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8/6/2019 Manual+de+Reparacion+Para+Transmision+Automatica+Modelo+CA

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PREVIOUSDMENU

INDEXACURA INTEGRA 1987

Automatic Transmission Service Group9200 South Dadeland Blvd.

Suite 720Miami, FL 33156(305) 661-4161


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Technical Service Information

INTRODUCTIONACURA INTEGRA 1987The Acura Integra transaxle is a hydraulic controlled 4speed front wheel drive unit with 4 forward speeds andone reverse with a converter clutch.The teardown - assembly and trouble-shooting arecovered in this manual.

We thank the Honda Motor Corporationfor the illustrations and informationthat have made this booklet possible.

ROBERT D. CHERRNAYTECHNICAL DIRECTOR

DALE ENGLANDFIELD SERVICE CONSULTANT

FRANK MIETUSHOTLINE TECHNICIAN

WAYNE COLONNAHOTLINE TECHNICIAN

ED KRUSELAYOUT

AUTOMATIC TRANSMISSION SERVICE GROUP9200 SOUTH DADELAND BLVD.

SUITE 720MIAMI, FLORIDA 33156(305) 661-4161

1


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Service InformationThe Automatic Transmission is a combination of a 3-element torque converter and dual-shaft automatic transmission whichprovides 4 speeds forward and 1 speed reverse. The entire unit is positioned in line with the engine.TORQUE CONVERTER, GEARS, AND CLUTCHESThe torque converter consists of a pump, turbine and stator, assembled in a single unit .They are connected to the engine crankshaft so they turn together asa unit asthe engine turns. Around the outside of the torqueconverter. is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converterassembly serves as a flywheel while transmitting power to the transmission mainshaft.The transmission has two parallel shafts, the mainshaft and countershaft. The mainshaft is in line with the engine crankshaft.The mainshaft includes the clutches for 1st. and 2nd/4th, and gears for 3rd, 2nd, 4th, Reverse and 1st (3rd gear is integral withthe mainshaft, whi le reverse gear is integral with 4th gear).The countershaft includes 3rd clutch and gears for 3rd, and 4th, Reverse and 1st.4th and reverse gears can be locked to the countershaft at its center, providing 4th gear or Reverse. depending on which waythe selector is moved.The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears in thetransmission are engaged by the clutches, power istransmitted from the mainshaft to the countershaft to provide I 03]. [Q~],[2]and~.HYDRAULIC CONTROLThe valve assembly includes the main valve body, secondary valve body. serve valve body, modulator valve body, regulator valvebody and lock-up shift valve body, through the respective separator plates.They are bolted to the torque converter case as an assembly.The main valve body contains the manual valve, 1-2 shift valve, 2-3 shift valve, 3-4 shait valve. pressure rel ief valve. 2nd orificecontrol valve. and oi l pump gear.The-secondary valve body includes the CPC valve. REV control valve. lock-up cut valve, kickdown valve, 3-2 timing valve andshift timing valves.The serve valve body contains the accumulator pistons. 3rd orifice control valve. throttle A and B valves. and the modulator valve.The regulator valve body contains the lock-up timing valves, pressure regulator valve and lock-up control valve. Fluid from theregulator passes through the manual valve to the various control valves.The lock-up shift valve body contains a lock-up timing valve and lock-up shift valve. The 1st. 3rd and 4th clutches receive oil fromtheir respective feed pipes.LOCK-UP MECHANISMIn I 041, pressurized fluid is drained from the back of the torque converter through an oil passage. causing the lock-up piston tobe held against the torque converter cover. As this takes place, the mainshaft rotates at the same speed asthe engine crankshaft.Togehter with hydraulic control, an electronic control unit optimizes the timing of the lock-up mechanism.The lock-up shift valve body controls the range of lock-up according to vehicle speed and throttle pressure. The lock-up timingvalve controls the flow of oil to the lock-up shift valve in 3rd and 4th gear (in lQ,! Irange).The lock-up cut valve is housed in the secondary valve body and prevents lock-up from taking place when the throttle is notopened sufficiently.

Automatic Transmission Service Group3


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Service Information

The Automatic Transmission is a combination of a 3-element torque converter and dual-shaft automatic transmission whichprovides 4 speeds forward and 1 speed reverse. The entire unit is positioned in l ine with the engine.TORQUE CONVERTER. GEARS. AND CLUTCHESThe torque converter consists of a pump. turbine and stator. assembled in a single unit.They are connected to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torqueconverter ..is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converterassembly serves as a flywheel while transmitting power to the transmission mainshaft.The transmission has two parallel shafts. the mainshaft and countershaft. The mainshaft is in line with the engine crankshaftThe mainshaft includes the clutches for 1st. and 2nd/4th. and gears for 3rd. 2nd. 4th. Reverse and 1st (3rd gear is integral withthe mainshaft. while reverse gear is integral with 4th gear).The countershaft includes 3rd clutch and gears for 3rd. and 4th. Reverse and 1st.4th and reverse gears can be locked to the countershaft at its center. providing 4th gear or Reverse. depending on which waythe selector is moved.The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears in thetransmission are engag'ed by the clutches. power is transmitted from the mainshaft to the countershaft to provide I 031.1 041. [I]and f f i l .HYDRAULIC CONTROLThe valve assembly includes the main valve body. secondary valve body. serve valve body. modulator valve body. regulator valvebody and lock-up shift valve body. through the respective separator plates.They are bolted to the torque converter case as an assembly.The main valve body contains the manual valve. 1-2 shift valve. 2-3 shift valve. 3-4 shait valve. pressure relief valve. 2nd orif icecontrol valve. and oil pump gear.The secondary valve body includes the CPC valve. REV control valve. lock-up cut valve. kickdown valve. 3-2 timing valve andshift timing valves.The serve valve body contains the accumulator pistons. 3rd orifice control valve. throttle A and B valves. and the modulator valve.The regulator valve body contains the lock-up timing valves. pressure regulator valve and lock-up control valve. Fluid from theregulator passes through the manual valve to the various control valves.The lock-up shift valve body contains a lock-up timing valve and lock-up shift valve. The 1st. 3rd and 4th clutches receive oil fromtheir respective feed pipes.LOCK-UP MECHANISMIn i 041. pressurized fluid is drained from the back of the torque converter through an oil passage. causing the lock-up piston tobe held against the torque converter cover. As this takes place. the mainshaft rotates at the same speed as the engine crankshaft.Togehter with hydraulic control. an electronic control unit optimizes the timing of the lock-up mechanism.The lock-up shift valve body controls the range of lock-up according to vehicle speed and throttle pressure. The lock-up timingvalve controls the flow of oil to the lock-up shift valve in 3rd and 4th gear (in I 041 range).The lock-up cut valve is housed in the secondary valve body and prevents lock-up from taking place when the throttle is notopened sufficiently.



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Service InformationGEAR SELECTIONThe selector lever has six positions: L ! : J PARK,lB] REVERSE, [ ! ' ! J NEUTRAL, I T 8 J 1st through 4th gear ranges, f D 3 l 1 st through3rd gear ranges, and ~ 2nd gear.

Position Description~-p; . PARK: ' a l REVERSE[N i NEUTRAL! 041 DRIVE(1 through 4)

Front wheels locked; parking pawl engaged with parking gear on countershah. All clutches released.Reverse; reverse selector engaged with countershaft reverse gear and 4th gear clutch locked.All clutches released.General driving; starts off in 1st. shifts automatically to 2nd, 3rd, then 4th, depending on vehiclespeed and throttle position. Downshift through 3rd, 2nd and 1st on deceleration to stop.The lock-up mechanism comes into operation in I 04 :For rapid acceleration at highway speeds and general driving; starts off in 1st, shifts automaticallyto 2nd, then 3rd, depending on vehicle speed and throttle position. Downshifts through 2nd to1st on deceleration to stop.For engine braking or better traction start ing off on loose or slippery surfaces; stays in 2nd gear,does not shift up or down.

: 03, DRIVE(1through 3):_~ SECOND,

Starting is possible only In L ~ I and ~! through use of a slide-type, neutral-safety switch.POSITION INDICATORA position indicator in the instrument panel shows what gear has been selected without having to look down at the console.

MAINSHAFT REVERSE GEAR

PARKING GEAR

COUNTERSHAFT 1ST GEARCOUNTERSHAFT2ND GEAR COUNTERSHAFT REVERSE

GEAR

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Service Information[1st Clutch]The 1st clutch is on the right end of the mainshaft. In the [ Q ; j orlQ!jrange. constant hydraulic pressure is applied to the mainshaftthrough the 1st clutch to the mainshaft 1st gear.The clutch plate is mounted on the clutch drum. while the clutch disc is fitted to the mainshaft 1st gear.The 1st gears are attached to the mainshaft and countershaft through needle bearings. one for each gear.When select lever is placed in the ~ o@ range. hydraulic pressure is applied from the right side cover through the mainshaft.and thus to the clutch drum; as the pressure rises. the clutch piston presses the clutch plate and clutch disc. thus causing theclutch to engage.Power is'transmitted from the mainshaft 1st gear. through the countershaft 1st gear. to the one-way clutch. parking gear. andfinally to the countershaft. The one-way clutch locks in the forward direction when in 1st gear. In the ! P i ! or[Q!i range. all othersbeside 1st gear are not engaged. thus transmitting no power.[2nd Clutch]The 2nd clutch is left of center on the mainshaft. and is the same construction as the 1st clutch;The 2nd clutch is joined back-to-back to the 4th clutch. The mainshaft 2nd gear uses a needle bearing. The countershaft 2ndgear is splined on the countershaft.In 2nd gear of r n . [5 ;j or [ Q ; I . hydraulic pressure isapplied to the clutch drum from the mainshaft. thus transmitting power fromthe mainshaft 2nd g~r to the countershaft 2nd gear.[3rd Clutch]The 3rd clutch is on the left end of the countershaft.The clutch hub isjoined to the countershaft 3rd gear. on the countershaft. supported by a single needle bearing.In 3rd gear of [ Q i l or [ Q ; I . hydraulic pressure is applied to the 3rd clutch on the countershaft. thus causing the clutch to engage.and transmitting power.[4th Clutch]The 4th clutch is identical to the 2nd clutch. to which it is joined on the mainshaft. The clutch hub is joined to the mainshaft 4thgear and reverse gear. supported by two needle bearings.In 4th gear of ! ill. hydraulic pressure is generated within the mainshaft. applying pressure to the 4th clutch on the mainshaft.

