Overhaul - U140E & U140F: Overhaul Lexus RX I

Disassembly

Using 2 screwdrivers, turn drive gear and check for smooth rotation. Remove 2 oil seal rings. Using T30 Torx socket, remove 11 bolts attaching oil pump body and stator shaft. Remove "O" ring from oil pump body. (Scheme 17) Note direction and location of drive and driven gears. Leave gears in oil pump body for inspection.

Reassembly

1. Install front oil seal. Install driven gear and drive gear. Ensure top of gears are facing upward. Install stator shaft on oil pump body. Align bolt holes. Install 11 stator shaft-to-oil pump body bolts. Tighten bolts in crisscross pattern to 87 INCH lbs. (9.8 N.m).
2. Install 2 oil seal rings on oil pump. DO NOT expand ring ends excessively. Turn drive gear with screwdrivers to ensure a smooth rotation. DO NOT damage oil seal lip.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

1. Prior to disassembly, measure piston stroke of direct clutch. Install direct clutch and needle roller bearing on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying and releasing 57 psi (4 kg/cm 2 ) of compressed air to transaxle rear cover. (Scheme 23) Piston stroke should be.024-.030" (.61-.77 mm). If piston stroke is not within specification, inspect each component during disassembly.
2. Remove direct clutch from transaxle rear cover. Using a screwdriver, remove snap ring from direct clutch drum. Remove flange, 4 discs and 4 plates. Note location of components during removal for reassembly reference. Position clutch balancer on a press. Compress piston return springs and remove snap ring. (Scheme 24)
3. Remove clutch balancer and piston return springs from clutch drum. Install direct clutch on transaxle rear cover. While holding direct clutch piston, apply 57 psi (4 kg/cm 2 ) of compressed air to transaxle rear cover to remove direct clutch piston. (Scheme 23)

1. Coat piston with ATF. Using hand pressure, press piston into direct clutch drum. Ensure piston lip seal is not damaged. Install piston return springs and clutch balancer onto direct clutch drum. Set snap ring in position.
2. Using appropriate press positioned on clutch balancer, compress piston return springs. Using snap ring expander, install snap ring in direct clutch drum groove. Ensure end gap of spring is not aligned with gaps in clutch balancer hub.
3. Install 4 plates and 4 discs, starting with plate and alternating with disc. Install flange on top of disc. (Scheme 24) Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of direct clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install direct clutch and needle roller bearing on transaxle rear cover. Using a dial indicator, measure direct clutch piston stroke by applying and releasing 57 psi (4 kg/cm 2 ) of compressed air to transaxle rear cover. (Scheme 23)
5. Piston stroke should be.024-.030" (.61-.77 mm). If piston stroke is not within specification, disassemble and reassemble direct clutch components.
6. Measure piston stroke again. If measurement is still not within specification, replace flange. Flange is available in 6 thicknesses, from.118" (3.00 mm) to.138" (3.50 mm) in increments of.004" (.10 mm).
7. Check direct clutch operation. Insert rear planetary sun gear into direct clutch. Ensure rear planetary sun gear rotates in both directions. If sun gear does not rotate as described, disassemble and inspect direct clutch.

Scheme 25

Scheme 26

1. Prior to disassembly, measure piston stroke of forward clutch. Install forward clutch on oil pump assembly. Using a dial indicator, measure forward clutch piston stroke by applying and releasing 57 psi (4 kg/cm 2 ) of compressed air to oil pump. (Scheme 25) Opening in oil pump is large. To prevent air from discharging, surround air nozzle with shop towel. Piston stroke should be.082-.088" (2.09-2.23 mm). If piston stroke is not within specification, inspect each component during disassembly.
2. Remove forward clutch from oil pump assembly. Using a screwdriver, remove snap ring from forward clutch drum. Remove flange, 6 discs and 6 plates. Note location of components during removal for reassembly reference. Using appropriate press, compress piston return springs. Using snap ring expander, remove snap ring. (Scheme 26)
3. Remove press and piston return springs. Install forward clutch on oil pump assembly. While holding forward clutch piston, apply 57 psi (4 kg/cm 2 ) of compressed air to oil pump to remove forward clutch piston. (Scheme 25) Opening in oil pump is large. To prevent air from discharging, surround air nozzle with shop towel.
4. If piston cannot be removed using compressed air, wrap needle nose pliers tips with vinyl tape and remove piston using pliers. Remove 2 "O" rings from piston.

