mitsub hyu

AUTOMATICTRANSAXLEReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TRANSAXLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 4 9

AUTOMATIC TRANSAXLE SHIFT LOCKCONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 5 7

AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 59

AUTOMATIC TRANSAXLE OIL COOLERASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

AUTOMATIC TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . 6 4

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 100

FRONT CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 104

REAR CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 107

END CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 110

PLANETARY GEAR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

INTERNAL GEAR AND TRANSFER DRIVEGEAR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

KICKDOWN SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

SPEEDOMETER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . 140

TRANSAXLE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

*CAUTION

For automatic transaxle (KM175, 4 SPEED) which does nothave the function of POWER/NORMAL SYSTEM, pleaserefer to ‘89 MODEL SONATA SHOP MANUAL.

GENERAL

GENERAL

SPECIFICATIONS

Type

Torque converter

TypeEngine stall speedStall torque ratio

Transaxle

Type

Gear ratioFirstSecondThirdFourthReverse

Final gear ratioSpeedometer gear ratio

Automatic four speed with torque converter andintegral differential-KM175

With damper clutch2,200 ± 200 rpm2.17

Electronically controlled 4-speedfull-automatic

2.5511.4881.0000.6852.1764.007Drive 36/Driven 29

4 5 - 2

GENERAL

TIGHTENING TORQUENm kg.cm Ib.ft

Air filter mounting boltTie rod end to knuckle

Lower arm ball joint to knuckleTransaxle mounting bracket to transaxleTransaxle mounting bracket to bodySelector knob set screwSelector lever mounting nutIndicator panel mounting screwStarter motor mounting boltBell housing cover to transaxleBell housing cover bolt

Engine to transaxleTorque converter to drive plateDrive plate-to-converter tightening bolt

Transaxle mounting bolt [10 mm (0.39 in.) diameter bolt]Transaxle mounting bolt [8 mm (0.31 in.) diameter bolt]Drain plugPressure check plugPulse generator mounting boltBearing retainer screwLock plate boltOil cooler connectorConverter housing boltOil pan boltKickdown servo piston plate screwOne-way clutch outer race bolt

Differential drive gear boltManual control lever nutManual control shaft set screwInhibitor switchSprag rod support bolt

Pump housing-to-reaction shaft support boltOil pump assembly mounting boltValve body bolt

Valve body assembly mounting boltOil filter boltSpeedometer sleeve locking plate bolt

8 - 1 0 8 0 - 1 0 02 4 - 3 4 2 5 0 - 3 4 06 0 - 7 2 6 0 0 - 7 2 06 0 - 8 0 6 0 0 - 8 0 04 0 - 5 0 4 0 0 - 5 0 02.0 201 4 - 2 0 1 4 0 - 2 0 01.5 152 2 - 3 2 2 2 0 - 3 2 01 5 - 2 2 1 5 0 - 2 2 01 0 - 1 2 1 0 0 - 1 2 0Refer to page 45-591 3 0 - 1 4 0 1300-14004 6 - 5 3 4 6 0 - 5 3 04 3 - 5 5 4 3 0 - 5 5 03 0 - 3 5 3 0 0 - 3 5 03 0 - 3 5 3 0 0 - 3 5 08 - 1 0 8 0 - 1 0 01 0 - 1 2 1 0 0 - 1 2 01 7 - 2 2 170-2202 0 - 2 7 2 0 0 - 2 7 01 5 - 2 2 1 5 0 - 2 2 01 9 - 2 3 1 9 0 - 2 3 01 0 - 1 2 1 0 0 - 1 2 06 - 8 6 0 - 8 08 - 1 0 8 0 - 1 0 01 3 0 - 1 4 0 1300-140017-21 1 7 0 - 2 1 08 - 1 0 8 0 - 1 0 01 0 - 1 2 1 0 0 - 1 2 02 0 - 2 7 2 0 0 - 2 7 01 0 - 1 2 1 0 0 - 1 2 01 5 - 2 2 1 5 0 - 2 2 04 - 6 4 0 - 6 01 0 - 1 2 1 0 0 - 1 2 05 - 7 5 0 - 7 03 - 5 3 0 - 5 0

6 - 71 7 - 2 54 3 - 5 24 3 - 5 72 9 - 3 61.51 0 - 1 41.11 6 - 2 31 1 - 1 67 - 9

94-1013 4 - 3 83 2 - 3 92 2 - 2 52 2 - 2 56 - 77 .5 -8 .51 2 - 1 51 5 - 1 91 1 - 1 61 4 - 1 67 .5 -8 .55 - 66 - 794-1011 3 - 1 56 - 77 .5 -8 .51 5 - 1 97 .5 -8 .51 1 - 1 53 - 47 .5 -8 .54 - 52 .5 -3 .5

4 5 - 3

GENERAL

LUBRICANTS

Items

Transaxle fluid lit. (U.S.qts., Imp.qts.)

Drive shaft oil seal lip

Sliding part of bushing

Selector lever sliding portion

Specified lubricant

DIAMOND ATF SP, APOLLOIL ATF D-II,GENUINE HYUNDAI ATF AUTOMATIC TRAN-SAXLE FLUID OR *MOPAR ATF PLUS TYPE7176

Automatic transaxle fluidDEXRON II type

Chassis grease SAE J310, NLGI No.0

Multipurpose grease SAE J310, NLGI No.2

Quantity

5.8 (6.1, 5.1)

As required

As required

As required

*MOPAR ATF PLUS TYPE 7176 is recommended lubricant

4 5 - 4

GENERAL

SPECIAL TOOLS

4 5 - 5

GENERAL

Tool(Number and name)

09432-21000Bearing outer race remover

Illustration Use

Removal of transfer shaft bearing outerrace

09432-21601Bearing installer

Installation of transfer shaft bearing

09432-21701Bearing outer race installer

Installation of transfer shaft bearing outerrace (use with 09500-21000)

09432-33500Taper bearing puller

Removal of transfer shaft bearing

09433-21000Removing plate

Removal of differential tapered rollerbearing

09452-21001Oil pressure gauge adapter

Measurement of the oil pressure (use with09452-21500 and 09452-21002)

09452-21002Oil pressure gauge adapter


09452-21200Oil pump oil seal installer

1) Installation of the oil pump seal2) Installation of differential case taper

roller bearing

4 5 - 6

GENERAL


09452-21301Oil pump band

Illustration Use

Assembling the oil pump

09452-21401Guide pin

1) Assembling the oil pump2) Installation of the oil pump

09452-21500Oil pressure gauge


09452-33100Oil pump remover

09453-24000Spring compressor

Removal of the oil pump

Removal and installation of snap ring andreturn spring of front clutch


Removal and installation of the rear clutch


Removal and installation of snap ring oflow-reverse brake

09453-21400Dial gauge support

1) Measurement of the input shaft endplay (use with dial gauge)

2) Measurement of the transfer shaft endplay (use with dial gauge)

4 5 - 7

GENERAL


09453-33000Snap ring installer

09453-33100Dial gauge extension

09453-21310Center support remover andinstaller

09454-21100Wrench adapter

09454-33000Kickdown servo wrench

09454-33190Socket wrench

09455-24000Bearing and gear puller


Illustration U s e

Installation of end clutch snap ring

Measurement of the low and reversebrake end play (use with a dial indicatorand 09453-21400)

Removal and installation of the centersupport

Loosening and tightening of the transferidler shaft

Adjustment of kickdown(use with 09454-331 DO)

Adjustment of kickdown(use with 09454-33000)

Removal of ball bearing and transfer drivegear

Installation of ball bearing and transferdrive gear

4 5 - 8

GENERAL



Illustration Use

1) Installation of the transfer shaft rearside bearing

2) Installation of the transfer driven gear

09455-21301Transfer shaft retainer

09456-21000Guide pin

Supporting the transfer shaft

Assembly of the valve body and transferplate

09456-21100Adapter set

Removal and installation of kickdownservo (use with 09222-21001)

09458-33000Wrench adapter

Preload measurement of transfer idlershaft

09500-11000Bar

Installation of differential bearing outerrace (use with 09532-11500)

09500-21090Bar

Installation of transfer shaft bearing outerrace (use with 09432-21701)

09532-11500Pinion bearing outer raceinstaller

Installation of differential bearing outerrace (use with 09500-11000)

4 5 - 9

GENERAL

TROUBLESHOOTING

Malfunctions of the KM175-4A/T can lead to other problems,such as those described below:1. Improper maintenance and/or adjustments2. Malfunctions of the electronic control functions3. Malfunctions of mechanical functions4. Malfunctions of hydraulic control functions5. Malfunctions of engine performanceetc.In order to properly Troubleshoot the source of these mal-functions, it is first essential to methodically question the ownerconcerning the problem, the situation at the time the problemoccurred, and any other relevant information, all in as muchdetail as possible. The user should also be asked whether or notthe problem has occurred more than once.Subsequently, certain tests should be conducted in a certainorder, as described at the right.

Based upon use of the troubleshootingguide, the probable location of the problemshould be estimated.

Checks should be made of fluid levels andthe condition of the ATF, as well as thecondition of the manual control cables;adjustments should then be made if foundto be necessary.

If a presumption has been made that thereis an abnormal condition somewhere in theelectronic-control system, the diagnosistester should be used to estimate theprobable location by checking the mal-function-indication pattern. If the ignitionkey was already turned to OFF, however,check by making a road test.

When the abnormal system is discoveredduring the road test, check each element(sensors, etc.) one by one, and make repairsas necessary.

When the abnormal condition is presumedto be in the oil-pressure-control system,check by making an oil-pressure test.

When the result of the oil-pressure testdoes not satisfy the specified pressure,check each system at places related, to thevalve body, check the oil-pressure passagesfor leakage, etc.

If the problem is unusually dirty ATF,abnormal noises, oil leakage, or slippage ofthe clutch or brakes, or an abnormalcondition of the transaxle itself, disassembleand repair the transaxle.

4 5 - 1 0

GENERAL

TROUBLESHOOTING GUIDE

NOTE: X indicates items of high priority during inspection.Abbreviations: TPS = Throttle position sensor SCSV = Shift control solenoid valve

45 -11

GENERAL

PSCV = Pressure control solenoid valveDCCSV = Damper clutch control solenoid valve

4 5 - 1 2

GENERAL

DIAGNOSIS AND TEST

FLUID LEVEL AND CONDITION

1.2.

3.

4.

5.

6.

