4. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress the
springs with a press.
SST 09350 32014 (09351 32070)
(b) Remove the snap ring with the snap ring pliers.
(c) Remove the piston return spring.
AT0165
AT2735
AX62
A245E AX (RM757E)
5. REMOVE CLUTCH PISTON
(a) Install the direct clutch on the oil pump.
(b) Apply compressed air to the oil pump to remove the piston
(if the piston does not come out completely, use needle
nose pliers to remove it).
(c) Remove the direct clutch from the oil pump.
(d) Using a screwdriver, remove the 2 Orings from the pis-
ton.
AX06N02
AT0166 AT0167 D02424
Q02605
Printed
Number
AT3231
AX63
A245E AX (RM757E)
INSPECTION
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying lowpres-
sure compressed air.
2. INSPECT DISC, PLATE AND FLANGE
Check if the sliding surfaces of the discs, plates and flanges are
worn or burnt. If necessary, replace them.
HINT:
S If the lining of the disc is peeling off or discolored, or even
if a part of the printed number is defaced, replace all discs.
S Before assembling new discs, soak them in ATF for at
least 15 minutes.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the direct
clutch bushing.
direct clutch.
AX06O02
AT0168
AT2734
AT2733
SST
D02352
Plate
Flange
Disc
AT0163
AX64
A245E AX (RM757E)
REASSEMBLY
1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
(a) Install new Orings to the piston. Coat the Orings with
ATF.
(b) Being careful not to damage the Orings, press the piston
into the drum with the cup side up.
2. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring onto the piston.
(b) Place SST on the return spring, and compress the return
spring with a press.
SST 09350 32014 (09351 32070)
(c) Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install the plates and discs in order.
Install in order: P = Plate D = Disc F = Flange
P D P D P D F
(b) Install the flange with the flat side facing downward.
4. INSTALL SNAP RING
(a) Using a screwdriver, install the snap ring.
(b) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
Q02344
SST
AT7710
AX65
A245E AX (RM757E)
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch onto the oil pump.
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, and measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392 785 kPa, 4
8 kgf/cm
2
, 57 114 psi).
SST 09350 32014 (09351 32190)
Piston stroke:
1.12 1.52 mm (0.0441 0.0598 in.)
If the piston stroke is nonstandard, select another flange.
HINT:
There are 4 different thickness for the flange.
Flange thickness: mm (in.)
thickness thickness
2.60 (0.1024) 3.00 (0.1181)
2.80 (0.1102) 3.20 (0.1260)
AX06P02
Q02377
Assembled Bearing
and Race
Thrust Washer
Oil Seal Ring
Clutch Drum
Piston
z Oring
Return Spring
Snap Ring
z Nonreusable part
Disc
Plate
Flange
Snap Ring
Bearing
AX66
AUTOMATIC TRANSAXLE FORWARD CLUTCH
A245E AX (RM757E)
FORWARD CLUTCH
COMPONENTS
AX06Q02
Q02346
SST
AT0176
AT2738
AT0177
SST
AX67
A245E AX (RM757E)
DISASSEMBLY
1. CHECK PISTON STROKE OF FORWARD CLUTCH
Set a dial indicator and measuring terminal (SST) together, and
measure the forward clutch piston stroke while applying and re-
leasing compressed air (392 785 kPa, 4 8 kgf/cm
2
, 57 114
psi).
SST 0935032014 (0935132190)
If the piston stroke is greater than the maximum, inspect each
component.
2. REMOVE SNAP RING FROM CLUTCH DRUM
4. REMOVE RETURN SPRING
(a) Place SST on the spring retainer and compress the
springs with press.
SST 0935032014 (0935132070)
(b) Using snap ring pliers, remove the snap ring.
AT3621
Q02555
AT2735
AT0181
AX68
A245E AX (RM757E)
5. REMOVE CLUTCH PISTON
(a) Apply compressed air into the oil passage to remove the
piston.
If the piston does not come out, use needlenose pliers to re-
move it.
(b) Using a screwdriver, remove the 2 Orings from the pis-
ton.
6. IF NECESSARY, REMOVE OIL SEAL RING
Remove the 3 oil seal rings from the shaft.
AX06R02
AT0179 AT0180
D02433
Q02606
Printed
Number
AX69
A245E AX (RM757E)
INSPECTION
(b) Check that the valve does not leak by applying lowpres-
HINT:
if a part of the printed numbers are defaced, replace all
discs.
least 15 minutes.
AX06S02
AT0181
AT2736
AT0182
AT0177
SST
Q02347
Flange
Disc
Plate
AX70
A245E AX (RM757E)
REASSEMBLY
Install the 3 oil seal rings to the shaft.
NOTICE:
HINT:
After installing the oil seal rings, check that they move smoothly.
2. INSTALL CLUTCH PISTON TO CLUTCH DRUM
(a) Install 2 new Orings to the piston.
(b) Coat the Orings with ATF.
(c) Press the piston into the drum with the cup side up, being
careful not to damage the Oring.
3. INSTALL RETURN SPRING
(a) Place the return spring and snap ring onto the piston.
(b) Place SST on the return spring, and compress the springs
with press.
SST 0935032014 (0935132070)
(c) Using snap ring pliers, install the snap ring.
HINT:
Be sure the end gap of the snap ring is not aligned with the
spring retainer claw.
(a) Install the plates and discs in order.
Install in order: P = Plate D = Disc
P D P D P D P D
(b) Install the flange with the flat side facing downward.
AT7713
Q02346
SST
AX71
A245E AX (RM757E)
(a) Using a screwdriver, install the snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
6. RECHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or SST), measure the for-
ward clutch piston stroke while applying and releasing com-
pressed air (392 785 kPa, 4 8 kgf/cm
2
, 57 114 psi).
