Daewoo 8140le Repair PDF

[ RM-1 ]
FOREWORD
This REPAIR MANUAL covers Disassembly, Inspection and Assembly

procedures for the following Automatic Transmission:
Automotic Transmission Engine Type REF No.
81-40LE
FAN I
DAEWOO: 96 484 421 DW-01M-MRM002
1.5L SOHC
AW: 30510-81C008
All information contained in this manual is the most up-to-date at the time
of publication. However, specifications and procedures are subject to
change without notice.
QUALITY ASSURANCE DEPT.
© 2003
All rights reserved. This book may not be
reproduced or copied, in whole or in part,
without the written permission of AISIN AW
CO., LTD.
First Printing: Jul, 2003
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

© All Rights Copyright AISIN AW CO., LTD.
[ RM-2 ]
ABBREVIATIONS
ASSY ............................................................ Assembly

A/T .......................................... Automatic Transmission
ATF ................................ Automatic Transmission Fluid
B1 ........................................... O/D & 2nd Coast Brake
B2 ................................................................. 2nd Brake
B3 ................................................ 1st & Reverse Brake
C1 ......................................................... Forward Clutch
C2 ............................................................ Direct Clutch
C3 ........................................................ Reverse Clutch
F1.................................................... 1 Way Clutch No.1
F2.................................................... 1 Way Clutch No.2
O/D ............................................................. Over Drive
V/B .............................................................. Valve Body
FIPG ...................................... Formed In Place Gasket
SST ............................................... Service Special Tool
TT .................................................... Tightening Torque
T/M........................................................... Transmission
T/C .................................................... Torque Converter
FR ......................................................................... Front
RR......................................................................... Rear
MID .................................................................... Middle
DIA ................................................................. Diameter
B/G.................................................................... Bearing

[ RM-3 ]
ABBREVIATIONS
SLT ........................ Throttle Pressure Control Solenoid

S1,S2 ..................................... Shift Solenoid No.1,No.2
ST ....................................................... Timing Solenoid
SL ................................................... Lock-Up Solenoid
Th.................................................................. Thickness
L ......................................................................... Length
V........................................................................... Valve
Acum......................................................... Accumulator
Cont. ................................................................. Control
Reg. .............................................................. Regulator
Press............................................................... Pressure
Mod. .............................................................. Modulator
Pla.................................................................. Planetary
STD................................................................ Standard
LUB. ...................................................................... Lube
HSG ................................................................. Housing
Diff ............................................................... Differential

[ RM-4 ]
BLANK

[ RM-5 ]
TABLE OF CONTENTS
FOREWORD ........................................................................................ RM-1

ABBREVIATIONS ................................................................................ RM-2
DESCRIPTION ..................................................................................... RM-6
OPERATION ........................................................................................ RM-7
REPAIR PROCEDURES ...................................................................... RM-9
GENERAL REPAIR INSTRUCTIONS ................................................. RM-9
REMOVAL OF COMPONENT PARTS ............................................... RM-10
ASSEMBLY AND DISASSEMBLY OF CONPONENTS .................... RM-32
1. OIL PUMP .......................................................................................................... RM-32
2. DIRECT CLUTCH (C2) ...................................................................................... RM-36
3. PLANETARY RING GEAR ................................................................................ RM-43
4. 1 WAY CLUTCH ................................................................................................. RM-45
5. FORWARD AND REVERSE CLUTCH (C1,C3) ................................................. RM-48
6. COUNTER DRIVEN GEAR ................................................................................ RM-56
7. VALVE BODY .................................................................................................... RM-59
8. DIFFERENTIAL ................................................................................................. RM-60
INSTALLATION OF COMPONENT PARTS....................................... RM-61
SERVICE SPECIFICATIONS ............................................................. RM-87

[ RM-6 ]
DESCRIPTION
The new automatic transmission AW 81-40LE is an electronically controlled

4-speed automatic transmission with Lock-up mechanism.
The transmission is mainly composed of the torque converter with lock up
clutch, newly developed 4-speed planetary gear unit, the hydraulic control
system and the electric control system.
SECTIONAL VIEW
AW 81-40LE

[ RM-7 ]
OPERATION
F1 F2
C1 B2 B3 C2
FR OM T /C
Co u n te r Dr iv e G e a r As s y
C ou n te r Dr iv e n G e a r As s y
C3 B1
Diff e re n tia l Ge a r As s y

[ RM-8 ]
OPERATION
Solenoid Clutch Brake 1 Way Clutch

POSITION
S1 S2 ST C1 C2 C3 B1 B2 B3 F1 F2
P ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
R V<9 ON ON OFF OFF OFF ON OFF OFF ON OFF OFF
V>=11 ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF
N ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
D 1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON
2nd ON OFF OFF ON OFF OFF OFF ON OFF ON OFF
3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF
3<=>4 OFF ON ON ON<=>OFF ON OFF OFF<=>ON ON OFF OFF OFF
4th OFF ON OFF OFF ON OFF ON ON OFF OFF OFF
2 1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON
2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF
3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF
L 1st ON ON OFF ON OFF OFF OFF OFF ON OFF ON
2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF

[ RM-9 ]
REPAIR PROCEDURES
1. Most repair operations begin with an overview illustration.

2. It identifies the components and shows how the parts fit together.
3. The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other
information such as specifications and warnings.
You never have to leave the procedure to look up your specs.
GENERAL REPAIR INSTRUCTIONS
1. During disassembly, keep parts in order to facilitate reassembly.

2.(1) Always replace gaskets, O-rings and oil seals etc. with new ones.
(2) Parts which cannot be reused are indicated by the symbol “ ”.
3. When necessary, use a sealer on gaskets to prevent leaks.
4. Carefully observe all specification for bolt tightening torque.
Always use a torque wrench.
5. Use of SST may be required, depending on the nature of the repair.
Be sure to use SST where specified and follow the proper work
procedure.