MAINSHAFT 3RD GEARMAINSHAFT 2ND GEAR

2ND CLUTCH4TH CLUTCH

MAINSHAFT 1ST GEARMAINSHAFT

3RD CLUTCHREVERSE SELECTOR

COUNTERSHAFT 4TH GEAR

COUNTERSHAFT3RD GEAR

~~FINAL-"",-or--"" DRIVEN~- GAER COUNTERSHAFT2ND GEAR

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Service Information

GOVERNOR PRESSURE ~I: ;=:=:; l

TIC PRESSURE ==::::::j

LINE PRESSURE

LIC PISTON

TiC CHECK VALVE

TIC: Torgue ConverterL/C: Lock-up Clutch

[One-way Clutch]A one-way sprag clutch disengages 1st gear when in the 2nd and 3rd gear ranges. The clutch is splined to the countershaftbetween the 1st gear and the parking gear. It iscomposed of sprag elements and the retainer which supports the central sectionof the sprags. When the respective gaers move in the ~ directions. the sprags incline to the left. with the result that they lockthe gears together.When shifting from 1st to 2nd in the r Q i ] or I Q ; j range. the different ratio of the two gears causes the countershaft to rotate (via2nd gear) at a speed greater than that of 1st gear. As a result. the parking gear is rotated in the c~ direction. and the sprags moveaway from their locking position. In the 3rd gear of [ D ; ] or [Q ~the same difference of ratio keeps the sprags from locking and keeps1st gear disengaged.

PRESSURE

COUNTERSHAFT 1ST GEARFREE

.- . : - : - : . ; : : ; : : : : ; : : ; : : ; : ; ; : : : : : :FREE

PARKING GEAR



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Service Information[Lock-up Clutch]Operation (clutch on)With the lock-up clutch on. the oil in the chamber between the converter cover and lock-up piston is discharged. and theconverter oil exerts pressure through the piston against the converter cover. As a result. the converter turbine is locked on theconverter cover firmly. The effect is to bypass the converter. thereby placing the car in direct drive.

Power flow LIC PISTON

Engine TORQUE CONVERTERCOVER COMP

The power flows by way of:

Drive plateTorque converter coverJLock-up pistonDamper springTurbineMainshaft

Operation (clutch off)With the lock-up clutch off. the oil flows in the reverse of CLUTCH ON. As a result. the lock-up Psiton is moved away from theconverter cover; that is. the torque converter lock-up is released.[Power flowlEngineDrive plate

Pump

To oi l cooler

Torque converter cover

TurbineMainshaft

INLET+

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Service Information

~ TORQUE 1ST GEAR1ST GEAR

2ND GEAR 3RD GEAR 4TH REVERSE PARKINGCONVERTER 1ST CLUTCH ONE-WAY 2ND CLUTCH 3RD CLUTCH GEAR GEARE CLUTCH GEAR LUTCH:P J 0 x x x x x x x 0-- - ]J 0 x x x x x 0 0 x-- - N ' 0 x x x x x x x x..-._ _ C-- --- -- - -- - _ ..-- ---__-------1ST 0 0 0 x x x x x x

0; 2ND 0 *0 x 0 x x x x x3RD 0 *0 x x 0 x x x x._ .. -1ST 0 0 0 x x x x x x2ND 0 *0 x 0 x x x x xD . 3RD 0 lIE 0 x x 0 x x x x4TH 0 *0 x x x 0 0 x x----2 2ND 0 x x 0 x x x x x

0: Engaged x : Not Engaged l I E : Although the 1st clutch engages, driving power in not transmitted as the one-way clutchraces.

OIL PUMP

MAINSHAFTREVERSE GEAR

COUNTERSHAFT,< i n I r O N E - W A V CLUTCHCOUNTERSHAFT \ B2ND GEAR \ . f t : : - - PARKING PAULCOUNTERSHAFT 0 - - - ' - - - ' - \RD GEAR COUNTERSHAFT 1ST GEAR

1 COUNTERSHAFTREVERSE GEARREVERSE SELECTORSERVO VALVE

TORQUE CONVERTER

3RD CLUTCH

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No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION No. DESCRIPTIONOF PRESSURE OF PRESSURE OF PRESSURE OF PRESSURE1 LINE 10 1ST CLUTCH 40 4TH CLUTCH 90 TORQUE CONVERTER I

2 i 11 i 41 i 91 i3 i 20 2ND CLUTCH 42 i 92 ii i -.--3' 21 50 THROTTLE A 93 OIL COOLER3" i 22 i 51 i 94 TORQUE CONVERTER4 i 23 i 55 THROTTEL B 95 LUBRICATION I4' i 24 i 56 i 96 TORQUE CONVERTER IIi 3RD CLUTCH GOVERNOR i I5 30 60 976 MODULATOR 31 i 61 i 99 SUCTION !i

REVERSE CONTROL VALVE

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Service InformationIn the hydraulic control unit, the regulator valve, manual valve and oil pump connected to the torque converter are unified andcontained inside the valve body. The valve body includes the main valve body, the regulator valve body, the secondary valvebody, the servo body, and the lock-up valve body.The oil pump is driven by splines on the left end of the torque converter which is attached to the engine. Oil flows through theregulator valve, to maintain specified pressure through the main valve body to the manual valve, governor lalve, and servo body,directing pressure to each of the clutches.

LOCK-UP VALVE BODY REGULATOR VALVE BODY OIL PUMP DRIVEN GEAR

STATOR SHAFTTransmits torque converterreaction to the regulator valve

MANUAL VALVEChanges hydraulic flow accordingto the seleclor position.

SERVO VALVEShifts gear Into reverse in ~.

RELIEF VALVEKeepsconstant fluid pressurefor lubrication.

REGULATOR VALVE

SECOND ORIFICECONTROL VALVE

MAIN VALVE BODY

Reduces clutch pressure toabsorb shock when the clutchengages.

SERVO BODY

MODULATOR VALVE MODULATOR BODY THROTTLE VALVE A THROTTLE VALVE B



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Service Information[Regulator Valve]The regulator valve maintains a constant hydraulic pressure sent from the oil pump to the hydraulic control system, while alsofurnishing oil to the lubricating system and torque converter.Oil flows through Sand S'. The oil which enters through S flows through the valve orifice to A pushing the regulator valve tothe right. According to the level of hydraulic pressure through S, the position of the valve changes, and the amount of the oilthrough S' from D thus changes. This operation is continued, thus maintaining the line pressure.

(ENGINE'NOT RUNNING) (ENGINE RUNNING)TO TORQUE CONVERTERt c

FROM OIL PUMPREGULATOR VALVE SPRING

(Stator Reaction Hydraulic Pressure Control)Hydraulic pressure increase according to torque is performed by the regulator valve using stator torque reaction. The stator shaftis splined in the stator and its arm end contacts the regulator spring cap. When the car is accelerating or climbing (TorqueConverter Range), stator torque reaction acts on the stator shaft and the stator arm pushes the regulator spring cap ... directionin proportion to the reaction. The spring compresses and the valve moves to increase the regulated control pressure or linepressure. Line pressure is maximum when the stator reaction is maximum.

REGULATOR VALVE

STATOR REACTION SPRING

STATOR SHAFT ARM



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Service Information[Throttle Valve A]Throttle Valve A converts changes in the throttle opening to changes in transmission hydraulic pressure, to determine transmis-sion shift timing. The end of the valve contacts the throttle cam which is connected by a cable to the throttle body. The cablepulls the cam, which, in turn moves the valve. The valve-to-cam engagement is adjustable to allow setting of specifeid shiftspeeds.

[Throttle Valve B, Mdulator Valve]Thrott le valve B is similar to valve A. except that it operates on accumulator back pressure, to make smooth changes from onegear to another. An assist function is used to lessen the throttle load. The modulator valve maintains line pressure from theregulator, after which the pressure to throttle valve A, thus maintaining accurate shift characteristics.[Second Orifice Control Valve]For smooth shifing between second to third, the open pressure on the second gear side is rel ieved through a fixed orif ice. Thevalve also moves to equalize pressure differences between second and third gears.

x XMODULATOR VALVE SECOND ORIFICECONTROL VALVE

THROTTLE VALVE B



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Technical Service InformationCheck these Check these Check thesei tems on i tems on Check theseSYMPTOM PROBABLE i tems on PROBABLECAUSE NOTES The fol lowing symptoms can be caused CAUSE DUE ITEMS ONPAGE NOTESLIST by improper repair or assembly. TO 1M PAGEEngine runs, but car does not move in 1,6,7,16 K, L, R.S PROPERREPAIRany gear.

Car moves in Rand 2, but not in 03. or B,29,44,48 C,M,O Car creeps in N. Rl, R204.Car moves in 03, 04 and R, but not in Car does not move in 03 or 04. R59,30,49 C, L? Trans lock uo in R. R4Car moves in 03, 04 and 2, but not in I, II, 12,22, C, L,aR. 38,39.40 Trans has no park. R3Car moves in N. 1,8,9,10, II, C,D Excessive drag in trans. R8 RK46,47Excessive idle vibration. 5,17 8,K,L Excessive vibration, rpm related. R9Slips in all gears. 6,7,16 C, L, U Noise with wheels moving only. R7S lips in low gear. 8, 29, 44, 45, C,N,O,U

