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AISIN 55-51LE AUTOMATIC TRANSAXLE

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or
when a tool or equipment could easily come in contact with exposed electrical erminals.
Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition
must also be in LOCK unless otherwise noted.

SPECIFICATIONS
General Specifications
Definition
2.0S DIESEL
ESSO JWS 3309 US ATF
6.94 0.15 L (7.33 0.15 qts)

.
Transaxle Fluid Type
Transaxle Fluid Capacity

Transaxle Gear Ratio


Ratio
2.0S DIESEL
4.575
2.979
1.947
1.318
1.000
5.024
2.700

Gear
First
Second
Third
Fourth
Fifth
Reverse
Final Drive

Fluid Capacity
.
Transaxle Fluid

Capacity
2.0S DIESEL
6.94 0.15 L (7.33 0.15 qts)

Notice : Fluid capacity could be changed according to the some condition, therefore be sure to
check the fluid using the oil stick guage.

Line Pressure Specification


Application

Idling

At "D" range

0.33-0.39 Mpa (47.86-56.56 psi)

At "R" range

0.50-0.62 Mpa (72.52-89.92 psi)

Stall
1.28-1.40 Mpa (185.65-203.05
psi)
1.71-1.99 Mpa (248.01-288.63
psi)

Shift Speed
1-2 Shift : mph
2-3 Shift : mph
3-4 Shift : mph
4-5 Shift : mph
(km/h)
(km/h)
(km/h)
(km/h)
Model
10% 25% 50% 10% 25% 50% 10% 25% 50% 10% 25% 50%
TP
TP
TP
TP
TP
TP
TP
TP
TP
TP
TP
TP
55-51LE : 2.0S
16
13
16
28
19
25
44
51
51
63
7 (12) 9 (15)
DIESEL
(26) (21) (26) (45) (30) (41) (71) (82) (82) (102)
4th gear 5th gear
Min TCC Min TCC
5-4 : mph
4-3 : mph
3-2 : mph
2-1 : mph
Apply : Apply :
(km/h)
(km/h)
(km/h)
(km/h)
mph
mph
Model
(km/h)
(km/h)
10% 25% 50% 10% 25% 50% 10% 25% 50% 10% 25% 50%
.
.
TP TP TP TP TP TP TP TP TP TP TP TP
5551LE : 25 25 37 14 14 20 10 10 11
5 (8) 5 (8) 5 (8) 47 (75)
59 (95)
2.0S
(32) (34) (59) (22) (22) (32) (16) (16) (18)
DIESEL

Fastener Tightening Specifications


Application
Drain Plug
Shift Control Lever Assembly Mounting Bolts and Nuts
Control Cable Adjusting Nut
Transmission Range (TR) Switch Nut
TR Switch Bolts
TR Switch Lever Nut
Input Speed Sensor Bolt
Output Speed Sensor Bolt
TCM Retaining Nuts
Oil Cooler Line Assembly Bolt
Outlet Pipe Union Bolt
Outlet Pipe Clip Bolt
Inlet Pipe Union Bolt
Left Three Transaxle Mounting Bracket Bolts
Transaxle Mounting Bracket Cage Bolt and Nut
Right Lower Engine-to-Transaxle Bolts
Left Lower Engine-to-Transaxle Bolts
Oil Pan Flange-to-Transaxle Bolts
Rear Transaxle Mounting Bracket Bolt
Flywheel-to-Torque Converter Bolts
Upper Transaxle-to-Engine Bolts
Engine Front Mount

Nm
40
8
8
7
25
16
6
6
8
10
33
9
33
47
65
73
73
50
90
45
73
60

Lb-Ft
30
18
12
24
24
35
48
54
54
37
66
33
54
44

Lb-In
71
71
62
53
53
71
89
80
-

Oil Apply Tube Clamp Retaining Bolt


Rear Case Bolt
Underdrive Brake (B4) Anchor Bolt
Transaxle Housing Bolt
No.2 Torsion Spring Retaining Bolt
Detent Spring Retaining Bolt (16.7mm)
Detent Spring Retaining Bolt (14mm)
Underdrive Brake(B4) Apply Tube Clamp Retaining
Bolt
Oil Reservoir Plate (Transaxle Case) Bolt
Transaxle Case Plate Bolt
Oil Strainer Bolt
Oil Reservoir Plate (Transaxle Housing) Bolt
Differential Gear Lube Apply Tube Clamp Bolt
Oil Pump Assembly Bolt
Valve Body Assembly Bolt
Suction Cover Bolt
TFT Sensor Bolt
Side Cover Bolt
Oil Level Gauge Bolt
Oil Pump Cover Bolt (14mm)
Oil Pump Cover Bolt (17mm)
Forward Clutch (C1) Accumulator Bolt
Underdrive Clutch Bolt
Solenoid Bolt

6
30
167
30
10
10
6

22
123
22
-

53
89
89
53

53

6
6
6
6
6
25
10
10
10
13
10
12
7
10
7
7

18
10
-

53
53
53
53
53
89
89
89
89
106
62
89
62
62

SCHEMATIC DIAGRAMS
Transmission Control Module (1 of 3)

Transmission Control Module (2 of 3)

Transmission Control Module (3 of 3)

GENERAL DESCRIPTION AND SYSTEM OPERATION


Transaxle Description
The new automatic transmission (AISIN 55-51LE) is an electronically controlled five-speed automatic
transmission.
The transmission is mainly composed of the torque converter, the planetary gear unit, the hydraulic control
system and the electric control system.

Electronical Components
Transmission Control Module (TCM)
The TCM primarily controls shift points and lockup engagement. It is located on the driver side under the
instrument panel.
The transmission is controlled by an electronic shift system. The Transmission Control Module (TCM)
processes input signals. From the information received, the TCM controls the transmission hydraulic system.
The electronic shift system consists of the following :
Transmission control module (TCM)
Shift solenoids (SS1, SS2 SS3, SS4, SS5)
Input shaft speed (ISS) sensor
Output shaft speed (OSS) sensor
Transmission Fluid Temperature (TFT) sensor
Transmission Range (TR) Switch

Transmission Range (TR) Switch


Transmission Range (TR) Switch transmits the information which range includes shift lever of A/T to Starter
and TCM.
It is possible for TR switch to start an engine in only "P" and "N". (Prevention of reckless driving)
TR switch makes backup lamp turn on when reversing.
It is used for TR switch to shift control.
TR switch transmits the information by combination of starter and reverse circuit to vehicle side directly
without TCM.

Shift Solenoid No 1, 2, 3, 4, 5 (SS1, SS2, SS3, SS4, SS5)


5 shift solenoids are installed directly in the valve body. The solenoids operate of ON and OFF by the
control signal from TCM. Combinations of 5 solenoids, SS1, SS2, SS3, SS4 and SS5 changes gear ranges.

Line Pressure Control Solenoid (SLT)


Line pressure control solenoid (SLT) controls linear throttle pressure by control signal from TCM and line
pressure for clutches and brakes to reduce shift shock.

TCC Lock-up Control Solenoid (SLU)


TCC lock up control solenoid (SLU) controls linear SLU pressure by control signal from TCM and hydraulic
pressure for lock-up clutch to reduce shift shock.
<Direct control>
1st engine brake - 1st and reverse brake (B3)
2nd - 2nd brake (B2)

Shift Pressure Control Solenoid (SLS)


Shift pressure control solenoid (SLS) controls linear SLS pressure by control signal from TCM.
<Direct control>
2nd, 3rd, 4th - 2nd coast brake (B1)
5th, Reverse - Direct clutch (C2)

Transmission Fluid Temperature (TFT) Sensor


TFT sensor is located in the valve body.
TFT sensor provides TCM with information on the transmission fluid temperature.
The TCM uses information from the TFT sensor to calculate the gear shift points and to engage the torque
converter lockup function.

Input Shaft Speed (ISS) Sensor


ISS sensor (1) is located on the upper position of the transaxle and detects A/T input speed from the rotation
number of the direct clutch drum (2).
They transmit to TCM as a signal.

Output Shaft Speed (OSS) Sensor


OSS sensor (1) is located on the upper position of the transaxle and detects the vehicle speed from the
rotation number of the parking gear (2).

Hydraulic Control System


Based on the hydraulic pressure created by the oil pump, TCM sends signals to solenoid and hydraulic
control system governs the hydraulic pressure acting on the torque converter, planetary gear, clutches and
brakes in accordance with the vehicle driving conditions.

Automatic Transaxle System


Function of Components

C1
C2
C3
B1
B2
B3
B4
B5
F1
F2

Clutch & Brake


Operation
Forward clutch (1) Connects input shaft and rear ring gear.
Direct clutch (2) Connects input shaft to rear sun gear.
Underdrive clutch
Connect underdrive sun gear to underdrive front carrier.
(3)
2nd coast brake (4) Lock front sun gear.
2nd brake (5)
Lock counterclockwise rotation of front sun gear.
1st & reverse brake
Lock front ring gear.
(6)
Underdrive brake (7) Lock underdrive sung gear.
B5 brake (8)
Lock underdrive rear carrier.
1 way clutch No.1
Lock counterclockwise rotation of front sun gear, when B2 operations.
(9)
1 way clutch No.2
Lock counterclockwise rotation of front ring gear.
(10)

Operations of Clutches and Brakes

Position
P
V<=7
R
V>7
N
D 1st
M 1st
2nd
D, M
3rd
4th
5th
1st
4
2nd
3rd
1st
2
2nd

S1
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON
OFF

Solenoid
S2 S3 S4
OFF OFF OFF
OFF ON OFF
OFF OFF OFF
OFF OFF OFF
ON ON OFF
ON ON OFF
OFF ON OFF
OFF ON ON
OFF OFF ON
ON OFF ON
ON ON OFF
OFF ON OFF
OFF ON ON
ON ON OFF
OFF ON OFF

S5
OFF
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF

Clutch
C1 C2 C3
OFF OFF OFF
OFF ON OFF
OFF OFF OFF
OFF OFF OFF
ON OFF OFF
ON OFF OFF
ON OFF OFF
ON OFF OFF
ON OFF ON
ON ON ON
ON OFF OFF
ON OFF OFF
ON OFF OFF
ON OFF OFF
ON OFF OFF

B1
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
ON
ON
OFF
ON

Brake
B2 B3 B4
OFF OFF OFF
OFF ON OFF
OFF OFF OFF
OFF OFF OFF
OFF OFF OFF
OFF ON OFF
ON OFF OFF
ON OFF ON
ON OFF OFF
ON OFF OFF
OFF OFF OFF
ON OFF OFF
ON OFF ON
OFF ON OFF
ON OFF OFF

B5
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
OFF
ON
ON

1Way clutch
F1
F2
OFF OFF
OFF OFF
OFF OFF
OFF OFF
OFF
ON
OFF
ON
ON
OFF
ON
OFF
ON
OFF
OFF OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
ON
OFF

D-1st Gear
Solenoid

Position
D 1st

S1
ON

S2
ON

S3
ON

1 way
Clutch
C1 C2 C3 B1 B2 B3 B4 B5 F1 F2
ON OFF OFF OFF OFF OFF OFF ON OFF ON
Clutch

S4
OFF

S5
OFF

Brake

"D" - 1st Gear


1. Input shaft rotates clockwise.
C1 operates (Connect input shaft to rear planetary ring gear)
2. Rear planetary ring gear rotates clockwise.
3. Rear planetary pinion rotates itself clockwise.
4. Front large planetary pinion rotates itself clockwise for rear planetary pinion and one.
5. Front small planetary pinion rotates itself counterclockwise.
6. Front ring gear is going to rotate counterclockwise.
F2 operates (Lock counterclockwise rotation of Front ring gear).
7. Front & rear planetary carrier revolves clockwise due to reaction force of front small pinion.
8. Counter drive gear rotates clockwise for front & rear planetary carrier and one.
9. Counter driven gear rotates counterclockwise.
10. Front planetary ring gear rotates counterclockwise for counter driven gear and one.
11. Front planetary pinion rotates itself counterclockwise.
12. Front planetary sun gear rotates clockwise.
13. Rear planetary sun gear rotates clockwise for front planetary sun gear and one.
14. Rear planetary pinion rotates itself counterclockwise.
B5 operates (Lock rotation of rear carrier).
15. Rear planetary ring gear rotates counterclockwise.
16. Front carrier and differential drive pinion gear rotates counterclockwise for rear ring gear and one.
17. Differential rotates clockwise.
( Engine Brake)

1. Counter drive gear and main front & rear planetary carrier rotates clockwise.
2. Rear planetary carrier rotates clockwise, but rear planetary pinion revolves clockwise while rotating
itself counterclockwise due to resistance of rear planetary ring gear.
3. Front large pinion revolves clockwise while rotating itself counterclockwise and front small pinion
revolves clockwise while rotating itself clockwise. And front carrier revolves clockwise.
4. Front ring gear rotates clockwise due to rotation itself clockwise of front small pinion, but driving
force loses due to free of F2. Therefore engine brake does not operate.

D-2nd Gear
Solenoid

Position
D 2nd

S1
OFF

S2
OFF

S3
ON

Clutch
S4
OFF

S5
OFF

C1 C2 C3 B1
ON OFF OFF ON

1 way
Clutch
B2 B3 B4 B5 F1 F2
ON OFF OFF ON ON OFF
Brake

"D" - 2nd Gear


1. Input shaft rotates clockwise.
C1 operates (Connect input shaft to rear planetary ring gear)
2. Rear planetary ring gear rotates clockwise.
3. Rear planetary pinion rotates itself clockwise.
4. Front large planetary pinion rotates itself clockwise for rear planetary pinion and one.
B2 & F1 and B1 operates (Lock rotation of front planetary sun gear)

5.
6.
7.
8.
9.
10.
11.
12.

Front & rear planetary carrier revolves clockwise due to reaction force of front large pinion.
Counter drive gear rotates clockwise for front & rear planetary carrier and one.
Counter driven gear rotates counterclockwise.
Front planetary ring gear rotates counterclockwise for counter driven gear and one.
Front planetary pinion rotates itself counterclockwise.
Front planetary sun gear rotates clockwise.
Rear planetary sun gear rotates clockwise for front planetary sun gear and one.
Rear planetary pinion rotates itself counterclockwise.
B5 operates (Lock rotation of rear carrier)
13. Rear planetary ring gear rotates counterclockwise.
14. Front carrier and differential drive pinion gear rotates counterclockwise for rear ring gear and one.
15. Differential rotates clockwise.
( Engine Brake)
1. Driving force is connected to input shaft directly without 1 way clutch. Therefore engine brake
operates.