[ RM-10 ] REMOVAL OF COMPONENT PARTS
REMOVAL OF COMPONENT PARTS

Clip
Breather Hose No.1 Breather Plug
"O" Ring
Bracket
Transaxle Revolution
Sensor
Speed Sensor
Union
"O" Ring
Union
"O" Ring
"O" Ring
Screw Plug
Gasket
SS-01-81A
Non Reusable Part

REMOVAL OF COMPONENT PARTS [ RM-11 ]
Oil Seal
Apply
Gasket
Brake Drum
Gasket
Torque Converter "O" ring
Spacer
Valve Body
Assembly
Gasket Oil Seal
Newtral Start
Switch
"O" ring
Gasket
"O" ring
"O" ring
Non Reusable Part "O" ring SS-01-01A

Apply Gasket Transaxle Rear

Cover
"O" Ring
Forward Clutch & Reverse
Clutch Assembly
O/D Brake
"O" Ring
Piston
Rear Planetary
Sun Gear
One-Way Clutch
Assembly
Forward Clutch Hub
"O" Ring
Front Planetary
Sun Gear
2nd Brake
Piston
"O" Ring
Planetary Gear
1st & Reverse

Brake Piston
Planetary Ring
Gear
Non Reusable Part
SS-01-02A

Counter Driven Gear
Differential Gear Oil Seal
Counter Drive
Gear
Direct Clutch Hub
Nut
Direct Clutch
Assembly Apply Gasket
Oil Pump
Non Reusable Part
SS-01-03A

SEPARATE EXTERNAL PARTS

1. REMOVE TORQUE CONVERTER
2. REMOVE NEUTRAL START SWITCH
(1) Remove the nut, washer and control lever.
(2) Using a screwdriver, unstake the lock washer.
(3) Remove the 2 bolts and nut, and pull out the
neutral start switch.
SS-01-04A
3. REMOVE UNION
(1) Remove the 2 unions.
(2) Remove the 2 “O” rings from the unions.
SS-01-05A
4. REMOVE SCREW PLUG

(1) Remove the screw plug from the transaxle
case.
(2) Remove the “O” ring from the screw plug.
SS-01-06A
5. REMOVE BRACKET
(1) Remove the 1 bolt and bracket.
SS-01-80A
6. REMOVE INPUT SPEED SENSOR AND NO.1

BREATHER PLUG
(1) Remove the 1 bolt and input speed sensor.
(2) Remove the clip and breather hose.
(3) Remove the No.1 breather plug.
(4) Remove the “O” ring from the No.1 breather
plug.
SS-01-07A

7. PLACE TRANSAXLE ON WOODEN

BLOCKS
SS-01-08A
8. REMOVE OIL PAN AND GASKET

(1) Remove the 18 bolts.
(2) Remove the oil pan and gasket.
(3) Remove the gasket and drain plug from the
oil pan.
SS-01-09A
9. EXAMINE PARTICLES IN PAN

(1) Remove the magnets and use them to
collect any steel chips. Examine the chips
and particles in the pan and on the magnet
to determine what type of wear has occurred
in the transaxle:
Steel (magnetic)..... bearing, gear and plate
SS-01-10A
ware
Brass (non-magnetic)..... bushing wear
10. REMOVE OIL STRAINER
(1) Remove the 3 bolts and oil strainer.
SS-01-11A
(2) Remove the gasket from the oil strainer.
SS-01-12A

11. REMOVE VALVE BODY ASSEMBLY

(1) Remove the bolt and ATF temperature
sensor with clamp.
(2) Disconnect the 5 connectors.
SS-01-13A
(3) Support the valve body assembly and

remove the 14 bolts.
(4) Disconnect the manual valve control rod
from the manual valve lever, then remove
the valve body assembly.
SS-01-14A
12. REMOVE CHECK VALVE

(1) Remove the check valve and spring.
SS-01-15A
13. REMOVE BRAKE DRUM GASKET

(1) Remove the brake drum gasket.
SS-01-16A
14. REMOVE APPLY GASKET
SS-01-17A

15. REMOVE ACCUMULATOR SPRING AND

PISTON
(1) Apply compressed air (4.0 kgf/cm2) to the oil
hole and remove the C2 accumulator piston
and spring.
(2) Remove the spring.
CAUTION: Blowing off the air may cause the
SS-01-18A piston's jump-out. When removing
the piston, hold it with your hand
using a waste cloth. Take care not
to splash ATF when air-blowing.
(3) Remove the 2 “O” rings from the C2

accumulator piston.
SS-01-19A

hole and remove the C1 accumulator piston
and spring.
(5) Remove the spring.
piston's jump-out. When removing
SS-01-20A using a waste cloth. Take care not
(6) Remove the 2 “O” rings from the C1
accumulator piston.
SS-01-21A

(7) Apply compressed air (4.0 kgf/cm2) to the

oil hole and remove the B1 accumulator
piston and spring.
SS-01-22A to splash ATF when air-blowing.
(8) Remove the 2 “O” rings from the B1

accumulator piston.
SS-01-23A
16. REMOVE TRANSAXLE WIRE

(1) Remove the 1 bolt.
(2) Remove the transaxle wire from the
transaxle case.
SS-01-24A
(3) Remove the “O” ring from the transaxle wire.
SS-01-25A

17. REMOVE VEHICLE SPEED SENSOR

(1) Remove the 1 bolt and the vehicle speed
sensor.
SS-01-82A
18. REMOVE TRANSAXLE HOUSING

(2) Tap on the circumference of the transaxle
housing with a plastic hammer to remove the
transaxle housing from the transaxle case.
CAUTION: Differential gear assembly may be
accidentally removed when the
SS-01-26A transaxle housing is removed.
19. INSPECT INPUT SHAFT END PLAY

(1) Using a dial indicator, measure the input
shaft end play.
SS-01-27A
20. REMOVE OIL PUMP

(1) Remove the 6 bolts and oil pump.
SS-01-28A
21. REMOVE DIFFERENTIAL GEAR

ASSEMBLY
SS-01-29A

22. REMOVE APPLY GASKET
SS-01-30A
23. REMOVE DIRECT CLUTCH ASSEMBLY
SS-01-31A
(1) Remove the direct clutch assembly from

the transaxle case.
(2) Remove the thrust needle roller bearing
from the direct clutch assembly.
SS-01-32A
24. REMOVE DIRECT CLUTCH HUB