Place vehicle on level floor.Before removing dipstick, wipe all dirt from area arounddipstick.With selector lever in “P” Park and parking brakes applied,start engine.Engine should be running at idle speed. Fluid should be atnormal operating temperature [70-80°C (160-180°F)].Move selector lever sequentially to every position to filltorque converter and hydraulic circuit with fluid, then placelever in “N” Neutral position. This operation is necessary tobe sure that fluid level check is accurate.Check to see if fluid level is in “HOT” range on dipstick. Iffluid is low, add automatic transaxle fluid until level reaches“HOT” range.Low fluid level can cause a variety of conditions because itallows pump to take in air along with fluid. Air trapped inhydraulic circuit forms bubbles which make fluid spongy.Therefore, pressure will be erratic.Improper filling can also raise fluid level too high. Whentransaxle has too much fluid, gears churn up foam and causesame conditions which occur with low fluid level, resultingin accelerated deterioration of automatic transaxle fluid. Ineither case, air bubbles can cause overheating, fluidoxidation, and varnishing, which can interfere with normalvalve, clutch, and servo operation. Foaming can also resultin fluid escaping from transaxle vent where it may bemistaken for a leak.Along with fluid level, it is important to check the conditionof the fluid. When fluid smells burned, and is contaminatedwith metal bushing or friction material particles, a completetransaxle overhaul is needed. Be sure to examine fluid ondipstick closely. If there is any doubt about its conditions,drain out sample for double check. After fluid has beenchecked, seat dipstick fully to seal out water and dirt.

Fluid level must bewithin this range.

4 5 - 1 3

GENERAL

MANUAL CONTROL CABLE

Whether manual linkage is properly adjusted can be confirmedby checking whether inhibitor switch is performing well.1.2.3.4.

5.

6.

7.

Apply parking brakes and service brakes securely.Place selector lever to “R” range.Set ignition key to “ST” position.Slowly move the selector lever upward until it clicks at it fitsin notch of “P” range. If starter motor operates when levermakes a click, “P” position is correct.Then slowly move selector lever to “N” range by the sameprocedure as in foregoing paragraph. If starter motoroperates when selector lever fits in “N”, “N” position iscorrect.Also check to be sure the vehicle doesn’t begin to move andthe lever doesn’t stop between P-R-N-Q.The manual-control cable is properly adjusted if, as describedabove, the starter motor starts at both the “P” range and the“N” range.

OBTAINING FAULT CODES

1. Connect the voltmeter or multi-use tester to the connectorfor diagnosis.

2. Read the output fault codes.Then follow the remedy procedures according to the “FAULTCODE DESCRIPTION” on the following page.

NOTEAs many as ten fault codes, in the sequence ofoccurrence, can be stored in the Random AccessMemory (RAM) incorporated within the control unit.The same fault code can be stored as many as threetimes.If the number of stored fault codes or fault patternsexceeds ten, already stored fault codes will be erased,in sequence beginning with the oldest.Do not disconnect the battery until all fault codes orfault patterns have been read out, because all storedfault codes or fault patterns will be canceled when thebattery is disconnected.

4 5 - 1 4

GENERAL

3. If the fail-safe system is activated and the transaxle is lockedin 3rd gear, the fault code in the Fail-Safe Code Descriptionwill be stored in the RAM.Three of these fault codes can be stored.

4. The cancellation will occur if, with the transaxle locked in 3rdgear, the ignition key is turned to the OFF position, but thefault code is stored in the RAM.

<Multi-use tester>

4 5 - 1 5

GENERAL

FAULT CODE DESCRIPTION

Cause RemedyFaultcode

Fault code (for voltmeter)

o Check the throttle position sensorconnector.

o Check the throttle position sensoritself.

o Adjust the throttle position sen-sor.

o Check the accelerator switch(No.28: output or not).

o Check the throttle position sensoroutput circuit harness.

21 Abnormal increase of TPS output

22 Abnormal decrease of TPS output

Incorrect adjustment of the throt-tle-position sensor system

23

24

25

Damaged or disconnected wiring ofthe oil temperature sensor system

o Check the oil temperature sensorcircuit harness.

o Check the oil temperature sensorconnector.

o Check the oil temperature sensoritself.

Damaged or disconnected wiring ofthe kickdown servo switch system,or improper contact

o Check the kickdown servo switchoutput circuit harness.

o Check the kickdown servo switchconnector.

Short circuit of the kickdown servo o Check the kickdown servo switchswitch system itself.

26

o Check the ignition pulse signalline.

27 Damaged or disconnected wiring ofthe ignition pulse pick-up cablesystem

Short circuit of the acceleratorswitch system or improper adjust-ment

o Check the accelerator switchoutput circuit harness.

o Check the accelerator switchconnector.

o Check the accelerator switchitself.

o Adjust the accelerator switch.

28

Malfunction of the microprocessor o Replace the control unit.31

4 5 - 1 6

G E N E R A L

Faultcode

32

Fault code (for voltmeter) Cause Remedy

First gear command during high- o Replace the control unit

speed driving

3 3 Damaged or disconnected wiring of o Check the pulse generator B

the pulse generator B system output circuit harness.o Check pulse generator B itself.o Check the vehicle speed reed

switch (for chattering).

41

42

Damaged or disconnected wiring of o Check the solenoid valve con-the shift control solenoid valve A nector.

system o Check shift control solenoid valveA itself.

Short circuit of the shift-control o Check the shift control solenoidsolenoid valve A system valve A drive circuit harness

43

44

Damaged or disconnected wiring of o Check the solenoid valve con-the shift control solenoid valve B nector.system o Check shift control solenoid valve

B itself.Short circuit of the shift control o Check the shift control solenoidsolenoid valve B system valve B drive circuit harness.

45

46

Damaged or disconnected wiring of o Check the solenoid valve con-the pressure control solenoid valve nector.system o Check the pressure control

solenoid valve itself.Short circuit of the pressure control o Check the pressure control

solenoid valve system solenoid valve drive circuit har-ness.

47

48

Damaged or disconnected wiring of o Check the solenoid valve con-

the damper clutch control solenoid nector.valve system o Check the damper clutch control

solenoid valve itself.

Short circuit of the damper clutch o Check the damper clutch control

control solenoid valve system solenoid valve drive circuit har-

ness.

4 5 - 1 7

GENERAL

Faultcode

Fault code (for voltmeter) Cause Remedy

49 Malfunction of the damper clutch o Check the damper clutch controlsystem solenoid valve drive circuit har-

ness.o Check the damper clutch

hydraulic pressure system.o Check the damper clutch control

solenoid valve itself.o Replace the control unit.

First gear non-synchronous o Check the pulse generator outputcircuit harness.

o Check the pulse generator con-nector.

o Check pulse generator A andpulse generator B themselves.

o Kickdown brake slippage.

52 Second gear non-synchronous o Check the pulse generator Aoutput circuit harness.

o Check the pulse generator Aconnector.

o Check pulse generator A itself.o Kickdown brake slippage.

53 Third gear non-synchronous o Check the pulse generator Aoutput circuit harness.

o Check the pulse generator con-nector.

o Check pulse generator A andpulse generator B themselves.

o Front clutch slippage.o Rear clutch slippage.

Fourth gear non-synchronous o Check the pulse generator Aoutput circuit harness.

o Check the pulse generator Aconnector.

o Check pulse generator A itself.o Kickdown brake slippage.

4 5 - 1 8

GENERAL

FAIL-SAFE ITEM

Output code NoteFail-safe

CodeDescription (relation to

No.Output pattern (for voltmeter) fault code)

11 Malfunction of the Locked in 3rd gear When code No. 31 ismicroprocessor generated 4th time.

12 First gear command Locked in 3rd (D) or When code No. 32 isduring high speed 2nd (2, L) gear generated 4th time.driving

Damaged or discon- Locked in 3rd (D) or When code No. 33 isnected wiring of the 2nd (2, L) gear generated 4th time.pulse generator Bsystem

Damaged or discon- Locked in 3rd gear When code No. 41 ornected wiring, or 42 is generated 4thshort circuit, of shift time.control solenoid valveA

Damaged or discon- Locked in 3rd gear When code No. 43 ornected wiring, or 44 is generated 4thshort circuit, of shift t ime.control solenoid valveB

16 Damaged or discon- Locked in 3rd (D) or When code No. 45 ornected wiring, or 2nd (2, L) gear 46 is generated 4thshort circuit, of the time.pressure control sole-noid valve

Shift steps non-synchronous

Locked in 3rd (D) or When either code2nd (2, L) gear No. 51, 52 53 or 54 is

generated 4th time.

4 5 - 1 9

GENERAL

CHECKING THE CONTROL SYSTEM (WHEN A MULTI-USE TESTER IS USED)

No. Description and display data Check conditionsStandard value forjudgement

1 Pulse generator A D range (3rd) 50 km/h (31 mph) constant Upper: 1,600 ± 200 rpmo Upper No.19 speed driving

Kickdown drum rpmLower: 3rd

o Lower No.38 D range (4th) 50 km/h (31 mph) constant Upper: 0 rpmShift step speed driving

Lower: 4th

2 Pulse generator B D range (creep), stop idle Upper: 0 rpmo Upper No.13

Transaxle output shaft rpmUpper: 0 km/h (0 mph)

o Lower No.33 D range (4th) 50 km/h (31 mph) constant Upper: 1,800 ± 200 rpmVehicle speed reed switch speed driving

Lower: 50 km/h (31 mph)

3 Vehicle speed reed switch P range, idle Upper: 0 km/h (0 mph)o Upper No.33 -

Vehicle speed reed switch o Lower, no designation D range, speedometer reading 50 km/h (31 Upper: 50 km/h (31 mph)

mph) driving -

4 Throttle position sensor Accelerator fully open (engine stopped, Upper: 4.5-5.0Vo Upper No.21 ignition switch : ON)

TPS outputLower: OFF

o Lower No.28 Accelerator fully closed (engine stopped, Upper: 0.5-0.6VAccelerator switch ignition switch : ON)

Lower: ON

5 Kickdown servo switch L range, idle Upper: ONo Upper No.25

Kickdown servo switchLower: 1st

o Lower No.38 D range, idle Upper: OFFShift step

Lower: C (creep)

6 Oil temperature sensor Start when transaxle cold, urban driving. Upper: temperature riseso Upper No.24

Oil temperature sensor After driving, stop engine and leave as is. Upper: temperature even-o Lower, no designation tually decreases.

7 Accelerator switch Depress accelerator pedal slowly. Upper: change from ON too Upper No.28 OFF at a throttle-position

Accelerator switch sensor output of abouto Lower No.21 0.5V.

TPS outputRelease accelerator pedal slowly. Upper: change from OFF to

ON at a throttle-positionsensor output of about0.5V.

4 5 - 2 0

GENERAL

No. Description and display data Check conditionsStandard value forjudgement

8 Overdrive control switch Overdrive control switch ON Upper: OD-ONo Upper No.35 -

Overdrive control switcho Lower, no designation Overdrive control switch OFF Upper: ON-OFF

-

9 Ignition signal line D range, idle Upper: 700 ± 50 rpmo Upper No.27 -

Ignition pulseo Lower, no designation D range, tachometer reading 2,500 rpm Upper: 2,500 rpm

-

10 Inhibitor switcho Upper No.34

Shift lever positiono Lower, no designation

Move shift lever in P-R-N-D-2-L sequence. Upper: changes in P-R-N-D-2-L sequence in accordancewith the lever position.