D-3rd Gear
Solenoid

Position
D 3rd

S1
OFF

"D" - 3rd Gear

S2
OFF

S3
ON

Clutch
S4
ON

S5
OFF

C1 C2 C3 B1
ON OFF OFF ON

1 way
Clutch
B2 B3 B4 B5 F1 F2
ON OFF ON OFF ON OFF
Brake

1. Input shaft rotates clockwise.


C1 operates (Connect input shaft to rear planetary ring gear)
2. Rear planetary ring gear rotates clockwise.
3. Rear planetary pinion rotates itself clockwise.
4. Front large planetary pinion rotates itself clockwise for rear planetary pinion and one.
B2 & F1 and B1 operates (Lock rotation of front planetary sun gear)
5. Front & rear planetary carrier revolves clockwise due to reaction force of front large pinion.
6. Counter drive gear rotates clockwise for front & rear planetary carrier and one.
7. Counter driven gear rotates counterclockwise.
8. Front planetary ring gear rotates counterclockwise for counter driven gear and one.
9. Front planetary pinion rotates itself counterclockwise.
B4 operates (Lock rotation of front & rear planetary sun gear)
10. Front planetary carrier revolves counterclockwise due to reaction force of front planetary pinion.
11. Rear ring gear and differential drive pinion gear rotates counterclockwise for front carrier and one.
12. Differential rotates clockwise.
( Engine Brake)
Driving force is connected to input shaft directly without 1 way clutch. Therefore engine brake
operates.

D-4th Gear
Solenoid

Position
D 4th

S1
OFF

S2
OFF

S3
OFF

Clutch
S4
ON

S5
OFF

C1 C2 C3
ON OFF ON

1 way
Clutch
B2 B3 B4 B5 F1 F2
ON OFF OFF OFF ON OFF
Brake

B1
ON

"D" - 4th Gear


1. Input shaft rotates clockwise.
C1 operates (Connect input shaft to rear planetary ring gear)
2. Rear planetary ring gear rotates clockwise.
3. Rear planetary pinion rotates itself clockwise.
4. Front large planetary pinion rotates itself clockwise for rear planetary pinion and one.
B2 & F1 and B1 operates (Lock rotation of front planetary sun gear)
5. Front & rear planetary carrier revolves clockwise due to reaction force of front large pinion.
6. Counter drive gear rotates clockwise for front & rear planetary carrier and one.
7. Counter driven gear rotates counterclockwise.
8. Front planetary ring gear rotates counterclockwise for counter driven gear and one.
C3 operates (Connect planetary sun gear to front planetary carrier )
9. Front planetary pinion can not rotate itself, and underdrive unit rotates counterclockwise as one.
10. Differential drive pinion gear rotates counterclockwise for underdrive unit and one.
11. Differential rotates clockwise.
<Engine Brake>
1. Driving force is connected to input shaft directly without 1 way clutch. Therefore engine brake
operates.

D-5th Gear
Solenoid

Position
D 5th

S1
OFF

"D" - 5th Gear

S2
ON

S3
OFF

Clutch
S4
ON

S5
OFF

C1
ON

C2
ON

1 way
Clutch
C3 B1 B2 B3 B4 B5 F1 F2
ON OFF ON OFF OFF OFF OFF OFF
Brake

1. Input shaft rotates clockwise.


C1 operates (Connect input shaft to rear planetary ring gear)
C2 operates (Connect input shaft to rear planetary sun gear)
2. Rear planetary pinion can not rotate itself, and rear planetary unit rotates clockwise as one.
3. Front large planetary pinion can not rotate itself for rear planetary pinion and one, and front planetary
unit rotates clockwise as one.
4. Counter drive gear rotates clockwise for front planetary unit and one.
5. Counter driven gear rotates counterclockwise.
6. Front planetary ring gear rotates counterclockwise for counter driven gear and one.
C3 operates (Connect planetary sun gear to front planetary carrier )
7. Front planetary pinion can not rotate itself, and underdrive unit rotates counterclockwise as one.
8. Differential drive pinion gear rotates counterclockwise for underdrive unit and one.
9. Differential rotates clockwise.
<Engine Brake>
1. Driving force is connected to input shaft directly without 1 way clutch. Therefore engine brake
operates.

Reverse Gear
Solenoid

Position
S1
V<=7km/h OFF
R
V>7km/h ON

S2
OFF
OFF

S3
ON
OFF

1 way
Clutch
S5
C1 C2 C3 B1 B2 B3 B4 B5 F1 F2
ON OFF ON OFF OFF OFF ON OFF ON OFF OFF
OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF
Clutch

S4
OFF
OFF

Reverse Gear
1. Input shaft rotates clockwise.
C2 operates (Connect input shaft to rear planetary sun gear)

Brake

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Rear planetary sun gear rotates clockwise.


Rear planetary pinion rotates itself counterclockwise.
Front large planetary pinion rotates itself counterclockwise for rear planetary pinion and one.
Front small planetary pinion rotates itself clockwise.
B3 operates (Lock rotation of front planetary ring gear)
Front & rear carrier revolves counterclockwise due to reaction force of front small pinion.
Counter drive gear rotates counterclockwise for front & rear planetary carrier and one.
Counter driven gear rotates clockwise.
Front planetary ring gear rotates clockwise for counter driven gear and one.
Front planetary pinion rotates itself clockwise.
Front planetary sun gear rotates counterclockwise.
Rear planetary sun gear rotates counterclockwise for front planetary sun gear and one.
Rear planetary pinion rotates itself clockwise.
B5 operates (Lock rotation of rear carrier)
Rear planetary ring gear rotates clockwise.
Front carrier and differential drive pinion gear rotates clockwise for rear ring gear and one.
Differential rotates counterclockwise.

<Engine Brake>
1. Driving force is connected to input shaft directly without 1 way clutch. Therefore engine brake
operates.

Control Functions of TCM


Shift Control and Lock-up Control
According to each shift schedule, TCM sends signals to the S1, S2, S3, S4, S5 which operates ON/OFF
control "Shift Control" and the TCC lock up control solenoid (SLU) which operates linear control "Lock-up
Control" on the basis of the vehicle speed and the throttle opening.
<Each solenoid operation>
Gear
S1
S2
S3
S4
S5
1st
ON
ON
ON
OFF
OFF
2nd
OFF
OFF
ON
OFF
OFF
3rd
OFF
OFF
ON
ON
OFF
4th
OFF
OFF
OFF
ON
OFF
5th
OFF
ON
OFF
ON
OFF
55-51LE for automatic transaxle does not have several driving mode that user can select. Basically TCM
programmed for "Economy mode", but TCM changes to several shift schedule automatically according to
specified condition. But, only "Winter mode" can be chosen by the switch.
1. Driver's adaptive shift control (Economy, Medium, Sport mode)
Economy mode is used for normal driving condition after ignition ON. And driver's liking is
detected by using fuzzy logic from accelerator operation. This control changes shift points to Economy
(low speed), Medium(middle speed) and Sport(high speed) according to the liking degree.
Start (1) & (2)
End (1) or (2) or (3)

(1) "D"
(2) Vehicle speed >= 5 km/h (3 mph)
(1) Except "D"
(2) Vehicle speed > 240 km/h (149 mph)
(3) Driver's liking detection is Economy mode

2. Winter mode
This mode is used for vehicle start on a slippery road due to pushing the winter mode switch.
(Vehicle start in 3rd gear)
Range
D

Winter
3(L) 4(L) 5(L)
: Shift up/down, (L) : Lock-up Operation

3. Upslope mode
When TCM detects upslope from load of engine torque and decrease of acceleration, this mode
changes shift points in high-speed side according to the upslope degree and avoids busy shift of A/T.
4. Downslope mode
When TCM detects downslope from increase of acceleration with accelerator full close, this
mode operates moderate engine brake by changing shift points in high-speed side.
5. Hot mode control
This control lowers ATF temperature by changing shift points when the temperature is
extremely high. (ATF temperature > 140C (284F))
6. Altitude control
This control makes up for low engine power by establishing shift points at a slightly higher
vehicle speed range in high altitude where air pressure is low.
7. Cold offset control
This control makes up for low engine torque by establishing shift points at a slightly higher
vehicle speed range when air temperature is extremely low. (Engine coolant temperature < -30C (-22
F))

Manual Shift Control (Tap Mode)


Driver oneself can select favorite gear and enjoy sports driving of manual transmission sense by shifting
shift lever from "D" to manual gear position and Manual+(Up shift) / Manual-(Down shift). But lock-up
control is operated automatically. Shift control is operated again by shifting from manual gear position to
"D".

Lock-up Cut Control


This control cuts lock-up operation at shift down or idle condition and avoid engine stall by depressing brake
pedal at low speed driving.

Up/Down Learning Control


This control learns the pressure to each clutch or brake in order to reduce shifting shock at each shifting (Up,
Down, Manual down, Coast down).
<Learning control method>
(1) 65C (149F) =< Oil temperature < 110C (230F)
(2) Constant low throttle opening (about 20-30%)
(3) Plenty shifting interval (about 3 sec)
(4) Repeat each shifting about 10 times

N-D Shift Control


This control improves the N-D shift quality due to controlling line pressure control solenoid according to
forward clutch (C1) piston stroke learned in N-D learning control and applying best hydraulic pressure to
forward clutch (C1) at N-D shift.

N-D Learning Control


This control learns the forward clutch (1) hydraulic pressure due to monitoring a forward clutch (1) engaging
time and a rotation change rate.
(1) 500 rpm =< Engine speed < 1,200 rpm
(2) 65C (149F) =< Oil temperature < 110C (230F)
Start (1) & (2) & (3) & (4)
(3) 450 rpm =< forward clutch (C1) revolution < 1,200 rpm
(4) Throttle opening < 3.0 %
<Learning control method>
(1) When above start condition
(2) Shifting interval more than 3 sec
(3) Repeat N-D shifting about 10 times

N-R Shift Control


This control improves the N-R shift quality due to controlling shift pressure control solenoid according to
direct clutch (C2) piston stroke learned in N-R learning control and applying best hydraulic pressure to C2
clutch at N-R shift.

N-R Learning Control


This control learns the direct clutch (C2) hydraulic pressure due to monitoring a C2 clutch engaging time and
a rotation change rate.
(1) 500 rpm =< Engine speed < 1,200 rpm
(2) 65C (149F) =< Oil temperature < 110C (230F)
Start (1) & (2) & (3) & (4)
(3) 450 rpm =< forward clutch (C1) revolution < 1,200 rpm
(4) Throttle opening < 3.0 %
<Learning control method>
(1) When above start condition
(2) Shifting interval more than 3 sec
(3) Repeat N-R shifting about 10 times

Torque Reduction Control


This control improves the shift quality due to sending torque reduction request signal from TCM to ECM
and cutting engine torque increase of shift at N-D shift, N-R shift and 12345.
If accelerator pedal is depressed rapidly, this control establishes the upper limit value of engine torque and
avoids "Engine flare" at 23, 34 and 4=>2 of "clutch to clutch shift".

Transmission Adaptive Learn Procedure


Perform the transmission adaptive learn procedure after any of the following service procedures :
Transmission Control Module (TCM) replacement
TCM calibration change
Control valve body replacement
Transaxle overhaul
Transaxle replacement
1. Drive the vehicle to warm the transaxle fluid until 65-110C (150-230F). The adaptive learn
procedure will not work unless transaxle fluid is the correct temperature.
2. Reset the transaxle adaptive learns using a scan tool.
3. Perform the following steps for the garage shifts adaptive learn.
1. Apply the parking brake and the foot brake.
2. Shift from NEUTRAL to REVERSE and keep in REVERSE for 3 seconds.
3. Shift from REVERSE to NEUTRAL.
4. Repeat the above two steps five times.
5. Shift from NEUTRAL to DRIVE and keep in DRIVE for 3 seconds.
6. Shift from DRIVE to NEUTRAL.
7. Repeat the above two steps five times.
4. Perform the following steps for the Up/Down shifting adaptive learn.
1. Drive the vehicle in DRIVE with light (15-20 percent) throttle until above 50 km/h (31 mph) in
4th gear.
2. Decelerate and apply the brakes until vehicle comes to a stop. Brake the vehicle so that it takes
at least 14 seconds.
3. Repeat the above steps five times.
5.
In case the shift indicator positions are labeled P, R, N, D, 4, 2
Perform the following steps for 42 Manual down shift adaptive learn (No Tap shift).

1. Drive the vehicle in "4" until over 25 km/h (16 mph) in 2nd with any throttle position.
2. Decelerate, shift from "4" to "2" manually and stop the vehicle.
3. Repeat the above two steps ten times.
In case the shift indicator positions are labeled P, R, N, D, M
Perform the following steps for 21 Tap down shift adaptive learn (Tap shift).
1. Drive the vehicle in "Tap 2" until over 25 km/h (16 mph) in 2nd with any throttle position.
2. Decelerate, shift from "Tap 2" to "Tap 1" manually and stop the vehicle.
3. Repeat the above two steps ten times.
Important : If shift quality does not improve, ensure the TCM has the correct transmission
calibration.
6. Confirm shift quality.

COMPONENT LOCATOR
Shift Select Control

1.
2.
3.
4.
5.
6.
7.
8.

Shift Control Lever Assembly


Bolt
Nut
Select Control Cable
Clamp
E-ring
Cable Fastener
Bolt

Automatic Transaxle Components

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Output Speed Sensor


Transmission Range (TR) Sensor
Input Speed Sensor
O-ring
O-ring
O-ring
O-ring
Transaxle Wire
Gasket
Torque Converter
Valve Body
Side Cover

1.
2.
3.
4.
5.
6.