(1) Remove the direct clutch hub, thrust needle
roller bearing and thrust bearing race from
the transaxle case.
SS-01-33A
25. REMOVE COUNTER DRIVEN GEAR

ASSEMBLY
SS-01-34A

26. REMOVE TRANSAXLE REAR COVER

(2) Tap on the circumference of the transaxle
rear cover with a plastic hammer to remove
the transaxle rear cover from the transaxle
case.
SS-01-35A
27. REMOVE 4 APPLY GASKETS
SS-01-36A
28. REMOVE 2ND COAST & O/D BRAKE

FLANGE, DISC AND PLATE
(1) Remove the flange, 2 discs and 2 plates
from the transaxle case.
SS-01-37A
29. REMOVE FORWARD & REVERSE CLUTCH

ASSEMBLY
(1) Remove the thrust needle roller bearing and
forward & reverse clutch assembly.
SS-01-38A

thrust bearing race from the forward &
reverse clutch assembly.
SS-01-39A

30. REMOVE FORWARD CLUTCH HUB

(1) Remove the forward clutch hub from the
transaxle case.
SS-01-40A
(2) Remove the thrust bearing race and thrust

needle roller bearing from the forward clutch
hub.
SS-01-41A
31. REMOVE REAR PLANETARY SUN GEAR

AND 1 WAY CLUTCH ASSEMBLY
(1) Remove the rear planetary sun gear and 1
way clutch assembly.
SS-01-42A
(2) Remove the thrust bearing race from the

rear planetary sun gear and 1 way clutch
assembly.
SS-01-43A

planetary carrier thrust washer from the rear
planetary sun gear and 1 way clutch
assembly.
SS-01-44A

(4) Remove the 1 way clutch assembly and

thrust washer from the rear planetary sun
gear.
SS-01-45A
32. REMOVE FRONT PLANETARY SUN GEAR

(1) Remove the front planetary sun gear from
the transaxle case.
(2) Remove the thrust bearing race from the
front planetary sun gear.
SS-01-46A
33. REMOVE 2ND BRAKE

(1) Using SST and a press, remove the 2 snap
rings, 2ND brake and 2ND brake piston
return spring.
SST CAUTION: Stop the press when the 2nd brake
is lowered 1 - 2 mm from the snap
ring groove, preventing the 2nd
brake from being deformed.
SS-01-83A

2nd brake to remove the 2nd brake piston
from the 2nd brake clutch cylinder.
(3) Remove the 2 “O” rings from the 2nd brake

piston.
SS-01-48A

(4) Remove the 2 plates, 2 discs and flange.
SS-01-49A
34. REMOVE NO.2 1 WAY CLUTCH AND

PLANETARY GEAR
(1) Remove the No.2 1 way clutch and planetary
gear from the transaxle case.
SS-01-50A
(2) Remove the No.2 one-way clutch from the

planetary gear.
(3) Remove the anti-rattle clip.
SS-01-51A
35. REMOVE COUNTER DRIVE GEAR AND

PLANETARY RING GEAR
(1) Fix the counter drive gear with the parking
lock pawl.
SS-01-52A

(2) Using SST, lift the transaxle case.
SST
SS-01-86C
SST (3) Using SST and a hammer, unstake the

counter drive gear nut.
SS-01-84A
(4) Remove the nut.

CAUTION: Remove the nut without unstaking
the planetary ring gear. If chisel or
other tool is used to unstake the
planetary ring gear, such impact
may damage the bearing.
SS-01-53A

(5) Install the 3 bolts to the counter drove gear.

Bolt (M6):
L = 40 - 80 mm
Pitch = 1.0 mm
(6) Rotate 3 bolts in order and remove the
counter drive gear and planetary ring gear.
SS-01-62A
SST
SS-01-63C
36. REMOVE PARKING LOCK PAWL

(1) Remove the 2 bolts and parking lock pawl
bracket.
SS-01-54A
(2) Remove the parking lock pawl shaft, torsion

spring and parking lock pawl.
SS-01-55A

37. REMOVE MANUAL VALVE LEVER SHAFT

(1) Remove the 1 bolt and manual detent spring.
SS-01-56A
(2) Using a chisel and hammer, unstake and

remove the spacer.
SS-01-57A
(3) Using a pin punch and hammer, drive out the

pin.
SS-01-58A
(4) Remove the manual valve lever shaft and

manual valve lever.
SS-01-59A
(5) Remove the parking lock rod from the

manual valve lever.
SS-01-60A

(6) Using a screwdriver, remove the oil seal.
SS-01-61A
38. REMOVE 1ST & REVERSE BRAKE

(1) Using SST and a press, remove the snap
ring.
SST
SS-01-83A
(2) Remove the flange, 4 plates, 4 discs and

return spring.
SS-01-64A

transaxle case to remove the 1st & reverse
brake piston.
thee piston, hold it with your hand
(4) Remove the 2 “O” rings from the 1st &

reverse brake piston.
SS-01-66A

39. REMOVE NO.1 TRANSAXLE CASE PLATE

(1) Remove the 1 bolt and No.1 transaxle case
plate from the transaxle case.
SS-01-67A
40. REMOVE OUTER TAPERED ROLLER

BEARING RACE AND SHIM FROM
TRANSAXLE CASE
(1) Using SST, remove the outer tapered roller
SST bearing race and shim.
SS-01-68A
41. REMOVE OIL RESERVOIR LOCK PLATE

(1) Remove the 3 bolts and oil reservoir lock
plate from the transxle housing.
SS-01-70A
42. REMOVE APPLY PIPE

(1) Remove the 1 bolt and No.1 transaxle apply
pipe clamp from the transaxle housing.
(2) Remove the transaxle lube apply pipe and
differential gear lube apply pipe from the
transaxle housing.
SS-01-71A
43. REMOVE OIL SEAL

(1) Using SST and a hammer, remove the oil
seal from the transaxle housing.
SST
SS-01-72A