1. Coat NEW piston "O" rings with ATF. Install "O" rings on forward clutch piston. Using hand pressure, press piston into forward clutch drum. Ensure "O" rings are not damaged. Set piston return springs in position.
2. Position spring seat on a press. Compress piston return springs. Using snap ring expander, install snap ring in forward clutch drum groove. Ensure end gap of spring is not aligned with gap in spring retainer hub.
3. Install 6 plates and 6 discs, starting with plate and alternating with disc. Install flange on top of disc. (Scheme 26) Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of forward clutch drum.
4. If disc, plate or flange have been replaced, check piston stroke. Install forward clutch on oil pump assembly. Using a dial indicator, measure forward clutch piston stroke by applying and releasing 57 psi (4 kg/cm 2 ) of compressed air to oil pump. (Scheme 25) Opening in oil pump is large. To prevent air from discharging, surround air nozzle with shop towel. Piston stroke should be.082-.088" (2.09-2.23 mm). If piston stroke is not within specification, disassemble and reassemble forward clutch components.
5. Measure piston stroke again. If measurement is still not within specification, replace flange. Flange is available in 5 thicknesses from.118" (3.00 mm) to.142" (3.60 mm) in increments of.006" (.15 mm). Coat thrust bearings with ATF and install.
6. Check forward clutch operation. Insert multiple clutch hub into forward clutch. Ensure forward clutch rotates in both directions. If forward clutch does not rotate as described, disassemble and inspect forward clutch.

Scheme 27

Scheme 28

1. Using appropriate press, position press on piston return springs and compress springs. Using a screwdriver, remove snap ring. Remove press and piston return springs. (Scheme 27) While holding 2nd brake piston, apply 57 psi (4 kg/cm 2 ) of compressed air to 2nd brake cylinder to remove piston. (Scheme 28) Remove 2 "O" rings from piston.
2. Using vernier calipers, measure 2nd brake piston return spring free length with spring mounted to spring seat. Free length should be.654" (16.61 mm). Replace springs as necessary. Coat NEW "O" rings with ATF and install on piston.
3. Carefully press 2nd brake piston by hand into 2nd brake cylinder. (Scheme 27) Using appropriate press, compress piston return springs and install snap ring. Ensure end gap of snap ring is not aligned with gap in piston return spring hub.

Scheme 29

Scheme 30

1. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of 6.30" (160.0 mm), measure underdrive input shaft starting torque for reference. (Scheme 29) Starting torque should be 4.3-28.6 INCH lbs. (.5-3.3 N.m).
2. Using pin punch and hammer, loosen staked part of lock nut. Clamp underdrive planetary gear in a soft-jawed vise. Use care not to damage differential drive pinion. Using appropriate socket, remove lock nut. Remove gear from vise. Using appropriate puller, remove cylindrical roller bearing inner race. (Scheme 30)
3. Using gear stand and appropriate press, remove differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear and front tapered roller bearing. (Scheme 30)
4. Clamp underdrive planetary gear in soft-jawed vise. Using appropriate puller, remove rear tapered roller bearing from underdrive planetary gear. Using snap ring pliers, remove snap ring. Remove underdrive planetary ring gear from counter driven gear.

1. Install underdrive planetary ring gear into counter driven gear. Install snap ring. Using appropriate press, install rear tapered roller bearing onto underdrive planetary gear. Press bearing until it becomes flat at the bottom.
2. Install counter driven gear with underdrive planetary ring gear onto underdrive planetary gear. Using appropriate press, install front tapered roller bearing onto underdrive planetary gear while rotating counter driven gear.
3. Using appropriate press, install parking lock gear while rotating counter driven gear. Using press, install differential drive pinion, then install cylindrical roller bearing inner race while rotating counter driven gear.
4. Clamp underdrive planetary gear in a soft-jawed vise. Use care not to damage differential drive pinion. Using appropriate socket, install NEW lock nut and tighten to 194 ft. lbs. (262 N.m). Remove gear from vise. Using gear stand, lock nut socket, adapter and INCH-lb. torque wrench with a fulcrum length of 6.30" (160.0 mm), ensure underdrive input shaft starting torque is 4.3-28.6 INCH lbs. (.5-3.3 N.m). (Scheme 29) Using pin punch and hammer, stake lock nut. Ensure lock nut is not cracked.

1. Prior to disassembly, check piston stroke of underdrive clutch. Install underdrive clutch into transaxle case. DO NOT damage oil seal rings. Install dial indicator onto underdrive clutch flange. (Scheme 31) Apply and release 57 psi (4 kg/cm 2 ) of compressed air to transaxle case. (Scheme 32)
2. Piston stroke should be.059-.070" (1.51-1.77 mm). If piston stroke is not within specification, inspect discs and plates during disassembly. Using a screwdriver, remove drum snap ring. Remove flange, 4 discs and 4 plates from underdrive clutch drum. Note location of components during removal for reassembly reference. (Scheme 33)
3. Using appropriate press placed on clutch balancer, compress piston return springs. Using snap ring expander, remove snap ring. Remove press, clutch balancer and piston return springs.
4. Install underdrive clutch into transaxle case. DO NOT damage oil seal rings. While holding underdrive clutch piston, apply 57 psi (4 kg/cm 2 ) of compressed air to transaxle case to remove underdrive clutch piston. (Scheme 32) Remove "O" ring from underdrive clutch drum.