Oil Reserver Plate


Magnet
Seal Ring
Differential Oil Seal
O-ring
Oil Level Gauge

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Parking Lock Pawl Shaft


Torsion Spring No.1
Parking Lock Pawl
Sleeve
Torsion Spring No.2
Parking Lock Pin
Anchor Bolt
O-ring
Differential Oil Seal
O-ring
Gasket
Oil Reserver Plate
Oil Strainer
Trnasaxle Case Plate
Bracket
Manual Detent Spring
Manual Valve Lever
Parking Lock Rod

19. Manual Valve Oil Seal


20. Gasket

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Differential Gear Assembly


Underdrive Brake (B4)
Underdrive Rear Planetary Gear Assembly
Rear Case and B5 Brake (B5)
Underdrive Front Planetary Gear and Counter Driven Gear Assembly
Underdrive Clutch (C3)
1st and Reverse Brake (B3) & One Way Clutch No.2 (F2)
Planetary Gear
Forward Clutch (C1) and Direct Clutch (C2)
Oil Pump and 2nd Coast Clutch (B1),2nd Brake (B2)
B1&B2 Hub and One Way Clutch No.1 (F1)
Counter Drive Gear

Oil Pump and 2nd Coast Clutch (B1), 2nd Brake (B2)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Oil Seal
Oil Pump Body
Pin
Oil Pump Driven Gear
Oil Pump Drive Gear
O-ring
Oil Pump Plate
Oil Pump Cover
O-ring
2nd Brake (B2) Piston
O-ring
2nd Brake (B2) Sleeve
O-ring
Snap Ring
2nd Brake (B2) Return Spring
2nd Brake (B2) Plate
2nd Brake (B2) Flange

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

2nd Brake (B2) Disc


Snap Ring
O-ring
2nd Coast Brake (B1) Piston
O-ring
2nd Coast Brake (B1) Return Spring
Snap Ring
Thrust Washer
2nd Coast Brake (B1) Plate
2nd Coast Brake (B1) Disc
2nd Coast Brake (B1) Flange
Snap Ring

2nd Coast Brake (B1), 2nd Brake (B2) Hub and One Way Clutch No.1 (F1)

1.
2.
3.
4.
5.

2nd Coast Brake (B1) Hub


Thrust Washer
One Way Clutch No.1 (F1)
One Way Clutch Outer Race
Thrust Washer

Rear Case and B5 Brake

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Snap Ring
B5 Brake Return Spring
O-ring
B5 Brake Piston
O-ring
Rear Case
Accumulator Cover
O-ring
Spring
Seal Ring
Forward Clutch(C1) Accumulator Piston
Clamp
Underdrive Clutch(C3) Apply Tube
O-ring
Seal Ring
Snap Ring
B5 Flange
B5 Plate

19. B5 Disc
20. B5 Cushion Plate

Forward Clutch (C1) and Direct Clutch (C2)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Snap Ring
Forward Clutch (C1) Flange
Forward Clutch (C1) Disc
Forward Clutch (C1) Plate
Snap Ring
Direct Clutch (C2) Flange
Direct Clutch (C2) Plate
Direct Clutch (C2) Disc
Direct Clutch (C2) Cushion Plate
Snap Ring
Return Spring
O-ring

13.
14.
15.
16.
17.
18.
19.
20.
21.

Direct Clutch (C2) Piston


O-ring
O-ring
Forward Clutch (C1) Piston
O-ring
Input Shaft Assembly
Thrust Race
Thrust Bearing
Seal Ring

Planetary Gear Assembly

1.
2.
3.
4.
5.
6.
7.
8.

Planetary Gear
Thrust Race
Thrust Bearing
Rear Planetary Ring Gear
Thrust Race
Thrust Bearing
Planetary Sun Gear
Thrust Bearing

1st and Reverse Brake (B3) & One Way clutch No.2 (F2)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

O-ring
1st and Reverse Brake (B3) Piston
O-ring
1st and Reverse Brake (B3) Return Spring
Snap Ring
1st and Reverse Brake (B3) Flange
1st and Reverse Brake (B3) Disc
1st and Reverse Brake (B3) Plate
1st and Reverse Brake (B3) Flange
Snap Ring
Thrust Bearing Race
Thrust Bearing
One Way Clutch No.2 (F2) Assembly
Front Planetary Ring Gear
Front Planetary Ring Gear Flange
Snap Ring
Thrust Bearing

Underdrive Clutch (C3)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Snap Ring
Underdrive Clutch (C3) Flange
Underdrive Clutch (C3) Disc
Underdrive Clutch (C3) Plate
Snap Ring
Underdrive Clutch (C3) Return Spring
O-ring
Underdrive Clutch (C3) Piston
O-ring
Underdrive Clutch (C3) Drum

Underdrive Brake (B4)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Underdrive Brake (B4) Band


Outer Spring
Underdrive Brake (B4) Piston Rod
Inner Spring
Sleeve
Cushion Plate
Washer
Cushion Plate
Washer
Underdrive Brake (B4) Piston
O-ring
E-ring
O-ring
Underdrive Brake (B4) Cover
Snap Ring

Underdrive Rear Planetary Gear Assembly

1.
2.
3.
4.
5.
6.
7.

Thrust Washer
Underdrive Planetary Gear
Thrust Washer
Thrust Bearing
Underdrive Rear Planetary Ring Gear
Shim
Thrust Bearing

Valve Body Assembly

1.
2.
3.
4.
5.
6.
7.
8.
9.

Valve Body Assembly


No.1 Shift Solenoid (SS1)
No.2 Shift Solenoid (SS2)
No.3 Shift Solenoid (SS3)
No.4 Shift Solenoid (SS4)
No.5 Shift Solenoid (SS5)
Shift Pressure Control (PC) Solenoid (SLS)
Line Pressure Control (PC) Solenoid (SLT)
Torque Converter Clutch (TCC) Lock Up Pressure Control (PC) Solenoid (SLU)

Race and Bearing Specifications

.
Race
(Front)

Bearing

Race
(Rear)

(mm)
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Outer
74.30 77.30 99.30 58.00 - 61.00 74.00 - 41.00 - 77.60 Diameter
Inner
47.00 56.50 56.50 43.80 - 43.20 53.00 - 13.50 - 66.80 Diameter
Outer
- 61.95 89.00 64.00 65.00 43.40 41.70 70.65 - 58.10 57.70
Diameter
Inner
- 45.80 73.50 46.40 50.00 22.75 23.00 49.00 - 39.60 37.00
Diameter
Outer
- 41.00 71.00 77.60 Diameter
Inner
- 22.00 49.10 66.80 Diameter

DIAGNOSIS
Electric Connector View

A1
A2
A3
A4
A5
A6
A7
A11
A12
A13
A14
A15
A16
A17
A19
A21
A22
A23
A24

X-1 : TCM Vehicle Side Wiring Connector


Ground
B1
Tap-Up
Line Pressure Control Solenoid (-)
B3
Winter Mode Lamp
TCC Lock Up Pressure Control Solenoid
B4
Winter Mode Switch
(-)
Line Pressure Control Solenoid (+)
B5
Output Speed Sensor (-)
TCC Lock Up Pressure Control Solenoid
B6
Input Speed Sensor (-)
(+)
Ignition Switch
B7
"B" Signal (TR switch)
CAN Communication (Low)
B8
"A" Signal (TR switch)
TFT Sensor (+)
B9
Driver Shift Control Switch
TFT Sensor (-)
B14
Output Speed Sensor (+)
Shift Solenoid (SS) 4
B15
Vehicle Speed Output
Shift Solenoid (SS) 3
B16
Input Speed Sensor (+)
Shift Solenoid (SS) 2
B17
Serial Data
Shift Solenoid (SS) 1
B18
Tap-Down
CAN Communication (High)
B19
"PA" Signal (TR switch)
Shift Pressure Control Solenoid (-)
B20
"C" Signal (TR switch)
Shift Pressure Control Solenoid (+)
B22
Brake Switch
Shift Solenoid (SS) 5
Ground
Battery Voltage
-

Wiring Harness and Connector Inspection


1. Reproducing test
Perform symptom simulation test on the basis of user's condition. Refer to the below factors.
Occurring-road condition, speed, accelerate, reduce speed, straight, curve, air temperature,
weather, etc.
2. Inspect the connection condition of between connectors.
Inspect the failure between connectors by visual check and contact pressure check.
Connector disconnected
Terminals rusted
Terminals deformation or loose fit
3. Inspect the Continuity of the wiring harness.
Disconnect both ends connector of wiring harness, measure resistance between one connector
terminal and other.
Normal : 1 or less (No open circuit)
Abnormal : (Open circuit)
Notice : Measure the resistance while slightly shaking wire harness vertically and horizontally.
It is rare case wiring harness is broken at the middle of it, and most cases occur at the connector.
4. Inspect the short circuit of the wiring harness.
Disconnect the connectors of the wiring harness at both ends, measure resistance between the
applicable terminals of the connector and body earth.
Normal : 1M or higher (No short circuit)
Abnormal : Low resistance (Short circuit)

Measure the resistance between one terminal an another terminal in the same connector.(Except
between power supply or between earth).
Normal : 1M or higher (No short circuit)
Abnormal : Low resistance (Short circuit)
Notice : Measure the wiring harness while slightly shaking vertically and horizontally.
It is usual case of the short circuit that wiring harness is crowded body and clamping failure.
5. Temporary connection failure of the connector.
It is thought that temporally the connection failure of the connector is cause when you can not
decide cause of DTC detection.
Therefore make sure to inspect and clean the connector and delete the memorized DTC.

Road Test
Road test is to diagnosis failure symptom accurately and check the failure symptom after procedure.
Confirm whether below condition before road test. Oil temperature is hot condition (50C (122F) ~ 80C
(176F)).
1. D range test
Check for up-shift, down-shift, kick-down and lock-up operation at the shift point.
Check for engine brake operation.
Check for Check abnormal shock, noise and harshness.
2. "P" range test
Park vehicle on a gradient (more than 5), shift into the "P" range and release parking brake.
Then, check to see no moving vehicle by operation of parking lock pawl.

Function Check
Confirm whether below condition before function check.
Oil temperature is hot condition (50C (122F) ~ 80C (176F)).
Switch of A/C and light etc are off.

Stall Test
Stall test' purpose is to inspect overall performance of A/T and engine by measuring the stall speed in "D"
and "R" range.
1. Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.
2. Fully pressed on foot brake pedal with left foot.
3. Shift into "D" and "R" range, fully press on accelerator pedal with right foot.
Quickly read stall speed at this time.
Standards

2.0S DIESEL

2,400 rpm

Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temperature.
Make sure to keep interval for more than 1 min between stall tests.
Result of Stall Test
Cause of Failure
Lower than standards
Less engine power
both "D" and "R"
Torque converter one way clutch failure
Lower line pressure

Higher than standards


only "D"
Higher than standards
only "R"
Higher than standards
both "D" and "R"

Forward clutch (C1) failure (Slipping)


No.2 One-way clutch (F2) failure
Lower line pressure
Direct clutch (C2) failure (Slipping)
1st & reverse brake (B3) failure (Slipping)
Lower line pressure
B5 brake failure
Oil strainer failure (clogging)
Oil leak for each range circuit

Time Lag Test


Time lag is time till slightly shock can be felt when shift lever is shifted "N" "D" and "N" "R" while
engine idling.
Time lag test can inspect hydraulic condition and clutch/brake condition.
1. Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.
2. Measure time lag by using stop watch from moment when shift lever is shifted in "N" "D" and "N"
"R" until moment slightly shock can be felt.
"N" "D"
"N" "R"

less than 0.7 sec


less than 1.2 sec

Notice : Make sure to take 3 measurement and take the average value.
Make sure to keep interval for more than 1 min between time lag tests. (That purpose is to remove
clutch/brake pressure was left unfinished.)
Result of Time Lag Test
Cause of Failure
Lower line pressure
Longer than standards "N"
Forward Clutch (C1) failure (Slipping)
"D"
One way clutch No.2 (F2) failure
Lower line pressure
Longer than standards "N" Direct clutch (C2) failure (slipping)
"R"
1st & reverse brake (B3) failure (slipping)
B5 brake failure (slipping)

Hydraulic Test
Tools Required
J 21867-50 Transmission Line Pressure Adapter
J 21867 Pressure Gage
Hydraulic test can inspect working condition inside A/T by measuring line pressure in "D" / "R" range and
"idle" / "stall" condition.

1. Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.

2. Install J 21867 and J 21867-50 to test hole for line pressure.


3. Fully pressed on foot brake pedal with left foot, shift into "D" and "R" range and measure line pressure
"idle" / "stall" condition.
Line pressure Mpa (psi)
Engine idle
Engine stall

D
0.33-0.39 (47.86-56.56)
1.28-1.40 (185.65-203.05)

R
0.50-0.62 (72.52-89.92)
1.71-1.99 (248.01-288.63)

Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temperature.
Make sure to keep interval for more than 1 min between stall tests.
Make sure to check no oil leak after installing oil pressure gage adapter.
Result of Hydraulic Test
Cause of Failure
Higher than standards
Line pressure control solenoid failure
both "D and "R"
Primary regulator valve failure
Line pressure control solenoid failure
Lower than standards
Primary regulator valve failure
both "D and "R"
Oil pump failure
B5 brake failure
Lower line pressure
Lower than standards
B5 brake failure (slipping)
only "D
"D" hydraulic circuit failure
Forward clutch (C1) failure

"R" hydraulic circuit failure


Direct clutch (C2) failure
1st and reverse brake (B3) failure
B5 brake failure

Lower than standards


only "R"

Manual Shifting Test


Manual shifting test is to determine whether failure symptom is within electrical failure or mechanical
failure.
1. Disconnect wire harness of shift solenoid, check the range and gear positions correspond with below
table when driving by manual shifting.
Range
D
R

Gear
4th gear
Reverse

Notice : Make sure to disconnect only wire harness of shift solenoid.

Unit Inspection
Drive Plate Deflection
Inspect drive plate deflection if within standard value.
Standard Value

within 0.2mm (0.008 in)

Action :
Standard value is not within the specified value, replace drive plate.
When "abnormal wear" or "stick" on torque converter sleeve or oil pump is found, replace torque converter
and A/T.
Notice :
When assembling torque converter and drive plate. Be sure to use correct bolt with correct length. The
bolt pushes up torque converter front cover, and it damages lock-up clutch lining. As a result, it cause
major failure "No move".
Do not tighten the bolts by using impact wrench.