11 Power Economy select switch Select power pattern. Upper: ON

o Upper No.36 -Power Economy selectswitch Select economy pattern. Upper: OFF

o Lower, no designation -

12 Air conditioner relay Switch ON the air conditioner switch (while Upper: ONo Upper No.37 idling in D range). -

Air conditioner relayo Lower, no designation Switch OFF the air conditioner switch Upper: OFF

(while idling in D range). -

1 3 Amount of damper clutch D range tachometer reading 1,500 rpm TPS Upper: 250 ± 50 rpmslippage output approx. 1Vo Upper No.47

Lower: 1.0V

Amount of damper clutch D range tachometer reading 3,500 rpm TPS Upper: 40 ± 10 rpmslippage output approx. 2.5V

o Lower No.21Lower: 2.5V

TPS output

14 Transaxle gear positiono Upper No.38

Shift stepo Lower No.21

TPS output

D range, idle Upper: C (creep)

Lower: 0.5-0.6V

Economy pattern D range (overdrive pos- Upper: 1st-2nd-3rd-4thsible condition)Accelerate to 100 km/h (62 mph) with fixed

Lower: 2.5V

throttle position sensor output of 2.5V

45 -21

GENERAL

No. Description and display data

15 DCCSV controlo Upper No.49

DCCSV control dutyo Lower No.21

TPS output

Check conditionsStandard value forjudgement

D range tachometer reading 1,500 rpmThrottle-position sensor output approx. 1.0V Lower: 1.0V

Upper: 0-60% changeaccording to load

D range tachometer reading 3,500 rpmThrottle position sensor output approx. 2.5V

Upper: 0%

Lower: 2.5V

ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER

Selectorlever

position

P

R

N

D

D

2

L

OverdriveShifting Engine Parking Clutch Brake

control Gear ratioswitch

gear start mechanismC 1 C2 C3 OWC B1 B2

- Neutral - Possible O

- Reverse 2.176 O O

- Neutral - Possible O

1st 2.846 O O

2nd 1.581 O OON

3rd 1.000 O O O

OD 0.685 O O

1st 2.846 O O

OFF 2nd 1.581 O O

3rd 1.000 O O O

1st 2.846 O O-

2nd 1.581 O O

- 1st 2.846 O O

4 5 - 2 2

GENERAL

SHIFT PATTERNS

Two shift patterns are pre-stored in the control unit of thistransaxle. One is the power pattern (for more powerfulperformance), and the other is the normal pattern (for improvedfuel consumption and quieter operation). (Refer to the diagrambelow.)The driver can select and switch to the desired pattern by usingthe power/economy select switch on the center console.The solid lines shown in these shift patterns indicate up-shifts,and the broken lines indicate down-shifts. The reason why thereis a difference between the shift points for up-shifts and fordown-shifts is so that up-shifts and down-shifts will not occurfrequently when driving at a speed in the vicinity of the shiftpoint.When the vehicle is stopped, there is a shift to 2nd gear in orderto obtain a suitable “creeping”, but when the accelerator pedalis then depressed the vehicle starts off is 1st gear.

4 5 - 2 3

GENERAL

POWER RANGE

NORMAL RANGE

4 5 - 2 4

GENERAL

INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS

4 5 - 2 5

GENERAL

4 5 - 2 6

GENERAL

4 5 - 2 7

GENERAL

4 5 - 2 8

GENERAL

4 5 - 2 9

GENERAL

4 5 - 3 0

GENERAL

45 -31

GENERAL

ELC AUTOMATIC TRANSAXLE-ELECTRICAL WIRING DIAGRAM

4 5 - 3 2

GENERAL

4 5 - 3 3

G E N E R A L

OIL PRESSURE TESTS

1. Completely warm up the transaxle.2. Raise the vehicle by using a jack so that the front wheels

can be rotated.3. Connect an engine tachometer and place it in a position

where it’s easy to see.4. Attach the special oil-pressure gauge 30 kg/cm2

(09452-21500) and the adaptor (09452-21001) to eachoil-pressure outlet port.When the reverse pressure is to be tested, the 30 kg/cm2

type of gauge should be used.

5. Measure the oil pressure under various conditions, andcheck to be sure that the measured results are within thestandard value range shown in the “Standard oil pressuretable” below.If the oil pressure is not within the specified range, checkand repair as described in the section “Remedial steps if oilpressure is not normal” on the next page.

Standard Oil Pressure Table

N O T E :- must be 9.8 kPa (1.4 psi) or less.SW-ON : Switch ON the overdrive control switch.SW-OFF : Switch OFF the overdrive control switch.* : Hydraulic pressure is generated, but not the standard value.

4 5 - 3 4

GENERAL

Remedial Steps If Oil Pressure Is Not Normal

Trouble symptom

1. *Line pressuresare all low (or high).NOTE*“Line pressures”refers to oil press-ures 2, 3, 4 and5 in the “Standardoil pressure table”on the previous

page.

2. Improper reducingpressure

3. Improper kick-downbrake pressure

Probable cause

a. Clogging of oil filter

b. Improper adjustment of oil pressure(line pressure) of regulator valve

c. Sticking of regulator valve

d. Looseness of valve body tightening

parte. Improper oil pump dischange pressure

a. Improper line pressure

b. Clogging of the filter (L-shaped type) ofthe reducing-pressure circuit

c. Improper adjustment of the reducingpressure

d. Sticking of the reducing valve

e. Looseness of valve body tighteningpart

a. Malfunction of the D-ring or seal ringof the sleeve or kickdown servopiston.

b. Looseness of valve body tighteningpart

c. Functional malfunction of the valvebody assembly

Remedy

a. Visually inspect the oil filter; replacethe oil filter if it is clogged.

b. Measure line pressure 2 (kickdownbrake pressure); if the pressure is notthe standard value, readjust the linepressure, or, if necessary, replace thevalve body assembly.

c. Check the operation of the regulatorvalve; repair if necessary, or replacethe valve body assembly.

d. Tighten the valve body tightening boltand installation bolt.

e. Check the side clearance of the oilpump gear; replace the oil pumpassembly if necessary.

a. Check the 2 kickdown brake pressure(line pressure); if the line pressure isnot the standard value, check asdescribed in item 1 above.

b. Disassemble the valve body assemblyand check the filter; replace the filterif it is clogged.

c. Measure the 1 reducing pressure; ifit is not the standard value, readjust,or replace the valve body assembly.

d. Check the operation of the reducingvalve; if necessary, repair it, orreplace the valve body assembly.

e. Tighten the valve body tightening boltand installation bolt.

a. Disassemble the kickdown servo andcheck whether the seal ring or D-ringis damaged.If it is cut or has scratches, replacethe seal ring or D-ring.

b. Tighten the valve body tightening boltand installation bolt.

c. Replace the valve body assembly.

4 5 - 3 5

GENERAL

Trouble symptom Probable cause Remedy

4. Improper front clutch a. Malfunction of the D-ring or seal rin a. Disassemble the kickdown servo andpressure of the sleeve or kickdown servo piston. check whether the seal ring or D-ring is

damaged.If it is cut or has scratches, replace theseal ring or D-ring.

b. Looseness of valve body tightening b. Tighten the valve body tightening boltpart and installation bolt.

c. Functional malfunction of the valve c. Replace the valve body assembly.body assembly

d. Wear of the front clutch piston or d. Disassemble the transaxle itself andretainer, or malfunction of the D-ring check whether or not there is wear ofand seal ring. the front clutch piston and retainer(Refer to the figure on the next page.) inner circumference, or damage of the

D-ring or seal ring. If there is any wearor damage, replace the piston, retainer,D-ring and/or seal ring.

5. Improper end clutch a. Malfunction of a seal rings, D-ring of a. Disassemble the end clutch and checkpressure the end clutch or O-ring 8 of the pipe the seal ring, D-ring of the piston, seal

(Refer to the following figure.) ring of the retainer, O-ring of the pipe,etc.; replace if there are cuts, scars,scratches or damage.

b. Looseness of valve body tightening b. Tighten the valve body tightening boltpart and installation bolt.

c. Functional malfunction of the valve c. Replace the valve body assembly.body assembly

6. Improper low-reverse a. O-ring between valve body and tran- a. Remove the valve body assembly andbrake pressure saxle damaged or missing check to be sure that the O-ring at the

upper surface of the upper valve body isnot missing or damaged; install orreplace the O-ring if necessary.

b. Looseness or improper tightening or b. After removing the valve body assembly,center support tightening bolt check the tightened condition of the

bolt; re-tighten it if necessary.c. Looseness of valve body tightening c. Tighten the valve body tightening bolt

part and installation bolt.d. Functional malfunction of the valve d. Replace the valve body assembly.

body assemblye. Malfunction of the D-ring 4 of the e. Disassemble the transaxle itself and

low-reverse brake piston or the O-ring check the D-ring and O-ring for damage;

3 of the retainer (Refer to the figure replace if there are cuts, scars,on the next page) scratches or damage.

4 5 - 3 6

GENERAL

Trouble symptom

7. Improper torqueconverter pressure

Probable cause Remedy

a. Sticking of the damper clutch control a. Check the operation of the dampersolenoid valve (DCCSV) or the damper clutch system and the DCCSV.

clutch control valve.b. Clogging or leaking of the oil cooler b. Repair or replace, as necessary, the

and/or piping cooler and/or piping.

c. Damaged seal ring of the input shaft c. Disassemble the transaxle itself and(Refer to the figure above.) check for damage of the seal ring;

replace the seal ring if there is damage.d. Malfunction of the torque converter d. Replace the torque converter.

4 5 - 3 7

GENERAL

CONVERTER STALL TEST

Stall test consists of determining maximum engine speedobtained at full throttle in “D” and “R” positions. This test checkstorque converter stator overrunning clutch operation, andholding ability of the transaxle clutches and the low-reversebrake.

Warning:During this test, make sure that no one stands in front of orbehind vehicle.

1. Check transaxle fluid level. Fluid should be at normaloperating temperature [70-80°C (160-180°F)]. Enginecoolant should also be at normal operating temperature[80-90°C (180-190°F)].

2. Apply chocks to both rear wheels.3. Attach engine tachometer.4. Apply parking and service brakes fully.5. Start engine.6. With selector lever in “D” position, depress accelerator pedal

fully to read engine maximum rpm. Do not hold throttle wideopen any longer than is necessary to obtain maximumengine rpm reading, and never longer than 5 seconds at atime. If more than one stall test is required, operate engineat approximately 1,000 rpm in neutral for 2 minutes to cooltransaxle fluid between test.