SST 0935032014 (0935132190)
HINT:
thickness thickness
2.80 (0.1102) 3.37 (0.1327)
3.00 (0.1181) 3.60 (0.1417)
3.20 (0.1260)
AX06T02
Q02376
Bearing Race
Snap Ring
Front Ring Gear Flange
Front Ring Gear
Front Bearing
Race
Bearing
Planetary Gear
Sun Gear
Snap Ring
Sun Gear
Input Drum
Snap Ring
Thrust Washer
No. 1 OneWay Clutch
AX72
AUTOMATIC TRANSAXLE FRONT PLANETARY GEAR
A245E AX (RM757E)
FRONT PLANETARY GEAR
COMPONENTS
AX06U02
AT0185
Hold
Lock
Free
Turn
AT0186
AT0187
AT8676
AT2740
AX73
A245E AX (RM757E)
DISASSEMBLY
1. CHECK OPERATION OF ONEWAY CLUTCH
Hold the sun gear and turn the hub. The hub should turn freely
clockwise and should lock if turned counterclockwise.
2. REMOVE NO. 1 ONEWAY CLUTCH FROM SUN GEAR
While turning the hub clockwise, remove the one-way clutch
from the sun gear.
3. REMOVE THRUST WASHER FROM SUN GEAR INPUT
DRUM
4. REMOVE SUN GEAR FROM DRUM
(a) Using snap ring pliers, remove the snap ring from the
drum.
(b) Remove the sun gear from the drum.
5. REMOVE SHAFT SNAP RING
Using snap ring pliers, remove the shaft snap ring from the sun
gear.
AT7714
AX74
A245E AX (RM757E)
6. REMOVE FRONT RING GEAR FLANGE
(b) Remove the flange from the ring gear.
AX06V02
AT8091
AT4306
AT2741
AX75
A245E AX (RM757E)
INSPECTION
1. INSPECT SUN GEAR FLANGE BUSHING
Using a dial indicator, measure the inside diameter of the sun
gear.
Standard inside diameter:
22.025 22.046 mm (0.86712 0.86795 in.)
Maximum diameter: 22.096 mm (0.86992 in.)
2. MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust
clearance.
Standard clearance:
0.2 0.5 mm (0.008 0.020 in.)
Maximum clearance: 0.5 mm (0.020 in.)
If the clearance is greater than the maximum, replace the plane-
tary gear assembly.
3. INSPECT FRONT RING GEAR FLANGE BUSHING
Using a dial indicator, measure the inside diameter of the flange
bushing.
19.025 19.050 mm (0.74901 0.75000 in.)
If the inside diameter is greater than maximum, replace the
flange.
AT7715
AX06W02
AT2739
AT0187
AT0185
Lock
Hold
Free
Turn
AX76
A245E AX (RM757E)
REASSEMBLY
1. INSTALL FRONT RING GEAR FLANGE
(a) Position the flange onto the ring gear.
(b) Using a screwdriver, install the snap ring.
2. INSTALL SHAFT SNAP RING TO SUN GEAR
3. INSTALL SUN GEAR TO DRUM
(a) Install the sun gear to the drum.
(b) Using snap ring pliers, install the snap ring to the drum.
4. INSTALL THRUST WASHER TO SUN GEAR INPUT
DRUM
5. INSTALL NO. 1 ONEWAY CLUTCH ONTO SUN GEAR
While turning the hub clockwise, slide the oneway clutch onto
the sun gear.
6. RECHECK OPERATION OF ONEWAY CLUTCH
AX07101
Q02394
2nd Brake Drum
Piston Return Spring
z Nonreusable part
Snap Ring
z Oring
Disc
Flange
Plate
Piston
AUTOMATIC TRANSAXLE SECOND BRAKE
AX77
A245E AX (RM757E)
SECOND BRAKE
COMPONENTS
AX07202
AT7716
AT2742
AX78
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE 2ND BRAKE PISTON
(a) Apply compressed air into the oil hole to remove the pis-
ton.
ton.
AX07302
Q02607
Printed
Number
AX79
A245E AX (RM757E)
INSPECTION
INSPECT DISC, PLATE AND FLANGE
HINT:
if a part of the printed numbers are defaced, replace all
discs.
least 15 minutes.
AX07401
AT2743
AT2744
AX80
A245E AX (RM757E)
REASSEMBLY
INSTALL PISTON
(a) Coat 2 new Orings with ATF.
(b) Install the 2 Orings on the piston.
(c) Press the piston into the drum, being careful not to dam-
age the Orings.
AX06X02
Q02426
No. 2 OneWay Clutch
Outer Race
Rear Planetary Gear
Thrust Washers
Snap Ring
Retainers
Snap Ring
Race
Bearing
AUTOMATIC TRANSAXLE REAR PLANETARY GEAR
AX81
A245E AX (RM757E)
REAR PLANETARY GEAR
COMPONENTS
AX06Y02
AT0191
Lock
Turn
Free
Hold
AT0323
Thrust Washer
AT0192
AX82
A245E AX (RM757E)
DISASSEMBLY
1. CHECK OPERATION OF NO. 2 ONEWAY CLUTCH
Hold the outer race and turn the hub. The hub should turn freely
counterclockwise and should lock if turned clockwise.
2. REMOVE THRUST WASHER
Remove the 2 thrust washers from the both sides of the rear
planetary gear.
3. SEPARATE NO. 2 ONEWAY CLUTCH FROM PLAN-
ETARY GEAR
4. REMOVE NO. 2 ONEWAY CLUTCH FROM OUTER
RACE
(a) Using a screwdriver, remove the 2 snap rings and retain-
ers from the both sides.
(b) Remove the No. 2 oneway clutch from the outer race.
AX06Z01
AT4304
AX83
A245E AX (RM757E)
INSPECTION
MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
clearance.
Standard clearance: 0.2 0.5 mm (0.008 0.020 in.)
If the clearance is greater then maximum, replace the planetary
gear assembly.
AX07002
AT0193
Shiny Side
Flanged Side
Outer Race
AT0192
AT0649
Black Side
AT0191
Free Lock
Hold
Turn
AT0323
Thrust Washer
AX84
A245E AX (RM757E)
REASSEMBLY
1. INSTALL NO. 2 ONEWAY CLUTCH
(a) Install the oneway clutch into the outer race, facing the
flange side of the No. 2 oneway clutch toward the shiny
side of the outer race.
(b) Using a screwdriver, install the 2 retainers and snap rings
to the both sides.
2. INSTALL PLANETARY GEAR INTO ONEWAY
CLUTCH
Install the planetary gear into the oneway clutch, facing the
inner race of the planetary gear toward the back side of the
oneway clutch outer race.