44. REMOVE OIL SEAL OF TRANSAXLE

HOUSING
(1) Using SST and a hammer, remove the oil
seal.
SST
SS-01-73A
45. REMOVE O/D BRAKE PISTON

SST
(1) Using SST and a press, remove the snap
ring.
CAUTION: Stop the press when the O/D
brake piston is lowered 1 - 2 mm
from the snap ring grove,
preventing the O/D brake piston
SS-01-85A from being deformed.
(2) Remove the O/D brake return spring.
SS-01-75A

transaxle rear cover to remove the O/D
brake piston.
(4) Remove the 2 “O” rings from the O/D brake

piston.
SS-01-77A

46. DISASSEMBLE TRANSAXLE REAR

COVER
(1) Remove the 2 seal rings from the transaxle
rear cover.
CAUTION: Do not expand the seal ring
excessively.
SS-01-78A
(2) Remove the 4 screw plugs and 4 “O” rings

from the transaxle rear cover.
SS-01-79A

[ RM-32 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
ASSEMBLY AND DISASSEMBLY OF

COMPONENT PARTS
1. OIL PUMP
Stator Shaft
Oil Pump Body
Oil Pump Drive Gear
Oil Pump Drive Gear
SS-02-01A

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS [ RM-33 ]
DISASSEMBLY OF OIL PUMP

1. CHECK OIL PUMP DRIVE GEAR ROTATION
(1) Turn the drive gear with the 2 screwdrivers
and make sure it rotates smoothly.
CAUTION: Be careful not to damage the oil lip.
SS-02-02A
2. REMOVE STATOR SHAFT

(1) Remove the 8 bolts and stator shaft.
CAUTION: Be careful not to let the drive gear
drop as it might come off attached
to the stator shaft.
SS-02-03A
3. REMOVE OIL PUMP DRiVE GEAR AND

DRIVEN GEAR
SS-02-04A
INSPECTION OF OIL PUMP

1. CHECK BODY CLEARANCE OF DRIVEN
GEAR
(1) Push the driven gear to one side of the body.
Using a feeler gauge, measure the
clearance.
Body Clearance STD. 0.10-0.17 mm
SS-02-05A MAX 0.22 mm
2. CHECK TIP CLEARANCE OF DRIVEN GEAR

(1) Measure the tip clearance between the
driven gear teeth and drive gear teeth.
Tip Clearance Driven STD. 0.07-0.15 mm
MAX 0.20 mm
SS-02-06A

3. CHECK SIDE CLEARANCE OF BOTH GEAR

(1) Using a steel straight edge and feeler gauge,
measure the side clearance of both gears. If
the side clearance is greater the the
maximum, select the drive and driven gear.
Side Clearance of STD. 0.02-0.05 mm

SS-02-07A Drive and Driven Gear MAX 0.10 mm
Gear Thickness Mark Drive Gear

Type 1 Th= 8.440-8.449 mm
2 Th= 8.450-8.459 mm
3 Th= 8.460-8.470 mm
4 Th= 8.471-8.480 mm
5 Th= 8.481-8.490 mm
Mark Driven Gear
1 Th= 8.440-8.449 mm
2 Th= 8.450-8.459 mm
3 Th= 8.460-8.470 mm
4 Th= 8.471-8.480 mm
5 Th= 8.481-8.490 mm
4. CHECK OIL PUMP BODY BUSHING

(1) Using a dial indicator, measure the inside
diameter of the oil pump body bushing.
Body Bush STD. 38.113-38.138 mm
MAX 38.188 mm
SS-02-08A
5. CHECK STATOR SHAFT BUSHING

(1) Using a dial indicator, measure the inside
diameter of the stator shaft bushings.
Stator Shaft Bush STD. 18.424-18.450 mm
MAX 18.50 mm
SS-02-09A

ASSEMBLY OF OIL PUMP

1. INSTALL OIL PUMP DRIVE GEAR AND
DRIVEN GEAR
SS-02-04A
2. INSTALL STATOR SHAFT

(1) Align the stator shaft with each bolt hole.
(2) Install the 8 bolts.
TT = 7.8-11.8 N.m (80-120 kgf.cm)
SS-02-03A
3. CHECK PUMP DRIVE GEAR ROTATION

(1) Turn the drive gear with 2 screwdrivers and
make sure it rotates smoothly.
CAUTION: Be careful not to damage the oil lip.
SS-02-02A

2. DIRECT CLUTCH
Return Spring
"O" Ring
"O" Ring
Input Shaft
Sub-assembly
Snap Ring
Seal Ring
Piston
Disc
Snap Ring
Flange
Plate
Non Reusable Part
SS-03-01A

DISASSEMBLY OF DIRECT CLUTCH

1. CHECK PISTON STROKE OF DIRECT
CLUTCH
(1) Install the direct clutch and thrust needle
roller bearing on the oil pump.
(2) Using a dial indicator, measure the direct
clutch piston stroke while applying and
SS-03-02A releasing compressed air (4.0 kgf/cm2).
Piston Stroke 0.40-0.70 mm
2. REMOVE SNAP RING

(1) Using a screwdriver, remove the snap ring.
SS-03-03A
3. REMOVE FLANGE, DISC AND PLATE

(1) Remove the flange, 2 discs and 2 plates.
SS-03-04A

4. REMOVE DIRECT CLUTCH RETURN

SST SPRING
(1) Place SST on the return spring and
compress.
(2) Using a snap ring expander, remove the
snap ring.
CAUTION: Stop the press when the piston
SS-03-05A
return spring is lowered to the place
1-2 mm from the snap ring groove,
preventing the piston return spring
from being deformed. Do not
expand the snap ring excessively.
(3) Remove the direct clutch return spring.
SS-03-06A
5. REMOVE DIRECT CLUTCH PISTON

(1) Install the direct clutch on the oil pump.
pump to remove the direct clutch piston.
piston' jump-put. When removing
SS-03-07A using a waste cloth. Take care not
HINT: When the piston cannot be removed as it is
slanted, either blow the air again with the
protruding side pushed or remove the
piston using needle nose pliers with vinyl
tape on the tip.