48 Main seal pops out. RIO 5Sl ips in 2nd gear. ~ 9, 20, 23, 30, C, L,U Various shifting problems. Rll, R1245,49Slips in 3rd gear. 10,21,23,31, C, L,U Harsh upshifts. R1344,45 In 03 or 04 tr ans star ts in 2nd gear. R6Slips in ,4th gear. 11,23,32,45 C, L,USlips in reverse gear. 11,32 C PROBABLE CAUSESl ips on 2-3 upshi ft . 3,15,24 E, L, V 1. Shi ft cable broken/out of adjustmentSl ips on 3-4 upshi ft . 3,15.25 E, L. V 2. Throttle cable too shortNo upshif t; t rans s tays in low gear. 12,13,14,19, E, F, G, L 3. Thrott le cab le too long23 4. Wrong type ATFNo downshif t to low gear. 12,19 G,L 5. Idle rpm too low/highLate upshift. 2,12,13,14 E, F, L , V 6. Oi I pump worn or se izedEarly upshift. 3,13,14 E, F, L, V 7. Pressure regulator stuckErratic shifting. 2,14,26 E, F. V B. Low clutch defective9. 2nd clutch defectiveHarsh shift (up & down shifts). 2, 4, IS, 23, 24, A, E, H,I, L, 10. 3rd clutch.defective25,27,47 V 11. 4th clutch defectiveHarsh shift (, 2). 2.9 C,D.V 12.Harsh shift (2-3). 2,10.23,24 Governor valve stuckC.D. H. L. V 13. Throttle A valve stuckHarsh sh'ft (3-4). 2, 11,23,25 C, 0,1. L. V 14. Modulator valve stuckHarsh kickdown shifts. 2,23,27 L, v.a 15. Throttle B valve stuckHarsh kickdown shi ft (2 I). 48 0 16. Oil screen cloggedHarsh downshif t (3-2) a t c losed 15 E, T 17. Torque convertor defectivethrottle. is. Torque governor check valve stuckAx le fs) s li ps out o f t rans on turns . 43 50 L, P, 0 19. 1-2 shi ft valve s tuckAxle{s) stuck in trans. 43 L,U 20. 2 3 shi ft valve stuckRatchet ing noise when shi ft ing into R. 6,7,38,39,40 K, L,a 21. 3-4 shift valve stuckLoud popping noise when tak ing off 38,39,40 c.o 22. Reverse control valve stuckin R. 23. Clutch pressure control valve stuckRatchet ing noise when shi ft ing f rom R 38,39,40,51 K, L,a 24. 2nd ori fice control valve stuckto P, o r from R t o N. 25. 3rd ori fice control valve stuckNoise from trans in all selector lever 6,17 K, L,a 26. 3-2 t irninq valve s tuckpositions. 27. Kickdown valve stuckNoise from trans only when wheels 39,42 L,a 2B. Shi ft t iming valve/accur stuckrolling. 29. Low clutch accumulator defectiveGear whine, rpm related (pi tch changes 6,41 K, L,a 30. 2nd clutch accumulator defecnvewith shifts). 31. 3rd clutch accumulator defectiveGear whine. speed related 39,42 L. a 32. 4th/reverse accumulator defective(pitch changes with speed), 33. Lockup clutch cut valve stuckTrans will not shift into 4th gear in 04. 1,21,28 L 34. Lockup c lu tch t iming valve A stuckEngine s talls on emergen cy stop s (shift 2, 33 L. V 35. Lockup c lu tch t iming va lve B stucklever in 04 only). 36. Lockup clutch shi ft valve stuckLockup clutch does not lock up 35,37, 17 L 37. Lockup clutch control valve stucksmoothly. 38. Shif t fork bentLockup clutch does not operate 2,3,12.15,18, E, L. V 39. Reverse gears worn/damaged (3 gears)properly. 33,34.35,36,3 40. Reverse selector gear wornTransmission has multitude of problems 43 L,a 41. 3rd gears worn/damaged (2 gears)shifting, at disassembly large deposits of 42. Final gears worn/damaged (2 gears)metal found on magnet. 43. Dif ferent ial pinion shaft worn44. Feedoioe OriM broken

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Technical Service InformationPROBABLE CAUSE NOTES

45. Servo valve check valve loose K Improper alignment of main valve body and torque converter4S. Gear clearance incorrect casemay cause oil pump seizure. The symptoms are mostly47. Clutch clearance incorrect an rpm rela ted- ticking noise h igh p itched squeak. In severe4B. Sprag clutch defective ins tances, i t may s ta ll the engine. Fo llow ins truc tion pro-49. Sealing rings/guide worn cedure on page 14-58.50. Axle-inboard joint clip missing L I f the oil screen isclogged with particles of steel or aluminum,51. 4th gears worn/damaged (2 gears) inspect the oil pump and dif ferent ial pinion shaft . If both areOK, and no cause for the contaminat ion is found, rep lace the

PROBABLE CAUSES DUE TO IMPROPER REPAIR torque converter.M I f the low c lu tch feedpipe guide in the end cover i sscored by theRl Improper clutch clearance mainshaft , inspect the bal l bearing for excessive movement in theR2 Improper gear clearance transmission housing. I f OK, replace the end cover asi t isdented.The O-ring under the guide i . probably broken.R3 Parking pawl installed upside down N Replace the mainshaf t i f the bush ings for the low-end 4th feed

p ipe are loose or damaged. I f the low feedpipe isdamaged orR4 Parking shi ft arm instali led upside down out of round, rep lace i t. It the 4th feedpipe is damaged or outof round. replace the end cover.R5 Sprag clutch installed upside down 0 A worn or damaged spragc lutch is most ly a result o f shi ft ing theRS Feed pipe missing in governor shaft t rans in 03 or D4 whi le the wheels rotate in reverse, such asrockinq the car in snow.R7 Reverse hub installed upside down P Inspect the frame for collision damaqe.RS Oil pump binding Q Inspect for damage or wear:R9 Torque conver ter not ful ly seated in o il pump 1.Governor shaf t woodruff key2. Reverse selector gear teeth chamfersRIO Main seal improperly installed 3. Engagement teeth chamfers of countershaft 4th & reversegearRll Springs improperly Installed 4. Shif t fork, for scuff marks in center5 . D if ferentia l p in ion shaft for wear under p in ion gearsR12 Valves improperly installed S. Bottom of 3rd clutch for swirl marksR13 Ball check valves not installed Replace i tems 1,2,3 and 4 i f worn or damaged. I f t rans makesc l icking, grinding or whirr ing noise. also replace mainshaft 4thR14 Shift fork bolt not installed gearand reverse idler gear and counter 4 th gear in add it ion to1,2,3, or 4.I f dif ferent ial pinion shaft isworn, overhaul dif ferent ial assy

NOTES and replace oil screen and thoroughly clean trans f lush torqueA Flushing procedure (repeat 3 timesl: 1. Drain the trans. converter and cooler and l ines.It bot tom of 3rd c lu tch is swir led and t rans makesgear noise.2 . Ref il l w ith 3 qts . o f Dexron recommended type ATF. 3. Start replace countershaft and rinq qear.engine and shi ft t rans 10 D4. 4. Let trans shift through gearsa t

least 5 times. 5. Shif t to reverse and neutral a t least 5 t imes. R Bevery careful not to damage the torque converter casewhenS. Drain and refil l. replac ing the main ball bear ing. You may also damage the oi l pumpB Set idle rpm in gear to specified idle speed. If still no good. ad when you torqua down the main valve body; this wi ll resul t in oi l pumpj us t the motor mounts asout li ned in engine sec tion of service seizure if not detected. Use proper tools.

manual.C If the large clutch piston Oring ISbroken, inspect the pistongroove for rough machining. S Ins ta ll the main sea l f lush wi th the torque converter case.

0 I f the c lu tch pack isseized. or i sexcess ive ly worn. inspect the When pushing it into the torque converter case unti l it bottomsothe r clutches for wear , and check the ori fice control valves out . i t w il l b lock the o il return passageand resul t i n damage.and throttle valves for free movement. T Harsh downshif ts when coast ing to a s top wi th zero throt tl e may

E I f throt tl e valve B iss tuck . inspect the c lu tches for wear . be caused by a bent-in throttle valve retainer/cam stopper.F I f the modula tor valve is stuck open (does not modulate l ine Throttle cable adjustment may clear this problem,pressurel . the trans wil l shi fl normally with lessthan 5/S throttle check this adjustment, too. See page 14-75.but wi ll shi ft up very late over 5/8 throt tle . I f the modula tor va lve U Check i f servo valve check valve stopper cap is installed. If i t wasiss tuck c losed. throt tl e va lve A pressure will bezero and resul t i n not instal led, the check va lve may havebeen pushed out byeartv upshi fts and no forced downshi fts. hydraul ic pressure causing a leak (internal) affecting all forwardG If the 1-2 va lve iss tuck c losed, the transmiss ion wil l not upsh if t. gears.I f stuck open. the t ransmission has no low gear. V Throttle cable adjustment isessent ial for proper operation of theH I f the 2nd ori fice cont ro l valve is stuck, inspec t the 2nd and 3rd t ransmiss ion. Not only does i t a ffec t the shi ft points i f misadclutch packs for wear. [usted but also the shi ft quali ty and lockup clutch operation.

I f the 3rd ori fice control valve iss tuck . inspec t the 3rd and 4th A too long adjus ted cable wi ll result i n throt tle pressure being tooI low for the amount of engine torque input into the transmission,clutch packs for wear. and may cause c lu tch s lippage. A too short adjus ted cable willresul t in too high throttle pressures which may cause harsh shi fts,J I f the c lutch pressure control valve iss tuck c losed, the tr' !Jns erratic shifts and torque converter hunting.

mission will not shift out of low gear.

Automatic Transmission Service Group1 5


16/80

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Serviceechnical InformationNOTE: Stop engine when attaching hoses for pressuretests.Torque hose fitting to 18 Nm (1.8 kg-m. 12 Ib-ttl.

Do not reuse aluminum washers. Forthrottle and governor test. use Low PressureGauge. 07406-0070000.

LINE PRESSURE

GAUGE SET 07406-0020003 LOW PRESSUREGAUGE!includes pressure hose set 07406-0020201) (07406-0070000)

3rd CLUTCHPRESSURE

THROTTLEB PRESSUREHOSE FITTING

CAUTION: Before checking. be sure transmissionis filled to proper level.

SELECTOR FLUID PRESSUREPRESSURE MEASUREMENT SYMPTOM PROBABLE CAUSE ..POSITION Standard Service Limit With parking brake applied. No (or low) Torque converter. oil 834 883 kpa (8.5 785 kpa (8.0 kg/em.

UNE Nor P Run engine at 2.000 rpm. LINE pressure pump pressure regu- -S.O kg/cm.121 114 psi)lator. torque governor -128 psi)check valve. oil pump

1st 03 or 04 MEASUREMENTS No (or low) 1st clutch or 834-883 kpa (8.5- 785 kpa (8.0 kg/em . With parking brake applied raise FIRST pressure O-rings S.Dkglem.121-128psol 114 psi)f ront wheels off ground and suppon No. (or low) 2nd clutch or 834-883 kpa (8.5- 785 kPa (8.0 kg/cm .2nd 2 with safety stands. Run engine at 2.000 rpm. SECOND pressure O-rings 9.0kglcm.121-128psi) 114 psi)

2nd 03 or 04 No (or low) 2nd clutch or 441-883 kpa (4.5 392 kpa (4.0 kg/cmSECOND pressure O..rings -9.0 kg/cm.64 57 psi) with leverNo (or low) 3rd c lutch or -128 psi) released. 785 kPa (8.03rd 03 THIR0 pressure O-rings varies with throttle kg/em .114 psi) withopen. lever in full throttle

04 4th clutch position4th No (or low) FOURTH

R pressure Se rvo va lve o r 834-883 kpa (8.5- 785 kpa (8.0 kg/em .4th clutch 9.0kglcm .121-128psi) 114 psi) With parking brake applied raise No (or low) THROTo Throttle valve A OkPa (0 kg/cm .O psi) 539 kPa (5.50 kg.front wheels of f ground and suppon TLE pressure Throttle modulator w it h l eve r i s r el eased. cm.78 psi)with safety stands. valve 544-559 kPa (5.55 with lever in ful l throt -

Run engine at 1.000 rpm. -5.70 kg/cm.79 tie position. Disconnect throt tle control cable at -81 psi) with leve r in

THROTTLE 03 or 04 throttle lever. full throttle position. Read pressure with lever released. Throttle valve B OkPa (0 kg/cm .O psi) 785 kPa (8.0 kg/em. Manually push lever up simulating full with lever is released. 114 psi)throttle. 834-883 kP. (8.5

Read pressure with lever in ful l tbrct- -9.0 kg/cm . 1 21tie position. - 128 psi) With lever in

full throttle position. Place vehicle on chassis dynamo- No (or low) GOVER- Governor valve 213-223 kP. (2.17 208 kPa (2.12kg/cm.meter, or jack up front of car.support NOR pressure -2.27 kg/cm.31 30 psi)

GOVERNOR 03 or 04 with safety stands. block rear wheels. -32 psi)and set hand brake.