Cooler Pipe Bending and Choke


Inspect it whether there is abnormal pipe bending in the cooler pipe, pipe deformation and small crosssection area of pipe line.
Action : Replace failure parts.
Apply compressed air of 2kg/cm from cooler pipe inlet side, inspect whether there is not cooler pipe
choke by confirming air flow smooth.
Action : Remove foreign particles and clean inside of pipe line.

Input Speed Sensor and Output Speed Sensor


1. Remove the connector of output or input speed sensor, connect 12V power supply and 100 ohm
resistance and ammeter to the terminal. (Do not mistake polarity)
2. Inspect the current of high and low signal by shaking magnetic body from side to side at the speed
sensor tip. (gap is within 5mm)
Notice : Make sure to shake the direction from bolt hole to sensor-self when shaking the magnetic
body. If not, the current value can not change.
Signal
High
Low

Current (mA)
12.0-16.0
4.0-8.0

Action : If the result of inspection is bad, replace the input or output speed sensor.

Transmission Range (TR) Switch


Remove TR switch connector and inspect continuity each range according to the connection chart.

Action : If the result of inspection is bad, replace the TR switch.

Transmission Fluid Temperature Sensor


Inspect the resistance between the terminals of TFT sensor at 10C (50F) and 110C (230F).
10C (50F)
5.80~7.09 k
Action : If the result of inspection is bad, replace the TFT sensor.
Standard Value

110C (230F)
0.231~0.263 k

1. TFT sensor ground


2. TFT sensor signal

Shift Solenoid (NO.1, 2, 3, 4, 5)


1. Inspect the resistance of each shift solenoid between the terminal and the body earth.

Action : If the result of inspection is bad, replace each solenoid.


Notice :
Make sure to inspect resistance again at 20C (68F) when resistance differ from standards except 20
C (68F).
It might become infinity ohm when inspecting resistance at higher temperature.
2. Inspect the operation of each shift solenoid.
Solenoid (No.1, 4) (Normal open type)
No battery connection
Battery connection

Leak air
No leak air

Solenoid (No. 2, 3, 5) (Normal close type)


No battery connection
Battery connection

Action : If the result of inspection is bad, replace the each solenoid.


Notice : Do not damage the solenoid filter.

No leak air
Leak air

Pressure Control Solenoid


Inspect the resistance of each pressure control solenoid between terminals.
Action : Replace the valve body assembly. (No replacement of solenoid by itself)
Notice :
Make sure to inspect resistance again at 20C (68F) when resistance differ from standards except 20
C (68F).
It might become infinity ohm when inspecting resistance at higher temperature.

On-Vehicle Repair (Matrix Chart)

MAINTENANCE AND REPAIR


ON-VEHICLE SERVICE

Transaxle Fluid Level Checking Procedure


1. Park the vehicle on a flat level surface.
2. Operate the vehicle in order for the transaxle fluid temperature to reach the normal operating range.
Notice : Transaxle normal temperature: 70-80 C (158-176 F)
3. With the engine at idle, manual shift through all transaxle ranges and return to the PARK position. Leave the
engine idling.

4.
5.
6.
7.

Remove the transaxle fluid level indicator bolt.


Remove the transaxle fluid level indicator.
Wipe away any transaxle fluid from the indicator.
Insert the indicator into the transaxle until fully seated.
Important : Inspecting transaxle fluid level when not at normal temperature can give an incorrect
measurement. The transaxle fluid expands when warm.

8. Remove the indicator and inspect the level and the condition of the fluid on the indicator:
Transaxle fluid level at normal operating temperature (1).
Transaxle fluid level if cold (2).

9. If the fluid level is incorrect, inspect for the following conditions:


Fluid below level, inspect for a leak and add the fluid through the fluid level indicator location.
Fluid above level, transaxle is overfilled.
Drain some of the fluid through the drain plug. Check the fluid level.
Important : When adding the fluid or making a complete fluid change, always use ESSO JWS 3309 US
ATF.

10. Install the fluid level indicator and bolt.


Tighten
Tighten the fluid level indicator bolt to 10 Nm (89 lb-in).

Transaxle Fluid Replacement


Removal Procedure
1. Raise and support the vehicle.
2. Remove the drain plug and drain fluid. Allow at least 5 minutes for the fluid to drain completely.
3. Remove the gasket from the drain plug and discard.

Installation Procedure
1. Install the new gasket on the drain plug.
2. Install the drain plug.
Tighten
Tighten the drain plug to 40 Nm (30 lb-ft).
3. Make sure vehicle is level.

4. Remove the fluid level indicator bolt and indicator.


Important : Always use ESSO JWS 3309 US ATF.
Important : Do not remove the anchor bolt located on top of the transaxle for checking fluid or adding
fluid. Removing the bolt will dislocate internal components and require the transaxle to be removed
from the vehicle and disassembled for repair.
5. Add the transaxle fluid to the transaxle, using the fluid level indicator location.
6. Start engine and operate vehicle until transaxle fluid temperature reaches 70-80 C (158-176 F).

7. Apply parking brake.


8. Depress brake pedal and move shift lever slowly through all gear ranges from park (P) to low range, pausing
for about 3 seconds in each range. Return the shift lever to park (P) range at idle condition.
9. Pull level gauge out again and check if fluid level is within the HOT range.
10. Install the fluid level indicator.

Shift Control Cable Adjustment


Adjustment Procedure
1. Move the shift control lever into the N - Neutral position.
Important : The various shift control cable positions must match at the shift control lever in the vehicle
and at the selector lever on the transaxle to provide proper transaxle shifting.

2. Loosen the control cable adjusting nut.

3. Put the TR switch lever in neutral (N).

4. Pull the shift control cable until it is tight and tighten the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 Nm (71 lb-in).
5. Install the floor console.

Shift Control Cable


Removal Procedure
1.
2.
3.
4.

Remove the battery and tray.


Remove the floor console.
Apply the parking brake.
Place the shift control lever into N position.

5. Remove the cable adjust nut.


6. Disconnect the shift control cable from the shift control lever assembly.

Important : The shift control cable must be disconnected from the transmission range switch lever
prior to disconnecting it from the control cable bracket. Otherwise damage to the manual shift shaft
may result, requiring transaxle disassembly.
7. Remove the clip from the transmission range swich lever and disconnect the shift control cable from the lever.
8. Remove the clip from the shift control cable bracket.

9. Remove the shift control cable from the dash panel.


10. Remove the shift control cable from the vehicle.

Installation Procedure
1. Route the shift control cable through the cable bracket.
2. Secure the cable to the bracket with a new control cable retaining clip.
3. With the TR switch lever in neutral(N), install the clip onto the TR switch lever.

4. Secure the shift control cable grommet by pressing the cable into the pass-thru hole in the dash panel.

5. Ensure the shift control lever is in the neutral (N) position.


6. Connect the shift control cable to the shift control lever assembly.
7. Install the shift control cable adjuster pinch nut.
Tighten
Tighten the nut to 8 Nm (71 lb-in).
8. Adjust the shift control cable.

9. Install the front console.


10. Install the battery and tray.

Shift Control Lever Assembly


Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console.
3. Disconnect the wiring harness connectors from the shift control lever.

4. Loosen the control cable adjusting nut.


5. Disconnect the control cable from the shift control lever assembly.

6. Remove the shift control lever assembly mounting bolts and nuts.
7. Remove the shift control lever assembly.

Installation Procedure
1. Install the shift control lever assembly and mounting bolts and nuts.
Tighten
Tighten the shift control lever assembly mounting bolts and nuts to 8 Nm (71 Ib-in).

2. Connect the control cable to the shift control lever assembly.


3. Tighten the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 Nm (71 Ib-in).

4.
5.
6.
7.

Connect the harness connector.


Adjust the control cable.
Install the floor console.
Connect the negative battery cable.

Shift Control Knob


Removal Procedure
1. Apply the parking brake.
2. Remove the knob from the shift control lever.

Installation Procedure
1. Install the shift control knob into the shift control lever.

Transmission Range (TR) Switch


Tools Required
J 45404 Transmission Indicator Alignment Tool

Removal Procedure
1. Remove the battery and tray.
Important : The transaxle manual shaft must be in neutral (N) position prior to re-installing the switch.
2. Apply the parking brake and place control shift lever in neutral (N).

3. Disconnect the TR switch electrical connector (1) and the transaxle electrical connector (2).
4. Disconnect the cable from the TR switch lever.

5. Remove the TR switch lever nut and lever.

6. Using a screwdriver, bend the lockwasher tabs down away from the manual shaft nut.

7. Remove the nut, lock tab washer, and flat washer.

8. Remove the TR switch bolts.


9. Remove the TR Switch.

Installation Procedure
1. Install the transmission range (TR) switch to the manual shaft lever.
2. Install the bolts. Hand tighten ONLY at this time.

3. Install the flat washer, lock tab washer, and nut.


Tighten
Tighten the TR switch nut to 7 Nm (62 lb-in).
4. Ensure the manual shaft is in neutral (N) position.

5. Bend the lock washer tabs up to secure the nut.

6. Install the J 45404 to the manual shaft and rotate the TR switch until the neutral base line on the switch lines
up with the indicator line on the J 45404.
7. Tighten the TR switch bolts.
Tighten
Tighten the TR switch bolts to 25 Nm (18 lb-ft).
8. Remove the J 45404 from the manual shaft.

9. Install the TR switch lever and nut.


Tighten
Tighten the TR lever nut to 16 Nm (12 lb-ft).

10. Install the cable to TR switch lever and adjust the cable.
11. Connect the electrical connector (1,2).

12. Install the battery and tray.


13. After adjusting the TR switch, verify the engine only starts in park (P) or neutral (N). If the engine starts in
any other position, readjust the switch.

Transmission Range (TR) Switch Adjustment


Tools Required
J 45404 Transmission Indicator Alignment Tool

Adjustment Procedure
1. Remove the battery and tray.
2. Shift the control lever into neutral (N) position.
3. Remove the shift control cable from the TR switch lever.

4. Loosen the TR switch bolts.

5. Install the J 45404 to the manual shaft and rotate the TR switch until the neutral base line on the switch lines
up with the indicator line on the J 45404.
6. Tighten the TR switch bolts.
Tighten
Tighten the TR switch bolts to 25 Nm (18 lb-ft).
7. Remove the J 45404 from the manual shaft.

8. Install the shift control cable to the TR switch lever and adjust the cable.
9. Install the battery and tray.
10. After adjusting the transaxle range switch, verify the engine only starts in park (P) or neutral (N). If the
engine starts in any other position, readjust the switch.

Input Speed Sensor


Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the battery and tray.
3. Remove the input speed sensor electrical connector (3) from the input speed sensor.

4. Remove the input speed sensor bolt.


5. Remove the input speed sensor from the transaxle.
6. Remove the input speed sensor O-ring. Discard the O-ring.

Installation Procedure
1.
2.
3.
4.

Apply the transaxle fluid to the new input speed sensor O-ring.
Install the new input speed sensor O-ring onto the input speed sensor.
Install the input speed sensor to the transaxle.
Install the input speed sensor bolt.
Tighten
Tighten the input speed sensor bolt to 6 Nm (53 lb-in).

5. Connect the electrical connector (3) to the input speed sensor.


6. Install the battery and tray.
7. Connect the negative battery cable.

Output Speed Sensor


Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the battery and tray.
3. Remove the output speed sensor electrical connector (4) from the output speed sensor.

4. Remove the output speed sensor bolt.


5. Remove the output speed sensor from the transaxle.
6. Remove the output speed sensor O-ring. Discard the O-ring.

Installation Procedure
1.
2.
3.
4.

Apply the transaxle fluid to the new output speed sensor O-ring.
Install the new output speed sensor O-ring onto the input speed sensor.
Install the output speed sensor to the transaxle.
Install the output speed sensor bolt.
Tighten
Tighten the output speed sensor bolt to 6 Nm (53 lb-in).

5. Connect the electrical connector (4) to the output speed sensor.


6. Install the battery and tray.
7. Connect the negative battery cable.

Transmission Control Module (TCM)


Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the TCM wiring connectors.
3. Remove the transmission control module (TCM) and nuts.

Installation Procedure
1. Install the TCM retaining nuts.
Tighten
Tighten the TCM retaining nuts to 8 Nm (71 lb-in).
2. Connect the electrical connectors.
3. Connect the negative battery cable.

Oil Cooler Line Assembly


Removal Procedure
1. Raise and suitably support the vehicle.
2. Place a drain pan or suitable container under the vehicle.
3. Disconnect the oil cooler hoses from the radiator.

4. Remove the oil cooler line assembly bolt from the transaxle.
5. Remove the oil cooler line assembly.
6. Replace the transaxle oil cooler line seals.

Installation Procedure
1. Install the oil cooler line assembly to the transaxle.
2. Install the oil cooler line assembly bolt.
Tighten
Tighten the oil cooler line assembly bolt to 10 Nm (89 lb-in).

3.
4.
5.
6.

Connect the oil cooler hoses to the radiator.


Lower the vehicle
Add fluid to the transaxle.
Check the fluid level.

Oil Cooler Line Seals


Tools Required
J 41239-1 Cooler Line Seal Installer
J 45201 Cooler Line Seal Remover

Removal Procedure
1. Raise and suitably support the vehicle.
2. Place a drain pan or suitable container under the vehicle.
3. Remove the transaxle oil cooler line assembly from the transaxle.

Important : Ensure that the J 45201 is fully seated into the transaxle seal bore.
4. Insert the collet piece (2) of the J 45201 into the cooler line seal.
5. Insert the forcing screw piece (1) of the J45201 into the collet (2).
6. Tighten the forcing screw (1) until snug.

7. Thread the collar piece (1) of the J 45201 onto the collet (3) until snug.

8. Turn the collar clockwise in order to remove the cooler line seal.
9. Discard the seal.
10. Clean the case bores for the cooler line seals.

Installation Procedure
1.
2.
3.
4.

Insert 2 new transaxle cooler line seals (1) into the case bore.
Remove the nub from the J 41239-1.
Install the nub of the J 41239-1 on the transaxle cooler line seals.
Tap the 2 new transaxle cooler line seals (1) into the case bore.

5.
6.
7.
8.

Install the oil cooler line assembly.


Lower the vehicle.
Add fluid to the transaxle.
Check the fluid level.

Left Transaxle Mounting Bracket


Tools Required
DW110-060 Engine Support Fixture

Removal Procedure
1. Remove the battery and tray.
2. Install the DW110-060.
3. Support the transaxle with a supporting jack.