Stall speed : 2,200 ± 200 rpm

7. Place selector lever to “R” position and perform stall test bythe same procedure as in foregoing item.

Stall Speed Above Specification in “D”

If stall speed is higher than specification, rear clutch oroverrunning clutch of transaxle is slipping. Perform hydraulictest.

Stall Speed Above Specification in “R”

If stall speed is higher than specification, front clutch of transaxleor the low-reverse brake is slipping. Perform hydraulic test.

Stall Speed Below Specification in “D” and “R”

If stall speed is lower than specification, insufficient engineoutput or a faulty torque converter is suspected. Check for enginemisfiring, ignition timing, valve clearance etc. If these are good,torque converter is faulty.

4 5 - 3 8

GENERAL

FLUID LEAKAGE-TRANSAXLE CONVERTERHOUSING AREA

1.

2.

3.

Check for any source of leakage. Since fluid leakage at oraround the converter area may originate from engine oil leak,area should be examined closely. Transaxle factory fill fluidis dyed red and therefore, can be distinguished from engineoil.Prior to removing transaxle, perform following checks: Whenleakage is determined to originate from transaxle, check thefluid level prior to removal of transaxle and torque converter.High oil level can result in oil leakage out of vent locatedin top of oil pump. If fluid level is high, adjust to proper leveland recheck for leakage.After completing these steps, recheck once more for leakage.

4 5 - 3 9

GENERAL

E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL- COMPONENTS LAYOUT

LIST OF CONTROL COMPONENTS

Name Symbol

E.L.C. 4-speed automatic transaxlecontrol unit

D

M.P.I. control unit C

Pulse generator A B

Pulse generator B B

Self diagnosis check connector G

Solenoid A

Throttle position sensor E

Oil temperature sensor F

GENERAL

45 -41

GENERAL

SERVlCE ADJUSTMENT PROCEDURES

INSPECTION OF TRANSAXLE FLUID QUANTITY

1.

2.

3.

4.

5.

6.

Place vehicle on level floor.Before removing dipstick, wipe all dirt from area arounddipstick.With selector lever in “P” park and parking brakes applied,start engine.Engine should be running at idle speed.Transaxle should be sufficiently warmed up [fluid temper-ature 70-80°C (160-180°F)].Move selector lever sequentially to every position to filltorque converter and hydraulic circuit with fluid, then placelever in “N” Neutral position.Check to see if fluid level is in “HOT” range on dipstick. Iffluid level is low, add automatic transaxle fluid until levelreaches “HOT” range.

Transaxle fluid :DIAMOND ATF DEXRON, APOLLOIL ATF D-II, GENUINEHYUNDAl ATF AUTOMATIC TRANSAXLE FLUID ORMOPAR ATF PLUS TYPE 7176

Low fluid level can cause a variety of conditions because itallows pump to take in air along with fluid. Air trapped inhydraulic circuit forms bubbles which make fluid spongy.Therefore, pressures will be erratic, causing delayed shift,slippy clutch and brakes, etc.Improper filling can also raise fluid level too high. Whentransaxle has too much fluid, gears churn up foam and causethe same conditions which occur with low fluid level,resulting in accelerated deterioration of automatic transaxlefluid.In either case, air bubbles can cause overheating, fluidoxidation, and varnishing, which can interfere with normalvalve, clutch, and servo operation.Foaming can also result in fluid escaping from transaxle ventwhere it may be mistaken for a leak. Along with fluid level,it is necessary to check conditions of fluid. When fluid smellsburned, indicating contamination with metal bushing orfriction material particles, a complete transaxle overhaul isneeded. Be sure to examine fluid on dipstick closely. If thereis any doubt about its condition, drain out sample for doublecheck. After fluid has been checked, seat dipstick fully to sealout water and dirt.

REPLACEMENT OF TRANSAXLE FLUID

Refer to LUBRICATION AND MAINTENANCE PART.

4 5 - 4 2

GENERAL

INHIBITOR SWITCH AND CONTROLCABLE ADJUSTMENT

1. Place selector lever in “N” (Neutral) position.2. Loosen control cable to manual control lever coupling

adjusting nuts (2 pcs.) to set cable and lever free.3. Place manual control lever in “N” (Neutral) position.

4. Turn inhibitor switch body until 12 mm (0.47 in.) wide endof manual control lever aligns with switch body flange [12mm (0.47 in.) wide portion]. Or turn switch body until 5 mm(0.20 in.) hole in manual control lever aligns with 5 mm (0.20in.) hole in switch body.

5. Tighten attaching bolts (2 pcs.) carefully so that switch bodyis not displaced.

6. Make sure that selector lever is in “N” (Neutral) position.7. Remove slackness of control cable by adjusting nut and then

check that selector lever moves smoothly.8. Check that control cable has been adjusted correctly.

GENERAL

ADJUSTMENT OF KICKDOWN SERVO

1.

2.3.4.

5.

6.

7.

8.

Completely remove all dirt and other materials adheredaround the kickdown servo cover.Remove the kickdown servo switch.Remove the snap ring and cover.Loosen the lock nut.

While holding with special tool (09454-33000) so that thekickdown servo piston won’t turn, use special tool(09454-33100) to “tighten”, at 9.8 Nm (100 kg.cm, 7.2Ib.ft), and “return” the adjustment screw two times each, andthen tighten at a torque of 4.9 Nm (50 kg.cm, 3.6 Ib.ft). Thenreturn the adjustment screw 2 to 2-1/4 turns.While holding with special tool (09454-33000) so that thekickdown servo piston won’t turn, tighten the lock nut to thespecified torque.

Lock nut : 26-32 Nm (255-326 kg.cm, 18-23 Ib.ft)

After fitting a new D-ring in the groove around the cover,install the cover to the case so that the D-ring won’t betwisted, and then install the snap ring.Install the kickdown servo switch to the cover.

Kickdown servo switch screw:1.0-1.4 Nm (10.2-14.3 kg.cm, 0.7-1.0 Ib.ft)

ADJUSTMENT OF LINE PRESSURE

1. Drain out the ATF.2. Remove the oil pan.3. Remove the oil filter and oil temperature sensor.4. Remove the valve body assembly. The manual valve can

come out, so be careful not to drop it.5. Turn the adjustment screw of the regulator valve and adjust

so that the line pressure (kickdown brake pressure) becomesthe standard value.

4 5 - 4 4

G E N E R A L

When the adjustment screw is turned to the right, the linepressure becomes lower; when it is turned to the left, itbecomes higher.

Standard value: 870-890 kPa (124-126 psi, 8.9-9.1kg/cm*)Oil pressure change for each turn of adjustment screw :38 kPa (4.6 psi, 0.39 kg/cm2)

6. Check to be sure that the O-ring is installed on the uppersurface of the valve body at the place shown in the figure.

7. Replace the O-ring of the solenoid valve connector with anew one.

8. Install the valve body assembly to the case and then insertthe solenoid valve connector into the case. Be sure, at thistime, that the notched part of the connector faces as shownin the figure.Also be careful that the lead wiring isn’t caught.

9. Tighten valve body assembly mounting bolts (10 pieces) to10-12 Nm (100-120 kg.cm, 7.5-8.5 Ib.ft).

A bolt : 20 mm (0.787 in.) longB bolt : 28 mm (1.102 in.) longC bolt : 45 mm (1.772 in.) long

10. Install the oil filter.11. Install a new oil pan gasket and oil pan, and tighten the 2

bolts.12. Pour in the specified amount of ATF.13. Make the oil pressure test. Readjust if necessary.

ADJUSTMENT OF REDUCING PRESSURE

1. Remove parts up to the oil filter in the same way as foradjustment of the line pressure. The valve body need not beremoved.

2. Turn the adjustment screw of the lower valve body andadjust so that the reducing pressure is the standard value.When the adjustment screw is turned to the right, thereducing pressure becomes lower; when it is turned to theleft, it becomes higher.

GENERAL

Standard value : 425 ± 10 kPa (60 ± 1 psi, 4.3 ± 1kg/cm2)Oil pressure change for each turn of adjustment screw :30 kPa (4.3 psi, 0.3 kg/cm2)

3. Install the oil filter and oil pan in the same way as foradjustment of the line pressure.

4. Make the oil pressure test. Readjust if necessary.

ADJUSTMENT OF THROTTLE-POSITIONSENSOR (TPS)

Refer to FUEL SYSTEM-Service Adjustment Procedures.

REPLACEMENT OF DRIVESHAFT OILSEALS

1. Disconnect the drive shaft from the transaxle.(Refer to FRONT SUSPENSION-Drive Shaft)

2. Using a flat-tip (-) screwdriver, remove the oil seal.

4 5 - 4 6

GENERAL

4. Apply a coating of the transaxle fluid to the lip of the oil seal.

Transaxle fluid : Automatic transaxle fluid DEXRON II type

3. Using the special tool (09431-21200), tap the drive shaftoil seal into the transaxle.

REPLACEMENT OF SPEEDOMETER CABLE

1. Replace the cable assembly if there is a malfunction.2. When connecting the cable to the meter, insert the cable

until its stopper properly fits to the meter side groove.

3. Install the grommet so that, as shown in the illustration, thecable attachment part and the projecting part are horizontal.

CAUTIONThe cable arrangement should be made so that the radiusof cable bends is 150 mm (5.9 in.) or more.

4.4.

At the transaxle end of the speedometer cable, the key jointAt the transaxle end of the speedometer cable, the key jointshould be inserted into the transaxle, and the nut should beshould be inserted into the transaxle, and the nut should besecurely tightened.securely tightened.

CAUTIONCAUTIONIf the cable is not correctly and securely connected, it mayIf the cable is not correctly and securely connected, it maycause incorrect indication by the speedometer, orcause incorrect indication by the speedometer, orabnormal noise. Be sure the connect it correctly.abnormal noise. Be sure the connect it correctly.

GENERAL

ACCELERATOR SWITCH CHECK ANDADJUSTMENT

1. After warming up the engine, confirm that the acceleratorswitch is on with the accelerator pedal in the free state.

NOTECheck that the accelerator switch is on or off by checkingthe voltage between the G wire and the ground wire atthe accelerator switch connector (2-pin).

When the accelerator switch is ON : 0 VWhen the accelerator switch is OFF : 12 V

2. Measure stroke B, shown in the illustration of theaccelerator pedal, at the point when the accelerator switchgoes from ON to OFF when the pedal is depressed.

Standard value : 4-8 mm (0.18-0.31 in.)

3. If the figured stroke B deviates from the standard value,adjust it by the adjusting bolt.

TP

0.5G (L) 0.5GR (E)

OFF (FREE)

ON (PUSH)

CRUISE EXCEPT

4 5 - 4 8

TRANSAXLE CONTROL

TRANSAXLE CONTROL

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

4 5 - 4 9

TRANSAXLE CONTROL

REMOVAL

1. Remove the console box assembly. (Refer to Body Group).2. Remove the selector knob installation screws.3. Disconnect the overdrive switch connector and then remove

the selector knob.’