4. INSTALL THRUST WASHER
(a) Coat the 2 thrust washers with petroleum jelly.
(b) Align the tab of the washers with the hollow of the carrier.
AX07502
D08587
Return Spring
z Oring
Flange
Snap Ring Plate
Disc
Snap Ring
Piston
z Nonreusable part
AUTOMATIC TRANSAXLE FIRST AND REVERSE BRAKE
AX85
A245E AX (RM757E)
FIRST AND REVERSE BRAKE
COMPONENTS
AX0PT01
Q02990
SST
AT2889
AT8662
AT2891
AX86
A245E AX (RM757E)
DISASSEMBLY
(a) Using SST and a press, press in the return spring until the
snap ring is free from the return spring.
SST 0935032014 (0935132040)
2. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air into the oil passage of the case to
remove the piston.
HINT:
Hold the piston so it is not slanted and blow with the gun slightly
away from the oil hole.
(b) If the piston does not pop out with compressed air, use
needlenose pliers to remove it.
(c) Using a screwdriver, remove the 2 Orings from the pis-
ton.
AX07602
Q02610
Printed
Number
AX87
A245E AX (RM757E)
INSPECTION
INSPECT DISC PLATE AND FLANGE
HINT:
S If the lining of the disc is peeled off or discolored, or even
if a part of the printed number is defaced, replace all disc.
least 15 minutes.
AX0Q001
AT2962
Q02999
Q02990
SST
AX88
A245E AX (RM757E)
REASSEMBLY
1. INSTALL 1ST AND REVERSE BRAKE PISTON
(b) Coat the Orings with ATF.
(c) Place the piston into the bore of the case, facing the
spring seats upward.
NOTICE:
Be careful not to damage the Orings.
(a) Install the piston return spring and snap ring in place.
(b) Place SST on the return spring, and compress the return
spring with a press.
SST 0935032014 (0935132040)
HINT:
Visually check to make sure it is fully seated and centered by
the 3 lugs on the spring retainer. Be sure the end gap of snap
ring is not aligned with the spring retainer claw.
AX07701
Q02374
Snap Ring
Intermediate Shaft
Ring Gear
Oil Seal Ring
AUTOMATIC TRANSAXLE INTERMEDIATE SHAFT
AX89
A245E AX (RM757E)
INTERMEDIATE SHAFT
COMPONENTS
AX0Q101
Q02395
Q02396
Q02397
AX90
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE RING GEAR
(b) Remove the intermediate shaft from the ring gear.
2. IF NECESSARY, REMOVE OIL SEAL RING
Remove the oil seal ring from the intermediate shaft.
AX07902
Q02396
Q02395
AX91
A245E AX (RM757E)
REASSEMBLY
1. INSTALL RING GEAR
(a) Install the intermediate shaft to the ring gear.
AX07A02
Q03847
z Bearing
Counter Drive Gear
z Non reusable part
AX92
AUTOMATIC TRANSAXLE COUNTER DRIVE GEAR
A245E AX (RM757E)
COUNTER DRIVE GEAR
COMPONENTS
AX07B01
D02360
SST
SST
SST
D02359
SST
SST
SST
AX93
A245E AX (RM757E)
DISASSEMBLY
REMOVE COUNTER DRIVE GEAR BEARING
(a) Using SST, pull up the bearing to about 20 mm (0.79 in.).
SST 09631 20040, 09950 40011
(b) Using SST, remove the bearing.
SST 09631 20040, 09950 40011
AX07C01
Q03851
SST
AX94
A245E AX (RM757E)
REASSEMBLY
INSTALL COUNTER DRIVE GEAR BEARING
Using SST and a press, install a new bearing to the counter
drive gear.
SST 09350 32014 (09351 32120)
AX07D02
D02852
Inner Race
Outer Race
Snap Ring
Counter Shaft
Ring Gear
Bearing
Race
Planetary Sun Gear
z Lock Nut
Drive Pinion with
Output Flange
z Spacer
U/D Planetary Gear
Outer Race
Bearing
Bearing
Snap Ring
z Nonreusable part
See page AX100
AUTOMATIC TRANSAXLE COUNTER SHAFT
AX95
A245E AX (RM757E)
COUNTER SHAFT
COMPONENTS
AX07E02
Q04376
Q04383
SST
Q04384
SST
Q04383
SST
AX96
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE U/D PLANETARY SUN GEAR FROM COUNT-
ER SHAFT
2. MEASURE STARTING TORQUE OF COUNTER SHAFT
(a) Using SST, temporarily tighten the lock nut.
SST 0935032014 (0935132170)
(b) Using soft jaws, hold the drive pinion by a vise.
(c) Using SST and spring tension gauge, measure the start-
ing torque of the counter shaft.
SST 0935032014 (0935132170)
Starting torque:
with spring tension gauge
1.2 2.0 kg (2.6 4.4 lb)
with torque wrench (hexagon nut side)
New bearing
0.6 1.0 Nm (6 10 kgfcm, 5.2 8.7 in.lbf)
Reused bearing
0.3 0.5 Nm (3 5 kgfcm, 2.6 4.3 in.lbf)
If the torque exceeds the limit, replace the spacer.
(d) Using SST, remove the lock nut.
SST 09350 32014 (09351 32170)
AT2927
AT0563
AT0564
AT0565
D02362
SST
AX97
A245E AX (RM757E)
3. REMOVE SNAP RING FROM SUN GEAR
Using snap ring pliers, remove the snap ring from the sun gear.
4. REMOVE U/D PLANETARY GEAR
(a) Using a screwdriver, remove the snap ring from the count-
er shaft assembly.
(b) Remove the U/D planetary gear from the counter shaft as-
sembly.
5. REMOVE THRUST NEEDLE ROLLER BEARING AND
RACE
6. REMOVE DRIVE PINION WITH OUTPUT FLANGE,
BEARING, INNER RACE AND SPACER
(a) Using SST, remove the drive pinion with output flange,
bearing and inner race.
SST 09950 40011
AT2929
AT2930
AT2931
AT0568
SST
AT2932
AX98
A245E AX (RM757E)
(b) Remove the spacer from the counter shaft.