Run vehicle at 38 mph.

Automatic Transmission service Group1 6


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Service InformationTest--------------------------~1. Engage parking brake and block front wheels.2. Connect safety chains to both front tow hooks and

attach. with minimumslack, to somestrongstationaryobject.

3. Connect tachometer, and start engine.4. After engine has warmed up to normal operating

temperature, shift into I 031.5. Fully depressbrake pedaland acceleratorfor 6 to 8

seconds, and note engine speed.CAUTION: To prevent transmission damage. donot test stall sp,eedfor more than 10 seconds at atime.

6. Allow 2 minutes for cooling, then repeat same testin 1041, r n and f f i JStall speed in 1031, 1041,[)], and [[] must be thesame, and must also be within limits:

Stall Speed RPM:Specification:Service Limit:

2,650 rpm2,300 - 2.900 rpm

TROUBLE PROBABLECAUSEStall rpm high Low fluid level or oil pumpin [1], 1031, 1041 output, clogged oil strainer,&[ ID . pressure regulator valve

stuck closed.Slipping clutch.

Stall rpm high Slippage of 1st clutchin 1031, 10410nly.Stall rpm low Engineoutput low,in~, 1031, 1041 throttle cable misad-& [ J i J . justed. Oil pump seized. Torque converter one-way clutch slipping.

1 7

Checking/Changing --------.CheckingWith the car on level ground. unscrew the transmissiondipstick and check the level of fluid immediately afterthe engine is shut off (within one minute). The fluidlevel should be between the full and low marks. 00 notscrew dipstick in to Checkthe fluid level. If the level isat, or below. the low mark, add DEXRON-type automat-ic transmission fluid.

Changing1. Bring the transmission up to operating temperature

bydriving the car. Parkthe car on level ground, turnthe engine off, then remove drain plug.

2. Reinstall the drain plug with a new washer, thenrefill the transmission to the full mark on the dip-stick.Automatic transmission Capacity:2.4 r (2.5 U.S. qts. 2.1 Imp. qt.) at change5.4 f (5.7 U.S. qts. 4.8 Imp. qt.] after overhaul

___ FULLDIPSTICK

DRAIN PLUG40 N'm (4.0 kg-m, 29 Ib-ft)


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Service Information, . Disconnect the ground cable at battery and

transmission.2. Releasethe steering lock, and shift gear selector toN.3. Disconnect the wiring: Battery positive cable from starter. Black/white wire from starter solenoid.

4. Drain transmission fluid. Reinstall drain plug andwasher.5. Disconnect the speedometer cable.CAUTION: Be careful not to damage the speedom-eter cable during transmission removal.

6. Disconnect the cooler hoses, andwire them upnext toradiator so ATF won't drain out.7. Removethe cqnter console, then disconnect the shift

cable by removing the adjusting pin.CAUTION: Be careful not to damage the transmission shiftcable during transmission removal.

Take care not to bend the cable when removingit.Do not use pliers to remove the cable from thelinkage.Always replace a kinked cable with a new one.

8. Unscrew the cable guide bolt. and pull the throttlecontrol cable out of the cabin.CAUTION: Be careful not to damage the throttlecontrol cable during transmission removal.

9. Removethe right and left driveshafts and intermediateshaft (seesection 16).

10. Screw' 0 mmbolt into the cylinder headandattatch ahoist chain to the bolt and the other end to the enginehanger plate, then lift the engineslightly to unloadthemounts:

11. Remove the engine under cover and splashshield.(seesection,S).12. Disconnect the header pipe at exhaust manifold.(seesection,S)

13. Placea jack under the transmission andraisetransmis-sion just enough to take weight off mounts.

14. Remove the bolts from the front mount at the frontengine bracket.

FRONT ENGINE BRACKET

TRANSMISSION

15. Removethe rear transmissionmount bracket by remov-ing the mounting bolts.

REAR TRANSMISSIONMOUNT BRACKET

65 N'm (6.5 kg-m. 48 Ib-ft)



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, I I C i I A T S G I . Tee h n ic a I~41rC y IO YJC iii

Service Information

, 6. Remove the transmission housing bolts from fronttransmission mount bracket.

FRONT TRANSMISSIONMOUNT BRACKET

'7. Remove the torque converter cover.

-TORQUECONVERTER COVER

12 Nm (1.2 kg-m, 9Ib-ft)

, 8. Remove the drive plate tightening bolts by rotating theengine crankshaft pulley.CAUTION: The pulley bolt is a right-hand thread,and may occasionally be loosened when the pulleyis turned counterclockwise. After removing thedrive plate, check that the bolt is tightned securely.

, 9. Remove the bolts attaching the starter motor, andremove the starter motor.

20. Remove the rest of the transmission mount bolts.45 Nm (4.5 kg-m, 33 Ibft)

58 Nm (5.8 kg-m, 42 Ibft)

2'. Pull the transmission away from the engine until itclears the 14 mm dowel pins, then lower on the trans-mission jack.



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Information

Torque Bolt sizeA- 8 Nom(0.8 kg-m, 6 lb-ft) 1-5xO.8mm8-12 Nom(1.2 kg-m, 9Ib-ft) 2-6 x 1.0 mmC-14 Nom(1.4 kg-m, 10 Ib-ft) 3-8 x 1.25 mmD-18 Nom(1.8 kg-m, 12Ib-ft)E-27 Nom(2.7 kg-m, z o e -rnF-29 Nom(2.9 kg-m, 21 Ib-ft)G-40 Nom(4.0 kg-m, 29 lb-ft)H-95-+0-+95 Nm (9.5-+0-+

9.5 kg-m, 70-+0-+70 Ib-ft)1- 110-+0-+110 Nm (11.0-+0-+

11.0 kg-m, 80-+0-+80 Ib-ft)

(2 )ReplaceH(Left hand~thread) ~

< D WASHER 8 mm@ O-RING 6 x 2.3 mm@ END COVER@ GASKET BREATHER CAP DOWEL PIN 8 x 14 mm(2 ) LOCK NUT 1st CLUTCH

THRUST WASHER 23 mm@ THRUST NEEDLEBEARING 31 x 47 x 2 mm NEEDLE BEARING28x33x16.8mm@ MAINS HAFT 1st GEAR

@ THRUST WASHER@ COLLAR 23 mm@ SNAP RING 70 mm@ MAINSHAFT BEARING@ LOCKNUT@ PARKING GEAR@ ONE-WAY CLUTCH@ COUNTERS HAFT 1st GEAR NEEDLE BEARING 1st GEAR COLLAR@ SNAP RING 64 mm COUNTERSHAFT BEARING@ WASHER 8 mm@ SPRING REVERSE IDLERBEARING HOLDER

@ REVERSE GEAR SHAFT@ PARKING PAWL PARKING PAWL SPRING PARKING PAWL SHAFT STOP PIN LOCK PLATE PARKING LEVER@ PARKING PAWL ROLLER ROLLER PINQ 7 ) PARKING SHIFT ARM RETURN SPRING@ WASHER 5mm@ COTTER PIN@ WASHER 14 mm@ SPRING@ STEEL BALL(44 DIFFERENTIAL

OIL SEAL@ LOCK PLATE~.\ THROTTLE CONTROL

LEVER

~i) THROTTLE CONTROLSHAFT SPRING

@ THROTTLE CONTROLSHAFT SEAL@ LOCK PLATE@ THROTTLE CONTROLCABLE BRACKET\511 DIPSTICK~2\ DOWEL PIN 14 x 25 mm(~3:GASKET(541 TRANSMISSION HOUSING~I NEEDLE BEARING\ 2 . 6 \ REVERSE IDLER GEAR



21/80

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Replace

~) REVERSE GEAR COLLAR NEEDLE BEARING@ l COUNTERSHAFTREVERSE GEAR SELECTOR HUB REVERSE GEARSELECTOR REVERSE SHIFT FORK LOCK PLATE@ COUNTERSHAFT ASSY COUNTERSHAFT NEEDLEBEARING@ l OIL GUIDE PLATE MAINSHAFT ASSY@ LOCK UP SHIFTVALVE BODY~) SEPARATOR PLATE

@ DOWEL PIN REGULATOR VALVE BODY

@ MODULATOR VALVE BODYRemoval, page 14-25@ SEPARATOR PLATE@ CHECK VALVE STOP PLATE 4th ACCUMULATOR COVER O-RING 2nd/3rd ACCUMULATOR COVER@ SERVO VALVE BODY ASSY

@ RETURN SPRING SERVO VALVE O-RING 31 x 2.7 mm SECONDARY VALVE BODYASSY@ DOWEL PINS

SERVO SEPARATOR PLATE@ DOWEL PIN STOP PIN O-RING STATOR SHAFT DOWEL PIN 1st CLUTCH PIPE STEEL BALLS@ MAIN VALVE BODYASSY THROTTLE CONTROLSHAFT(E l E-CLIP LOCK PLATE GOVERNOR VALVE PUMP DRIVE GEAR@ PUMP DRIVEN GEAR@ MAIN VALVE SEPARATORPLATE


J O O ) FILTER SCREENI~/ SUCTION PIPE11~MANUAL VALVE PINO !t ROLLER~. WASHER 5 mm@ COTTER PIN~j$ CONTROL SHAFT~i~DIFFERENTIAL~1SNAP RING 80 mm@ TORQUE CONVERTER

HOUSINGJ Il DIFFERENTIAL OILSEAL, 1 } p MAINS HAFT BEARINGO !~ MAINS HAFT OILSEAL SECONDARYSEPARATOR PLATE


22/80

; , l r : i I ATSIi I . Tee h n I c a I Se r v Ice I n for mat Ion"''''7IC ,. 111 '0 re .,

1. Removethe dipstick.2. Remove the nine bolts from the end cover, then

remove the cover.