4. Remove the indicator panel, slider.5. Disconnect the position indicator light connector.6. Remove the indicator panel lower.

7. Remove the snap ring, cable end pin, nut.

8. Remove the cable mounting bolt.

4 5 - 5 0

TRANSAXLE CONTROL

9. Remove the air cleaner assembly.10. Remove the clip, cotter pin, adjusting nut.

INSPECTION

1. Check the control cable for function and for damage.2. Check the bushing for wear or damage.3. Check the spring for damage or deterioration.4. Check the overdrive switch for continuity.

Terminal 1 2 3Switch position (0.3-RW)* (0.3-LR)* (0.3-SW)*

Overdrive activation

Overdrive non-activation

NOTE

*Color code Color of wire *Color code Color of wire

R Red B Black

W White L Blue

4 5 - 5 1

TRANSAXLE CONTROL

5. Check the P/N switch for continuity

INSTALLATION

1. Apply a coating of the specified grease to the interior of thebushing.

Specified grease : Chassis grease SAE J310, NLGI No. 0

2. Move the shift lever and the inhibitor switch to the “N”position, and install the control cable.

4 5 - 5 2

TRANSAXLE CONTROL

3. When connecting the control cable to the transaxle mountingbracket, install the clip until it contacts the control cable, inposition switch in the figure.

4. Install the cable mounting bolt.5. Install the air cleaner assembly.

6. Install the nut, cable end pin, snap ring.

7. Connect the position indicator light connector.8. Install the indicator panel, slider, indicator panel lower.

9. Apply the specified grease at the places shown in the figure.

Specified grease : Multipurpose grease SAE J310 NLGINo. 2

TRANSAXLE CONTROL

10. Place the shift lever in the “N” position, and then turn thesleeve so that the clearance between the sleeve and thelever assembly end in within the standard value.

Standard value (A) : 15.2-15.9 mm (0.598-0.625 in.)

NOTEBe sure to face B of the adjusting cam to the push button(driver’s side).

11. Install the selector knob.12. Install the console box. (Refer to BODY GROUP).

ADJUSTMENT OF CONTROL CABLE

1. Eliminate slack from the control cable with the adjustingflange nut and check that the select lever operates smoothly.

2. Driving the car, check that the transaxle is set in the properrange when the select lever is shifted to each position.

4 5 - 5 4

AUTOMATIC TRANSAXLE SHIFT LOCK CONTROL SYSTEM

SPECIFICATIONS

I tems

Electronic control unitRated voltageOperating voltage rangeOperating temperature rangeRated Load

SolenoidRated voltageRated currentOperating voltage rangeOperating temperature rangeInitial pushing forceStroke

Specification

DC 12VDC 9 - 16 V-30°C - +80°CMAX. 2A (A/T solenoid)

DC 12VMAX. 2ADC 9 - 16V- 3 0 - + 8 0 ° C1.2 at 10V 20°C9 ± 1 mm

COMPONENTS

NOTEAutomatic transaxle shift lock control system is applied from the production of July 1, 1989.

4 5 - 5 5

AUTOMATIC TRANSAXLE SHIFT LOCK CONTROL SYSTEM

CIRCUIT DIAGRAM

4 5 - 5 6

SHIFT LEVER ASSEMBLY


COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

INSPECTION

o Check the detent place for wear.o Check the bushing for wear or damage.o Check the spring for damage or deterioration.o Check the pin at the end of rod assembly for wear.

ASSEMBLY

1. Apply a coating of grease to the sliding part of the bushing.

Specified grease : Chassis grease SAE J310, NLGI No. 0

4 5 - 5 7


2. Apply the specified grease at the places shown in the figure.

Specified grease: Multipurpose grease SAE J310,NLGI No. 2

4 5 - 5 8

AUTOMATIC TRANSAXLE

AUTOMATIC TRANSAXLE

COMPONENTS

A

BCDEFG

Nm Kg.cm Ib.ft O.D. x Length mm (in.) Bold identification

4 3 - 5 5 4 3 0 - 5 5 0 3 1 4 0 7 10 x 40 (1.6) 7 A x B4 3 - 5 5 4 3 0 - 5 5 0 3 1 4 0 7 10 x 65 (2.6)2 2 - 3 2 2 2 0 - 3 2 0 1 6 - 2 3 7 10 x 55 (2.2)3 0 - 3 5 3 0 0 - 3 5 0 2 2 - 2 5 10 10 x 60 (2.4)1 0 - 1 2 1 0 0 - 1 2 0 7 - 9 7 8 x 14 (0.6)1 5 - 2 2 1 5 0 - 2 2 0 1 1 - 1 6 7 8 x 20 (0.8)3 5 4 2 3 5 0 - 4 2 0 2 5 - 3 0

4 5 - 5 9

AUTOMATIC TRANSAXLE

REMOVAL

1. Remove the drain plug and drain out the transaxle oil.2. Remove the air cleaner assembly.

3. Remove the control cable.4. Remove the speedometer cable.

5. Disconnect the pulse generator connector, inhibitor switchconnector, kickdown servo switch connector, solenoidconnector.

6.7.

Remove the starter motor.Remove the stabilizer bar, tie rod end, lower arm ball joint,drive shaft under cover.(Refer to drive shaft and front axle).

4 5 - 6 0

AUTOMATIC TRANSAXLE

8. Remove the bell housing.

9. Remove the special bolts.1) Remove the three special bolts connecting the converter

to the drive plate.

NOTETo remove the special bolts of torque converter, turnengine crankshaft with a box wrench to bring one ofthe bolts to the position appropriate for removal. Afterremoving the bolt, turn the crankshaft in the samemanner as above and remove all remaining bolts oneafter another.

2) After removing the special bolts, push the torqueconverter toward the transaxle so that it does not remainon the engine side.

10. Disconnect the oil cooler hose.

11. Remove the caps and bolts.

4 5 - 6 1

AUTOMATIC TRANSAXLE

12. Remove the transaxle assembly.

4 5 - 6 2

AUTOMATIC TRANSAXLE OIL COOLER ASSEMBLY

AUTOMATIC TRANSAXLE OIL COOLER ASSEMBLY

COMPONENTS

REMOVAL AND INSTALLATION

1. Remove the battery assembly and air cleaner assembly.2. Remove the front bumper assembly.3. Disconnect the automatic transaxle oil cooler hoses from the

automatic transaxle.

CAUTIONPlug the ends of the oil cooler hoses and the automatictransaxle port to prevent the transaxle fluid from spillingout and foreign material from getting in.Plug the nipple at the automatic transaxle in order toprevent entrance of foreign material into the automatictransaxle.

NOTEWhen removing each part, avoid spilling the transaxlefluid.

3. Installation is the reverse of removal.

4 5 - 6 3

AUTOMATIC TRANSAXLE ASSEMBLY

DISASSEMBLY

CautionBecause the automatic transaxle is composed of componentparts of an especially high degree of precision, these partsshould be very carefully handled during disassembly andassembly so as not to scar or scratch them.A rubber mat should be placed on the workbench, and itshould always be kept clean.During disassembly, cloth gloves or rags should not be used.If such items must be used, use articles made of nylon, or usepaper towels.All disassembled parts must be thoroughly cleaned. Metalparts may be cleaned with ordinary detergents, bet must bethoroughly air dried.Clean the clutch disc, resin thrust plate and rubber parts byusing ATF (automatic transmission fluid), being very carefulthat dust, dirt, etc. do not adhere.If the transaxle main unit is damaged, also disassemble andclean the cooler system.

1. Clean away any sand, mud, etc. adhered around thetransaxle.

2. Place the transaxle assembly on the workbench with the oilpan down.

3. Remove the torque converter.4. Measuring input shaft end play before disassembly will

usually indicate when a thrust washer change is required(except when major parts are replaced). Thrust washers arelocated between reaction shaft support and rear clutchretainer, and between reaction shaft support and front clutchretainer.Mount a dial indicator to converter housing with the DialIndicator Support Make sure that the indicator plunger isseated against end of input shaft.When checking end play, pull out or push in the input shaftwith pliers. Be careful not to scratch the input shaft. Recordindicator reading for reference when reassembling transaxle.

5. Remove the pulse generator “A” and “B”.

4 5 - 6 4


6. Remove manual control lever, then remove inhibitor switch.

7. Remove snap ring then remove kickdown servo switch.

8. Remove the oil pan and gasket.

9. Remove the oil filter from the valve body.

4 5 - 6 5


10. Remove the oil-temperature sensor installation bolt; then,after removal from the bracket, pull out from the connectorside.

11. Press the tabs of the solenoid valve harness grommet, andthen push into the case and remove the ELC connector.

12. Remove 10 bolts and remove valve body.

13. Remove the end clutch cover mounting bolt the cover holder,and the end clutch cover.

4 5 - 6 6


14. Remove the end clutch assembly.

15. Remove the thrust plate.

16. Remove the end clutch hub and thrust bearing.

17. Pull out the end clutch shaft.

4 5 - 6 7


18. Remove 13 bolts and remove converter housing.

19. Remove six oil pump mounting bolts. Screw special tool(09452-33100) into two oil pump removing holes in oilpump housing. Turn both removers simultaneously anduniformly to remove oil pump assembly.Oil pump may sometimes tilt to A side, because straight lineconnecting oil pump removing holes does not pass center ofpump. If this is the case, tap oil pump lightly on B side ortilt removers to B side as pump is removed.

20. Remove the oil pump gasket and adapter.

21. Remove the spacer and the differential assembly.

22. Remove the fiber thrust washer.

4 5 - 6 8


23. Pull up the input shaft, and then remove the front clutchassembly and the rear clutch assembly together.

24. Remove the thrust bearing.

25. Remove the clutch hub.

26. Remove the thrust race and bearing.

4 5 - 6 9


27. Remove the kickdown drum.

28. Remove the kickdown band.

29. Using special tools (09222-21001, 09456-21100), push inthe kickdown servo and remove the snap ring.

30. Remove the kickdown servo piston and spring.

4 5 - 7 0


31. Remove the anchor rod.

32. Remove the snap ring.

33. Attach special tool (09453-33310) on center support.Holding handle of tool, pull center support straight upward.

34. Remove reverse sun gear and forward sun gear together.

35. Remove planet carrier assembly and thrust bearing.


36. Remove the wave spring, return spring, reaction plate, brakedisc, and brake plate.

37. Since screw lock paste is coated on the bolt threads, tap thebolt head for easier removal.

38. Using an impact driver, loosen the bolt.

4 5 - 7 2


If an impact driver is not available, use a punch or somethingsimilar.

39. Remove the transfer shaft cover.

40. Stand the transfer shaft lock nut rotation stopper up.

41. Fax the transfer shaft converter housing side.


42.