4. Remove the left three transaxle mounting bracket bolts.


5. Remove the transaxle mounting bracket cage bolt and nut.
6. Remove the left transaxle mounting bracket.

Installation Procedure
1. Install the left transaxle mounting bracket and three transaxle mounting bracket bolts.
Tighten
Tighten the left three transaxle mounting bracket bolts to 47 Nm (35 lb-ft).
2. Install the transaxle mounting bracket cage bolt and nut.
Tighten
Tighten the transaxle mounting bracket cage bolt and nut to 65 Nm (48 lb-ft).

3. Remove the DW110-060.


4. Install the battery and tray.

Transaxle Assembly
Tools Required
DW110-060 Engine Support Fixture

Removal Procedure
1. Remove the battery and tray.
2. Remove the fuel filter assembly
3. Drain the transaxle fluid.

4. Disconnect the shift control cable from the transaxle.

5. Disconnect the transmission range (TR) switch electrical connector (1).


6. Disconnect the transaxle wiring electrical connector (2).
7. Disconnect the input speed sensor electrical connector (3) and the output speed sensor electrical connector
(4).

8.
9.
10.
11.
12.

Remove the upper two transaxle-to-engine bolts.


Remove the starter.
Support the engine assembly using the engine support fixture DW110-060.
Raise and suitably support the vehicle.
Remove the engine under covers.

13. Remove the centermember.


14. Remove the exhaust front pipe.
15. Remove the crossmember.

16. Remove the engine front mount.


17. Remove the drive axle.

18. Remove the oil cooler line from the transaxle.

19. Remove the six flywheel-to-torque converter bolts after removing the plastic cover.

20. Remove the rear transaxle mounting bracket bolts.

21. Support the transaxle assembly using the supporting jack.

22. Remove the oil pan flange-to-transaxle bolts.

23. Remove the left lower engine-to-transaxle bolts near the rear transaxle mounting bracket side.

24. Remove the right lower engine-to-transaxle bolt near the engine front mount.

25. Remove the left transaxle mounting bracket bolts.

26. Carefully remove the transaxle assembly from the vehicle.

Installation Procedure
1. Install the transaxle into the vehicle and support the transaxle assembly using the supporting jack.

2. Install the left transaxle mounting bracket bolts.

3. Install the right lower engine-to-transaxle bolt near the engine front mount.
Tighten
Tighten the right lower engine-to-transaxle bolt to 73 Nm (54 lb-ft).

4. Install the left lower engine-to-transaxle bolts near the rear transaxle mounting bracket side.
Tighten
Tighten the left lower engine-to-transaxle bolts to 73 Nm (54 lb-ft).

5. Install the oil pan flange-to-transaxle bolts.


Tighten
Tighten the oil pan flange-to-transaxle bolts to 50 Nm (37 lb-ft).

6. Install the rear transaxle mounting bracket bolts.


Tighten
Tighten the rear transaxle mounting bracket bolts to 90 Nm (66 lb-ft).

7. Install the six flywheel-to-torque converter bolts and the plastic cover.
Tighten
Tighten the flywheel-to-torque converter bolts to 45 Nm (33 lb-ft).

8. Install the upper transaxle-to-engine bolts.


Tighten
Tighten the upper transaxle-to-engine bolts to 73 Nm (54 lb-ft).

9. Install the oil cooler line to the transaxle.


10. Install the starter.

11. Install the engine front mount bolts and mount.


Tighten
Tighten the engine front mount bolts to 60 Nm (44 lb-ft).
12. Install the drive axle.

13.
14.
15.
16.
17.
18.

Install the exhaust front pipe.


Install the centermember.
Install the crossmember.
Install the engine under covers.
Lower the vehicle.
Remove the DW110-060 from the engine.

19. Install the transmission range (TR) switch electrical connector (1).
20. Connect the transaxle wiring electrical connector (2).
21. Connect the input speed sensor electrical connector (3) and the output speed sensor electrical connector (4).

22. Install the shift control cable to the transaxle.


23. Adjust the shift control cable.

24.
25.
26.
27.

Install the fuel filter assembly.


Install the battery and tray.
Add fluid to the transaxle.
Check the fluid level.

Major Component Disassembly


Tools Required
J 45053 Universal Clamp Press
DT 47599 Anchor Bolt Socket
J 45161 Manual Shift Shaft Bearing Replacer
J 45000 Seal Remover

Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.

2. Remove the torque converter.


1. Remove the torque converter from the transaxle.

3. Remove the drain plug.


1. Remove the drain plug and drain ATF.
2. Remove the gasket from the drain plug.

4. Remove the oil level gauge.


1. Remove the 1 bolt and the oil level gauge.

5. Remove the output speed sensor.


1. Remove the 1 bolt and pull out the output speed sensor.
Important : Be careful not to damage the output speed sensor and transaxle case.

6. Remove the input speed sensor and transmission range (TR) switch.
1. Remove the 1 bolt and pull out the input speed sensor.
Important : Be careful not to damage the input speed sensor and transaxle case.

1. Using a screwdriver, pry off the lock washer.

1. Remove the nut and lock washer.

1. Remove the 2 bolts and pull out the TR switch.

7. Remove the transaxle side cover.


1. Remove the 9 Torx bolts and the transaxle side cover.
Important : Be careful not to damage the transaxle side cover and transaxle case.

8. Disconnect the transaxle wire connectors.


1. Disconnect the 8 solenoids wire connectors.

1. Remove the 1 bolt and the clamp, pull out the transaxle oil temperature (TFT) sensor.
Important : Be careful not to damage the wire connector.

9. Remove the valve body assembly.


1. Remove the 2 bolts, the suction cover and gasket.

1. Remove the 6 bolts.

1. While holding the valve body assembly, disconnect the manual valve connecting rod from the manual
valve lever and remove the valve body assembly.
Important : Shift position is "N".

10. Remove the gasket.


1. Remove the 2 gasket.

11. Remove the switch and sensor assembly from the transaxle case.
1. Remove the transaxle wire from clamps.
2. Push the solenoid wire out of inside and remove it.
Important : Be careful not to break the wire connector and TFT sensor.

12. Remove the oil pump assembly.


1. Remove the 8 bolts.

1. Pull the oil pump assembly from the transaxle case with J 45053.
Important : Be careful not to damage the stator shaft bushing.

13. Remove the 2nd coast brake (B1), 2nd brake (B2) and 1 way clutch asssembly (F1).
1. Remove the 2nd coast brake (B1) and 2nd brake (B2) hub and washer.

14. Remove the transaxle housing.


1. Remove the 17 bolts.

1. Remove the transaxle housing with a plastic hammer.

15. Remove the apply gasket.

16. Remove the differential gear lube apply tube.


1. Remove 1 bolt and clamp.

1. Using a screwdriver and remove the differential gear lube apply tube.
Important : Be careful not to bend or damage the apply tube.

17. Remove the oil reservoir plate (transaxle housing).


1. Remove the 3 bolts and the oil reservoir plate.

1. Remove the 4 magnets from the oil reservoir plate.

18. Remove the differential assembly.

19. Remove the oil strainer.


1. Remove the 1 bolt and the oil strainer.

20. Remove the transaxle case plate.


1. Remove the 2 bolts and the transaxle case plate.

21. Remove the oil reservoir plate(transaxle case).


1. Remove the 3 bolts and the oil reservoir plate.

22. Remove the underdrive brake (B4) apply tube.


1. Remove the 2 bolts and the clamp.

1. Using a screwdriver, remove the underdrive brake (B4) apply tube.


Important : Be careful not to bend or damage the apply tube and the O-ring. Be careful not to damage
the transaxle case.

23. Remove the manual valve lever and parking lock rod.
1. Disconnect the detent spring from the manual valve lever.

1. Disconnect the manual valve lever from the parking lock rod.

1. Remove the parking lock rod.

1. Remove the 2 bolts.

1. Remove the detent spring.

1. Remove the parking lock pawl shaft and torsion spring No.1.

1. Remove the cam plate and parking lock pawl.

1. Remove the parking lock pin.

1. Remove the 1 torx bolt, sleeve guide and torsion spring No.2.

1. Using a screwdriver, remove the manual valve oil seal.

1. Using J 45161 and a hammer, drive the manual shift shaft bearing through the transaxle case bore to
remove the bearing.

24. Remove the underdrive gear assembly.


1. Remove the thrust bearing and the thrust race from the underdrive gear assembly.

1. Remove the underdrive gear assembly from the transaxle case.

25. Remove the underdrive clutch assembly (C3).


1. Remove the underdrive clutch assembly (C3).

26. Remove the underdrive brake (B4) band.


1. Remove the underdrive brake (B4) band.
Important : Be careful not to damage the transaxle case.

27. Remove the underdrive rear planetary gear assembly.


1. Remove the underdrive rear planetary gear assembly.

1. Remove the underdrive rear planetary ring gear assembly.


2. Remove the thrust bearing and shim from the underdrive rear planetary ring gear.

28. Remove the underdrive brake (B4) piston.


1. Using the pliers, remove the snap ring.

1. Remove the underdrive brake (B4) cover assembly from the transaxle case.
2. Remove the 2 O-rings from the underdrive brake (B4) cover.

1. Remove the underdrive brake(B4) piston assembly and spring from the transaxle case.
2. Remove the O-ring from the underdrive brake (B4) piston assembly.

1. Using the anchor bolt socket DT 47599, remove the anchor bolt.

29. Remove the rear case assembly.


1. Remove the 13 bolts.

1. Remove the rear case assembly with a plastic hammer.


Important : Be careful not to damage the rear case.

1. Remove the rear case assembly.

1. Remove the 5 gaskets from the transaxle case.

30. Remove the apply tube.


1. Remove the 1 torx bolt and clamp.

1. Using a screwdriver, remove the apply tube.


Important : Be careful not to bend or damage the apply tube.

31. Remove the forward (C1) and direct clutch (C2).


1. Remove the forward (C1) and direct clutch (C2) assembly.

32. Remove the planetary sun gear assembly.


1. Remove the planetary sun gear assembly.

33. Remove the rear planetary ring gear assembly.


1. Remove the rear planetary ring gear assembly.

34. Remove the planetary gear assembly.


1. Remove the planetary gear assembly.

35. Remove the front ring gear & 1 way clutch no.2 (F2) and plate,disc,flange of 1st & reverse brake (B3).
1. Remove the bearing with race.

1. Remove the snap ring with a screwdriver.

1. Remove the plate, disc and flange.

1. Remove the front ring gear and 1 way clutch No.2 (F2).

1. Using a screwdriver, remove the snap ring.

1. Remove the 1st & reverse brake(B3) return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
36. Remove the 1st & reverse brake (B3) piston.
1. While pushing the piston by hand, apply compressed air (4kg/cm) into the oil passage of transaxle case
as shown in the figure and remove the B3 piston.

1. Remove the O-rings from the piston.


37. Inspect 1st & reverse brake (B3) disc and plate.
1. Check that the sliding surface of discs are not worn and burnt. If necessary, replace them.
Important : Replace new discs by soaking them at least 2 hours in ATF.

38. Remove the thrust race.


1. Remove the race from the counter drive gear.

39. Remove the counter drive gear.


1. Remove the snap ring with a plier.

1. Remove the counter drive gear.

40. Remove the oil seal.


1. Remove the oil seal of the transaxle case side and housing side with seal remover J 45000.

Major Component Assembly


Tools Required
J 45053 Universal Clamp Press
DT 47599 Anchor Bolt Socket
DT 47687 Rotational Torque Adapter
J 45187 Differential Output Shaft Oil Seal Installer
J 44809 Output Shaft Seal Installer
J 45124 Removal Bridge
J 45160 Differential Bearing Race Remover
J 8092 Driver Handle
J 45184 Differential Bearing Race Installer
J 45161 Manual Shift Shaft Bearing Replacer
J 45404 Transmission Indicator Alignment Tool

Assembly Procedure
1. Install the counter drive gear.
1. Install the counter drive gear.
2. Install the snap ring with a plier.

2. Install the 1st & reverse brake (B3) piston.


1. Coat the new O-rings with ATF and install them on the piston.
2. Coat the inner surface of the transaxle case with ATF.
3. Press the 1st & reverse brake(B3) piston into the transaxle case.
Important : Be careful not to damage the O-ring.

3. Install the 1st & reverse brake(B3) return spring assembly.


1. Place the 1st & reverse brake (B3) return spring assembly on the B3 piston.

1. While compressing the 1st & reverse brake(B3) return spring by hand, install the snap ring into the
groove with a screwdriver.

Important : Be careful not to damage the inner surface of transaxle case. Be sure to install the snap
ring correctly as shown in the figure.

4. Install the front ring gear & 1 way clutch NO.2 (F2) and flange, disc, plate of 1st & reverse brake (B3).
1. Install the race on the counter drive gear.

1. Install the front ring gear & 1 way clutch NO.2 (F2).
Important : Make sure that the ring gear should turn freely counterclockwise and should lock
clockwise.

1. Install the flange, disc and plate as shown in the figure.


Important : Be sure the number and order of them.
Order : F-D-P-D-P-D-P-D-P-D-F
Clutch/Brake
1st & reverse brake (B3)

Flange (F)
2

Plate (P)
4

Disc (D)
5

1. Using a screwdriver, install the snap ring.


Important : Check that the end gap of the snap ring is not aligned with one of the cutouts.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
5. Check the piston stroke of 1st & reverse brake (B3).
1. Set a dial indicator as shown in the figure.
2. Apply compressed air (4kg/cm) and measure the 1st & reverse brake (B3) piston stroke.
Piston stroke : 1.39-2.21mm (0.055-0.087 in.)

6. Install the planetary gear assembly.


1. Install the planetary gear assembly.
Important : Be careful the direction of thrust bearing.

7. Install the rear planetary ring gear assembly.


1. Install the rear planetary ring gear assembly.
Important : Be careful the direction of thrust bearing.

8. Install the planetary sun gear assembly.


1. Install the planetary sun gear assembly.
Important : Be careful the direction of thrust bearing.

9. Install the forward (C1) & direct clutch (C2).


1. Install the forward (C1) & direct clutch (C2) assembly.

1. Check the distance of "A".


A = 50.850 51.825 mm (2.002-2.040 in.)
Important : If the distance is out of standards,adjust within standards again.