1. Coat NEW "O" ring with ATF and install on underdrive clutch drum. Coat underdrive clutch piston with ATF. Using hand pressure, install piston into underdrive clutch drum. Use care not to damage "O" ring. Install piston return springs and clutch balancer to underdrive clutch drum. Set snap ring in position.
2. Using appropriate press positioned on clutch balancer, compress piston return springs. Using snap ring expander, install snap ring in underdrive clutch drum groove. Ensure end gap of spring is not aligned with gap in clutch balancer hub.
3. Install 4 plates and 4 discs, starting with plate and alternating with disc. Install flange on top of disc. (Scheme 33) Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of underdrive clutch drum.
4. Check piston stroke of underdrive clutch. Install underdrive clutch into transaxle case. DO NOT damage oil seal rings. Install dial indicator onto underdrive clutch flange. (Scheme 31) Apply and release 57 psi (4 kg/cm 2 ) of compressed air to transaxle case. (Scheme 32)
5. Piston stroke should be.059-.070" (1.51-1.77 mm). If piston stroke is not within specification, replace flange. Flange is available in thicknesses of.118" (3.00 mm),.126" (3.20 mm) and.134" (3.40 mm).

Scheme 31

Scheme 32

Scheme 33

VALVE BODY ASSEMBLY

Note. All valve body components must be installed in original location. Lay all components in sequence during removal for reassembly reference. Primary regulator valve position controls line pressure. Note location of primary regulator valve sleeve, plug and pin prior to disassembly. (Scheme 36)

1. Remove 5 bolts and 5 shift solenoids. (Scheme 34)and (Scheme 37). Using snap ring pliers, remove 2 snap rings securing accumulator assemblies. Remove 2 washers, 4 springs and 2 pistons from upper valve body. (Scheme 35)
2. Remove 8 upper valve body bolts. (Scheme 38) Remove 7 upper valve body cover bolts. (Scheme 39) Remove bolt, cover and 2 pressure relief check balls. (Scheme 40)
3. Remove 7 lower valve body bolts. (Scheme 41) Hold plate against lower valve body and carefully remove lower valve body from upper valve body. Remove plate from lower valve body. DO NOT lose check balls. Note location of check balls, keys, plugs and pins in valve body. see scheme 49- see scheme 52.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Install check balls in upper and lower valve bodies. Ensure check balls are installed in correct locations. see scheme 51and see scheme 52. Install plate to lower valve body. Install lower valve body with plate to upper valve body. Install 7 lower valve body bolts and tighten to 97 INCH lbs. (11 N.m). Bolts are 1.614" (41.00 mm) in length.
2. Install accumulator pistons, springs, washers and snap rings. Ensure spring free length and outer diameter are within specification. For spring specifications, see «ACCUMULATOR VALVE SPRING SPECIFICATIONS»(ref-99709-S05981026412001073000000) table. Ensure components are installed in correct locations. Install pressure relief check balls, retainer and bolt. Tighten bolt to 97 INCH lbs. (11 N.m). (Scheme 40)
3. Turn valve body over. Install 7 upper valve body cover bolts. Tighten bolts to 58 INCH lbs. (6.6 N.m). Install 8 upper valve body bolts. Tighten bolts to 97 INCH lbs. (11 N.m). Ensure bolts are installed in correct locations. For bolt identification, see «UPPER VALVE BODY BOLT IDENTIFICATION»(ref-99709-S40981509532001073000000) table.
4. Install 5 shift solenoids and bolts. Tighten shift solenoid SLT and SL1 bolts to 58 INCH lbs. (6.6 N.m). Bolt length is.47" (12.0 mm). Tighten all other shift solenoid bolts to 97 INCH lbs. (11 N.m). Bolt length is 1.77" (45.0 mm). (Scheme 37) Ensure primary regulator valve is installed in correct position. (Scheme 36)

ACCUMULATOR VALVE SPRING SPECIFICATIONS

UPPER VALVE BODY BOLT IDENTIFICATION

Scheme 42

Scheme 43

1. Perform pre-disassembly inspection. Position dial indicator assembly on transaxle case. Position dial indicator tip against side gear. (Scheme 43) Measure side gear backlash while holding one pinion gear toward case. Backlash should be.002-.008" (.05-.20 mm). Note and record reading.
2. Mark ring gear and differential case for reassembly reference. Remove 12 ring gear bolts. Using a plastic hammer, tap on ring gear to remove it from differential case. (Scheme 42)
3. Using appropriate puller, remove front and rear tapered roller bearings (if necessary). Using a pin punch and hammer, drive out pinion shaft pin from ring gear side of case. Remove differential pinion shaft from differential case.
4. Remove 2 differential pinion gears, side gears, and 4 thrust washers. Using appropriate puller, remove side gear bearing outer races and shim from transaxle housing and transaxle case. Remove oil seals from transaxle housing and transaxle case.