DIPSTICK

END COVER

3. Shift the transmission to PARK.4. Lock the mainshaft using the mainshaft holder.

MAINSHAFT HOLDER07923 - 6890202

MAINSHAFT

5. Removethe end cover gasket, dowel pins, and 0-rings.

6. Prythe stakededgeof the locknut flange out of thenotch in the' st clutch.

1st CLUTCH MAINSHAFT LOCKNUT

DOWEL PINS8 x 14mm

GASKET O-RINGS6 x 2.3 mmReplace

7. Removethe mainshaft locknut.CAUTION: The mainshaft locknut has left-handthreads.

22 mm SOCKET

MAINSHAFT LOCKNUT



23/80

i l r . : i l A T S & I . Tee h n ic a I.""rc 7a ' 1"0_ rc . .,

Service Information

8. Remove the 1st clutch.9. Remove the needle bearing and thrust washer from

the mainshaft.10 Remove the a-rings andfirst gearfrom the mainshaft.

THRUST WASHER23 mm

31 x 47 x 2 mm

1st GEAR -- ---~

NEEDLE BEARING ~28 x 33 x 16.8 mm ~

THRUST WASHER ~ O-RINGS

11. Pry the staked edge of the locknut out of the notchin the parking gear.

12. Remove the countershaft locknut.SOCKET WRENCH 30 nim

13. Remove the parking pawl. shaft. stop pin andspring.

PARKING PAWL STOP PINj

14. Remove the parking gear and countershaft 1st gearas a unit.

PARKING GEAR

COUNTERSHAFT



24/80

i l r : : a RTS61 . Tee h n i c a I Se r vic e_ . ~ ,. 'c " ' 10 'c.~

Information15. From the countershaft, remove the needle bearing

and 1st gear collar. From the mainshaft, removethe 1st gear collar.16. Remove the reverse idler bearing holder assembly.NEEDLE BEARING30 x 35x.~1 mm

COUNTERSHAFTO-RINGS19.8 x 1.9 mm

~ l~M~;L.,L"';'_ NEEDLEBEARING

IDLER BEARING HOLDERRETAINING BOLT I ~

REVERSEGEAR SHAFT

~R~RING1 0 ! f I ' / : : , ~ 1 E R ASSEMSL VSTEEL BALL---

17. Benddown the tab on the lock plate under the park-ing shift arm bolt.

18. Remove the bolt, then remove the parking shiftarm.

SPRING

19. Benddown the tab on the throttle control lever boltlock plate, then remove the bolt. Now, remove thethrottle control lever and spring from the throttlevalve shaft.

THROTTLE VALVE SHAFT

SPRINGTHROTTLE CONTROLLEVER

20. Removethe 8 x 1.25 mm bolts and 10x 1.25 mmbolt, (1) thru (15), in the sequenceshown.

THROTTLE CONTROLBRACKET

CONTROL ~rSPRINGPINSHAFT ~

21. Align the control shaft spring pinwith the cutout inthe transmission housing.



25/80

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Service Information22. Install the transmission housing puller over the

countershaft with four bolts and tighten securely.Then screw in the puller bolt against the end of thecountershaft until the transmission housing comesloose.

6x1.0x18mm

23. Remove the puller and separate the housings.Remove the reverse idler gear and needle bearingfrom the transmission housing.

24. Remove the gasket and the dowel pins.

REVERSE IDLER GEAR

TRANSMISSIONHOUSING

TORQUE CONVERTERHOUSING

1. Remove the reverse gear collar, countershaft re-verse gear and needle bearing.

REVERSE GEARCOLLAR ~.

COUNTERS HAFT ~REVERSE GEAR ~NEEDLE BEARING ~.

REVERSE GEAR iELECTOR HUBREVERSE GEAR __ I..SELECTOR ~REVERSE . ._;;;

SHIFT FORK IINEEDLE BEARING ~ \28 x 33 x 20 mm LOCK PLATE

COUNTERS HAFT4th GEARDISTANCECOLLAR

COUNTERSHAFT

2. Bend down the tab on the lock plate and removethe bolt from the reverse shift fork.Remove the reverse shift fork and reverse gear se-lector as a unit.Remove the selector hub, countershaft 4th gear,needle bearing and distance collar.Removethe mainshaft and countershaft together.NOTE: It will be necessary to pull up the counter-shaft at a slight angle to clear the governor.

3.

4.5.



26/80

\I~ AT561 . Tee h n I c a I:otr" 'I 'IC ' 1 ' . 1 . 0 laY IC . -,

Service Information

1. Bend down the tabs on the lock plates, removethebolts holding the governor to the torque converterhousing, and removethe governor.

GOVERNOR

1. Removethe suction pipe.SUCTION PIPE

2. Removethe accumulator covers.CAUTION: Accumulator covers are spring loaded;

f r- '. :: _ ! / to prevent stripping the threads in the torqueconverter housing, press down on the accumulatorcovers while unscrewing the bolts in a criss-crosspattern.LOCK PLATES

3. Removethe accumulator springs.

4th ACCUMULATORCOVER

2nd/3rd ACCUMULATORCOVER

4th ACCUMULATOR SPRING 2nd ACCUMULATOR SPRING00: 18.6mm (0.73 in) 00: 20.2 mm (0.79 in.)



27/80

\ ( I C I ATS61 . Tee h n ic a I Se r vic e~ " ' ' ' ' C T t ro ...... ,el f{t

In for rna t ion4. Remove the three bolts attaching the modulalor

valve body.5. Removethe 1st, 4th and 3rd clutch pipes.

4th CLUTCH PIPE1st CLUTCHPIPEI3rdCLUTCHPIPE

MODULATORVALVE BODY

6. Removethe servovalvebody (3 bolts).7. Removethe check valve stop plate.

SERVO VALVE BODY

CHECK VALVE

8. Remove the E-clip. Then remove the thottle controlshaft from the separator plate.

9. Remove the separator plate and dowel pins.

THROTTLE CONTROLSHAFTDOWEL PINS

SEPARATOR PLATE

10. Remove the secondary valve body, being carefulnot to losethe 2 steel balls, ball spring, timing accu-mulator piston and valve spring, and secondaryfilter.CAUTION: Do not use a magnet to remove thesteel bails; it may magnetize the balls.

BALL SPRING~/TEEL :-BALLSi \

SECONDARYFILTER



28/80

\1~AT5GI, Tee h n I c a I Se r vic e I n for mat ion; (r4l 'reya u ro Jc. fit'

11. Remove the separator plate and dowel pins.

DOWEL PINS

SEPARATOR PLATE

12. Remove the LC-Shift valve body and separatorplate (5 bolts).

LC-SHIFTVALVE BODY

13. Removethe regulator valve body.

REGULATORVALVE BODY

14. Remove the stator shaft arm, dowel pins and stoppin.

STATOR SHAFT ARM

DOWEL PINS 8 x 14 mm



29/80

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Information

, 5. Remove the cotter pin, washer, rollers, and pinfrom the manual valve.

MANUAL VALVE

,---- WASHER

,--- COTTER PIN, 6. Remove the main valve body being careful not to

losethe 3 steel balls, check ball spring, torque con-verter check valve and spring.CAUTION: Do not use a magnet to remove thesteel balls; it may magnetize the balls.NOTE: Top oil passage steel ball in this drawinghas a spring beneath it.

SEPARATOR PLATE

'7. Remove the pump gears and shaft.'8. Remove the separator plate, dowel pins, check

valve, and spring., 9. Removethe filter screen.

NOTE: Donot reuse filter screen; install a new oneon reassembly.

FILTER SCREEN



30/80

\ l r : : i I ATSG I , Tee h n I c a I Se r vic e I n for mat Ion~"'I'rc 7 ''0. , "'rcl: t f * '

Removal----------------------------------------------------------~1. Remove the cable holder.

2. Remove the cotter pin, control pin, and controllever roller from the control lever.

COTTER PIN

\d- l W ;~'

CONTROL PIN

/

3. Bend down the tab on the lock plate under the boltin the control lever . Then remove the bolt and lever.

f!. _ . _ I ~ g :4. Turn the torque converter housing over and remove

the control shaft.

Dsassembly/Reassembly-------------------------./1(JI/LE


31/80

\ l r . : : i i I A T 5 6 I , Tee h n ic a I. ... ..7IC " '''11''0 YIC. (Ii

Service Information

1. Separate the countershaft 1st gear from the park-ing gear by turning the parking gear in the directionshown.

PARKING GEAR

COUNTERSHAFT1st GEAR

2. Removethe one-way clutch by prying it up with theend of a screwdriver.CAUTION: Do not pry on the three copper frictionstrips; if you break a strip. the clutch will not workproperly.

COPPERFRICTIONSTRIP

COUNTRSHAFT1st GEAR

~~:

Inspect the parts as follows:

Inspect the parkinggear for wear orscoring

Inspect the one-wayclutch for damage orfaulty movement

Inspect the counter-shaft 1st gear for wear -~,-4~.or scoring

After the parts are assembled, hold the countershaft1st gearand turn the parking gearin direction shown tobe sureit turns freely.

PARKING GEAR

COUNTERSHAFT1st GEAR

SCREWDRIVERAutomatic Transmission Service Group

31


32/80

, I C lRTS61 . Tee h n ic a I.. .~,. 'c"a " , IfI IO ' l'JCK t f ' "

Service InformationNOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blowout all passages. Replacevalve body as an assembly if any parts are worn or damaged. Check all valves for free movement. See Section 3 for spring specifications. Coat all parts with ATF before reassembly.

2-3 S",FT SPRING -----\

VALVE SPRING CAP ~j ~ , \~

\....----1-2 SHIFT SPRING

E-

TORQUE CONVERTER _CHECK VALVE

Inspect for scoringor scratches

SPRING----~I

~ORIFICECONTROL ~\SPRING -=~

3-4 SHIFT SPRING

!3-4SHIFT~ VALVE\ I 3-4 SHIFT BALL SPRING. f ! I \ j p ( r :CK) STEEL BALLS

, ~ (4.76 rnrn.2nd GEAR ORIFICE _/ ~ 0,187 ln.lCONTROL VALVE ~Inspect for scoring ~ ~ 0~ SHIFT VALVEor damage. ~!! '


33/80

\ ( r . a ATS61. Tee h n ic a I Se r vic e_....I'IC n o YIC. fit

Information

NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.Blowout all passages.

Check all valves for free movement. SeeSection3 for springspecifications.