6. REMOVE “O” RING

(1) Using a small screwdriver, remove the “O”
ring from the direct clutch piston.
SS-03-08A
(2) Remove the “O” ring from the input shaft.
SS-03-09A
7. REMOVE SEAL RING

(1) Remove the 2 seal rings from the input shaft.
CAUTION: Do not expand the ring ends
excessively.
SS-03-10A
INSPECTION OF DIRECT CLUTCH

1. INSPECT DISC AND FLANGE
(1) Check to see if the sliding surface of the
disc, plate and flange are worm or burnt.
HINT: If the lining of the disc is peeling off or
discolored, or even if a part of the printed
number is defaced, replace all discs.
SS-03-11A Before assembling new discs, soak them in
ATF for at least 15 minutes.
2. CHECK DIRECT CLUTCH RETURN SPRING
(1) Using vernier calipers, measure the free
length of the spring together with the spring
sheet.
Piston Return STD
Spring Free Length 36.04 mm
SS-03-12A

3. CHECK DIRECT CLUTCH PISTON

(1) Check that the check ball is free by shaking
the piston.
(2) Check that the valve does not leak by
applying low-pressure compressed air.
SS-03-13A
ASSEMBLY OF DIRECT CLUTCH

1. INSTALL SEAL RING
(1) Install the 2 seal rings to the input shaft.
CAUTION: Do not expand the ring ends
excessively.
SS-03-10A
2. INSTALL O-RING
(1) Coat a new “O” ring with ATF, and install the
“O” ring to the input shaft.
SS-03-09A
(2) Coat a new “O” ring with ATF, and install the
“O” ring to the direct clutch piston.
SS-03-08A
3. INSTALL DIRECT CLUTCH PISTON

(1) Coat the direct clutch piston with ATF, install
it to the direct clutch drum.
CAUTION: Be careful no to damage the lip seal
of direct clutch piston.
SS-03-14A

4. INSTALL DIRECT CLUTCH RETURN

SPRING.
(1) Install the direct clutch return spring.
SS-03-06A
(2) Place SST on the return spring and

SST compress.
(3) Using a snap ring expander, install the snap
ring.
CAUTION: Stop the press when the piston
return spring is lowered to the place
1 - 2 mm from the snap ring groove,
SS-03-05A
preventing the piston return spring
from being deformed. Do not
expand the snap ring excessively.
5. INSTALL PLATE, DISC AND FLANGE

F (1) Install the 2 plates, 2 discs and flange.
D
HINT: Before installing the discs, coat them with
ATF.
P
SS-03-15A

(3) Check that the end gap of the snap ring is
not aligned with one of the cutouts.
SS-03-03A

6. CHECK PISTON STROKE OF DIRECT

CLUTCH
(1) Install the direct clutch on the oil pump.
(2) Using a dial indicator, measure the direct
releasing compressed air (4.0kgf/cm2).
SS-03-02A
HINT: If the piston stroke is out of standards,
select another flange.
Flange Thickness Th= 3.0 mm
Type Th= 3.2 mm
Th= 3.4 mm

3. PLANETARY RING GEAR
Planetary Ring Gear
Snap Ring
Planetary Ring Gear Flange
Non Reusable Part

SS-04-01A
DISASSEMBLY
DISASSEMBLYOFOFPLANETARY
PLANETARYRING
RINGGEAR
GEAR
1. REMOVE SNAP RING
SS-04-02A
2. REMOVE PLANETARY RING GEAR

FLANGE
(1) Remove the planetary ring gear flange from
the planetary ring gear.
SS-04-03A

ASSEMBLY OF PLANETARY RING GEAR

1. INSTALL PLANETARY RING GEAR FLANGE
(1) Install a new planetary ring gear flange to
the planetary ring gear.
SS-04-03A
2. INSTALL SNAP RING

(2) Using a screwdriver, install the snap ring.
SS-04-02A

4. 1 WAY CLUTCH
2nd Brake Hub

Retainer
Snap Ring
1 Way Clutch
SS-05-01A
DISASSEMBLY OF 1 WAY CLUTCH

Freely
1. CHECK OPERATION OF 1 WAY CLUTCH
(1) Install the 1 way clutch and thrust washer to
the rear planetary sun gear.
(2) Hold the rear planetary sun gear and turn
the 1 way clutch. The 1 way clutch should
turn freely clockwise and should lock
Lock SS-05-02A
counterclockwise.
2. REMOVE SNAP RING

SS-05-03A

3. REMOVE 1 WAY CLUTCH
SS-05-04A
4. REMOVE RETAINER
(1) Using a small screwdriver, remove the
retainer.
SS-05-05A
ASSEMBLY OF 1 WAY CLUTCH

1. INSTALL RETAINER
(1) Install the retainer to the 2nd brake hub.
HINT: Install the retainer closely.
2. INSTALL 1 WAY CLUTCH
SS-05-04A

SS-05-03A

4. CHECK OPERATION OF 1 WAY CLUTCH

Freely
(1) Install the 1 way clutch and thrust washer to
the rear planetary sun gear.
(2) Hold the rear planetary sun gear and turn
the 1 way clutch. The 1 way clutch should
turn freely clockwise and should lock
counterclockwise.
Lock SS-05-02A

5. FORWARD AND REVERSE CLUTCH
Flange
Disc
Flange
Snap Ring
Plate
Plate
Disc
Flange
Snap Ring
Snap Ring
Seal Ring
"O" Ring
Intermediate
Forward Clutch Drum Shaft Sub-assembly
"O" Ring
Forward Clutch Piston
Forward Clutch Return Spring

Clutch Balancer
Non Reusable Part SS-06-01C

DISASSEMBLY OF FORWARD AND

REVERSE CLUTCH
1. CHECK PISTON STROKE OF REVERSE
CLUTCH
(1) Install the forward and reverse clutch and
thrust needle roller bearing on the transaxle
rear cover.
SS-06-02A (2) Using a dial indicator, measure the reverse
releasing compressed air (4.0 kgf/cm2).
2. CHECK PISTON STROKE OF FORWARD