Reassembly (U140F)

Note. Coat all sliding and rotating surfaces with ATF prior to reassembly.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. Using appropriate race installer and a hammer, install transaxle housing bearing race. Install plate washer of lesser thickness than washer removed during disassembly into transaxle case. Using appropriate race installer and a hammer, install transaxle case bearing race. see scheme 56
2. Coat front differential side gear thrust washer, front differential side gear, front differential pinion shaft holder, 4 front differential pinion thrust washers and 4 front differential pinion gears with ATF, and install components into front differential case. Install 3 pinion shafts into front differential case. see scheme 56
3. Mount front differential case in soft-jawed vise. DO NOT damage surface of front differential case which contacts vise. Using a dial indicator, measure front differential pinion gear backlash while holding front differential side gear toward front differential case. (Scheme 44)
4. Backlash should be.002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "A" to "K" (except "I"), and are available in thicknesses from.037" (.95 mm) to.055" (1.40 mm) in increments of.002"(.05 mm).
5. Engage side gear to front differential case. Install left side differential case to front differential case. Ensure side gear is centered. Once side gear is centered, remove left side differential case.
6. Using a straightedge and feeler gauge, measure clearance between front differential case and side gear. (Scheme 45) Use the following formula to determine correct thrust washer thickness for specified clearance: thrust washer thickness equals clearance (feeler gauge thickness) minus.007-.010" (.17-.26 mm).
7. Thrust washers are marked in alphabetical order from "A" to "K" (except "I"), and are available in thicknesses from.037" (.95 mm) to.055" (1.40 mm) in increments of.002" (.05 mm). If clearance is not as specified, ensure components were assembled correctly.
8. Using a pin punch and a hammer, install 3 pinion shaft pins. Install snap ring on front differential case. Install center differential side gear thrust washer No. 1, conical spring and center differential side gear to right side differential case. Install conical spring with convex side facing right side differential case.
9. Mount right side differential case in soft-jawed vise. Install 5 center differential pinion gears, 5 thrust washers and center differential pinion spider onto right side differential case. Using dial indicator, measure center differential pinion gear backlash, while holding center differential side gear toward case. (Scheme 46)
10. Backlash should be.002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "MA" to "MN" (except "MI"), and are available in thicknesses from.032" (.80 mm) to.055" (1.40 mm) in increments of.002" (.05 mm).
11. Temporarily install center differential side gear thrust washer No. 2, conical spring, front differential side gear thrust washer, front differential side gear and front differential case into left side differential case. Install conical spring with convex side facing toward left side differential case. Temporarily install differential intermediate case and 4 bolts to left side differential case.
12. Install center differential pinion spider, center differential pinion gears and thrust washers onto differential intermediate case. Using dial indicator, measure front differential side gear backlash while holding front differential case on left side differential case. (Scheme 47)
13. Turn front differential side gear to seat gears and ensure maximum backlash value. Backlash should be.002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification.
14. Thrust washers are marked in numeric and alphabetic order and are available in thicknesses from 032" (.80 mm), marked with a zero, to.049" (1.25 mm), marked with the number "9", and from.051" (1.30 mm), marked with the letter "A", to.055" (1.40 mm), marked with the letter "C". Thrust washers increase in increments of.002" (.05 mm).
15. Remove 4 bolts and differential intermediate case from left side differential case. Remove front differential case from left side differential case. Install selected center differential side gear thrust washer No. 2, conical spring, front differential side gear thrust washer, and front differential side gear to left side differential case.
16. Install front differential case into left side differential case. Using mark made during disassembly procedure, align and install right side differential case to differential intermediate case. Install 15 bolts. Using appropriate Torx socket, tighten bolts to 46 ft. lbs. (63 N.m). Install left side differential case and 4 bolts to differential intermediate case.
17. Using appropriate adapter and press, install differential case tapered roller bearings. Remove any material from transaxle housing and transaxle case mating surfaces. DO NOT allow oil to contact surfaces. Install differential assembly into transaxle case. Install transaxle housing onto transaxle case. Install 16 bolts and tighten to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside torque converter housing. see scheme 14
18. Temporarily install transfer case intermediate shaft. Turn intermediate shaft right and left several times to allow bearings to seat. Remove intermediate shaft. Using appropriate adapter and INCH-lb. torque wrench, measure differential preload. (Scheme 48) Preload should be 6.9-11.3 INCH lbs. (.8-1.3 N.m) for new bearings and 3.5-5.2 INCH lbs. (.4-.6 N.m) for used bearings.
19. If preload is not within specification, remove 16 transaxle housing bolts. Using a plastic hammer, remove transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace plate washer behind transaxle case bearing race. see scheme 56
20. Plate washers are marked in numeric and alphabetic order and are available in thicknesses from.079" (2.00 mm), marked with a zero, to.096" (2.45 mm), marked with the number "9", and from.098" (2.50 mm), marked with the letter "A", to.112" (2.85 mm), marked with the letter "H". Washers increase in increments of.002" (.05 mm). Recheck preload after washer replacement.
21. Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F (100°C) in water. DO NOT heat ring gear above 230°F (110 °C).
22. Carefully remove ring gear from water and quickly align match marks made during disassembly. Install ring gear on differential case. Install but DO NOT tighten 8 ring gear bolts, in pairs of 2, in a crisscross pattern. Ensure ring gear is properly seated and aligned. Install remaining 8 ring gear bolts and tighten all bolts to 70 ft. lbs. (95 N.m). Install NEW oil seal in transaxle case. Coat oil seal lip with lubricant.
23. For transaxle housing oil seal, wrap vinyl tape around seal installer at a position.236" (6.00 mm) above bottom end of installer, until thickness of tape is about.197" (5.00 mm). Coat NEW oil seal lip with lubricant. Install oil seal until wound vinyl tape contacts transaxle housing. Oil seal installed depth should be.22-.26" (5.5-6.5 mm).