10. Install the apply tube.


1. Using a plastic hammer, install the apply tube as shown in the figure.
Important : Be careful not to bend and damage the apply tube.

1. Install the 1 clamp and tighten the 1 Torx bolt.


Tighten
Tighten the oil apply tube clamp retaining bolt to 6 Nm (53 lb-in).

11. Install the rear case assembly.


1. Coat the new 5 gaskets with grease and install them on the transaxle case.

1. Install the new 3 seal rings and bearing race onto the rear case.

1. Remove any packing material on the contacting surfaces of the rear case and transaxle case and wipe
off ATF on the contacting surfaces.
2. Apply formed in place gasket (FIPG) to the rear case as shown in the figure.
Important : Be careful that no oil on the contacting surfaces of the rear case and transaxle case.

1. Install the rear case.

1. Install and tighten the 13 bolts.


Tighten
Tighten the rear case bolt to 30 Nm (22 lb-ft).

12. Install the underdrive brake (B4).


1. Coat the new O-ring with ATF, install and tighten the 1 anchor bolt with anchor bolt socket DT 47599.
Tighten
Tighten the underdrive brake (B4) anchor bolt to 167 Nm (123 lb-ft).

13. Install the underdrive brake (B4) piston.


1. Coat the inner surface of transaxle case with ATF.
2. Install the spring and underdrive brake (B4) piston assembly to the transaxle case.

1. Coat the 2 new O-rings with ATF, and install them on the underdrive brake (B4) cover.

1. Using a plier, and install the snap ring while pressing the underdrive brake(B4) cover.
Important : If the snap ring is deformed, replace it.

14. Install the underdrive rear planetary gear assembly.


1. Install the underdrive rear planetary ring gear assembly.
Part Name
Specification
0.81 mm (0.032 in.)
0.90 mm (0.035 in.)
1.00 mm (0.039 in.)
1.10 mm (0.043 in.)
Washer Thickness Type
1.20 mm (0.047 in.)
1.30 mm (0.051 in.)
1.40 mm (0.055 in.)
1.50 mm (0.059 in.)
1.60 mm (0.063 in.)

Mark
8
9
10
11
12
13
14
15
16

1. Install the underdrive rear planetary gear assembly.

15. Install the underdrive brake(B4) band.


1. Install the underdrive brake (B4) band.

16. Install the underdrive clutch (C3) assembly.


1. Install the underdrive clutch (C3) assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
17. Inspect underdrive brake (B4) piston stroke.
1. Place a mark on the underdrive brake (B4) piston rod.
2. Measure the B4 piston stroke applying and releasing the compressed air (4Kg/cm) as shown in the
figure.
Piston Stroke : 5.76-6.76 mm (0.227-0.266 in.)
If the rod stroke is out of standards, select another rod.

Rod Length

R=76.2 mm (3.000 in.)


R=76.7 mm (3.020 in.)
R=77.2 mm (3.039 in.)

R=77.7 mm (3.059 in.)


R=78.2 mm (3.079 in.)

18. Install the underdrive gear assembly.


1. Install the underdrive gear assembly to the transaxle case.

1. Install the thrust bearing and race.


2. Check the distance of E.
Important : Be sure to measure from End face of the case to the bearing (part of a roller).
E : 1.269-1.645 mm (0.050-0.065 in.)
If the measured value is out of standards, select "L" race for installation.

Part Name

Specification
Mark
0.80 mm (0.031 in.)
(None)
0.90 mm (0.035 in.)
A
1.00 mm (0.039 in.)
B
1.10 mm (0.043 in.)
C
Washer Thickness Type
1.20 mm (0.047 in.)
D
1.30 mm (0.051 in.)
E
1.40 mm (0.055 in.)
F
1.50 mm (0.059 in.)
G
And, if the value doesn't full within standards by using above races, re-select "P" shim of "14. Install the
underdrive rear planetary gear assembly" for installation.

Be sure to use Thickness=0.80 mm (0.031 in.) with "L" race at that time.

19. Adjust preload of tapered roller bearing.


1. Install the differential case assembly into the transaxle case.
2. Install the transaxle housing into the transaxle case.

1. Install and tighten the 17 bolts as shown in the figure.


Tighten
Tighten the transaxle housing bolt to 30 Nm (22 lb-ft).

1. Rotate the differential in both directions to snug the bearing down.


2. Using rotational torque adapter DT 47687 and a torque meter, measure the preroad (at rotating) of the
side bearing without installing the underdrive gear & shaft assembly.
Rotational torque Spec.(new bearing) : 0.70-1.20 Nm (6-11 lb-in).
1. If the preroad is not within specification, differential bearing race shim must be replaced.
2. Remove the transaxle housing and differential assembly from the transaxle case.

20. Remove the differential bearing race and shim.


1. Install J 45160 onto the bearing race taking care to make sure the bottom of the tool is all the way down
inside the race and seats flat on top of the shim before tightening.
2. Using two wrenches, tighten J 45160 to firmly seat the tool into the bearing race for removal.

1. Position the adjustable leg sections of J 45124 to seat squarely onto the top of the case section around
the differential bearing race.
2. Attach J 45124 to J 45160 and hand tighten the center bolt to lightly apply tension to prevent movement
of the tool assembly. Reinspect the position of the adjustable legs of J 45124 to ensure that the
differential bearing race will clear the adjustable legs and no damage to the transaxle case assembly will
occur when removing the race.
3. Tighten the bolt on J 45124 to remove the differential bearing race from the transaxle case.

1. Remove the differential bearing race shim from the transaxle case.
2. Measure the differential bearing race shim to determine its size. Based on the obtained measurement,
refer to the following table in order to determine the correct size of shim that will be needed.
1.00 mm (0.039 in.)
1.48 mm (0.058 in.)
1.05 mm (0.041 in.)
1.51 mm (0.059 in.)
1.10 mm (0.043 in.)
1.54 mm (0.061 in.)
1.15 mm (0.045 in.)
1.57 mm (0.062 in.)
1.20 mm (0.047 in.)
1.60 mm (0.063 in.)
1.25 mm (0.049 in.)
1.65 mm (0.065 in.)
1.30 mm (0.051 in.)
1.70 mm (0.067 in.)
1.33 mm (0.052 in.)
1.75 mm (0.069 in.)
1.36 mm (0.053 in.)
1.80 mm (0.071 in.)
1.39 mm (0.055 in.)
1.85 mm (0.073 in.)
1.42 mm (0.056 in.)
1.90 mm (0.075 in.)
1.45 mm (0.057 in.)
If the obtained rotational torque measurement was less than the listed specification, then a lager/thicker shim
will be required. If the obtained rotational torque measurement was greater than the listed specification, then a
smaller/thinner shim will be required.

21. Remove the differential bearing race and shim.


1. Once the proper shim has been selected, install the new differential bearing race shim into the transaxle
case.

1. Using J 8092 and J 45184, install the differential bearing race into the transaxle case.
2. After the differential bearing race is correctly installed into case, repeat the measurement to verify that
the correct shim thickness was selected.

22. Install the manual shift shaft bearing.


1. Using the J 45161 and a hammer, install the manual shift shaft bearing into the transaxle case.

23. Install the manual valve oil seal. pressing the seal into the case.
1. Install the new manual valve oil seal. pressing the seal into the case.

1. Install the 1 torx bolt, sleeve guide and torsion spring No.2.
Tighten
Tighten the No.2 torsion spring retaining bolt to 10 Nm (89 lb-in).

1. Install the parking lock pin.

1. Install the cam plate and parking lock pawl.

1. Install the parking lock pawl shaft and torsion spring No.1.

1. Install the detent spring.

1. Temporally tighten the 2 bolts.

1. Install the parking lock rod.

1. Install the manual valve lever and connect the parking lock rod to it.

1. Using screwdriver, connect the detent spring to the manual valve lever.

1. Tighten the 2 bolts.


Tighten
Tighten the detent spring retaining bolt (16.7mm) (1) to 10 Nm (89 lb-in).
Tighten the detent spring retaining bolt (14mm) (2) to 6 Nm (53 lb-in).

24. Install the underdrive brake (B4) apply tube.


1. Install the 2 new O-rings in the groove of tube and install the underdrive brake (B4) apply tube with a
plastic hammer.

Important : Be careful not to damage the O-ring and not to bend or damage the tube.

1. Install the clamp and tighten the 2 bolts.


Tighten
Tighten the underdrive brake (B4) apply tube clamp retaining bolt to 6 Nm (53 lb-in).

25. Install the oil reservoir plate(transaxle case).


1. Install the oil reservoir plate and tighten the 3 bolts.
Tighten
Tighten the oil reservoir plate (transaxle case) bolt to 6 Nm (53 lb-in).

26. Install the transaxle case plate.


1. Install the transaxle case plate and tighten the 2 bolts.
Tighten
Tighten the transaxle case plate bolt to 6 Nm (53 lb-in).

27. Install the oil strainer.


1. Install the oil strainer and tighten the 1 bolt.
Tighten
Tighten the oil strainer bolt to 6 Nm (53 lb-in).

28. Install the differential assembly.

29. Install the oil reservoir plate(transaxle housing).


1. Place the 4 magnets to the oil reservoir plate.

1. Install the oil reservoir plate and tighten the 3 bolts.


Tighten
Tighten the oil reservoir plate(transaxle housing) bolt to 6 Nm (53 lb-in).

30. Install the differential gear lube apply tube.

1. Using a plastic hammer, install the differential gear lube apply tube.
Important : Be careful not to bend or damage the tube.

1. Install the clamp and tighten the 1 bolt.


Tighten
Tighten the differential gear lube apply tube clamp bolt to 6 Nm (53 lb-in).

31. Install the gasket.


1. Install the 1 new gasket.

32. Assemble the transaxle housing.


1. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle
housing and transaxle case.
2. Apply formed in place gasket (FIPG) to the transaxle housing as shown in the figure.

1. Install the transaxle housing to the transaxle case.

1. Install and tighten the 17 bolts as shown in the figure.


Tighten
Tighten the transaxle housing bolt to 30 Nm (22 lb-ft).
Important : Make sure to use new seal bolt.

33. Install the oil pump assembly.


1. Install the thrust washer with grease into the oil pump assembly.
2. Install the 2nd coast brake (B1) & 2nd brake (B2) hub and 1 way clutch No.1 (F1) to the oil pump
assembly.

1. Check the distance of B.


B : 51.09-51.71 mm (2.011-2.036 in)
Important : If the distance is out of standards,adjust within standards again.

1. Install the new O-ring to the oil pump assembly.


2. Place the oil pump assembly through the input shaft in the horizontal position, and align the bolt holes
of the pump body with the transaxle case. Lightly press the oil pump body.
Important : Be careful not to drop the 2nd coast brake (B1) & 2nd brake (B2) hub and 1 way clutch
No.1 (F1).

1. Install and tighten the 8 bolts.


Tighten
Tighten the oil pump assembly bolt to 25 Nm (18 lb-ft).

34. Check the end play.


1. Set a dial indicator as shown in the figure, move the input shaft and measure the end play.
End play : 0.188-0.570 mm (0.007-0.022 in)
If the end play is out of standards, select another bearing race "K" according to "No.11, 2) of MAJOR
COMPONENT ASSEMBLY" in ths section.
Part Name
Thickness Specification
Outer diameter
Inner diameter
0.81 mm (0.032 in.)
41.00 mm (1.614 in.)
22.00 mm (0.866 in.)
0.90 mm (0.035 in.)
41.00 mm (1.614 in.)
22.00 mm (0.866 in.)
1.00 mm (0.039 in.)
41.00 mm (1.614 in.)
21.70 mm (0.854 in.)
1.10 mm (0.043 in.)
41.00 mm (1.614 in.)
21.50 mm (0.846 in.)
Washer
Thickness type
1.20 mm (0.047 in.)
41.00 mm (1.614 in.)
21.30 mm (0.839 in.)
1.30 mm (0.051 in.)
41.00 mm (1.614 in.)
21.20 mm (0.835 in.)
1.40 mm (0.055 in.)
41.00 mm (1.614 in.)
21.00 mm (0.827 in.)
1.50 mm (0.059 in.)
41.00 mm (1.614 in.)
20.80 mm (0.819 in.)

Mark
(None)
9
10
11
12
13
14
15

35. Install the switch and sensor assembly to the transaxle case.
1. Install a new O-ring with ATF to the transaxle wire.
2. Install the switch & sensor assembly to the transaxle case.

36. Install the gasket.


1. Install the 2 new gaskets onto the transaxle case.

37. Install the valve body assembly.


1. While holding the valve body assembly, connect the manual valve connecting rod to the manual valve
lever.
Important : Shift position is "N".
Important : Be careful not to damage the transaxle wire.

1. Install and tighten the 6 bolts evenly.


Tighten
Tighten the valve body assembly bolt to 10 Nm (89 lb-in).

38. Install the suction cover.


1. Install the new gasket and suction cover, tighten the 2 bolts evenly.
Tighten
Tighten the suction cover bolt to 10 Nm (89 lb-in).

39. Connect the transaxle wire connectors.


1. Coat the new O-ring with ATF, install the groove of TFT sensor.
2. Install the clamp and tighten the 1 bolt.
Tighten
Tighten the TFT sensor bolt to 10 Nm (89 lb-in).

1. Connect the 8 solenoids wire connectors.


Important : Be careful not to bend the solenoid wire connector pin.

(1) No.1 solenoid (Black)


(2) No.2 solenoid (Gray)
(3) No.3 solenoid (Gray)
(4) No.4 solenoid (Blue)
(5) No.5 solenoid (Brown)
(6) Solenoid (Blue)
(7) Solenoid (Green)
(8) Solenoid (Black)

40. Install the transaxle side cover.


1. Remove any packing material on the contacting surface of the transaxle case, and wipe out the oil on
the contacting surface.
2. Apply formed in place gasket (FIPG) to the new side cover.
Important : Be careful that no oil on the contacting surface.
1. Install the side cover on the transaxle case.

1. Install and tighten the new 9 torx bolts evenly.


Tighten
Tighten the side cover bolt to 13 Nm (10 lb-ft).
Important : Make sure to use new seal bolt.