ROLLER ~ aCPCVALVE CAP ~

ROUER - - - - - - - 1 l ~ CPCVALVEREVCONTROL ~ ~~VALVE CAP--V ~ CPCVALVE SPRING

o ~ REV CONTROL VALVE,,'ROLLER ~ ~

LCCUT~% ~.VALVE CAP / ~~LCCUT SPRING

LCCUT VALVETIMINGACCUMULATOR -----,PISTON

REVCONTROLVAL~E SECONDARY FILTERSPRING STEEL BALL

C--SPRING~0-- STEEL BALL

VALVE

ACCUMULATORCONTROL VALVE --------SPRING

VALVE SPRING ( JSEAT -----



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Service InformationNOTE: This repair is only necessary if one or moreof the valves in a valve body do not slide smoothlyin their bores. You may usethis procedure to freethe valves in the main valve body, regulator valvebody, lock-up shift valve bodv, and servo valvebody. DONOTuse this procedure to free the valvesin the governor; if any governor valves are stuck,thegovernor must be replaced as an assembly.

1. Soak a sheet of #600 abrasive paper in ATF forabout 30-minutes.

2. Carefully tap the valve body so the sticking valvedrops out of its bore.CAUTION: It may be necessary to use a smallscrewdriver to pry the valve free. Be careful not toscratch the bore with the screwdriver.

3. Inspect the valve for any scuff marks. Usethe ATF-soaked#600 paperto polish off any burrs that areon the valve, then wash the valve in solvent anddry it with compressed air.

4. Roll up half a sheet ot ATF-soakedpaper and insertit in the valve bore of the sticking valve.Twist the paper slightly, so that it unrolls and fitsthe bore tightly, then polish the bore by twistingthe paper asyou push it in and out.CAUTION: The valve body is aluminum anddoesn't require much polishing to remove anyburrs.

ATFsoaked#600 abrasive

5. Removethe #600 paper and thoroughly wash theentire valve body in solvent, then dry with com-pressed air.

6. Coatthe valve with ATFthen drop it into its bore. Itshould drop to the bottom of the bore under itsown weight. If not, repeat step 4, then retest.

VALVEBODY

7. Remove the valve and thoroughly clean it and thevalve body with solvent. Dry all parts with com-pressed air. then reassembleusing ATF as a lubri-cant.



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Service Information

NOTE: Coat all parts with ATF before assembling.1. Slide the spring into the hole in the big end of the

shift valve.While holding the steel balls with the tips of yourfingers, put the sleeve over valve.

STEEL BALLS(4.76 mm. 0.187 in.)Place spring betweensteel balls.

SHIFT VALVE

2. Place the shift spring in the valve. then slip it intothe valve body and install the valve cover.

SHIFT VALVE

SHIFT VALVECOVER

3. Set the relief spring in the relief valve and install itin the main valve body.

4. Install the spring with a screwdriver, then installthe check valve cap with the cutout aligned withthe screwdriver.

VALVE SPRING CAP

SCREWDRIVERRELIEF SPRING

5. Install the manual valve. detent rollers and spring.

DETENT ROLLERS

DETENT SPRING



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Information

6. Install the pump gears and shaft in the main valvebody.

Chamfered side faces

1D R IV E G EA R

V ALV E B OD Y

7. Measure the thrust clearance of the driven gear-to-valve body.Drive/Driven Gear Thrust (Axial) Clearance:Standard (New): 0.03-0.05 mm

(0.001-0.002 in.)Service Umit: 0.07 mm (0.0028 in.)

PU MP D RIV EN G EA R

8. Install the oil pump shaft and. measure the sideclearance of the drive and driven gears.Pump GearsSide (Radial) Clearance:Standard (New): Drive gear 0.210-0.266 mm

(0.0083-0.0105 in.)Driven gear 0.05-0.088 mm

(0.0020-0.0035 in.)

-:~~I~ . . : > 1D R IV E G EA RInspect teethfor wear or elamage.



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Service Information

NOTE: Clean all parts thoroughly in solvent or carburetor cleaner. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement, SeeSection 3 for spring specifications. 'Coat all parts with ATF before reassembly.,. ~ RETAINERHold the retainer in place while removing the lock vbolt. Once the bolt is removed, release the retainer ~~slowly. ~ SPRING

6 x 1 .0 mm LOCK BOLT ~ '- SEAT~ , .. , ""STATOR REACTION, ~ ~ ) ~ " ' i $ ' - , SPRING_~~ OUTER SPRING

PRESSURE ~\ \REGULATOR 0 INNER SPRINGVALVE BODY . . . . . . . . . _ ~ o ~Inspect for wear. . ................~~~ G PRESSURE REGULATOR VALVEscratches. or sconng. , < ; ~

, ",.....--.'A"-"0Ul_"~, . .

ROLLER

Reassernbly--------------------------------------------------------~, . Clean all parts thoroughly in solvent or carburetor

cleaner, and dry with compressed air. Blowout allpassages.

2. Coat all valves with ATF.3. Install the pressure regulator valve, and the inner

and outer springs.4. Install the reaction spring, spring seat, and retainer.

Align the hole in the retainer with the hole in thevalve body, then press the retainer into the valvebody and tighten the lock bolt.

SPRINGSEAT

RETAINER REACTION SPRING LOCK BOLT12 Nom (1.2 kg-m,9Ib-ft)

3 7


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Information

NOTE: Clean all parts thoroughly in solvent or carburetor cleaner. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement, See Section 3 for spring specifications. Coat all parts with ATF before reassembly.

ROLLER/ 2 , . . 3 . 5mm~ _LC SHIFT VALVE CAP~

~ LC SHIFT VALVE~~~)~=:PRING

~LOCK-UP SHIFTVALVE BODYInspect for scoring ordamage.

~~/'PRING ~~ ~_ ROLLER21.8 x 3.5 mm,/~LC TIMING VALVE B '"lnspect for scoring or scratches. LC TIMING VALVE CAP



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Service Information

NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.Blowout all passages.

Check all valves for free movement. SeeSection 3 for spring specifications.

/6X152mm

MODULATOR VALVE BODY ~ iSPRING ~

RETAINER \ .:7' IX~" ' l IMODULATOR VALVE __ ----1

Replace

NOTE: Do not adjust orremove these bolts; they areadjusted at the factoryfor proper shift points.



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Service InformationNOTE: Clean all parts thoroughly in solvent or carburetorcleaner. and dry with compressed air. Blowout all passages. Check that the governor works smoothly; replace it if it does not. See Section 3 for spring specifications. Coat all parts with ATF before reassembly.

FILTERClean

WOODRUFFKEY3mm

HOLDERInspect for

SNAP RING14 mm

Inspect teethfor wear or damage.

LOCK PLATES

Inspect face for wear or damage.

Inspect for damage to ends.

GOVERNOR ~ 3rd WEIGHTSPRING A ~ Inspect for wear,~ ~ scratches. or scoring.~ SNAP RING 28 mm

SNAP RING 20 mm ~ ~ ERING 5 mmPush down on 3rd ~~..----- Replace.weight to ease snap ring @removal.

Automatic Transmission Se",';r.e Group40


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Service InformationNOTE: Lubricate all parts with ATF during reassembly. Install thrust needle bearings with unrolled edge of bearing retainer facing washer.

20mm

SPACER COLLAR20mm

METAL SEAL RINGS MAINSHAFTCheck splines for excessivewear or damage.Check bearing surface forscoring, scratches or excessivewear.

Inspect for gallingand rough movement.

Replace.

THRUST NEEDLE BEARING42x58x2mmInspect for galling and roughmovement. THRUST WASHER36 mm

2nd/4th CLUTCH

19.8 x 1.9mmReplace.

NEEDLE BEARING36 x 41 x 14.8 mmInspect for galingand rough movement. 36 x 52 x 2 mm

4th GEARCOLLAR 4th GEARNEEDLE BEARING32 x 38 x 14 THRUST NEEDLEBEARING

32 x 44 x 2 mmInspect for gallingand rough movement.

39 x 54 x 2 mm

32 x 38 x 20mmInspect for gallingand rough movement.

WASHER26 x 45 x 3 mm 26mm

Automatic Transmission service Group41


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; . l r J i I AT56 t Tee h n I c a I"'.'J'IC ' 1 ' . & . ' 10 ,C ..,

Service Information

1. Remove both the mainshaft and countershaftbearings from the transmission housing.

2. Assemble the mainshaft and the countershaftincluding bearings and all parts shown below.

3. Install the mainshaft and countershaft assembliesinto the torque converter housing.

4. Install the mainshaft holder to prevent the shaftsfrom turning.

5. Torque the mainshaft locknut to 35Nom (3.5kg-m,25 Ib-ft). (Left-hand threads.)6. Hold the parking gear on the countershaft with

your hand and torque the counters haft locknut to35 Nom(3.5 kg-m, 25 Ib-ft).

7. Measure clearances asdescribed on the next page.Lubricate all parts with ATF before finalreassembly.

Counters haft Assembly

~LOCKNUT~~:~ING

i;:\

ONE WAYCLUTCH

, 11/ 3~GURI , Q N:: BEARING

32 x 38 x 20 mm

OTHRUST NEEDLE8EARING35 x 52 x 2 mm~SPLINED WASHER

3rd CLUTCH

~ BALL BEARING~ REVERSE GEAR~COLLAR~ NEEDLE BEARINGW- 30 x 36 x 14 mm

REVERSEGEARSELECTOR HUBGroove faces~ reverse gear

~ REVERSE GEARSELECTORFlat s ide facesreverse gearu;;,.._--4th GEAR

NEEDLE~BEARING_ 28 x 33 x 20 mm

B--SPACER COLLAR28mm(Selective)~2ndGEAR~ ~~~~INERS

< b ~ THRUST NEEDLEBEARING~ v ; 39x54x2mmASSEMBLED COUNTERSHAFT



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Service Information

, 1 1~ LOCK NUT / - , ' . . r e . ~.:--=. . - = . : ' ~ , r { ~ 2nd GEAR( rG>~ .~ 1st CLUTCH ~ ~~:D~~ =E~4~~~m

~ ., THRUST NEEDLE----l . THRUST WASHER ~ BEARINGcgr-23mm ~ 42x58x2mm~~ THRUST NEEDLE ~.~BEARINGtOl 31 x 47 x 2 mm___ NEEDLEBEARING

28 x 33 x 16.8 mmr~~W 1st GEAR

Mainshaft Assembly

~ SPLINED WASHER~ 23 mm COLLAR0-NAP RING 70 mm

~ __ BALL BEARING

04 SNAP RING-WASHER0.-THRUST NEEDLE

BEARING~32x44x2mmW 4th GEAR

:' NEEDLE BEARING~32x38x14mmlOJ... NEEDLE BEARING., 32x38x20 mm~ 4th GEAR COLLAR

~ THRUST NEEDLE~- BEARING

39 x 54 x 2 mm--HRUST WASHER2nd/4th

1 11 1 _ - CLUTCH

MAINSHAFT

ASSEMBLED MAINSHAFT

- THRUST WASHER~~ (Selective)~I THRUST NEEDLE~BEARING~ 36x52x2mmI 'V

NOTE: Make all measurements before changingthe thrust washers. Recheck after making the ad-justments .