TRANSAXLE REASSEMBLY

Note. Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts of drum. Check thrust bearings and races for wear or damage. Use petroleum jelly to secure parts in place. Clutch discs should be soaked in ATF for at least 15 minutes before installation.

Note. Refer to illustration for thrust bearing and race locations. (Scheme 64) For component dimensions, see THRUST BEARING & RACE SPECIFICATIONS table.

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

1. Install oil deflector with 3 bolts to transaxle housing. Install apply pipe and clamp. see scheme 7 Install bolt and tighten to 87 INCH lbs. (9.8 N.m). Ensure pipe is installed to stopper. Install oil seal ring to transaxle housing. see scheme 23 Using appropriate adapter and press, install underdrive cylindrical roller bearing into transaxle housing. DO NOT apply excessive pressure to bearing.
2. Using vernier calipers, measure underdrive brake piston return spring free length with spring mounted to spring seat. Free length should be.521" (13.24 mm). Replace springs as necessary. Install 2 oil seal rings to transaxle case. see scheme 16
3. For needle roller bearing installation, wrap vinyl tape around bearing installer at a position.157" (4.00 mm) above bottom end of installer, until thickness of tape is about.197" (5.00 mm). Using bearing installer and press, install needle roller bearing to transaxle case until wound vinyl tape contacts transaxle case.
4. Coat 2 NEW "O" rings with ATF and install on underdrive brake piston. see scheme 16 Using hand pressure, install piston into transaxle case. Using appropriate adapter and press, compress underdrive brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
5. Install snap ring into transaxle case. Using appropriate bearing race adapter and press, install 2 bearing outer races into transaxle case. Press each outer race into transaxle case until race contacts snap ring. see scheme 15 Using appropriate adapter and press, install tapered roller bearing to counter drive gear until bearing contacts gear. DO NOT apply excessive force.
6. Using appropriate adapter and press, install counter drive gear and bearing into transaxle case. DO NOT apply excessive pressure. Using vernier calipers, measure 1st/reverse brake piston return spring free length with spring mounted to spring seat. Free length should be.693" (17.61 mm). Replace springs as necessary.
7. Coat 2 NEW "O" rings with ATF and install on 1st/reverse brake piston. Using hand pressure, install piston into transaxle case. see scheme 15 Using appropriate adapter and press, compress 1st/reverse brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
8. Install front planetary ring gear and snap ring to brake hub. Install front planetary gear to brake hub. Using appropriate adapter and press, install brake hub with front planetary gear into transaxle case. (Scheme 49) Install washer on counter drive gear in correct direction. (Scheme 50)
9. Using holding tool, socket and torque wrench, install nut and tighten to 207 ft. lbs. (280 N.m). Using socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing starting torque. Starting torque should be 5.2-9.0 INCH lbs. (.6-1.0 N.m). (Scheme 51) If starting torque is not within specification, gradually tighten nut until starting torque is within specification.
10. Install 2 thrust bearings, bearing race and front planetary sun gear to front planetary gear. Coat bearing race with ATF and install race to rear planetary gear. Install thrust washer No. 2. Install rear planetary gear into transaxle case. Install snap ring.
11. Install 1st/reverse brake. Install 7 plates and 7 discs, starting with a plate and alternating with a disc. DO NOT install flange. Measure 1st/reverse brake piston stroke. Using vernier calipers, measure distance between disc surface and contact surface of 2nd brake assembly at transaxle case. (Scheme 52)
12. Piston stroke should be.043-.049" (1.10-1.24 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are marked in numeric order and are available in thicknesses from.071" (1.80 mm), marked with the number "1", to.098" (2.50 mm), marked with the number "8", in increments of.004" (.10 mm). Recheck piston stroke after flange is installed.
13. Install 2nd brake assembly into transaxle case. Install snap ring and measure inside diameter. Snap ring inside diameter should be more than 6.57" (167.0 mm). Snap ring has a specific tapered installation direction. If inside diameter is not within specification, ensure snap ring is installed in correct direction. If snap ring is installed correctly, replace snap ring.