7. REMOVE RING GEAR
(a) Using a screwdriver, remove the snap ring from the count-
er shaft.
(b) Remove the ring gear from the counter shaft.
8. REMOVE BEARING
Using SST and a press, remove the bearing.
SST 09950 00020
9. REMOVE BEARING OUTER RACE
Using a brass bar and hammer, tap out the bearing outer race.
AX07F02
AT7998
AT4585
AX99
A245E AX (RM757E)
INSPECTION
1. MEASURE PLANETARY SUN GEAR BUSHING INSIDE
DIAMETER
Using a caliper gauge, measure the bushing inside diameter of
the planetary sun gear as shown in the illustration.
29.800 29.825 mm (1.17323 1.17421 in.)
2. MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
clearance.
Standard clearance: 0.2 0.5 mm (0.008 0.020 in.)
If the clearance is greater than the maximum, replace the
planetary gear assembly.
AX07G02
AT2933
SST
AT0581
AT2934
SST
AT7921
SST
SST
AT2929
AX100
A245E AX (RM757E)
REASSEMBLY
1. INSTALL BEARING TO COUNTER SHAFT
Using SST and a press, press in the bearing of the thick inner
race side.
SST 09350 32014 (09351 32180)
2. INSTALL RING GEAR
(a) Install the ring gear to the counter shaft.
(b) Install the snap ring.
3. INSTALL BEARING OUTER RACE TO DRIVE PINION
(a) Using SST and a press, press in the thick race to the
flange side of the drive pinion.
SST 09350 32014 (09351 32090, 09351 32180)
(b) Using SST and a press, press in the thick race to the other
side.
SST 09350 32014 (09351 32150, 09351 32180)
4. INSTALL DRIVE PINION TO COUNTER SHAFT
(a) Install a new spacer to the counter shaft.
AT0582
AT2935
SST
AT2936
SST
AT7922
SST
AT0588
SST
AX101
A245E AX (RM757E)
(b) Install the drive pinion to the counter shaft.
5. INSTALL ANOTHER BEARING TO COUNTER SHAFT
(a) Using SST and a press, press in the another bearing.
SST 09350 32014 (09351 32180)
NOTICE:
Be sure there is some clearance between the output flange
and bearing.
6. INSTALL BEARING INNER RACE
Using SST and a press, press in the inner race.
SST 09350 32014 (09351 32180)
NOTICE:
Be sure there is some clearance.
7. ADJUST COUNTER SHAFT STARTING TORQUE
(a) Using SST and a press, press in the counter driven gear
to the counter shaft.
SST 09350 32014 (09351 32100)
(b) Install SST to the driven gear.
SST 09350 32014 (09351 32032)
AT2937 SST
AT0589
SST
Fulcrum Length
AT0590
SST
AT0588
SST
AX102
A245E AX (RM757E)
(c) Secure the counter shaft by holding the SST by a vise.
SST 09350 32014 (09351 32032)
(d) Temporarily install a new lock nut, and using SST, tighten
the lock nut until the counter shaft starting torque comes
to the specified value.
SST 09350 32014 (09351 32170)
Torque (Reference):
177 216 Nm (1, 800 2, 200 kgfcm,
130 159 ftlbf)
HINT:
Use a torque wrench with a fulcrum length of 42 cm (16.54 in.).
(e) Using soft jaws, hold the drive pinion by a vise.
(f) Using SST and spring tension gauge, measure the start-
ing torque of the counter shaft.
SST 09350 32014 (09351 32170)
Starting torque:
with tension gauge
1.2 2.0 kg (2.6 4.4 lb)
with torque wrench (hexagon nut side)
New bearing
0.6 1.0 Nm (6 10 kgfcm, 5.2 8.7 in.lbf)
Reused bearing
0.3 0.5 Nm (3 5 kgfcm, 2.6 4.3 in.lbf)
If the starting torque exceeds the limit, replace the spacer and
retorque.
HINT:
Before measuring the starting torque, snug down the bearing
by turning the counter shaft.
(g) Using a punch and hammer, stake the lock nut.
(h) Remove SST from the counter driven gear.
SST 09350 32014 (09351 32032)
AT2939
SST
AT0565
AT0585
AT2940
AT2927
AX103
A245E AX (RM757E)
(i) Using SST, remove the counter driven gear.
SST 09350 32014 (09351 32061)
8. INSTALL RACE AND BEARING
Coat the race and bearing with petroleum jelly and install them
to the counter shaft.
Bearing and race:
Race 41.8 mm (1.646 in.) 30.0 mm (1.181 in.)
9. INSTALL U/D PLANETARY GEAR
(a) Install the U/D planetary gear to the counter shaft.
(b) Install the snap ring.
10. INSTALL U/D PLANETARY SUN GEAR
(a) Using snap ring pliers, install the snap ring to the sun gear.
AT2924
AX104
A245E AX (RM757E)
(b) Install the U/D planetary sun gear to the counter shaft.
AX07H02
D08588
Flange
Disc
Snap Ring
Plate
Oil Seal Ring
Spring Plate
Piston
U/D Oneway Clutch
Return Spring
z Oring
U/D Clutch
Drum
Thrust
Washer
AntiRattle
Clip
z Nonreusable part
Snap Ring
AUTOMATIC TRANSAXLE UNDERDRIVE CLUTCH
AX105
A245E AX (RM757E)
UNDERDRIVE CLUTCH
COMPONENTS
AX0PV01
AT8072
SST
AT7999
AT8001
Free
Lock
Turn
Hold
AT2942
Thrust Washer
AX106
A245E AX (RM757E)
DISASSEMBLY
1. CHECK PISTON STROKE OF U/D CLUTCH
(a) Set a dial indicator (long type pick or SST).
SST 0935032014 (0935132190)
(b) While applying and releasing compressed air (392 785
kPa, 4 8 kgf/cm
2
, 57 114 psi), measure the U/D clutch
piston stroke.
HINT:
There are 4 different flange thickness.
thickness thickness
2.04 (0.0803) 2.40(0.0945)
2.20 (0.0866) 2.50 (0.0984)
Hold the oneway clutch drum and turn the oneway clutch.
Check that the oneway clutch must be able to turn freely coun-
terclockwise and will lock if turned clockwise.