SST
CLUTCH
SST
rear cover.
(2) Using a dial indicator and measuring
terminal (SST), measure the forward clutch
SS-06-03A piston stroke while applying and releasing
compressed air (4.0 kgf/cm2).
HINT: The forward and reverse clutch will come
out as you apply the compressed air.
Therefore, while the checking is being
done, press on the input shaft of the
forward and reverse clutch using stamping
machine or alike so that the pressure is not
applied on the forward and reverse clutch.
3. REMOVE SNAP RING

SS-06-04A


(1) Remove the 2 flanges, 2 discs and plate
from the reverse clutch drum.
SS-06-05A
5. REMOVE SNAP RING

SS-06-06A

(1) Remove the flange, 4 discs and 4 plates
from the forward clutch drum.
SS-06-07A
7. REMOVE FORWARD CLUTCH RETURN

SPRING
SST
(1) Place SST on the clutch balancer and
compress the springs with a press.
(2) Using a snap ring expander, remove the
snap ring.
CAUTION: Stop the press when the clutch
balancer is lowered to the place 1 -
SS-06-19A
2 mm from the snap ring groove,
preventing the clutch balancer from
being deformed. Do not expand the
snap ring excessively.
(3) Remove the clutch balancer and forward
clutch return spring.
SS-06-08A

8. REMOVE FORWARD CLUTCH PISTON

(1) Install the forward and reverse multiple disc
clutch on the transaxle rear cover.
transaxle rear cover to remove the forward
clutch piston.
SS-06-09A piston's jump-out. When removing
HINT: When the piston cannot be removed as it is
protruding side pushed or remove the
piston using a needle nose pliers with vinyl
tape on the tip.
9. REMOVE FORWARD CLUTCH DRUM

transaxle rear cover to remove the forward
clutch drum.
drum's jump-out. When removing
the drum, hold it with your hand
SS-06-10A using a waster cloth. Take care not
HINT: When the drum cannot be removed as it is
protruding side pushed or remove the drum
using a needle nose pliers with vinyl tape
on the tip.
10. REMOVE “O” RING

ring from the forward clutch drum.
SS-06-11A


ring from the intermediate shaft sub-
assembly.
SS-06-12A
INSPECTION OF FORWARD AND REVERSE

CLUTCH
1. INSPECT DISC AND FLANGE
disc, plate and flange are worn or burnt.
HINT: If the lining of the disc is peeling off or
discolored, or even if a part of the printed
SS-06-13A number is defaced, replace all discs.
Before assembling new discs, soak them in
ATF for at least 15 minutes.
2. CHECK FORWARD CLUTCH RETURN
SPRING
seat.
Piston Return STD
SS-06-14A Spring Free Length 24.04 mm
ASSEMBLY OF FORWARD AND REVERSE

CLUTCH
1. INSTALL “O” RING
(1) Coat a new “O” ring with ATF, and install it to
the intermediate shaft sub-assembly.
SS-06-12A
(2) Coat a new “O” ring with ATF, and install it to

the forward clutch drum.
SS-06-11A

2. INSTALL FORWARD CLUTCH DRUM

(1) Coat the forward clutch drum with ATF,
install the forward clutch drum.
CAUTION: Be careful not to damage the “O”
ring and lip seal of forward clutch
drum.
SS-06-15A
3. INSTALL FORWARD CLUTCH PISTON

(1) Coat the forward clutch piston with ATF,
install the forward clutch piston.
CAUTION: Be careful not to damage the lip
seal of forward clutch piston.
SS-06-16A
4. INSTALL FORWARD CLUTCH RETURN

SPRING
(1) Install thee forward clutch return spring and
clutch balancer.
CAUTION: Be careful not to damage the lip
seal of forward clutch return spring.
SS-06-08A
(2) Place SST, on the clutch balancer and

SST compress the piston return spring with a
press.
(3) Using a snap ring expander, install the snap
ring.
CAUTION: Stop the press when the clutch
balancer is lowered to the place 1 -
SS-06-19A
2 mm from the snap ring groove,
preventing the clutch balancer form
being deformed. Do not expand the
snap ring excessively.


P F
(1) Install the 4 plates, 4 discs and flange.
SS-06-18A

SS-06-06A

F (1) Install the plate, 2 discs and 2 flanges.
D
P
D
SS-06-17A

SS-06-04A

9. CHECK PISTON STROKE OF REVERSE

CLUTCH
rear cover.
(2) Using a dial indicator, measure the reverse
SS-06-02A releasing compressed air (4.0 kgf/cm2).
Type Th= 3.2 mm
Th= 3.4 mm
Th= 3.6 mm
10. CHECK PISTON STROKE OF FORWARD

SST
CLUTCH
SST
rear cover.
terminal (SST), measure the forward clutch
SS-06-03A piston stroke while applying and releasing
compressed air (4.0 kgf/cm2).
Type Th= 3.1 mm
Th= 3.2 mm
Th= 3.3 mm
Th= 3.4 mm
Th= 3.5 mm
Th= 3.6 mm
HINT: The forward and reverse clutch will come
out as you apply the compressed air.
Therefore, while the checking is being
done, press on the input shaft of the
forward and reverse clutch using stamping
machine or alike so that the pressure is not
applied on the forward and reverse clutch.