14. Install one-way clutch outer sleeve to 2nd brake assembly. Ensure sleeve is positioned correctly. Install one-way clutch inner race to No. 1 one-way clutch. Ensure inner race is installed correctly. Check No. 1 one-way clutch operating direction. One-way clutch should rotate in counterclockwise direction and lock in clockwise direction. (Scheme 53)
15. Install No. 1 one-way clutch and thrust bearing into outer sleeve. Ensure Black race on thrust bearing is visible upon installation. Coat thrust washer No. 1 with petroleum jelly and install on rear planetary sun gear. Coat thrust bearing with petroleum jelly and install on rear planetary sun gear. Install rear planetary sun gear onto rear planetary gear.
16. Install 2nd brake. Install 4 discs and 4 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using vernier calipers, measure 2nd brake piston stroke between disc surface and snap ring surface. (Scheme 54) Piston stroke should be.026-.030" (.65-.75 mm).
17. Select appropriate flange to ensure piston stroke is within specification. Use the following formula to determine flange thickness: measured distance, minus flange thickness, minus snap ring thickness of.063" (1.60 mm). Flanges are available in thicknesses from.118" (3.00 mm) to.142" (3.60 mm) in increments of.004" (.10 mm), and are marked in numeric order from "1" to "7". Remove snap ring, install appropriate flange and reinstall snap ring. Ensure snap ring end gap is visible through groove in transaxle case.
18. Install bearing race over shaft and onto direct clutch. Install direct clutch assembly and thrust bearing onto rear planetary sun gear assembly. see scheme 15 Ensure discs in direct clutch completely mate with rear planetary sun gear to ensure rear cover can be installed correctly.
19. Ensure transaxle case and rear cover mating surfaces are clean. Place a straightedge onto direct clutch drum. Using vernier calipers, measure distance between bottom of straightedge and transaxle case (dimension "B"). (Scheme 55)
20. Measure dimension No. 1 and dimension No. 2 of rear cover in 2 places. (Scheme 56) Subtract dimension No. 2 from dimension No. 1. This total equals dimension "C". Calculate direct clutch end play by subtracting dimension "B" from dimension "C". End play should be.008-.035" (.20-.90 mm).
21. Select a thrust bearing to ensure end play is within specification. Thrust bearings are available in 2 thicknesses of.140" (3.55 mm) with an outside diameter of 2.74" (69.6 mm), and.152" (3.85 mm) with an outside diameter of 2.76" (70.18 mm). Inside diameter of both thrust bearings is 2.11" (53.6 mm). During installation, ensure Black race side of thrust bearing is facing transaxle rear cover.
22. Install 2 NEW apply gaskets to transaxle case. Install clamp to apply pipes prior to installing pipes to transaxle case. This will prevent apply pipes from being deformed or damaged. Install 2 apply pipes, clamp and bolt. see scheme 16 Ensure pipes are securely inserted into transaxle case until they reach the pipe stopper on pipe. Tighten bolt to 48 INCH lbs. (5.4 N.m).
23. Install needle roller bearing onto transaxle rear cover with inscribed mark on bearing facing up. Using appropriate adapter and press, install needle roller bearing to transaxle rear cover. Press bearing in to a depth of.474-.502" (12.05-12.75 mm). Coat 2 oil seal rings with ATF and install on transaxle rear cover. see scheme 15
24. Install underdrive brake. Install 4 discs and 4 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using a dial indicator, measure underdrive brake piston stroke by applying and releasing 57 psi (4 kg/cm 2 ) of compressed air to transaxle case. see scheme 22and (Scheme 57).
25. Piston stroke should be.071-.081" (1.81-2.07 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are available in 3 thicknesses of.118" (3.00 mm),.126" (3.20 mm) and.134" (3.40 mm), and are marked in numeric order from "1" to "3". Remove snap ring, install appropriate flange and reinstall snap ring.
26. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Coat needle roller bearing with ATF. Apply Three Bond (1281) or equivalent gasket sealant to rear cover around inside edges of bolt holes. Install rear cover onto transaxle case. Install 11 bolts and tighten to 18 ft. lbs. (24 N.m).
27. Install outer race retainer to No. 2 one-way clutch, ensuring long finger of retainer is facing up. see scheme 18 Install underdrive clutch to No. 2 one-way clutch. Rotate underdrive clutch to ensure correct installation. Underdrive clutch should rotate in a counterclockwise direction, and lock in a clockwise direction. (Scheme 58)