3. REMOVE U/D ONEWAY CLUTCH FROM CLUTCH
DRUM
Remove the oneway clutch and thrust washer from the U/D
clutch drum.
AT0572
Q02591
AT2944
SST
AT2945
AT5695
AX107
A245E AX (RM757E)
4. REMOVE SNAP RING
Using a screwdriver, remove the snap ring.
Remove the flange, discs and plates from the clutch drum.
6. REMOVE RETURN SPRING AND SPRING PLATE
(a) Using SST and a press, compress the return spring re-
tainer.
SST 09350 32014 (09351 32070)
(c) Remove the SST.
(d) Remove the return spring and spring plate.
7. REMOVE U/D CLUTCH PISTON
(a) Install the U/D clutch to the transaxle case.
HINT:
Before installing the clutch, install the oil seal rings to the trans-
axle case.
(b) Apply compressed air into the oil passage of the case,
and remove the piston from the clutch drum.
(c) If the piston does not pop out with compressed air, use
needlenose pliers to remove it.
AT2947
AX108
A245E AX (RM757E)
8. REMOVE ORING FROM PISTON
Using a screwdriver, remove the 2 Orings from the U/D clutch
piston.
AX07J02
Q02608
Printed
Number
AT5837
Z03801
AX109
A245E AX (RM757E)
INSPECTION
HINT:
if a part of the printed numbers are defaced, replace the
disc.
least 15 minutes.
(b) Check that the valve does not leak by applying low pres-
AT2948
Front Side
Rear Side
AX110
A245E AX (RM757E)
3. INSPECT U/D CLUTCH DRUM
Using a caliper gauge, measure the bushing inside diameter of
the U/D clutch drum.
Front side:
46.500 46.525 mm (1.83071 1.83169 in.)
Rear side:
55.000 55.030 mm (2.16535 2.16653 in.)
Maximum inside diameter:
Front side: 46.570 mm (1.83346 in.)
Rear side: 55.080 mm (2.16850 in.)
AX0Q201
AT2949
AT2950
AT2945
AT2944
SST
AT8000
Stopper
Stopper
AX111
A245E AX (RM757E)
REASSEMBLY
1. INSTALL U/D CLUTCH PISTON INTO CLUTCH DRUM
HINT:
Before installing, coat the Orings with ATF.
(b) Install the U/D clutch piston into the clutch drum.
NOTICE:
Be careful not to damage the Orings.
2. INSTALL SPRING SEAT AND RETURN SPRING
(a) Install the spring seat and return spring to the U/D clutch.
(b) Using SST and a press, compress the return spring re-
tainer.
SST 09350 32014 (09351 32070)
HINT:
Install the snap ring, as shown.
(d) Remove the SST
SST 09350 32014 (09351 32070)
D08590
Plate
Disc Disc
Plate
Flange
Flange
AT2952
AT2942
Thrust Washer
AT8001
Hold
Turn
Lock
Free
Q02597
AX112
A245E AX (RM757E)
Install in order: F = Flange D = Disc P = Plate
P D P D P D F
HINT:
Install the flange with the flat side facing downward.
(a) Using a screwdriver, install the snap ring to the U/D clutch.
5. INSTALL U/D ONEWAY CLUTCH TO CLUTCH DRUM
(a) Install the thrust washer to clutch drum.
(b) Install the oneway clutch with the claw of retainer up.
Hold the oneway clutch drum and turn oneway clutch.
Check that the oneway clutch must be able to turn freely coun-
terclockwise and will lock if turned clockwise.
7. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the
inner race.
Height: 17.3 18.2 mm (0.681 0.717 in.)
Q02598
SST
AT7999
AX113
A245E AX (RM757E)
8. CHECK PISTON STROKE OF U/D CLUTCH
(a) Set a dial indicator and measuring terminal (SST) togeth-
er.
SST 0935032014 (0935132190)
(b) While applying and releasing compressed air (392 785
kPa, 4 8 kgf/cm
2
, 57 114 psi), measure the U/D clutch
piston stroke.
Piston stroke:
1.5 1.9 mm (0.059 0.075 in.)
If the piston stroke is less than the limit, parts may have been
misassembled. Check them.
If the piston stroke is non standard, select another flange.
HINT:
thickness thickness
2.04 (0.0803) 2.40 (0.0945)
2.20 (0.0866) 2.50 (0.0984)
AX07L02
D08616
Disc
Plate
Flange
Snap Ring
Return Spring
U/D Brake Piston
z Oring
z Nonreusable part
Oil Seal Ring
AX114
AUTOMATIC TRANSAXLE UNDERDRIVE BRAKE
A245E AX (RM757E)
UNDERDRIVE BRAKE
COMPONENTS
AX0PX01
Q02392
AT2898
Q04390
SST
Q02588
Q02593
AX115
A245E AX (RM757E)
DISASSEMBLY
1. CHECK PACK CLEARANCE OF U/D BRAKE
Using a dial indicator, measure the U/D brake pack clearance.
Pack clearance
1.15 1.97 mm (0.0453 0.0776 in.)
If clearance is nonstandard, check the disc.
2. REMOVE OIL SEAL RING
Remove the 2 oil seal rings.
3. REMOVE SNAP RING
(a) Using SST and a press, press in the flange until the snap
ring is free from the flange.
SST 0935032014 (0935132070)
(b) Using a screwdriver, remove the snap ring.
4. REMOVE FLANGE, PLATES AND DISCS
AT8661
AT2903
Oring
AX116
A245E AX (RM757E)
6. REMOVE PISTON
2
,
14 psi), pop out the brake piston into a rag.
ton.
AX07M02
AT5823
Printed
Numbers
AX117
A245E AX (RM757E)
INSPECTION
1. INSPECT DISCS PLATES AND FLANGE
HINT:
if a part of the printed numbers are defaced, replace the
disc.
least 15 minutes.
AX0PY01
AT2960
Q02592
Q02593
Q02588
Q02594
SST
AX118
A245E AX (RM757E)
REASSEMBLY
1. INSTALL U/D BRAKE PISTON
(a) Coat 2 new rings with ATF.
(b) Install the 2 Orings to the piston.
(c) Place the piston into the case with the cup side up, being
careful not to damage the Orings.