6. COUNTER DRIVEN GEAR
Outer Tapered Roller

Bearing Race
Outer Tapered Roller

Bearing Race
Counter Driven Gear
SS-07-01A
DISASSEMBLY OF COUNTER DRIVEN GEAR

1. REMOVE FRONT DRIVE PINION REAR
TAPERED ROLLER BEARING
SST (1) Using SST and a press, remove the front
drive pinion tapered roller bearing rear inner
race counter driven gear from the differential
drive pinion.
SS-07-02C
(2) Using SST, remove the front drive pinion

tapered roller bearing rear outer race and
drive pinion washer from the transaxle case.
SS-07-03C

2. REMOVE FRONT DRIVE PINION FRONT

(1) Using SST and a press, remove the front
drive pinion tapered roller bearing front inner
SST
race from the differential drive pinion.
SS-07-04C
(2) Using SST, remove the front drive pinion

tapered roller bearing front outer race from
the transaxle housing.
SS-07-05C
3. REMOVE SIFFERENTIAL DRIVEN PINION

PLUG
(1) Using extension bar and hammer, remove
the differential drive pinion plug.
SS-07-06C
ASSEMBLY OF COUNTER DRIVEN GEAR

1. INSTALL FRONT DRIVE PINION PLUG
(1) Using a socket wrench (10 mm) and
hammer, install a new differential drive
pinion plug to the differential drive pinion.
Pinion plug 2.3-2.8 mm
SS-07-07C
2. INSTALL FRONT DRIVE PINION FRONT

(1) Using SST and a press, install the front drive
SST
pinion tapered roller bearing front inner race
to the differential drive pinion.
SS-07-08C

(2) Using SST and a hammer, install the front

drive pinion tapered roller bearing front outer
race to the transaxle housing.
SST
SS-07-09C
3. INSTALL COUNTER DRIVE GEAR

(1) Using SST and a press, install the counter
drive gear to the differential drive pinion.
SST
SS-07-10C
4. INSTALL FRONT DRIVE PINION REAR

(1) Using SST and a press, install the front drive
pinion tapered roller bearing rear inner race
SST
to the differential drive pinion.
SS-07-11C
(2) Using SST and a hammer, install the pinion

washer and front drive pinion tapered roller
bearing rear outer race to the transaxle
case.
SST
SS-07-12C

7. VALVE BODY
SS-08-17A
SL Solenoid DISASSEMBLY OF VALVE BODY

1. REMOVE SHIFT SOLENOID (NO.1, NO.2, ST,
SL)
(1) Remove the each bolt and the solenoids.
No.2 Solenoid
No.1 Solenoid
ST Solenoid SS-11-01AM
ASSEMBLY OF VALVE BODY
SL Solenoid 1. INSTALL SHIFT SOLENOID (NO.1, NO.2, ST,
(28 mm, 49mm)
SL)
(1) Replace the “O” ring of each solenoid and
install the solenoid.
No.2 Solenoid CAUTION: Make sure to use new “O” ring and
(20 mm, 49 mm)
not to damage the “O” ring.
No.1 Solenoid
(20 mm, 49 mm)
(2) Tighten the 7 bolts.
ST Solenoid
(20 mm) SS-11-04AM TT = 10.0-12.0 N.m (100-200 kgf.cm)

8. DIFFERENTIAL
Differential Assembly
Side Bearing Outer Race
Side Bearing Outer Race
SS-10-01A

INSTALLATION OF COMPONENT PARTS [ RM-61 ]
INSTALLATION OF COMPONENT PARTS

RACE AND BEARING SPECIFICATIONS
C B
F
G
SS-09-01A
(mm) A B C D E F G
RASE Outer Dia. --- 30.60 45.50 --- 29.00 --- ---
(Front) Inner Dia. --- 19.30 34.95 --- 19.30 --- ---
BEARING Outer Dia. 62.00 29.60 46.50 57.50 --- 48.50 30.20
Inner Dia. 43.20 18.10 33.30 42.50 --- 32.50 or 32.90 17.80
RACE Outer Dia. --- 28.20 --- --- --- --- 32.60
(REAR) Inner Dia. --- 18.10 --- --- --- --- 20.50

[ RM-62 ] INSTALLATION OF COMPONENT PARTS
1. ASSEMBLY TRANSAXLE TEAR COVER

(1) Install 4 new “O” rings to the 4 screw plugs.
(2) Install the 4 screw plugs with the “O” rings to
the transaxle rear cover.
TT = 5.9-8.8 N.m (60-90 kgf.cm)
SS-01-79A
(3) Install the 2 seal rings to the transaxle rear

cover.
SS-01-78A
2. CHECK O/D & 2ND COAST BRAKE PISTON

RETURN SPRING
seat.
Piston Return STD
SS-09-02A
3. INSTALL O/D & 2ND COAST BRAKE

PISTON
(1) Coat 2 new “O” rings with ATF, install them
to the O/D & 2nd coast brake piston.
SS-01-77A
(2) Coat the O/D & 2nd coast brake piston with
ATF, install it to the transaxle rear cover.
rings of the O/D & 2nd coast brake
piston.
SS-09-03A

(3) Using SST and a press, install the O/D &

2nd coast brake return spring and snap ring
SST
to transaxle rear cover.
CAUTION: Stop the press when the O/D & 2nd
coast brake piston is lowered 1 - 2
mm from the snap ring groove,
preventing the O/D & 2nd coast
SS-01-85A brake piston from being deformed.
4. INSTALL TRANSAXLE HOUSING OIL SEAL

(1) Using SST and a hammer, drive in a new oil
SST seal.
SST Oil seal in depth 2.6-3.6 mm
SS-09-05A
SST 5. INSTALL OIL SEAL

seal.
A A = 0 mm
(2) Coat the lip of oil seal with MP grease.
SS-09-07A
6. INSTALL APPLY PIPE

(1) Install the transaxle lube apply pipe and
differential gear lube apply pipe to the
transaxle housing.
(2) Install the No.1 transaxle apply pipe clamp to
the transaxle housing with 1 bolt.
TT = 3.9-6.9 N.m (40-70 kgf.cm)
SS-01-71A
7. INSTALL OIL RESERVOIR LOCK PLATE

(1) Install the oil reservoir lock plate to the
transaxle housing with the 3 bolts.
TT = 3.9-6.9 N.m (40-70 kgf.cm)
SS-01-70A

8. INSTALL TRANSAXLE CASE OIL SEAL

seal.
SST Oil seal in depth 3.8-4.8 mm
SST
SS-09-09A
9. INSTALL NO.1 TRANSAXLE CASE PLATE

(1) Install the No.1 transaxle case plate to the
transaxle case with the bolt.
TT = 7.8-11.8 N.m (80-120 kgf.cm)
SS-01-67A
10. ADJUST COUNTER DRIVEN GEAR