28. Install No. 2 one-way clutch into transaxle case. Note position of index marks on No. 2 one-way clutch. Ensure marks are facing up. (Scheme 59) Install snap ring into transaxle case. Coat thrust bearing and bearing race with petroleum jelly and install onto underdrive clutch. Install underdrive clutch into transaxle case.
29. Install pawl pin and spring to parking lock pawl. Temporarily install parking lock pawl, shaft and spring to transaxle case. see scheme 16 Install underdrive planetary gear assembly into transaxle case. Engage all clutch discs and hub spline of planetary gear assembly firmly and securely. Install parking lock pawl shaft. Install lock pawl clamp and bolt. Tighten bolt to 87 INCH lbs. (9.8 N.m).
30. Using vernier calipers and a straightedge, measure gap between top of differential drive pinion in underdrive planetary gear, and contact surface of transaxle case. (Scheme 60) Record measurement as dimension "D".
31. Measure dimension No. 1 and dimension No. 2 of transaxle housing in 2 places. (Scheme 61) Subtract dimension No. 2 from dimension No. 1. Record measurement as dimension "E". Install bearing race onto counter drive gear in correct direction. see scheme 15
32. Coat needle roller bearing with petroleum jelly and install onto multiple clutch hub (shaft side). Install multiple clutch hub into transaxle case. Install thrust bearing onto multiple clutch hub (forward clutch side). Install forward clutch onto multiple clutch hub. see scheme 15 Align splines of all discs of forward clutch with multiple clutch hub. Install thrust bearing onto forward clutch. Ensure Black side of thrust bearing is visible.
33. Install 2 NEW apply gaskets to front of transaxle case. see scheme 15 Install differential assembly. Calculate transaxle housing-to-underdrive planetary gear assembly end play using the following formula: subtract dimension "D" from dimension "E", performed in steps 30 and 31, minus thrust bearing thickness of.129" (3.28 mm), equals bearing race thickness. End play should be.020-.039" (.50-.99 mm).
34. Select a bearing race to ensure end play is within specification. If dimension "E" minus dimension "D" is less than.292" (7.42 mm), bearing race thickness should be.138" (3.50 mm). If dimension "E" minus dimension "D" is.292" (7.42 mm) or more, bearing race thickness should be.150" (3.80 mm).
35. Install appropriate bearing race onto underdrive planetary gear assembly to ensure end play is within specification. Bearing race outside diameter is 3.268" (83.00 mm). Bearing race inside diameter is 2.220" (56.40 mm). Install appropriate thrust bearing onto bearing race. Thrust bearing outside diameter is 3.345" (84.96 mm). Thrust bearing inside diameter is 2.252" (57.20 mm).
36. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m). Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealant about.047" (1.20 mm) wide, to transaxle case around inside edges of bolt holes. Install transaxle housing to transaxle case.
37. Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts inside torque converter housing, and tighten these bolts to 16 ft. lbs. (22 N.m) within 10 minutes of installation. Tighten all other bolts to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside torque converter housing. see scheme 14
38. Inspect input shaft end play. Using a dial indicator, measure input shaft end play. see scheme 13 End play should be.011-.049" (.27-1.24 mm). Recheck differential preload. Using appropriate adapter and INCH-lb. torque wrench, measure differential preload. (Scheme 48) Preload should be 6.9-11.3 INCH lbs. (.8-1.3 N.m) for new bearings and 3.5-5.2 INCH lbs. (.4-.6 N.m) for used bearings.
39. If preload is not within specification, remove differential assembly from transaxle case and replace shim or plate washer behind transaxle case bearing race. (Scheme 42)and see scheme 56.
40. Place transaxle on 2 blocks of wood, with oil pan surface facing outward. Coat NEW manual valve lever shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock pawl rod to manual valve lever. Install NEW spacer and manual valve lever shaft into transaxle case. see scheme 7
41. Using a pin punch and hammer, drive in NEW roll pin. Turn spacer and lever shaft to align small hole for locating staking position in spacer with position mark on lever shaft. Using a pin punch and hammer, stake spacer through small hole. Ensure spacer does not turn.