Install the plates, discs and flange in order.
Install in order: D = Disc P = Plate F = Flange
P D P D P D F
HINT:
Install the flange with the flat side facing downward.
4. INSTALL SNAPRING
(a) Place SST on the flange, and compress the flange with
a press.
SST 0935032014 (0935132070)
HINT:
Be sure the end gap of the snap ring is not aligned with one of
the cutouts.
Q02392
AT2898
AX119
A245E AX (RM757E)
5. CHECK PACK CLEARANCE OF U/D BRAKE
Using a dial indicator, measure the U/D brake pack clearance.
Pack clearance:
1.15 1.97 mm (0.0453 0.0776 in.)
If the pack clearance is nonstandard, parts have been misas-
sembled. Check them.
6. INSTALL OIL SEAL RING TO TRANSAXLE CASE
Install the 2 oil seal rings to the transaxle case.
AX07N02
D08591
z Oring
No. 1 Solenoid
Valve
10 (102, 7)
6.5 (66, 58 in.lbf)
Upper Valve Body
z No. 1 Gasket
Plate
z No. 2 Gasket
Lower Valve Body
z Nonreusable part
Accumulator
SLT Solenoid Valve
SL Solenoid Valve
6.5 (66, 58 in.lbf)
No. 1 Lock Plate
6.5 (66, 58 in.lbf)
No. 2 Solenoid
Valve
z Oring
z Oring
z Gasket
Plate
Lower Valve Body Cover
z Gasket
6.5 (66, 58 in.lbf)
x19
No. 2 Lock Plate
AX120
AUTOMATIC TRANSAXLE VALVE BODY
A245E AX (RM757E)
VALVE BODY
COMPONENTS
AX0PZ01
D08592
D08593
No. 2 Lock Plate
SLT Solenoid
Valve
SL Solenoid Valve
Accumulator
No. 1 Lock Plate
No. 2 Solenoid
Valve
No. 1 Solenoid
Valve
AX121
A245E AX (RM757E)
DISASSEMBLY
NOTICE:
S Disassembling and reassembling should be con-
ducted on a clean vinyl sheet or mat, or aluminum
tray.
S Make the valve slide through the valve hole by its own
weight. Do not forcibly pull out the valve using needle
nose pliers. When having difficulty in removing it,
slant and shake the valve body or use a magnet hand.
S Do not place the disassembled parts directly on metal
work bench or waste cloth.
S Do not use dropped parts.
S Make sure that no burr is identified before assem-
bling.
1. NOTE THE POSITION OF PLUNGER SLEEVE
Check that the key for the plunger sleeve is set in the proper
position.
HINT:
Be certain to check this before disassembly because the line
pressure changes according to the set position of the plunger
sleeve.
2. REMOVE 4 SOLENOIDS
(a) Remove the bolt, and No. 1 and No. 2 solenoid valves.
(b) Remove the bolt and SL solenoid valve.
(c) Remove the bolt, No. 2 lock plate and SLT solenoid valve.
(d) Remove the 3 Orings from No. 1, No. 2 and SL solenoid
valves.
3. REMOVE ACCUMULATOR VALVE
Remove the bolt, No. 1 lock plate and accumulator.
D08594
D08595
D08596
D08597
D08598
AX122
A245E AX (RM757E)
4. REMOVE PRESSURE RELIEF VALVE
5. REMOVE LOWER VALVE BODY
(a) Remove the 17 bolts from the lower valve body.
(b) Lift off the lower valve body with plate.
6. REMOVE LOWER VALVE BODY COVER
(a) Remove the 2 bolts and cover.
(b) Remove the 2 gaskets and plate.
7. REMOVE PLATE FROM LOWER VALVE BODY
Remove the 2 screws and plate.
AX07P02
D08599
D08600
No. 1 Gasket No. 2 Gasket
D08598
AX123
A245E AX (RM757E)
REASSEMBLY
1. POSITION PLATE AND NEW GASKET ON LOWER
VALVE BODY
Position a plate and new No. 1 and No. 2 gaskets on the lower
valve body.
HINT:
The gaskets are not identical, but can be installed in any order.
2. INSTALL PLATE TO LOWER VALVE BODY
Install the plate with the 2 screws.
3. INSTALL LOWER VALVE BODY COVER
(a) Position 2 new gaskets to the plate.
D08610
Q02386 Q02385
Plate
Upper and Lower Gasket
D08597
D08596
D08595
A
B
C
A
A
A
B
AX124
A245E AX (RM757E)
(b) Install the 2 new gaskets and plate to the cover.
(c) Install the cover.
(d) Temporarily install the 2 bolts.
4. PLACE LOWER VALVE BODY WITH COVER, PLATE
AND GASKETS ON UPPER VALVE BODY
Align respective bolt holes of the valve bodies, gaskets and
plate.
5. INSTALL LOWER VALVE BODY
(a) Tighten the 19 bolts and install the lower valve body.
Torque:
6.5 Nm (66 kgfcm, 58 in.lbf)
HINT:
Each bolt length is indicated below.
Bolt A: 50 mm (1.969 in.)
Bolt B: 20 mm (0.787 in.)
Bolt C: 38 mm (1.496 in.)
D08594
D08593
A
B
C
B
AX125
A245E AX (RM757E)
6. INSTALL PRESSURE RELIEF VALVE
7. INSTALL 5 SOLENOIDS
(a) Coat 3 new Orings with ATF and install them on the No.
1, No. 2 and SL solenoid valves.
(b) Install the No. 1, No. 2 solenoid valves with the bolt.
(c) Install the SL solenoid valve with the bolt.
(d) Install the SLT solenoid valve and No. 2 lock plate with the
bolt.
Torque:
Bolt A: 10 Nm (102 kgfcm, 7 ftlbf)
Bolt B: 6.5 Nm (66 kgfcm, 58 in.lbf)
Bolt C: 6.5 Nm (66 kgfcm, 58 in.lbf)
HINT:
Each bolt length is indicated below.
Bolt A: 25 mm (0.984 in.)
Bolt B: 65 mm (2.559 in.)
Bolt C: 12 mm (0.472 in.)
8. INSTALL ACCUMULATOR VALVE
Install the accumulator valve and No. 1 lock plate with the bolt.