10. On the mainshaft measure the clearance betweenthe shoulder of 2nd gear and main 3rd gear, thesame way you did on the countershaft in step 9.Mainshaft 2nd GearClearance:Standard (New): 0.07 -0.15 mm

(0.003-0.006 in.)

If the clearance exceeds the service limit, measurethe thickness of the 2nd clutch thrust washer (36mm I .D . ) and select one which gives the correctclearance.

THRUST WASHER\Replacement washer (36 mm I .D . I

CLASS PIN THICKNESSA 90441-PC9-0 10 3.47-3.50 mm(0.137-0.138 in.)B 90442-PC9-010 3.52-3.55 mm(0.139-0.140 in.)C 90443-PC9-0 10 3.57-3.60 mm(0.141-0.142 in.)0 90444-PC9-0 10 3.62-3.65 mm(0.143-0.144 in.)E 90445-PC9-0 10 3.67-3.70 mm(0.145-0.146 in.)F 90446-PC9-0 10 3.72-3.75 mm(0.147-0.148 ln.)G 90447-PC9-0 10 3.77-3.80 mm(0.149-0.150 in.]H 90448-PC9-0 10 3.82-3.85 mm(0.151-0.152 in.)I 90449-PC9-010 3.87-3.90 mm(0.153-0.154 in.l



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Service InformationNOTE: The 1st and 3rd clutches are identical except for the

piston plate installed in the 1st clutch . To disassemble the 2nd/4th clutch, use the special

toot.in Step 3 in the same manner as for the 1st and3rd clutches.

1.. ' Remove the snap ring.END PLATE

SCREWDRIVER

CLUTCH DRUM CLUTCH DISC

2. Remove the end plate, clutch discs and plates., st clutch only: Also remove the clutch piston plate.

CLUTCHPISTON PLATE

CLUTCH DRUM

3. Install the clutch spring compressor as shown.

CLUTCH SPRINGCOMPRESSORATT07GAE-PG40100

CLUTCH SPRINGCOMPRESSOR SET07GAE-PG40000

CLUTCH SPRINGCOMPRESSOR ATT07960-6120100

CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLY07GAE-PG40200

1st and 3rd Clutches

CAUTION: If either end of the compressor attach-ment is set over an area of the retainer which isunsupported by the spring, the retainer may bedamaged.

COMPRESSOR/ ATTACHMENT

DONOT SET HEREIRatainer unsupportedby spring)



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Service Information

Compress the clutch return spring.

CLUTCH SPRINGCOMPRESSOR SET07GAE-PG40000

CLUTCH RETURN SPRING

2nd/4th Clutch Assemble the spring compressor on the clutchdram.

CLUTCH SPRINGCOMPRESSOR ATT07GAE-PG40100

CLUTCHSPRINGCOMPRESSORSET07GAEPG40000 CLUTCH SPRING

}~COMPRESSOR ATT07960-6120100

CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLY07GAEPG40200



CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLY07GAE-PG40200 CLUTCH RETURN

SPRING

Automatic Trar (lmission servtce Group47


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Service Information

4. Remove the snap ring. Then remove the clutchspring compressor, spring retainer and spring.

SNAP RING40mm

5. Wrap a shop rag around the clutch drum and applyair pressure to the oil passage to remove the piston.Place a finger tip on the other end while applyingair pressure.

OIL PASSAGE COMPRESSED AIRHOSE NOZZLE



49/80

. c a Ie c h n l Service 0 nn t o r rn a t l. mbly /Inspectionisasse

=------------:CHHIEECCIK VALVE with----- Clean thorou9h~~etor cleaner.

solvent or carb1st Clutch . he 1st clutch.. late is installed In tOTE: Piston p

END PLATE CLUTCH DISCS

SPRINGRETAINER

CLUTCHPLATES

3rd ClutchO-RING104 x 2.2 mm O-RING104 x 2.2 mm

Replace

ENDPLATE

SNAP RING40mm

49


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Disassembly/Inspection (cont'd) ---------------------,2nd/4th Clutch

CLUTCH DISCS

I )~-SPRING RETAINER SNAP RING

40mm

O-RING39.S x 2.2 mmReplace. 104 x 2.2 mm

Replace.RETURN SPRING

104x2.2 mmReplace. O-RING39.S x 2.2 mm

Replace.

PISTONInspect for restriction,loose check valve, orrough aring groove.

/NAP RING119mm END PLATE

CLUTCH DISCS40mm SPRING RETAINER

50


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Service Information

NOTE: The 1st and 3rd clutch assembliesare identicalexcept install ing the clutch piston plate in the

1st clutch. To reassemble the 2nd/4th clutch, use the spe-cial tool in Step 7 in the same manner asfor the1st and 3rd clutches.

1. Clean all parts thoroughly in solvent, and dry withcompressed air. Blowout all passages.

2. Lubricate all parts with ATF before reassembly.

CLUTCH PISTON O-RINGIi

O-RING104 x 2.2 mm

SPRING WASHER(2nd/4th and 3rd Clutches)., Sl clutch has no spring washer.

3. Install new a-ring on clutch piston.2nd/4th and 3rd Clutches:Make sure the spring washer is properly positionedas shown.

O-RING39.8 x 2.2 mm

O-RING104 x 2.2 mm

SPRINGWASHER(2nd/4th and3rd Clutches)

(1stclutchonly)

4. Install the piston inthe clutch drum. Apply pressureand rotate to ensure proper seating.NOTE: Lubricate the piston a-ring with ATF beforeinstalling .CAUTION: Do not pinch O-ring by forcing pistoninstallation.

PISTON

1stc lutch only:Install the clutch piston plate.

CLUTCH PISTONPLATE

I

CLUTCH DRUM



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\I~ ATSIi I , Tee h n ic a I~41rC " r ro ICI .,

Service Information

5. Install the return spring and retainer.6. Position the 40 mm snap ring on the spring re-

tainer.

SNAP RING40mm

7. Assemble the spring compressor on the clutchdrum.CAUTION: If either end of the compressor attach-ment is set over anareaof the retainer which isun-supported by the spring. the retainer may be dam-aged.


SET HERE

(Retainer unsupportedby spring)

1st and 3rd clutches Assemble the spring compressor on the clutchdrum.


53/80

I.(~ ATS61.. Tee h n ic a I. . .. , . 'c " . .. . .. 11 '0. I Y'CI 0:

Service Information2nd/4th Clutch

Assemble the spring compressor on the clutchdrum.

./ CLUTCH SPRING, COMPRESSOR SET

07GAE-PG40000


CLUTCH SPRINGCOMPRESSOR ATT07GAE-PG40100

CLUTCH SPRINGCOMPRESSOR BOLTASSEMBLY07GAc-PG40200 CLUTCH RETURN

SPRING

9. Then install the snap ring (with its rounded edgefacing in ) in the hub groove and remove the springcompressor.

SNAP RING40 mm

10. Soak the clutch discs thoroughly in automatictransmission fluid for a minimum of 30 minutes.NOTE:Clutch piston plate isinstalled only in the 1st clutch,

11. Starting with a clutch plate, alternately install theclutch plates and discs. Install the clutch end platewith flat side toward the disc.NOTE: Before installing the plates anddiscs, makesure the inside of the clutch drum is free of grit orother foreign matter.

DISCSAND PLATES END PLATE



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\1~AT5GI, Tee h n ic a I~.t'IC "." 1" '0 1'Jca (fi'

Service Information

12. Install the 119 mm snapring.

SNAP RING

13. Using bent feeler gauges, carefully measure theclearance between the clutch end plate and the topdisc. Do not damage the disc.

End Plate-to-Top Disc Clearance:Service Limit

LOW 0.65 - 0.85 mm (0.026 -0.033 in.)2ND 0.65-0.8 mm (0.026-0.031 in.)3AD 0.4-0.6 mm (0.016-0.023 in.)4TH 0.4-0.6 mm (0.016-0.023 in.)

END PLATE TOP DISC

14. If not within service limit, select a new clutch endplate from following table.

PIN PLATE NO. THICKNESS22551-PC9-000 1 2.4 mm (0.094 in.)22552-PC9-000 2 2.5 mm (0.098 in.)22553-PC9-000 3 2.6 mm (0.102 in.)22554-PC9-000 4 2.7 mIT)(0.106 in.)22555-PC9-000 5 2.8 mm (0.110 in.).22556-PC9-000 6 2.9 mm (0.114 in.)22557-PC9-000 7 3.0 mm (0.118 in.)22558-PC9-000 8 3.1 mm (0.122 in.)22559-PC9-000 9 3.2 mm (0.126 in.)22560-PC9-000 10 3.3 mm (0.130 in.)

NUMBERh---,END PLATE

15. Check the clutch engagement by blowing air intothe oil passage in the clutch drum hub. Remove theair pressure and check that the clutch releases.

CLUTCH ASSEMBLY OSHA APPROVED30 psi NOZZLE



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Information

, . If sealsareto be replaced, orif differential needsre-pair, remove the differential.

ATTACHMENT07947-6340500

2. On the torque converter housing, remove the 80mm snap ring, then drive out the seal as shown.

3. Removethe differential seal from the transmissionhousing in the same way.

DIFFERENTIAL SEAL

4. On the torque converter housing, install the differ-ential 80 mm snap ring if removed.

SNAP RING80mm

5. Install the differential seals into the torque convert-er housing and transmission housing.

DRIVER07749-0010000

DIFFERENTIAL SEALReplace if removed.

ATTACHMENT07947-6110500



56/80

\(~ ATS61. Tee h n ic a I~"'t' .c"" '0 'c. tI"

Service Information

Torque converter housing1. Remove the mainshaft bearing and seal from the

torque converter housing.

DRIVER07749-0010000

TORQUECONVERTERHOUSING

2. Drive in the new mainshaft bearing until it bottomsin housing.

ATTACHMENT07947-6340201 MAINSHAFTSEAL

3. Then install the new mainshaft seal flush with thehousing. using attachment 07947- 6340201.

4. Turn the torque converter housing over and removethe countershaft bearing.

orATTACHMENT07GAC-PF402105. Make sure the oil guide plate isinstalled inthe bear-

ing hole. then install a new countershaft bearingflush with the housing.