42. Using needle nose pliers, install retainer spring. Install parking lock pawl bracket. Install bolts and tighten to 15 ft. lbs. (20 N.m). Install cover, manual detent spring and 2 bolts. Ensure cover and detent spring are installed correctly. see scheme 7
43. Tighten 1.063" (27.00 mm) bottom bolt to 15 ft. lbs. (20 N.m). Tighten.630" (16.00 mm) top bolt to 106 INCH lbs. (12 N.m). Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat 4 springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. (Scheme 62) See «ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS»(ref-99709-S17763171582001073000000) table for spring specifications and identification. ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS Application (Color) Free Length - In. (mm) Outer Diameter - In. (mm) Forward Clutch (Red) 3.564 (90.53).728 (18.50) Underdrive Brake Inner (Green) 2.372 (60.24).626 (15.90) Outer (Blue) 2.859 (72.61).657 (16.70) Underdrive Clutch (Yellow) 3.412 (86.66).756 (19.20)
44. Install check ball body and spring. see scheme 9 Coat NEW "O" ring with ATF and install on transaxle solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten bolt to 48 INCH lbs. (5.4 N.m). Coat NEW apply gaskets with ATF and install them into transaxle case, below valve body assembly. see scheme 9
45. Install brake drum gasket, located near 3 apply gaskets. see scheme 7 Install valve body assembly. See «VALVE BODY ASSEMBLY»(ref-99709-S08833830322001073000000) under ON-VEHICLE SERVICE. Push valve body assembly against accumulator piston springs and check ball body to assist in installation. Coat NEW oil strainer gasket with ATF and install on oil strainer. Install oil strainer and tighten bolts to 97 INCH lbs. (11 N.m).
46. Connect 5 shift solenoid connectors. Install fluid temperature sensor, clamps and bolt. Tighten bolt to 58 INCH lbs. (6.6 N.m). see scheme 8 Install 3 magnets into oil pan in original locations. Apply Three Bond (2430) or equivalent to 18 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten bolts to 69 INCH lbs. (7.8 N.m) within 10 minutes of installation.
47. Coat NEW "O" rings with ATF and install on speed sensors. Install input turbine and counter gear speed sensors into top of transaxle case. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O" rings on oil line union and elbow. Install oil line union and elbow into transaxle case. Tighten to 20 ft. lbs. (27 N.m).
48. Coat NEW "O" ring with ATF and install on transaxle test plug. Install transaxle test plug into transaxle case. see scheme 3 Install park/neutral position switch onto manual valve lever shaft and temporarily install 2 adjusting bolts. see scheme 7
49. Install NEW lock tab and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control shift lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control shift lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48 INCH lbs. (5.4 N.m). Stake lock tab onto nut. Install control shift lever, washer and nut. Tighten nut to 61 INCH lbs. (6.9 N.m).
50. On U140F transaxle, remove any debris between transfer case and transaxle case contact surfaces. DO NOT allow oil to contact surfaces. Coat NEW round gasket with petroleum jelly and install onto transfer case.
51. Install intermediate shaft into transfer case assembly. Apply Three Bond (1281) or equivalent gasket sealant about.047" (1.20 mm) wide, to transfer case contact surface. Install transfer case by pushing straight up and into transaxle. Use care not to damage oil seal lip when installing transfer case. Install 2 bolts and 6 nuts and tighten to 51 ft. lbs. (69 N.m).
52. On both transaxles, install torque converter into transaxle housing while rotating. Ensure converter is properly installed by measuring distance from edge of transaxle housing. (Scheme 63) Distance should be.502" (12.75 mm) for all models. THRUST BEARING & RACE SPECIFICATIONS (1) Application Inner Diameter - In. (mm) Outer Diameter - In. (mm) A Bearing 2.252 (57.20) 3.345 (84.96) Rear Race 2.220 (56.40) 3.268 (83.00) B Bearing 1.485 (37.73) 2.283 (58.00) Rear Race 1.177 (29.90) 2.185 (55.50) C Bearing 1.333 (33.85) 2.055 (52.20) D Bearing.925 (23.50) 1.732 (44.00) E Bearing 1.429 (36.30) 2.055 (52.20) Rear Race 1.358 (34.50) 1.909 (48.50) F Bearing 1.362 (34.60) 1.909 (48.50) G Front Race 1.587 (40.30) 2.283 (58.00) Bearing 1.520 (38.60) 2.362 (60.00) Rear Race 1.520 (38.60) 2.283 (58.00) H Bearing 2.110 (53.60) 2.740 (69.60) I Bearing 1.327 (33.70) 1.898 (48.20) Rear Race 1.193 (30.30) 1.811 (46.00) J Bearing 2.110 (53.60) 2.740 (69.60) Or 2.763 (70.18) (1) Refer to illustration for component locations. (Scheme 64)