Torque:
Bolt B: 6.5 Nm (66 kgfcm, 58 in.lbf)
HINT:
The Bolt length is indicated below.
Bolt B: 65 mm (2.559 in.)
AX07Q02
D08601
Secondary Regulator
Valve
Plug A
Key
Check Valve
Key
Check Valve
Key
Sleeve
Plunger
B
Lockup Relay
Valve
Key
Check Valve
Reverse Shift
Restrict Ball
Check Valve
34 Shift Valve
Plug
Key
Reverse Shift
Restrict Ball
C
AX126
AUTOMATIC TRANSAXLE UPPER VALVE BODY
A245E AX (RM757E)
UPPER VALVE BODY
LOCATION
1. COMPONENTS
D08602
C
A
B
AX127
A245E AX (RM757E)
2. SPRING
HINT:
During reassembly please refer to the spring specifications below to help you to discriminate between the
different springs.
Mark Name (Color)
Free length / Outer diameter
mm (in.)
Total No. of coils
A Secondary regulator valve (None) 36.8 (1.449 ) / 10.3 (0.406) 13.2
B Lockup relay valve (None) 18.8 (0.740) / 5.1 (0.201) 14.5
C 3 4 shift valve (Red) 25.5 (1.004) / 9.7 (0.382) 7.75
D08603
A
B
C
D
E
AX128
A245E AX (RM757E)
3. KEYS
Mark Retainer
Height / Width / Thickness
mm (in.)
A Check valve (C
2
) 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
B 3 4 shift valve 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
C Check valve (B
3
) 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
D Lockup relay valve 21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
E Secondary regulator valve 29.0 (1.142) / 5.0 (0.197) / 3.2 (0.126)
D08611
A
A
B
B
A
AX129
A245E AX (RM757E)
4. CHECK BALL
Mark Check ball
Diameter
mm (in.)
A Rubber ball 5.5 (0.217)
B Rubber ball 6.4 (0.252)
AX07R02
D08604
Check Ball
B
6.4 (66, 58 in.lbf)
Cooler ByPass
Valve
A
Primary Regulator
Valve
F
Washer
No. 1 Plunger
Key
No. 2 Plunger
Sleeve
E
CutBack Valve
C
23 Shift Valve
12 Shift Valve
H
Plug
Key
Plug
Key
Reverse Control
Valve
Plug
D
2nd Coast
Modulator Valve
Key
Key
Plug
J
Low Coast
Modulator Valve
Plug
I
Accumulator
Control Valve
Key
Nm (kgfcm, ftlbf) :Specified torque
G
K
Plug
Key
Plug
Key
Solenoid
Modulator Valve
Plug
Key
AX130
AUTOMATIC TRANSAXLE LOWER VALVE BODY
A245E AX (RM757E)
LOWER VALVE BODY
LOCATION
1. COMPONENTS
D08605
B
D
A
I
J
G
H
E
F
C
K
AX131
A245E AX (RM757E)
2. SPRING
HINT:
During reassembly, please refer to the spring specifications below to help you differentiate among the differ-
ent springs.
Mark Name (Color)
Free length / Outer diameter
mm (in.)
Total No. of coils
A Cooler bypass valve (None) 24.5 (0.965) / 8.0 (0.315) 11.8
B Pressure relief valve (Red) 18.0 (0.709) / 7.0 (0.276) 9.5
C 23 shift valve (Red) 25.5 (1.004) / 9.7 (0.382) 7.75
D 2nd coast modulator valve (White) 32.2 (1.268) / 8.5 (0.335) 13.3
E Cutback valve (None) 18.8 (0.740) / 7.5 (0.295) 7.5
F Primary regulator valve (Red) 41.6 (1.638) / 16.9 (0.665) 9.5
G 12 shift valve (Red) 25.5 (1.004) / 9.7 (0.382) 5.75
H Reverse control valve (None) 25.6 (1.008) / 8.6 (0.339) 6.75
I Accumulator control valve (Pink) 26.7 (1.051) / 8.8 (0.346) 9.6
J Low coast modulator valve (Blue) 28.5 (1.122) / 8.3 (0.327) 12.8
K Solenoid modulator valve 32.1 (1.264) / 8.0 (0.315) 15.8
D08606
A
B
C
D
E
F
G
H
I
AX132
A245E AX (RM757E)
3. KEYS
Mark Retainer
Height / Width / Thickness
mm (in.)
A Accumulator control valve 21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
B Low coast modulator valve 21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
C Reverse control valve 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
D 12 shift valve 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
E 23 shift valve 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
F Cutback valve 21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
G Primary regulator valve / / 3.2 (0.126)
H 2nd coast modulator valve 21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
I Solenoid modulator valve 11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
D08607
AX133
A245E AX (RM757E)
4. STRAINERS
AX07S02
Q02371
z Oil Seal
(For Transaxle Housing)
Pinion Thrust Washer
Differential Pinion
Side Gear Thrust Washer
Ring Gear
Differential Side Gear
Differential Pinion Shaft
Differential Case
z Outer Race
Speedometer
Drive Gear
Side Bearing
Adjusting Shim
z Locking Plate
Side Bearing
Pin
: Specified torque
z Nonreusable part
z Oil Seal
(For Transaxle Case)
Adjusting Shim
Nm (kgfcm, ftlbf)
X4
X8
97 (985, 71)
z Outer Race
AX134
AUTOMATIC TRANSAXLE DIFFERENTIAL CASE
A245E AX (RM757E)
DIFFERENTIAL CASE
COMPONENTS
AX07T02
AT5731
Matchmarks
TA0016
AT8087
AT7984
D02361
SST
SST
AX135
A245E AX (RM757E)
DISASSEMBLY
1. REMOVE RING GEAR
(a) Place the matchmarks on the ring gear and differential
case.
(b) Using a chisel and hammer, loosen the staked part of the
locking plate.
(c) Remove the 8 bolts and 4 locking plates.
(d) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Setting SST to the cutout portion on the speedometer
drive gear, remove the bearing from the differential case.
SST 0995040011, 0995060010 (0995100340)
(b) Remove the speedometer drive gear.