ATTACHMENT DRIVER07749-0010000

H O U S I N C ~ DBEARING OIL GUIDE PLATE

~Automatic Transmission Setvtce Group

56


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Information

Transmission housing1. To remove the mainshaft and countershaft bear-

ings from the transmission housing, expand eachsnap ring with snap ring pliers, then push the bear-ing out by hand.NOTE: Do not remove the snap rings unless it'snecessary to clean the grooves in the housing.

SNAP RING PLIERS

~RSHAFT BEARING(64 mm snap ring'

Jol!gf,REMOVE

MAINSHAFT BEARING(70 mm snap ring)

2. Expandeach snap ring with snap ring pliers, insertthe new bearing part-way into it, then release thepliers. Pushthe bearingdown into the transmissionuntil the ring snaps in place around it.

Install withpart number out.

INSTALL

3. Make sure the snap rings are seated in the bearingand housing grooves.



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Service InformationInstalation-------------, Reassemby------------..,SPRING PIN 4 mm CHAMFERED

SHIFT LEVER\CONTROL SHAFT SPRING PIN 5 mm

Drive the 4 mm spring pin to adepth 1 mmin from the side that isopposite the cham-fer in the threaded hole.

SPRING PIN 4 mmt

ItCHAMFERED

~

NOTE: Lubricate all parts with ATF during re-assembly.1. Install the differential assembly. If the torque con-

verter housing, transmission housing and/or differ-ential side bearings were replaced, the differentialside clearance must be checked as shown in sec-tion 15.

2. Assemble the manual valve lever on the controlshaft, then install in the torque converter housingas shown.

MANUAL VALVELEVER CONTROL SHAFT

3. Install the control lever and new lock plate on theother end of the shaft. Tighten the bolt to thetorque shown, then bend the tab over against thebolt head.

CONTROL LEVER

6 x 1.0 mm Install newlockplate12 Nm (1.2 kg-m, 9lb-ttl

(cont'd)

59

\ ( r : a At56, . Tee h n i c a I Se r vic e Information


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~.I'ra" ' '.,0 Jc. tIf

4. Install the new filter screen.

Always replace

5. Install the separator plate, dowel pin, pump gears,and shaft.

6. Install the check valve and spring, then install themain valve body on the torque converter housing.

D A l V r E A R 0-S H A f T i iL, I I ~ 1[1- DRIVEN GEAR""'7 V

;;;; Chamfered side faces!!!! separator plate.VALVE BODY

SEPARATORPLATE DRIVE PUMP DRIVENGEAR GEAR

7. Tighten the 4 valve body bolts in the sequenceshown. Make sure the pump drive gear rotatessmoothly in the normal operating direction and thepump shaft moves smoothly in both the axial andnormal operating directions.

8. Torque the valve body bolts to 12 Nm (1.2 kg-m, 9Ib-tt), and again check that the pump gear andpump shaft move freely.CAUTION: If the pumpgearandpumpshaft donotmove freely, Loosen the valve body bolts, realignthe shaft, and then retighten to the specifiedtorque. Failureto align the pumpshaft correctly willresult in seizedpump gear or pump shaft.


\ I r . a ATS61 Tee h n ic a I Se r v Ice I n for mat ion


61/80

r~""IC ,...... 111 10 'Yres fIi9. Install the stator shaft arm, stop pin and dowel

pins.

STATOR SHAFT ARM STOP PIN

DOWEL PINS 8 x 14 mm

10. Install the regulator valve and torque its 2 bolts to12 Nm (1.2 kg-m, s Ib-tt).

6 mm BOLTS12 Nm (1.2 kg-m. 9lb-ftl

REGULATORVALVE

11. Install the dowel pin, andseparatorplate.

12. Install the regulator control valve body bolts asshown, and torque to 12 Nm (1 .2 kg-m, 9 Ib-ft).

6 mm BOLTS

SEALING BOLT



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\ 1 r : a A T S G I . Technical Service Information


63/80

.""Ie 1'..... n l o ,C ..,

17. Install the separator plate and dowel pins, then in-stall the throttle control shaft.

THROTTLECONTROL SHAFT .

SEPARATORPLATE

18. Install the servo valve body (2 bolts) and checkvalvestop plate (1 bolt) asshown.

BOLTS12 Nm (1.2 kg-m, 9Ib-ft)

SERVO VALVEBODY CHECKVALVE

19. Put the rollers on each side of the manual valvestem, then attach the valve to the lever with thepin. Secure with the lock pin.

COTTER PIN20. Install the separator plate.21. Install the 1st, 3rd and 4th clutch feed pipes.

6 mm BOLTS12 Nm (1.2 kg-m, 9Ib-ft)4th CLUTCHFEED PIPE

3rd CLUTCHFEED PIPE 1st CLUTCHFEED PIPE

6 mm BOLT12 Nm (1.2 kg-m,,__l.l-F!~.U9 Ib-ft)

MODULATOR SEPARATORPLATE

MODULATORVALVE BODY

Automatic T ra nsm is sio n Serv ic e G roup6 3

; , I r . a ATS61. Tee h n ic a I S e r vic e Information


64/80

~" l' IC " 1 10. fC. fit

, 3. Install the 3 steel balls in main valve body oil pas-sages.

OIL PASSAGES(Steel balls here)

, 4. Install the separator plate and dowel pins.

DOWEL PINS8 x 40 mm

SECONDARY SEPARATOR PLATE

, 5. Install the secondary valve body.

SECONDARY VALVE BODY

'6. Install the steel balls, ball spring, timing accumlatorpiston, piston spring and secondary filter in the secon-dary valve body.

SECONDARYFILTER

NOTE. The ball for the top oil passage has a spring topress the ball against the separator plate.


I . I I C i i I ATSG I . Tee h n i c a I Se r vic e Information


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'7. Install the separator plate and dowel pins, then in-stall the throttle control shaft.

THROTTLECONTROL SHAFT

DOWEL PINS

SEPARATORPLATE

, 8. Install the servo valve body (2 bolts) and checkvalvestop plate (1 bolt) asshown.

BOLTS12 Nom (1.2 kg-m, 9 Ib-ft)

BODY CHECKVALVE

, 9. Put the rollers on each side of the manual valvestem, then attach the valve to the lever with thepin. Securewith the lock pin.

COTTER PIN

20. Install the separator plate.21. Install the 1st, 3rd and 4th clutch feed pipes.

6 mm BOLTS12 Nom (1.2 kg-m, 9Ib-ft)

4th CLUTCHFEED PIPE

3rd CLUTCHFEED PIPE 1st CLUTCHFEED PIPE

MODULATOR SEPARATORPLATE

MODULATORVALVE BODY


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22. Install the accumulator springs.23. Install the 2nd/3rd accumulator cover, and torque

the bolts to 12 Nm (1.2 kg-m, 9 Ib-ft) in a criss-cross pattern.

24. Install the 4th accumulator cover, and torque the.'boltsto 12 Nm (1.2 kg-m, 9 Ib-ft) in a criss-crosspattern.CAUTION: To prevent stripping the threads, pressdown on accumulator cover, then install the bolts.

6 mm BOLTS6 mm BOLTS

2nd/3rdACCUMULATORCOVER

4th ACCUMULATORSPRING1/2nd ACCUMULATORSPRING

25. Install the governor valve using new lock plates,and the three 6 mm bolts.

BOLTSM6 x 1.0 rnrn. 12 Nm (1.2 kg-m. 9lb-ttl

26. Set the countershaft and mainshaft in place as anassembly.NOTE: Do not tap on the shafts with a hammer todrive in.

Automatic Transmission Servtce Group6 6

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27. Install 4th gear and its needle bearing, and thecountershaft 4th gear and its selector hub.

28. Assemble the reverse shift fork and selectorsleeve, then install them as an assembly on thecountershaft.NOTE: Install the sleeve with its flat face up. Install the reverse gear selector hub with thegroove facing up.

REVERSE GEARSELECTOR HUB --~

Flat face up'~~ I I s

REVERSESHIFT FORKNEEDLE BEARING _.2B x 33 x 20 mm ~COUNTERSHSAFT _((i(f)~4th GEAR ~

DISTANCECOLLARMAINS HAFT

LOCK PLATE

29. Install the reverse shift fork over the servo valvestem. Align the hole in the stem with holein fork asshown, and install the bolt and new lock plate.Bend the lock tab against the bolt head.

. ~'0 FORK BOLT HOLETurn valve stem so_...JY chamfered hole faces/L fork bolt hole.

r .J ~ dERVO VALVE BODY

30. Install the countershaft reverse gear, needle bear-ing, and reverse gear collar.

~ REVERSE GEAR~ COLLAR

31. Install the new gasket and three dowel pins in thetorque converter housing.14 x 25 mmDOWEL PIN

14 x 25 mmDOWEL PIN GASKET

32. Install the suction pipe.


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.~I'IC " 10., 'c. fit 33. Assemble the idler bearing holder.

NOTE: Align the hole in the shaft with the spring.

RETAININGBOL,..12 Nom (1.2 kg-m.91b-ft)

IDLER BEARING HOLDER/

34. Install the reverse idler gear.NOTE: Install the reverse idler gear so that thelarger chamfer on the shaft bore faces the torqueconverter housing.

REVERSE IDLER GEARInspectteethfor wear.

~ o'rChamfered end

35. Install the needle bearing into the idler gear.36. Install the idler bearingholder into the transmission

housing.

37. Tighten the reverse idler bearing holder bolts.38. Install the spring and then tighten the retaining boltandwasher.

IDLER BEARINGHOLDER

TRANSMISSION CASE

39. Place the transmission housing on the torque con-verter housing.NOTE: Be sure the main valve control shaft linesup with the holein the housing and that the reverseidler gear meshes with the mainshaft and counter-shaft, or the housing will not go on.

SPRING PIN

TRANSMISSIONHOUSING

TORQUE CONVERTER ---~HOUSING


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40. Install the bolts in the locations shown.Tighten the bolts in sequenceshown;tighten in twoor three stepsto prevent distortion:NOTE: When tightening the transmission housingbolts, take care that you do not distort or damagethe t.hrottle control bracket; distortion or damagetothe bracket will change transmission shift points.

THROTTLE CONTROLBRACKET

10 mm BOLTS 55 Nm(5.5 kg-m. 40Ib-ft)'@only

41. Install the throttle control lever and spring on thethrottle control shaft.

42. Install the bolt and new lock plate. Bend the locktab against the bolt head.

NEW LOCK PLATE THROTTLE VALVE SHAFTBOLT8 N'm (0.8 kg-m.6 Ib-ftl

JSPRING THROTTLE CONTROL

LEVER

43. Install the parking shift arm and spring on the shiftshaft with the bolt and a new lock plate. Bendthelock tab against the bolt head.NOTE: Thespring should put clockwise tension onthe shif

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