43. Knock off the transfer shaft to the converter housing side.

Remove the locking nut.

NOTEThe lock nut is left-hand threaded.

44. Using a screwdriver, remove the outer race.

45. Remove idler shaft lock plate.

4 5 - 7 4


46. Loosen transfer idler shaft with special tool.

47. Pull out transfer idler shaft. Remove transfer idle gearbearing inner races (2 pieces) from inside of case.

48. Remove the spacer.

49. Remove snap ring from bearing.


50. Remove internal gear, output flange, transfer drive gear andbearing as assembly from case.

51. Remove two bolts and parking sprag rod.

52. Remove the set screw and the manual control shaftassembly. Remove the steel ball, the seat and the springtogether at this time.

4 5 - 7 6


REASSEMBLY

CautionDo not reuse gaskets, oil seals and rubber parts. Replace themwith new ones at every reassembly. O-ring of oil level dipstickneed not be replaced.Do not use grease other than petrolatum or industrial vaseline.Apply automatic transaxle fluid to friction element, rotatingparts, and sliding parts before installation. Use “DEXRON c”type automatic transaxle fluid. New clutch disc should beimmersed in automatic transaxle fluid for more than two hoursbefore installation.Do not apply sealer or adhesive to gaskets.When bushing must be replaced, replace assembly whichincludes it.Do not use shop towels during disassembly and reassemblyoperation.The oil in the cooler should also be replace.

1. Before assembly of the transaxle, measure the end play ofthe low-reverse brake, and select a pressure plate to theused so that the end play will be the standard value.

1) Install the brake reaction plate, brake plate and brakedisc to the transaxle case.

CautionIf new brake discs are used, be sure to immerse themin ATF for two hours or longer.

2) Install the appropriate pressure plate and then install thereturn spring.

CautionBe sure that the return spring is installed so that itfaces in correct direction.

4 5 - 7 7


3)

4) Install the special tool (09453-33100) to the centersupport.

5) Install the snap ring.

6) Install the special tools (09453-21400, 09453-33000)and a dial gauge at the rear side of the transaxle case.

CautionInstall the dial gauge so that it contacts the brakereaction plate at a right angle from the transfer idlershaft hole.

4 5 - 7 8


7) Using a manual pump, pump air in from the positionshown in the illustration; then read the indication of thedial gauge, and select the pressure plate that will providethe standard value.

Standard value : 0.975-1.287 mm.

2. Using the special tools (09500-11000, 09532-11500), tapin the bearing outer race.

3. Insert manual control shaft into transaxle case and push itfully toward manual control lever.At this time, do not install O-ring (larger one of two O-rings)on manual control shaft.

NOTEIf installed before inserting shaft, the O-ring will interfacewith shaft set screw hole.

4. After installing new O-ring on manual control shaft, drawshaft back into case, then install set screw and gasket. Alsoinstall detent steel ball, seat and spring at the same time.

4 5 - 7 9


5. Install parking sprag rod to detent plate (manual controlshaft).Install sprag rod support and tighten two bolts.

Sprag rod support bolts :20-27 Nm (200-270 kg .cm, 15-19 Ib . f t )

6. Insert an assembly of the annular gear, output flange,transfer drive gear and bearing into the case.

7. Install snap ring on output flange rear bearing.

8. Coat petroleum jelly on the spacer and attach it to thetransaxle case.

4 5 - 8 0


9. Install two taper roller bearings and spacer to transfer idlegear.

10. Place the transfer idler gear (assembled in the precedingsection) into the case, and then insert the idler shaft fromthe outer side of the case and screw it in.

11. Tighten the idler shaft by using special tool (09454-21100).

12. Insert special tool (09458-33000) into output flange andmeasure preload using a low reading torque wrench.Adjust preload by tightening or loosening transfer idler shaft.

Preload: 1.5 Nm (15 kg.cm, 10 Ib.ft)

4 5 - 8 1


13. After the preload adjustment is completed, eliminate thebacklash between the idler shaft and the lock plate bymoving the idler shaft in the loosening direction. Attach thelock plate and tighten the lock plate bolt.

Lock plate bolt :38-60 Nm (480-600 kg .cm, 35-43 Ib . f t )

14. Press-fit the bearing inner race to the transfer driven gearand press-fit the bearing outer race to the transaxle endclutch side.

15. Press-fit the bearing inner race to the transfer shaft, andpress-fit the bearing outer race to the transaxle caseconverter housing side.

16. Attach the transfer shaft to the transaxle case.

4 5 - 8 2


17. Install the special tool (09455-21301) to the transaxle caseto support the transfer shaft.

18. Insert the thickest 1.80 mm (.0709 in.) spacer.

19. Attach the transfer driven gear.

20. After removing the special tool, affix the converter housingside of the transfer shaft.

4 5 - 8 3


21. Tighten the lock nut to the specified torque.

Transfer lock nut :200-230 Nm (2000-2300 kg .cm, 145-166 Ib . f t )

22. After installing the special tool, measure the end play of thetransfer shaft; then select the spacer(s) needed to obtain thestandard value, and refit.

Transfer shaft end play : 0-0.025 mm (0-0.0010 in.)

23. Using a punch, lock the lock nut to prevent rotation.24. Attach the transfer cover.

25. Install bearing retainer, and tighten screws to specifiedtorque, apply a 5 mm (0.2 in.) width of sealant (3M StudLocking No. 4176) the top. Sealant should not stick out ofscrew head.

Screw : 17-22 Nm (170-220 kg .cm, 13-15 Ib . f t )

26. Using a punch, lock the flush head screw to prevent rotation.

4 5 - 8 4


Identification of thrust bearings, thrust races and thrust washers Unit: mm (in.)

4 5 - 8 5


27. Apply a coating of petrolatum to thrust bearing #12 andattach to the planetary carrier.

28. install the planetary carrier to the case.

29. Assemble the reverse sun gear and the forward sun gearin the following order:1) Attach the seal ring and the snap ring to the reverse sun

gear. When attaching, squeeze the seal ring as shownin the figure.

2) Attach the thrust race ##9 to the forward sun gear.3) Attach the thrust race #10 to the forward sun gear.

4) Assemble the reverse sun gear and the forward sungear.

4 5 - 8 5


30. Install both of the previously assembled sun gears inside theplanetary carrier.

31. Install the brake disc and brake plate.

32. Install the selected brake pressure plate.

33. Install the return spring.

4 5 - 8 7


34. Apply a coating of petrolatum to the wave spring and attachit to the center support.

35. Install two new O-rings to the center support.

36. After applying a coating of ATF to the O-rings, install thespecial tool (09453-33310) to the center support, andinstall within the case.

CautionBe sure that the wave spring is not out of position.

37. Install the snap ring.

CautionThe mating hole of the snap ring must be aligned with theinstallation hole of pulse generator A.

4 5 - 8 8


38. Install the anchor rod.

39. Assemble a new seal ring (large diameter) and D-ring (smalldiameter) to the kickdown servo piston, and install a newO-ring in the groove around the sleeve; then assemble thekickdown servo spring, piston and sleeve in the transaxlecase.

40. Press the kickdown servo and sleeve in by using special tools(09222-21001, 09456-21100), and then install the snapring.

41. Install kickdown band; attach the ends of band to the endsof anchor rod and servo piston rod..

4 5 - 8 9


42. Install kickdown drum with its splines in mesh with sungear. Place kickdown band on kickdown drum and tightenkickdown servo adjusting screw to keep band in position.

43. Apply a coating of petrolatum to thrust bearing #8, and thenattach to the kickdown drum.

44. Apply a coating of petrolatum to thrust race #7, and thenattach to the rear clutch hub.

45. Install clutch hub to sun gear splines.

4 5 - 9 0


46. Attach thrust bearing #6 onto the hub with petrolatum.

47. Apply a coating of petrolatum to thrust washer #2 and thrustbearing #4, and then attach to the rear clutch assembly.

48. Combine the rear clutch assembly and the front clutchassembly.

49. Install the clutch assembly.


50. Install the differential assembly.

51. If end play which was measured and recorded atdisassembly is not standard value, adjust end play tospecification by selecting thrust washer #1.

Standard value : 0.3-1.0 mm (0.012-0.040 in.)

When thrust race is replaced with that of different thickness,replace also thrust race #3 located between oil pump andfront clutch with washer of proper thickness correspondingto thrust race.Find correct pair of thrust races (metal) and thrust washers(fiber) from following table.

Thrust washer #1 (metal) Thrust race #3 (fiber)

Thickness mm (in.) Thickness mm (in.)

1.4 (0.055) 1.0 (0.039)1.4 (0.055) 1.2 (0.047)1.8 (0.071) 1.4 (0.055)1.8 (0.071) 1.6 (0.063)2.2 (0.087) 1.8 (0.071)2.2 (0.087) 2.0 (0.079)2.6 (0.102) 2.2 (0.087)2.6 (0.102) 2.4 (0.095)

Example:When thick thrust race is selected, thrust washer is one to bepaired with it.

52. Attach the reused thrust washer #1, or the one selected instep 51 to the front clutch by using petrolatum.

4 5 - 9 2


53. Install special tool (09452-21401) to the case.

54. Attach the reused thrust race #3 or the one selected in step51 to the oil pump by using petrolatum.

55. Install new oil pump gasket and the oil pump assembly.

56.

57.

Install new O-ring in groove of oil pump housing and applyautomatic transaxle fluid lightly to outside surface of O-ring.Install oil pump assembly by tightening six bolts evenly.When installing this oil pump assembly, be careful thatthrust washer will not drop.


58. Check input shaft end play. Readjust if necessary (see step


59. Apply solder [length approx. 10 mm (0.40 in.) and diameter3 mm (0.118 in.)] to the differential assembly at the locationsshown in the illustration.

60. Install new case gasket to transaxle case.61. Install converter housing and tightening 14 bolts to 19-23

Nm (490-230 kg.cm, 14-16 lb.ft).

62. Remove the converter housing and gasket.63. Remove the crushed solder from outer race of differential

bearing.64. Measure the thickness of the crushed solder micrometer and

select and install a spacer of thickness that gives standardpreload.


4 5 - 9 4


65. Apply silicone grease to hatched area of transaxle case.66. Install new case gasket on transaxle case.

67. Install converter housing and tighten 14 bolts to 19-23 Nm(190-230 kg.cm, 14-16 Ib.ft).

68. Install end clutch shaft. Be sure to install the longest springtoward the front as shown.

69. Fit the thrust washer to the return spring at the end clutchside.


70. Install the end clutch hub to end clutch.

71. Attach, by petrolatum, thrust bearing #13 to the end clutchhub.

72. Install end clutch assembly.

73. Attach a new O-ring and D-ring to the end clutch cover.

Caution1. Install so that the D-ring is not twisted.2. Apply a sufficient amount of automatic transmission

fluid to the bearing.