D02358
SST
SST
AT8078
AT8059
AT2980
Pinion
Side Gear
Thrust Washer
Q02358
AX136
A245E AX (RM757E)
(c) Setting SST to the cutout portion on the differential case,
remove the bearing.
SST 0995040011, 0995060010 (0995100410)
3. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, drive out the pinion shaft
lock pin from the ring gear side.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions, 2 side gears and 4 thrust washers.
4. REMOVE OIL SEAL OF TRANSAXLE HOUSING
AT8487
SST
Q02359
AT8479
SST
AX137
A245E AX (RM757E)
5. REMOVE SIDE BEARING OUTER RACE OF TRANS-
AXLE HOUSING
(a) Using SST and a hammer, drive out the outer race and
shim.
SST 0935032014 (0935132090)
6. REMOVE OIL SEAL TRANSAXLE CASE
7. REMOVE SIDE BEARING OUTER RACE OF TRANS-
AXLE CASE
(a) Using SST and a hammer, drive out the outer race and
adjusting shim.
SST 0935032014 (0935132130, 0935132150)
AX07U02
AT8002
SST
AT8003
SST
AT8497
AT2980
Pinion
Thrust Washer
Side
Gear
AT8059
AX138
A245E AX (RM757E)
REASSEMBLY
1. INSTALL SIDE BEARING OUTER RACE OF TRANS-
AXLE HOUSING
(a) Place the shim onto the transaxle housing.
(b) Using SST and a press, press a new outer race into the
transaxle housing.
SST 0935032014 (0935132111, 0935132130)
2. INSTALL SIDE BEARING OUTER RACE OF TRANS-
AXLE CASE
(a) Place the adjusting shim onto the transaxle case.
(b) Using SST and a press, press a new outer race into the
transaxle case.
SST 0935032014 (0935132111, 0935132130)
3. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washers to the side gears.
(b) Install the side gears with the thrust washers, pinion gear,
pinion thrust washers into the differential case.
(c) Install the pinion shaft so as to align the lock pin holes in
both the pinion shaft and differential case.
AT2981
AT8093
AT8075
AT5833
SST
AX139
A245E AX (RM757E)
4. CHECK SIDE GEAR BACKLASH
(a) Measure the side gear backlash while holding 1 pinion
gear toward the case.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
If the backlash is out of the specified range, install a correct
thrust washer to the side gear.
(b) Referring to the table below, select thrust washers which
will ensure that the backlash is within specification. Try to
select washers of the same size for both sides.
Thrust washer thickness: mm (in.)
Thickness Thickness
0.95 (0.0374) 1.10 (0.0433)
1.00 (0.0394) 1.15 (0.0453)
1.05 (0.0413) 1.20 (0.0472)
If the backlash is not within the specified range, install a thrust
washer of a different thickness.
5. INSTALL LOCK PIN
(a) Using a hammer and punch, drive the lock pin into the
hole in the pinion shaft through the case.
(b) Stake the differential case.
6. INSTALL SIDE BEARING TO DIFFERENTIAL CASE
(a) Using SST and a press, install the side bearing into the
differential case.
SST 0971030030 (0971003160)
AT2982
AT8044
SST
Q02360
FIPG
AT8485
Q04360
A
A
A
B
A
A
AX140
A245E AX (RM757E)
(b) Install the speedometer drive gear to the differential case.
(c) Using SST and a press, install the side bearing into the
differential case.
SST 0935032014 (0935132090, 0935132120)
7. ADJUST SIDE BEARING PRELOAD
(a) Remove any FIPG material and be careful not to get oil
on the contacting surfaces of the transaxle housing or
transaxle case.
(b) Install the differential to the transaxle case.
(c) Install the transaxle housing to the transaxle case.
(d) Install and tighten the bolts.
HINT:
Bolt length:
Bolt A: 30 mm (1.18 in.)
Bolt B: 35 mm (1.38 in.)
Q05199
Q05179
Q05183
AX141
A245E AX (RM757E)
(e) Using SST, rotate the differential in both directions to
snug the bearing down.
SST 0956432011
(f) Using SST and a torque wrench, measure the preload of
the side bearing.
SST 0956432011
Preload (at starting):
New bearing:
0.8 1.4 Nm (8 14 kgfcm, 6.9 12.2 in.lbf)
Used bearing:
0.4 0.7 Nm (4 7 kgfcm, 3.5 6.1 in.lbf)
If the preload is not within the specified range, remove the differ-
ential from the transaxle case. Reselect the transaxle case
side adjusting shim according to the following table.
Adjusting shim thickness:
2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm(0.0827 in.)
2.15 mm (0.0846 in.) 2.20 mm(0.0866 in.) 2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm(0.0945 in.)
2.45 mm (0.0965 in.) 2.50 mm(0.0984 in.) 2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm(0.1122 in.)
2.90 mm (0.1142 in.)
HINT:
The preload will change about 0.3 0.4 Nm (3 4 kgfcm, 2.6
2.9 in.lbf) according to a change in shim thickness of 0.05 mm
(0.0020 in.).
(g) Using a plastic hammer, remove the bolts and transaxle
housing.
(h) Remove the differential from the transaxle case.
MT0089
AT2780
Case Side
TA0019
AT8005
SST
AT8004
SST
AX142
A245E AX (RM757E)
8. INSTALL RING GEAR TO DIFFERENTIAL
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear in water and boil for 10 minutes.
(c) Carefully remove the ring gear from the water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Install new locking plates and set bolts, tightening them
temporarily and evenly. When the ring gear has cooled
sufficiently, fully tighten the bolts.
Torque: 97 Nm (985 kgfcm, 71ftlbf)
(f) Using a hammer and drift punch, stake the locking plates.
HINT:
Stake a claw for the flat side of the nut. For the claw contacting
a corner of the nut, stake only the half on the tightened side.
9. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hummer, drive in a new oil seal.
SST 0935032014 (0935132111, 0935132130)
(b) Coat the lip of the oil seal with MP grease.
10. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 0935032014 (0935132130, 0935132150)
(b) Coat the lip of oil seal with MP grease.

07 Automatic Transaxle

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AUTOMATIC TRANSAXLE

AUTOMATIC TRANSAXLE SYSTEM AX1 . . . . . . .

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