41. Install the input speed sensor and TR switch.


1. Install the new O-ring with ATF to the input speed sensor.
2. Install the input speed sensor and tighten the 1 bolt.
Tighten
Tighten the input speed sensor bolt to 6 Nm (53 lb-in).
Important : Make sure to use new seal bolt.

1. Install the TR switch to the manual valve lever.


2. Temporary tighten the 2 bolts.

1. Install the lockwasher and nut and tighten the nut.


Tighten
Tighten the TR switch nut to 7 Nm (62 lb-in).

1. Manual valve lever must be adjusted to "N" position.


2. Install the J 45404 to the manual valve lever.
3. Rotate the TR switch until the neutral base line on the switch assembly lines up with the indicator line
on J 45404.

1. Tighten the 2 bolts of the TR switch.


Tighten
Tighten the TR switch bolts to 25 Nm (18 lb-ft).

1. Stake the lockwasher with a screwdriver.

42. Install the output speed sensor.


1. Install the new O-ring with ATF to the output speed sensor.
2. Install the output speed sensor and tighten the 1 bolt.
Tighten
Tighten the output speed sensor bolt to 6 Nm (53 lb-in).
Important : Make sure to use new seal bolt.

43. Install the oil level gauge.


1. Install the new O-ring with ATF and the oil level gauge.

1. Tighten the 1 bolt.


Tighten
Tighten the oil level gauge bolt to 10 Nm (89 lb-in).

44. Install the drain plug.


1. Install a new gasket to the drain plug.
Tighten
Tighten the drain plug to 40 Nm (30 lb-ft).

45. Install the torque converter.


1. Install the torque converter.

1. Check the distance of C.


C = 1.35 mm (0.053 in.)
Important : If the distance is out of standards, adjust within standards again.

46. Install the differential oil seal.


1. Install the oil seal of the transaxle housing side with J 45187.

1. Install the oil seal of the transaxle case side with J 44809.

Forward (C1) and Direct Clutch (C2) Disassembly


Tools Required
J 28585 Snap Ring Remover
J 45186 Forward and Direct Clutch Spring Compressor
J 25024-A Servo Piston/Clutch Spring Compressor
J 23327 Clutch Spring Compressor
1. Remove the seal ring, thrust bearing and race.
1. Remove the seal ring from the input shaft assembly.

1. Remove the thrust bearing and race.

2. Remove the flange, disc and plate of forward clutch (C1).


1. Using J 28585, remove the snap ring.

1. Remove the 1 flange, 4 discs and 4 plates.

3. Remove the flange, disc, plate and cushion plate of direct clutch (C2).
1. Using 28585, remove the snap ring.

1. Remove the 1 flange, 4 discs, 4 plates and 1 cushion plate.

4. Remove the return spring assembly.


1. Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
2. Place J 45186 over the shaft of the forward direct clutch housing and input shaft assembly.
3. Place J 21420-2 from J 23327 on the top of the forcing screw of J 24024-A.
4. With the forcing screw, compress the clutch spring to allow the removal of the snap ring.
5. Use J 28585 or snap ring pliers to remove the snap ring.
6. Remove the tools.

1. Remove the return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
5. Remove the direct clutch(C2) piston.
1. Install the input shaft assembly on the rear case.
While pushing the piston by hand, apply compressed air (4kg/cm) into the oil passage as shown in the
figure and remove the C2 piston.
Important : Be careful not to damage the seal rings in the rear case.

1. Remove the O-ring from the C2 piston.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
6. Remove the forward clutch (C1) piston.
1. While pushing the C1 piston by hand, apply compressed air (4kg/cm) into the oil passage as shown in
the figure and remove the C1 piston.

1. Remove the O-ring from the C1 piston.

Forward Clutch (C1) and Direct Clutch (C2) Inspection


1. Inspect the flange, disc and plate.
1. Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or
burnt, replace it.
Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

2. Inspect the forward clutch(C1) and direct clutch(C2) piston.


1. Check that the check ball is free by shaking the piston.
2. Check that the valve does not leak by applying compressed air.

Forward Clutch (C1) and Direct Clutch (C2) Assembly


Tools Required
J 28585 Snap Ring Remover
J 45186 Forward and Direct Clutch Spring Compressor
J 25024-A Servo Piston/Clutch Spring Compressor
J 23327 Clutch Spring Compressor
1. Install the forward clutch (C1) piston.
1. Coat the new O-rings with ATF and install them on the C1 piston.
2. Coat the inner surface of drum with ATF.
3. Press the C1 piston into the drum. Be careful not to damage the O-rings.

2. Install the direct clutch (C2).


1. Coat the new O-rings with ATF and install them on the piston.
2. Coat the inner surface of C1 piston with ATF.
3. Press the piston into the C1 piston.

3. Install the return spring assembly.


1. Place the return spring assembly on the direct clutch (C2) piston.

Important : Do not align the end gap of snap ring with the spring retainer claw.
1.
2.
3.
4.
5.
6.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 over the shaft of the forward direct clutch housing and input shaft assembly.
Place J 21420-2 from J 23327 on the top of the forcing screw of J 24024-A.
With the forcing screw, compress the clutch spring to allow the installation of the snap ring.
Use J 28585 or snap ring pliers to install the snap ring.
Remove the tools.

4. Install the flange, disc, plate and cushion plate of direct clutch (C2).
1. Install the cushion plate.
Important : Be sure the direction of cushion plate.
1. Install the flange, discs and plates as shown in the figure.
Important : Be sure number and order of flange and discs and plates.
Order : F-D-P-D-P-D-P-D-P-CP
Clutch/Brake
Flange (F)
Direct Clutch (C2)
1

Plate (P)
4

Disc (D)
4

Cushion Plate (CP)


1

1. Using J 28585, install the snap ring in the groove. Check that the end gap of snap ring is not aligned
with one of the cutouts.

5. Install the flange,disc and plate of direct clutch (C1).


1. Install the flange, discs and plates as shown in the figure.

Important : Be sure number and order of flange and discs and plates.
Order : F-D-P-D-P-D-P-D-P
Clutch/Brake
Forward Clutch (C1)

Flange (F)
1

Plate (P)
4

Disc (D)
4

1. Using J 28585, install the snap ring in the groove. Check that the end gap of snap ring is not aligned
with one of the cutouts.

6. Install the seal ring, thrust bearing and race.


1. Install the thrust bearing and race.

1. Coat the new seal ring with ATF, install it into the groove of the input shaft assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
7. Check the piston stroke of direct clutch (C2).

1. Install the input shaft assembly on the rear case and set a dial indicator as shown in the figure.
2. Apply the compressed air (4kg/cm) and measure the C2 piston stroke.
Piston stroke : 1.49-1.91 mm (0.059-0.075 in.)
If the C2 piston stroke is out of standards,select another flange.
Flange thickness type: 4.0 mm (0.157 in.), 4.2 mm (0.165 in.), 4.4 mm (0.173 in.)

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
8. Check the piston stroke of forward clutch (C1).
1. Install the input shaft assembly on the rear case and set a dial indicator as shown in the figure.
2. Apply the compressed air (4kg/cm) and measure the C1 piston stroke.
Piston stroke : 0.71-1.09 mm (0.028 - 0.043 in.)
If the C1 piston stroke is out of standards,select another flange.
Flange thickness type: 5.0 mm (0.197 in.), 5.2 mm (0.205 in.), 5.4 mm (0.213 in.)

Planetary Gear Assembly Inspection


1. Inspect the planetary gear bushing.
1. Using a dial indicator, measure the inner diameter of planetary gear bushing.
Important : Measure at different places and take an average. If it is greater than the maximum,
replace it with a new planetary gear assembly.
Inner diameter:
Standard : 30.056-30.082 mm (1.183-1.184 in.)
Maximum: 30.132 mm (1.186 in.)

2. Inspect the planetary sun gear.


1. Using a dial indicator, measure the inner diameter of planetary sun gear bushing.

Important : Measure at different places and take an average. If it is greater than the maximum,
replace it with a new planetary gear assembly.
Inner diameter:
Standard : 22.200-22.226 mm (0.874-0.875 in.)
Maximum: 22.276 mm (0.877 in.)

Front Planetary Ring Gear Disassembly


1. Remove the 1 way clutch No.2 (F2).

1. Remove the 1 way clutch No.2 (F2) from the front planetary ring gear.

1. Remove the snap ring with a screwdriver.


2. Remove the front planetary ring gear flange.

Front Planetary Ring Gear Assembly


1. Install the 1 way clutch No.2 (F2).
1. Install front planetary ring gear flange.
2. Install the snap ring.

1. Install the 1 way clutch No.2(F2) to the front planetary ring gear.

Operation Check Of 1 Way Clutch No.2 (F2)


1. Hold the front ring gear and check that the F2 inner race should turn freely counterclockwise and should
lock clockwise.

Underdrive Clutch (C3) Disassembly


Tools Required
J 28585 Snap Ring Remover
J 23327 Clutch Spring Compressor
J 25024-A Servo Piston/Clutch Spring Compressor
J 45186 Forward and Direct Clutch Spring Compressor
1. Remove the underdrive clutch(C3) flange, disc and plate.
1. Remove the snap ring with a screwdriver.

1. Remove the 1 flange, 4 discs and 4 plates.

Important : Be careful not to damage the underdrive front planetary sun gear.
2. Remove the underdrive clutch(C3) return spring assembly.
1. Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
2. Place J 45186 on the underdrive clutch(C3) return spring assembly.
3. Place J 21420-2 from J 23327 on top of the forcing screw of J 25024-A.
4. Place the clutch housing with the J 45186 on J 21420-2 and under the arms of J 25024-A.
5. With the forcing screw, compress the clutch spring to allow the removal of the snap ring.
6. Use J 28585 or snap ring pliers to remove the snap ring.
7. Remove the return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
3. Remove the underdrive clutch(C3) piston.
1. Cover any 2 holes among 4 holes for oil passage of underdrive clutch (C3) with figures. Apply
compressed air (4kg/cm) to any 1 hole and remove the C3 piston.

1. Remove the O-rings from the C3 piston.

Underdrive Clutch (C3) Inspection


1. Inspect the flange, disc and plate.
1. Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or
burnt, replace it.
Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

2. Inspect the underdrive clutch (C3) piston.


1. Check that the check ball is free by shaking the piston.
2. Check that the valve does not leak by applying compressed air.

3. Inspect the underdrive clutch(C3) drum.


1. Using a dial indicator, measure the inner diameter of underdrive clutch(C3) drum bushing.
Important : Measure at different places and take an average. If it is greater than the maximum,
replace it with a new one.
Inner diameter :
Standard : 36.125-36.150 mm (1.422-1.423 in )
Maximum: 36.200 mm (1.425 in.)

Underdrive Clutch (C3) Assembly


Tools Required
J 28585 Snap Ring Remover
J 23327 Clutch Spring Compressor
J 25024-A Servo Piston/Clutch Spring Compressor
J 45186 Forward and Direct Clutch Spring Compressor
1. Install the underdrive clutch (C3) piston.
1. Coat the new O-rings with ATF and install them on the piston.
2. Coat the inner surface of C3 drum with ATF.
3. Press the C3 piston into the C3 drum.
Important : Be careful not to damage the O-ring.

2. Install the underdrive clutch (C3) return spring assembly.


1. Place the underdrive clutch (C3) return spring assembly on the underdrive clutch (C3) piston.

1.
2.
3.
4.
5.
6.

Place J 25024-A in a vise with the forcing screw on the bottom and backed out.
Place J 45186 on the underdrive clutch(C3) return spring assembly.
Place J 21420-2 from J 23327 on top of the forcing screw of J 25024-A.
Place the clutch housing with the J 45186 on J 21420-2 and under the arms of J 25024-A.
With the forcing screw, compress the clutch spring to allow the installation of the snap ring.
Use J 28585 or snap ring pliers to install the snap ring.

Important : Be sure the end gap of snap ring is not aligned with the spring retainer claw.

3. Install the flange,disc and plate of underdrive clutch (C3).


1. Install the flange, plates and discs as shown in the figure.
Important : Be sure number and order of flange, plates and discs.
Order : F-D-P-D-P-D-P-D-P
Clutch/Brake
Underdrive Clutch (C3)

Flange (F)
1

Plate (P)
4

Disc (D)
4

1. Install the snap ring with a screwdriver in the groove. Check that the end gap of snap ring is not
aligned with one of the cutouts.
4. Check the piston stroke of underdrive clutch (C3).
Pistion Stroke : 1.52-1.90 mm (0.059-0.075 in.)
If the C3 piston stroke is out of standards, select another flange.
Flange thickness type : 3.6 mm (0.142 in.), 3.8 mm (0.150 in.), 4.0 mm (0.157 in.)

Underdrive Brake (B4) Pistion Disassembly


1. Remove the underdrive brake (B4) piston.
1. Using a screwdriver, remove the E-ring.

1. Remove the B4 piston assembly as shown in the figure.

2. Inspect the spring.


1. Measure the free length and outer diameter of outer and inner springs.

Part name
Outer spring
Inner spring

Free length
40.24 mm (1.584 in.)
13.5 mm (0.531 in.)

Underdrive Brake (B4) Pistion Assembly


1. Install the underdrive brake (B4) piston.
1. Install the B4 piston as shown in the figure.
2. Coat the new O-ring with ATF, install it into the groove of B4 piston.

Outer diameter
20.3 mm (0.799 in.)
10.0 mm (0.394 in.)

1. Using the needle nose pliers, install the new E-ring into the groove of the B4 piston rod.

Valve Body Disassembly


Note : The valve body is only available as a complete unit for a service. The only components that can
be independently serviced are the shift solenoids and the manual valve.
1. Remove the manual valve.
1. Remove the manual valve.

2. Remove the shift solenoids (SS1, SS2, SS3, SS4, SS5).


1. Remove the 5 bolts and the 5 solenoids.

Valve Body Inspection


1. Inspect the shift solenoid (SS1, SS2,S S3, SS4, SS5).
1. Check the resistance with an ohmmeter.

Standard value of SS1, SS2, SS3, SS4, SS5 : 11-16 (20C)

Valve Body Assembly


1. Install the shift solenoids (SS1, SS2, SS3, SS4, SS5).
1. Replace the O-ring of each solenoid and install the 5 solenoids.
Important : Make sure to use new O-ring and not to damage the O-ring.
1. Tighten the 5 bolts of each solenoids.
Tighten
Tighten the solenoid bolt to 7 Nm (62 lb-in).