4 5 - 9 6


74. Attach the end cover and fasten it with four bolts.

CautionWhen installing the end cover, be sure the screw hole iscorrectly aligned. If the end cover is turned (after it isinstalled) in order to align with the screw hole, the O-ringand/or the D-ring may be twisted as a result.

75. Install O-ring at center of top of valve body assembly (brakeoil pressure passage).

76. Install valve body assembly to case, fitting detent plate(manual control shaft) pin in slot of manual valve.

figure.

79. Tighten valve body assembly mounting bolts (10 pieces) to10-12 Nm (100-120 kg.cm, 7.5-8.5 Ib.ft)A : 18 mm (0.709 in.) longB : 25 mm (0.984 in.) longC : 40 mm (1.575 in.) long

77. Replace the O-ring of the solenoid valve connector with anew one.

78. Insert the solenoid valve connector into the case. Be surethat the notched part of the connector faces as shown in the


80. Install oil filter. Tighten four oil filter mounting bolts to 5-7Nm (50-70 kg.cm, 4-5 Ib.ft).

81. Install five magnets in the five depressions provided on theoil pan.

82. Install new oil pan gasket and oil pan by tightening 12 boltsto 10-12 Nm (100-120 kg.cm, 7.5-8.5 Ib.ft).

83. Install a new D-ring to the kickdown servo switch; then pressinto the case and secure it by using a snap ring.

4 5 - 9 8


84. Install inhibitor switch and manual lever.Adjust inhibitor switch.

85. Install the pulse generator A and B.

86. After applying automatic transaxle fluid to outside surfaceof oil pump-side cylindrical portion of torque converter, installtorque converter carefully so as not to damage oil seal lip.Make certain that torque converter is in mesh with oil pumpdrive gear.Measure distance between ring gear end and converterhousing end. Torque converter has been properly installedwhen measurement is about 12 mm (0.47 in.).

4 5 - 9 9

OIL PUMP ASSEMBLY

OIL PUMP ASSEMBLY

COMPONENTS

DISASSEMBLY

1. Remove O-ring from oil pump housing.2. Remove five bolts and remove reaction shaft support from

housing.3. Remove oil pump drive and driven gears from pump housing.4. Make reassembly alignment marks on drive and driven gear.5. Remove steel ball from housing.

6. Remove the snap ring and the oil seal from the oil pumpdrive gear.

4 5 - 1 0 0

OIL PUMP ASSEMBLY

7. Remove two seal rings from reaction shaft support.

INSPECTION

1. Measure the side clearance of the oil pump gear; if theclearance exceeds the standard value, or if an inspection ofthe surface (of the oil pump housing) that contacts the oilpump gear reveals indications of interference, replace theentire oil pump assembly.

Standard value: 0.03-0.05 mm (0.0012-0020 in.)

2. Check the surface of the reaction shaft support that contactsthe oil pump gear; if there are indications of interference,replace the entire oil pump assembly.

REASSEMBLY

1. Install the oil seal to the oil pump drive gear.

2. Install the snap ring.

OIL PUMP ASSEMBLY

3. After immersing drive and driven gears in automatictransaxle fluid, install them to pump housing. When reusinggears, install with mating marks properly aligned.

4. Fit a new O-ring into the groove at the inner circumferenceof the drive gear.

5. Install steel ball in hole as shown in the illustration.

6. Install two seal rings coated with automatic transaxle fluidto reaction shaft support.

7. Make sure that oil pump gear turns freely.8. Install new O-ring in groove provided in circumference of

pump housing and apply petrolatum or industrial vaseline tocircumference of O-ring.

9. Loosely install reaction shaft support on pump housing.Tighten five bolts fingertight.

10. With reaction shaft support properly positioned on pumphousing using special tools (08452-21301, 09452-21401)tighten five bolts to 10-12 Nm (100-120 kg.cm, 7.5-8.5Ib.ft).

4 5 - 1 0 2

OIL PUMP ASSEMBLY

OIL SEAL REPLACEMENT

1. Pry off pump housing oil seal using a screwdriver.

2. Using special tool (09452-21200) install oil seal to pumphousing. Apply thin coat of automatic transaxle fluid to oilseal lip before installation.

4 5 - 1 0 3

FRONT CLUTCH ASSEMBLY


COMPONENTS

4 5 - 1 0 4


DISASSEMBLY

1.2.

3.

4.5.

Remove snap ring from clutch retainer.Take out four clutch reaction plates and three clutch discs.If the clutch reaction plates and the clutch discs are to bereused, be sure not to change the installation order ordirection.With return spring compressed with special tool(09453-24000), remove snap ring, then spring retainer andreturn spring.Remove piston from retainer.Remove the D-section rings from the inner and outercircumferences of the piston.

REASSEMBLY

1. Install D-section ring in groove in outside surface of pistonwith its round side out. Install another D-section ring to frontclutch retainer.

2. Apply automatic transaxle fluid to outside surface ofD-section rings, then push piston into front clutch retainerby hand.

3. Install return spring and spring retainer.4. Compress return spring with special tool (09453-24000)

and install snap ring.

5. Install four clutch reaction plates and three clutch discs.Prior to installation, apply automatic transaxle fluid to them.

CautionWhen new clutch discs are used, they should be immersedin automatic transaxle fluid for more than two hoursbefore installation.

SHIFT LEVER- ASSEMBLY

6. After installing snap ring, check to see if there is a 0.7-0.9mm (0.028-0.035 in.) clearance between snap ring andclutch reaction plate.To check clearance, hold entire circumference of clutchreaction plate down with 50 N (11 lb.) force. If clearance isout of specification, adjust clearance by selecting proper snapring.

4 5 - 1 0 6

REAR CLUTCH ASSEMBLY


COMPONENTS


DISASSEMBLY

1. Remove snap ring and then remove thrust race.2. Remove the input shaft from the rear clutch retainer.3. Remove snap ring from clutch retainer.4. Remove the clutch reaction plate, two clutch plates, three

clutch discs and clutch pressure plate from retainer.

5. Compress the return spring by using the special tool(09453-21100).

6. Using screwdriver, remove wave spring.7. Remove return spring and piston.8. Remove the two D-section rings from the piston.

1.

2.

3.4.

5.

Install D-section rings in grooves in outside and insidesurfaces of piston.After applying automatic transaxle fluid to outside surface ofD-section rings, push piston into rear clutch retainer byhand.Install return spring on piston.Compress return spring with snap ring, by pushing downwith a screwdriver and setting snap ring in its groove.

Install clutch pressure plate, three clutch discs, two clutchplates and clutch reaction plate to rear clutch retainer. Whenreaction plate, clutch plate and clutch disc are removed,reinstall them by reversing order of disassembly. Prior toinstalling, apply automatic transaxle fluid to plates and discs.

CautionWhen new clutch discs are used, immerse them inautomatic transaxle fluid for more than two hours beforeinstallation.

4 5 - 1 0 8


6. Install snap ring. Check to see that clearance between snapring and clutch reaction plate is 0.4-0.6 mm (0.016-0.024in.). To check clearance, hold entire circumference of clutchreaction plate down with 50 N (11 lb.) force. If clearance isout of specification, adjust clearance by selecting a propersnap ring. Snap rings are common to those for front clutch.

7. Insert the input shaft into the clutch retainer.

8. Install thrust race, then snap ring.9. Install the three seal rings to the grooves in the input shaft.

4 5 - 1 0 9

END CLUTCH ASSEMBLY

END CLUTCH ASSEMBLY

COMPONENTS

DISASSEMBLY

1. Remove the snap ring by using snap-ring pliers, and thenremove the washer and return spring.

2. Remove the snap ring, and then remove the clutch reactionplate, the clutch disc, and the clutch plate. If the disc andplate are reused, be sure not to change the installation orderand direction when they are disassembled.

3. Remove the piston. If it is difficult to remove, face the pistonside downward, and, with the retainer on a base, blow airin through the oil passage on the rear surface.

4. Remove the seal ring from the retainer.5. Remove the two D-section rings and oil seal from the piston.

4 5 - 1 1 0

END CLUTCH ASSEMBLY

ASSEMBLY

1.

2.

3.4.

5.

6.

Install the D-section rings and oil seal in the piston innerand outer grooves.After applying a coating of automatic transaxle fluid to theD-section rings outer circumference, manually press thepiston into the end clutch retainer.Install the return spring and washer.After fitting a new snap ring into the guide of the specialtool (09453-33000), install the retainer. Fit the snap ringas for down on the guide as possible.Attach the installer and press until the snap ring enters thegroove. Do not press more than necessary. The placesindicated by arrows in the illustration (center projections) arenot to be supported.Install the clutch plate, clutch disc and reaction plate to theend clutch retainer. If the reaction plate, clutch plate andclutch disc are reused install them in the same order theywere disassembled. Apply a coating of automatic transaxlefluid.

CautionWhen a new clutch disc is used, soak it in automatictransaxle fluid for 2 hours before using it.

After installing the snap ring, check to be sure that theclearance between the snap ring and the clutch reactionplate is from 0.6-0.85 mm (0.024-0.033 in.). Whenmeasuring the clearance, apply a firm pressure 50 N (11 lb.)all around the circumference of the clutch reaction plate.If the clearance is not within the specified range, use a snapring of a thickness which will adjust to the specified range.

Types of snap rings

Snap ring thickness mm (in.) Ident. color

1.05 (0.04) White

1.30 (0.05) Yellow

1.55 (0.06) None

1.80 (0.07) Green

2.05 (0.08) Pink

4 5 - 1 1 1

PLANETARY GEAR SET

PLANETARY GEAR SET

COMPONENTS

DISASSEMBLY

1. Remove three bolts.

2. Remove overrunning clutch outer race assembly. Removeoverrunning clutch end plate.

4 5 - 1 1 2

PLANETARY GEAR SET

3. Remove pinion shaft. (any one place of the short pinion.).4. Remove spacer bushing and two front thrust washers.5. Remove only one short pinion. Use care not to drop and lose

17 rollers in short pinion.

6. Remove thrust bearing.

7. Push overrunning clutch out of outer race with fingers.

REASSEMBLY

1. Install thrust bearing to carrier. Be sure that it fits correctlyin carrier.

PLANETARY GEAR SET

2. Apply a generous amount of Vaseline to inside diameter ofshort pinion to hold to 17 rollers.

3. Line up holes in rear thrust washer and front thrust washerwith shaft of carrier.

4. Install short pinion, spacer bushing and two front thrustwashers and align holes. Use care not to allow rollers to getout of position.

5. Insert pinion shaft. Be sure that flattened end of pinion shaftfits properly into the hole in rear thrust plate when pinionshaft is inserted.