2. Install the manual valve.


1. Install the manual valve.

Oil Pump and 2nd Coast Brake (B1), 2nd Brake (B2) Disassembly
Tools Required
J 23327 Clutch Spring Compressor
J 28585 Snap Ring Remover
J 41236 Coast Clutch Spring Compressor
J 45164 Spring Compressor Bridge
1. Remove the thrust race.

2. Remove the flange, disc and plate of 2nd coast brake (B1).
1. Using J 45164, J 21420-2 and J 23327-2, which are part of J 23327, compress the spring.
2. Using J 28585, remove the snap ring from the oil pump assembly.

1. Remove the 1 flange, 3 discs, 3 plates.

3. Remove the brake piston return spring.


1. Install J 21420-2 and J 23327-2, which are part of J 23327, and J 41236 and compress the spring.
2. Remove the snap ring using the snap ring pliers.
3. Remove the return spring assembly from the oil pump assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
4. Remove the 2nd coast brake(B1) piston.
1. While pushing the piston by hand, apply compressed air (4Kg/cm) into the oil passage as shown in the
figure and remove the B1 piston.
Important : Be careful not to damage the O-ring and piston.
1. Remove the O-rings from the piston.

5. Remove the flange, disc and plate of 2nd brake (B2).


1. Remove the snap ring with a screwdriver.

1. Remove the 1 flanges, 4 discs, 4 plates.

1. Remove the return spring assembly.

1. Remove the snap ring.


Important : Be careful not to damage the oil pump cover and B2 piston.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
6. Remove the 2nd brake (B2) piston.
1. While pushing the piston by hand, apply compressed air (4Kg/cm) into the oil passage as shown in the
figure and remove the B2 piston.
Important : Be careful not to damage the oil pump cover and piston.
1. Remove the O- rings from the piston.

2nd Coast Brake (B1) and 2nd Brake (B2) Inspection


1. Inspect the flange, disc and plate.
1. Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or burnt,
replace it.
Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

2. Remove the oil pump cover.


1. Remove the 14 torx bolts.
Important : Be careful not to drop the oil pump body and oil pump cover.
1. Remove the oil pump cover.

3. Remove the oil pump plate.


1. Remove the oil pump plate.
2. Remove the O-ring from the pump body.

4. Remove the oil pump drive gear and oil pump driven gear.

5. Remove the oil seal.


1. Remove the oil seal with a screwdriver.
Important : Be careful not to damage the oil pump body bushing.

Oil Pump Bushing Inspection


1. Check the oil pump body bushing.
1. Using a dial indicator, measure the inner diameter of oil pump body bushing.
Inner diameter :
Standard:38.113-38.138 mm (1.500-1.501 i.n)
Maximum : 38.188 mm (1.503 in.)
Important : Measure at different places and take an average. If the measurement is greater than the
maximum, replace the oil pump body with a new one.

2. Check the stator shaft bushing.


1. Using a dial indicator, measure the inner diameter of stator shaft bushing.
Inner diameter :
Standard : 22.201-22.227 mm (0.874-0.875 in.)
Maximum : 22.257 mm (0.876 in.)
Important : Measure at different places and take an average. If the measurement is greater than the
maximum, replace the stator shaft with a new one.

3. Check the body clearance.


1. Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance.
Body clearance :
Standard : 0.075-0.150 mm
Maximum : 0.200 mm

4. Check the tip clearance of both gears.


1. Using a feeler gauge, measure between the drive gear teeth and the crescent-shaped part of the pump
body.
Drive gear tip clearance :
Standard : 0.013-0.292 mm (0.001-0.011 in.)
Maximum : 0.342 mm (0.013 in.)

1. Using a feeler gauge, measure between the driven gear teeth and the crescent-shaped part of the pump
body.
Driven gear tip clearance :
Standard : 0.004-0.248 mm (0.0001-0.010 in.)
Maximum : 0.298 mm (0.012 in.)

5. Check the side clearance of both gears.


1. Using a steel straightedge and a feeler gauge, measure the side clearance of both gears.
Drive and driven gear side clearance :
Standard : 0.03-0.05 mm (0.001 0.002 in.)
Maximum : 0.10 mm (0.004 in.)

Oil Pump Assembly


Tools Required
J 35582 Oil Pump Seal Installer
1. Install the oil seal.
1. Coat the inner surface of oil pump body with ATF.
2. Using J 35582, drive in a new oil seal. The seal end should be flush with the outer edge of pump body.

2. Install the oil pump drive gear and driven gear.


1. Coat the surface of oil pump body with ATF.
2. Install the oil pump drive & driven gear to the oil pump body.

3. Install the oil pump plate.


1. Coat the new O-ring with ATF and install them on the oil pump body.
2. Align the oil pump plate hole with the dowel pin of oil pump body.

4. Install the oil pump cover.


1. Align the oil pump cover with each bolt hole of the oil pump body and temporally tighten the 14 torx
bolts.

1. Tighten the 14 torx bolts.


Tighten
Tighten the oil pump cover bolt (14 mm) to 12 Nm (106 lb-in).
Tighten the oil pump cover bolt (17 mm) to 7 Nm (62 lb-in).

5. Check the oil pump drive gear rotation.


1. Make sure that the drive gear rotates smoothly when installed to the torque converter.
Important : Be careful not to damage the oil seal lip.

2nd Coast Brake (B1) and 2nd Brake (B2) Assembly


Tools Required
J 23327 Clutch Spring Compressor
J 28585 Snap Ring Remover
J 41236 Coast Clutch Spring Compressor
J 45164 Spring Compressor Bridge
1. Install the 2nd brake (B2) piston.
1. Coat the new O-rings with ATF and install them on the piston.
2. Coat the inner surfaces of oil pump cover with ATF.
3. Press the piston into the oil pump cover.

1. Install the snap ring.


Important : Be careful not to damage the oil pump cover.

2. Install the 2nd brake (B2) return spring.


1. Place the return spring on the piston with the spring side up.

3. Install plate, disc and flange of 2nd brake (B2).


1. Install the flange, disc and plate as shown in the figure.
Important : Be sure number and order of plates and discs.
Order : P-D-P-D-P-D-P-D-F
Clutch/Brake
2nd brake (B2)

Flange (F)
1

Plate (P)
4

Disc (D)
4

1. Using a screwdriver, install the snap ring.


2. Check that the end gap of snap ring is not aligned with one of the cutouts.

4. Install the 2nd coast brake (B1) piston.


1. Coat the O-rings with ATF and install them on the piston.
2. Coat the inner surfaces of oil pump cover with ATF.
3. Press the piston into the oil pump cover.

5. Install the 2nd coast brake(B1) return spring.


1. Place the J 21420-2 and J 23327-2, which are part of J 23327, and J 41236 on the return spring and
compress the spring.
2. Using the snap ring pliers, install the snap ring into the groove of the oil pump cover.

6. Install the flange, disc and plate of 2nd coast brake (B1).
1. Install the flange, disc and plate as shown in the figure.
Important : Be sure number and order of plates and discs.
Order : P-D-P-D-P-D-F
Clutch/Brake
2nd coast brake (B1)

Flange (F)
1

Plate (P)
3

Disc (D)
3

1. Using J 45164, J 21420-2 and J 23327-2, which are part of J 23327, compress the spring.
2. Using J 28585, install the snap ring into the groove of the stator shaft.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
7. Check the piston stroke of 2nd brake (B2).
1. Set a dial indicator as shown in the figure.
2. When applying compressed air (4kg/cm) into the oil passage as shown, measure the piston stroke and
check the piston moves smoothly.
Piston stroke : 1.10-1.50 mm (0.043-0.059 in.)
If the piston stroke is out of standards, select another flange.
Flange thickness type : 3.6 mm (0.142 in.), 3.8 mm (0.150 in.), 4.0 mm (0.157 in.)

8. Check the piston stroke of 2nd coast Brake(B1).


1. Set a dial indicator as shown in the figure.
2. When applying compressed air (4kg/cm) into the oil passage as shown, measure the piston stroke and
check the piston moves smoothly.
Piston stroke : 1.24-1.96 mm (0.049-0.077 in.)

9. Install the thrust washer.


1. Install the thrust washer with grease, facing the flat surface up.

2nd Coast Brake (B1) Hub, 2nd Brake (B2) Hub and 1 Way Clutch No.1 (F1) Disassembly

1. Remove the thrust washer.


1. Remove the thrust washer from the outer race.

2. Remove the 2nd coast brake (B1) hub.


1. Remove the B1 hub from the 1 way clutch outer race.
2. Remove the thrust washer from the B1 hub.

3. Remove the 1 way clutch No.1(F1).


1. Remove the F1 from the 1 way clutch outer race.

2nd Coast Brake (B1) Hub, 2nd Brake (B2) Hub and 1 Way Clutch No.1 (F1) Assembly
1. Install the 1 way clutch No.1 (F1).
1. Install the F1 into the 1 way clutch outer race.
Important : Don't mistake the direction of 1 way clutch.

1. Install the thrust washer onto the B1 hub.


Important : Coat the thrust washer with grease. Align the tab of the washer with the hollow of the B1
hub.
1. Install the B1 hub into the 1 way clutch outer race .
Important : While turning the B1 hub, slide it into the 1 way clutch outer race.

1. Coat the thrust washer with grease. Align the tab of the washer with the hollow of the 1 way clutch
outer race.

2. Check the operation of 1 way clutch.


1. Hold the 1 way clutch outer race, and check that the B1 hub should turn freely clockwise and should
lock counterclockwise.

Rear Case Disassembly


1. Remove the underdrive clutch (C3) apply tube.
1. Remove the 4 bolts and the 2 clamps from the rear case.

1. Using a screwdriver, remove the underdrive clutch(C3) apply tube.


Important : Be careful not to damage the C3 apply tube and the rear case.

2. Remove the thrust race and seal ring.


1. Remove the thrust race from the rear case.
2. Remove the 3 seal rings from the rear case.

3. Remove the forward clutch(C1) accumulator.


1. Remove the 2 torx bolts, and the accumulator cover.
2. Remove the accumulator piston and the spring, O-ring, seal ring from the accumulator cover.

B5 Brake Disassembly
Tools Required
J 23327 Clutch Spring Compressor
J 23456 Booster and Clutch Pack Compressor
J 45184 Differential Bearing Race Installer
J 28585 Snap Ring Remover
1. Remove the flange, disc, plates, and cushion plate.
1. Using J 28585, remove the snap ring.

1. Remove the 1 flange, 6 discs, 6 plates, and 1 cushion plate.

Important : Be careful not to bend the return spring assembly.


2. Remove the return spring assembly.
1. Place J 45184 on the center of J 23456.
2. Place the transaxle case cover onto J 45184.
3. Using J 23327-1,which is the bridge part of J 23327, compress the return spring and remove the snap
ring with a pliers.
4. Remove the all tools.
5. Remove the return spring assembly.

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
3. Remove the B5 brake piston.
1. While pushing the piston by hand, apply compressed air (4kg/cm) into the oil passage as shown in the
figure and remove the piston.

1. Remove the O-rings from the piston.

B5 Brake Inspection
1. Inspect the flange,disc,plate and cushion plate.
1. Check that the sliding surface of disc and plate is not worn or burnt. If the disc or plate is worn or burnt,
replace it.
Important : Replace new clutch discs by soaking them at least 2 hours in ATF.

B5 Brake & Rear Case Assembly


Tools Required
J 23327 Clutch Spring Compressor
J 23456 Booster and Clutch Pack Compressor
J 45184 Differential Bearing Race Installer
J 28585 Snap Ring Remover
1. Install the B5 brake piston.
1. Coat the new O-rings with ATF and install them on the piston.
2. Coat the inner surface of rear case with ATF.
3. Press the piston into the rear case. Be careful not to damage the O-rings.

Important : Be careful not to bend the return spring assembly.


2. Install the B5 return spring assembly.
1. Place the return spring assembly on the B5 brake piston.
2. Place J 45184 on the center of J 23456.
3. Place the transaxle case cover onto J 45184.
4. Using J 23327-1,which is the bridge part of J 23327, compress the return spring assembly.
5. Install the snap ring using a snap ring pliers.
6. Remove the all tools.

3. Install the flange,plate,disc and cushion plate.


1. Install the cushion plate.
Important : Be sure direction of cushion plate.
1. Install the flange, plates and discs as shown in the figure.
Important : Be sure number and order of plates and discs.
Order : F-D-P-D-P-D-P-D-P-D-P-D-P-CP
Clutch/Brake
Flange (F)
Plate (P)
B5 Brake
1
6

Disc (D)
6

Cushion Plate (CP)


1

1. Install the snap ring with a screwdriver in the groove.

Important : Be sure direction of the snap ring as shown in the figure.

4. Install the forward clutch (C1) accumulator.


1. Coat the new seal ring with ATF and install the accumulator piston.
2. Install the accumulator piston and spring into the accumulator cover.
3. Coat the new O-ring with ATF and install the accumulator cover.
4. Place the accumulator cover on the rear case and tighten the 2 torx bolts.
Tighten
Tighten the forward clutch (C1) accumulator bolt to 10 Nm (89 lb-in).

5. Install the seal ring.


1. Coat the 3 new seal rings and install them on the rear case.
2. Place the thrust race on the rear case.

6. Install the underdrive clutch (C3) apply tube.


1. Coat the new O-rings with ATF and install them into the underdrive clutch (C3) apply tube.

1. Install the C3 apply tube to the rear case with a plastic hammer.
Important : Be careful not to damage the O-rings and C3 apply tube.

1. Place the 2 clamps and tighten the 4 bolts.


Tighten
Tighten the underdrive clutch bolt to 7 Nm (62 lb-in).

Caution : Wear safety glasses when using compressed air in order to prevent eye injury.
7. Check the piston stroke of B5 brake.
1. Set a dial indicator as shown in the figure.
2. When applying compressed air (4kg/cm) into the oil passage as shown, measure the piston stroke and
piston moves smoothly.
Piston : 2.34-2.70 mm (0.092-0.106 in.)
If the piston stroke is out of standards, select another flange.
Flange thickness type : 5.0 mm (0.197 in.), 5.1 mm (0.201 in.), 5.2 mm (0.205 in.), 5.3 mm (0.209 in.),
5.5 mm (0.217 in.)