6. Install end plate to outer race.

4 5 - 1 1 4

PLANETARY GEAR SET

7. Push overrunning clutch into outer race. Be sure that arrowon outside circumference of cage is directed upward asshown in the illustration when overrunning clutch isinstalled.

8. Apply Vaseline to overrunning clutch end plate to retain itto overrunning clutch. Install the end plate to the clutch.

9. Install overrunning clutch assembly to carrier and align boltholes.

10. Install three bolts and tighten three bolts to 25 to 35 Nm(18 to 25 ft.lbs.).

11. Align with the bolt head, and bend the lock plate.

INTERNAL GEAR AND TRANSFER DRIVE GEAR SET


COMPONENTS

DISASSEMBLY

1. Remove snap ring from rear end of output flange.2. Using special tool (09455-24000) pull off ball bearings (2

pieces) and transfer drive gear from output flange.

4 5 - 1 1 6


3. Remove snap ring, and separate internal gear from outputflange.

REASSEMBLY

1. Using special tool (09455-21100) press ball bearing andtransfer drive gear onto output flange.

CautionReplace output flange and transfer drive gear as a set.

2. Install transfer drive gear in proper direction with attentionpaid to groove provided in side surface.

3. Install the ball bearing.

4. Select snap ring, which should be the thickest one that canbe installed in groove.

DIFFERENTIAL

DIFFERENTIAL

COMPONENTS

DISASSEMBLY

1. Remove the drive gear retaining bolts and remove the drivegear from differential case.

2. Remove the taper roller bearing inner race by using specialtool (09433-21000).

4 5 - 1 1 8

DIFFERENTIAL

3. Drive out lock pin with a punch inserted in hole “A”.4. Remove the pinion shaft, the pinion gears and washers.5. Remove the side gears and spacers.

Distinguish between the removed gears and spacers for theleft and right sides.

REASSEMBLY

1. With spacers installed to back of differential side gears,install gear in differential case. If reusing removed parts,install them in original positions noted during disassembly.If using new differential side gears, install spacers ofmedium thickness 1.0 mm (0.039 in.).

2. Install washers to back of pinion gears, install gears indifferential case, and then insert pinion shaft.

3. Measure back lash between side gear and pinion gear.Backlash should be 0.025-0.150 mm (0.0010-0.0059 in.)and right and left hand gear pairs should have equalbacklash. If backlash is out of standard value, disassembleand reassemble them by using spacers selected for correctbacklash.

Standard value :0.025-0.150 mm (0.0010-0.0059 in.)

4. Install pinion shaft lock pin in direction specified inillustration. After installation, check to ensure that projectionis less than 3 mm (0.118 in.).

CautionLock pin must not be reused. Lock pin not requiring morethan 2,000 N (440 lb.) installation load must not be used.

4 5 - 1 1 9

DIFFERENTIAL

5. Press taper roller bearing inner races onto both ends ofdifferential case. Apply load to inner race when pressing inbearings. Do not apply load to outer race.

6. Install the differential drive gear onto the case.

7. Apply ATF to bolts and tighten bolts to specified to torquein sequence shown in illustration.

Tightening torque :130-140 Nm (1300-1400 kg .cm, 94-101 Ib . f t )

4 5 - 1 2 0

VALVE BODY

VALVE BODY

COMPONENTS

1. Pressure control valve2. Pressure control spring3. Torque converter control valve4. Torque converter control spring5. Regulator valve6. Regulator spring7. Adjusting screw8. Stopper plate9. Shift control plate

10. Shift control spring11. Rear clutch exhaust spring12. Rear clutch exhaust valve B13. Rear clutch exhaust valve A14. 2nd-3rd/4th-3rd shift valve15. 2nd-3rd/4th-3rd shift valve16. Front end cover17. Valve stopper18. Upper separating plate19. Steel ball20. Relief spring21. Intermediate plate22. Nut23. Jet24. Oil filter25. Lower separating plate26. Lower valve body27. Reducing valve28. Reducing spring29. Adjusting screw30. End cover31. N-R control/accumulator valve

32. N-4 control/accumulator spring 48. 1-2 shift valve33. Damper clutch control spring 49. 1-2 shift spring

34. Damper clutch control valve 50. Rear end cover35. Damper clutch control sleeve 51. Shift control cover36. End clutch valve 52. Stopper plate37. End clutch spring 53. Shift control plug B38. End clutch plug 54. N-D control sleeve39. Stopper 55. N-D control valve40. Pin 56. Manual valve41. Dowel bushing 57. Upper valve body42. Block 58. Tefron ball

43. Pipe44. Pressure control solenoid valve (PCSV)45. Shift control solenoid valve B (SCSV-B)46. Shift control solenoid valve A (SCSV-A)47. Damper clutch control solenoid valve (DCCSV)

4 5 - 1 2 1

VALVE BODY

Remove the 4 solenoid valves.

DISASSEMBLY

1.

2. Remove the manual valve.

3. Remove the valve stopper and clamp.

4. Remove the bolts (13), and then remove the lower valvebody.

45-122

VALVE BODY

5. Remove the separating plate.

6. Remove the relief spring, two steel balls and oil filter fromthe intermediate plate.

7. Remove the bolts (8), and then remove the intermediate plateand upper separation plate.

8. Remove the block.

4 5 - 1 2 3

VALVE BODY

9. Remove the upper separating plate.

10. Remove, from the upper valve body, the three steel balls,the teflon ball, and the two stopper plates.

11. Remove, from the upper valve body, the seven bolts; thenremove the front end cover and the adjustment screw.

CautionWhen removing the bolts, be sure to firmly press the frontend cover (as shown in the illustration) so as to prevent thespring from causing the adjustment screw to pop out.

12. Remove the pressure control spring and the pressure controlvalve.

4 5 - 1 2 4

VALVE BODY

13. Remove the torque converter control spring and the torqueconverter control valve.

14. Remove the regulator spring and the regulator valve.

15. Remove the shift-control spring and shift-control plug A;

16. Remove rear clutch exhaust valves A and B as well as the

rear clutch exhaust spring.

4 5 - 1 2 5

VALVE BODY

17. Remove the 2-3/4-3 shift spring and the shift valve.

18. Remove, from the rear side of the upper valve body, the N-Dcontrol sleeve and the N-D control valve.

19. Remove the four bolts, and then remove the rear end cover.

20. Remove the l-2 shift spring and the l-2 shift valve.

4 5 - 1 2 6

VALVE BODY

13. Remove the torque converter control spring and the torqueconverter control valve.

14. Remove the regulator spring and the regulator valve.

15. Remove the shift-control spring and shift-control plug A.

16. Remove rear clutch exhaust valves A and B as well as therear clutch exhaust spring.

4 5 - 1 2 5

VALVE BODY

17. Remove the 2-3/4-3 shift spring and the shift valve.

18. Remove, from the rear side of the upper valve body, the N-Dcontrol sleeve and the N-D control valve.

19. Remove the four bolts, and then remove the rear end cover.

20. Remove the l-2 shift spring and the l-2 shift valve.

4 5 - 1 2 6

VALVE BODY

VALVE INSTALLATION POSITIONS

Upper valve body

4 5 - 1 2 9

VALVE BODY

Lower valve body

4 5 - 1 3 0

VALVE BODY

REASSEMBLY

1. Install to the lower valve body, the damper clutch controlspring, damper clutch control valve, and damper clutchcontrol sleeve.

2. Install the N-R control/accumulator spring and the N-Rcontrol/accumulator valve.

3. Install the reducing valve.

4. Install the reducing spring, adjustment screw, and end cover;then, using the special tool, tighten the bolts at the specifiedtorque.

VALVE BODY

5. Install the end clutch valve, end clutch spring, and end clutchplug.

6. Install the stopper and secure it by the push-in pin.

7. Install the 1-2 shift-control valve to the upper valve body.

8. Install the 1-2 shift-control plug.

4 5 - 1 3 2

VALVE BODY

9. Install the 1-2 shift valve and 1-2 shift spring.

10.

11. Install the N-D control valve and then N-D control sleeve.

Install the rear end cover; then, using the special tool tightenthe bolts at the specified torque.

12. Install the 2-3/4-3 shift valve and the 2-3/4-3 shift spring.

4 5 - 1 3 3

VALVE BODY

13. Install the rear clutch exhaust spring and rear clutch exhaustvalves A and 6.

14. Install the shift-control valve and shift control spring.

15. Install the regulator valve and regulator spring.

16. Install the torque converter control valve and torqueconverter control spring.

4 5 - 1 3 4

VALVE BODY

17. Install the pressure control valve and pressure controlspring.

18. Install the adjustment screw and front end cover; then, usingthe special tool, tighten the bolts at the specified torque.

19. Install, to the upper valve body, the three steel balls, theteflon ball, and the stopper plate.

20. Install the upper separating plate.

VALVE BODY

21. Install the block.

22. Install the special tool (09456-21000) then, after securingthe upper separating plate and the intermediate plate by theeight installation bolts, remove the special tool.

23. Install, to the intermediate plate, the oil filter, the two steelballs, and the spring.

24. Install the special tool (09456-21000) to the intermediateplate.

4 5 - 1 3 6

VALVE BODY

25. Install the separating plate.

26. After securing the lower valve body by the 13 installationbolts, remove the special tool.

27. Install the valve stopper and clamp.

28. Install the manual valve.

4 5 - 1 3 7

VALVE BODY

29. Secure the four solenoid valves by the installation bolts.

4 5 - 1 3 8

KICKDOWN SERVO

KICKDOWN SERVO

COMPONENTS

REASSEMBLY

1. Install the rod and nut to the kickdown servo piston.2. Install two new D-rings (one large and one small) around the

circumference of the piston, and then apply a coating of asmall amount of ATF to the D-ring.

3. Combine the kickdown servo piston and the sleeve.4. Install a new O-ring around the circumference of the sleeve,

and then apply a coating of a small amount of ATF to theO-ring.

4 5 - 1 3 9

SPEEDOMETER SLEEVE

SPEEDOMETER SLEEVE

COMPONENTS

DISASSEMBLY

Drive spring pin out, and gear and sleeve can be disassembled.

CautionDo not reuse O-rings and spring pin.

REASSEMBLY

1. Install a new O-ring to the shaft part of the gear, and coata small amount of automatic transaxle fluid onto the O-ring.

2. Insert the gear into the sleeve, and align the pin hole andthe groove of the gear’s shaft.

3. Tap a new spring pin into the sleeve. When tapping it in,be sure that the slit is not at the gear side.

4. Install a new O-ring into the outer groove of the sleeve, andthen apply a coating of a small amount of automatictransaxle fluid to the outer circumference of the O-ring.

4 5 - 1 4 0

TRANSAXLE CASE

TRANSAXLE CASE

COMPONENTS

REASSEMBLY

Using special tool (09431-21200) drive two drive shaft oil sealsinto transaxle case.

mitsub hyu

Documents