PRELOAD
(1) Install the differential gear to the transaxle
case.
SS-09-11A
(2) Install the transaxle housing and tighten the

16 bolts of the transaxle housing temporarily.
(3) Tighten 8 or 9 bolts out of 16 bolts of the
transaxle housing completely.
TT = 23.5-35.5 N.m (240-360 kgf.cm)
SS-01-26A
(4) Using a SST, turn the differential gear

assembly right and left 2 or 3 times to allow
the bearing settle.
SS-09-12A

(5) Using SST and small torque wrench,

measure the preload of the differential gear.
HINT: Note down the measured valve.
SS-09-13A
(6) Remove the transaxle housing and install

the counter driven gear.
SS-09-14A
(7) Install the transaxle housing and tighten the

16 bolts of the transaxle housing temporarily.
(8) Tighten the bolts of the transaxle housing in
the same manner as in step (3).
TT = 23.5-35.5 N.m (240-360 kgf.cm)
SS-01-26A
9) Using a SST, turn the differential gear

assembly right and left 2 or 3 times to allow
the bearing settle.
SS-09-12A
(10) Using SST and a small torque wrench,

measure the preload of the differential gear.
From this valve deduct the value measured
in step (4). This is the preload of the counter
driven gear.
New Bearing 0.78-13.7 N.m (8.0-14.0 kgf.cm)
Reused Bearing 0.39-0.69 N.m (4.0-7.0 kgf.cm)
SS-09-13A

(11) If the preload of counter driven gear does

not satisfy the specification, select the
adjuster shim from the table below and re-
measure the value. Until the valve is within
the specification, repeat the procedure.
HINT: When the preload is larger than the
specification, select a thinner adjuster shim.
When the preload is smaller than the
specification, select a thicker adjuster shim.
Mark Thickness Mark Thickness
A Th= 1.80 mm N Th= 2.26 mm
B Th= 1.85 mm P Th= 2.29 mm
C Th= 1.90 mm Q Th= 2.32 mm
D Th= 1.95 mm R Th= 2.35 mm
E Th= 2.00 mm S Th= 2.40 mm
F Th= 2.05 mm T Th= 2.45 mm
G Th= 2.08 mm U Th= 2.50 mm
H Th= 2.11 mm V Th= 2.55 mm
J Th= 2.14 mm W Th= 2.60 mm
K Th= 2.17 mm X Th= 2.65 mm
L Th= 2.20 mm Y Th= 2.70 mm
M Th= 2.23 mm
11. CHECK 1ST & REVERSE BRAKE PISTON

RETURN SPRING
length of the spring together with spring
seat.
Piston Return STD
SS-09-15A
12. INSPECT DISC, PLATE AND FLANGE OF

1ST & REVERSE BRAKE
(1) Check to see if the sliding surface of the disc,
plate and flange are worn or burnt.
CAUTION: If the lining of the disc is peeling off
or discolored, or even if a part of the
groove is defaced, replace all discs.
SS-09-16A Before assembling new discs, soak
them in ATF for at least 15 minutes.
13. INSTALL 1ST & REVERSE BRAKE

to the 1st & reverse piston.
SS-01-66A
(2) Install the 1st reverse brake piston to the

transaxle case.
rings of the 1st & reverse brake
piston.
SS-09-17A
(3) Install the return spring to the transaxle

case.
SS-09-18A
(4) Install the 4 plates, 4 discs and flange.
SS-09-19A
P
(5) Using SST and a press, install the snap ring.

CAUTION: Make sure that the snap ring is
installed in the groove of the
transaxle case correctly.
SST
SS-01-83A

14. CHECK PISTON STROKE OF 1ST &

REVERSE BRAKE
terminal (SST), measure the 1st & reverse
brake piston stroke while applying and
releasing compressed air (4.0 kgf/cm2).
SS-09-20A
15. INSTALL MANUAL VALVE LEVER SHAFT

(a) Coat a new oil seal with ATF.
(b) Install the oil seal to the transaxle case.
Oil seal in depth 0.75-1.25 mm
A
SS-09-22A
(3) Install the parking lock rod to the manual

valve lever.
SS-01-60A
(4) Install a new spacer to the manual valve

lever.
SS-09-23A
(5) Install the manual valve lever shaft and

manual valve lever.
SS-09-68A

(6) Using a pin punch and hammer, drive in a

new pin.
SS-01-58A
(7) Turn the spacer and lever shaft to align the

small hole for locating the staking position in
the spacer with the staking position mark on
the lever shaft.
(8) Using a pin punch, stake the spacer through
the small hole.
(9) Check that the spacer does not turn.
SS-09-24A
(10) Install the manual detent spring with 1 bolt.

TT = 7.8-11.8 N.m (80-120 kgf.cm)
SS-01-56A
16. INSTALL PARKING LOCK PAWL

(1) Install the parking lock pawl shaft, torsion
spring and parking lock pawl.
SS-01-55A
CAUTION: Check that the edge of torsion

spring fits into the groove securely.
SS-09-25A

(2) Install the parking lock pawl bracket with the

2 bolts.
TT = 5.9-8.8 N.m (60-90 kgf.cm)
SS-01-54A
17. INSTALL COUNTER DRIVE GEAR

(1) Using SST and a press, install the counter
drive gear.
CAUTION: Be careful not to apply excessive
SST force to thee transaxle case.
SST
SS-09-21A
18. INSTALL PLANETARY RING GEAR

HINT: Before installing the planetary ring gear, be
sure to replace the planetary ring gear
flange of the planetary ring gear with a new
SST
one.
(1) Using SST and a press, install the planetary
ring gear.
SST
SS-09-26A

(3) Install a new nut.
SS-01-53A
(4) Using a small torque wrench, while turning to

counter drive gear 100 turn par minute and
measure the preload.
New Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm)
Reused Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm)
HINT: When the preload is smaller than the

specification, tighten the nut more and
SS-09-29A adjust the preload.
(5) Using SST, lift the transaxle case.
SST
SS-01-86C
(5) Using a chisel and a hammer, stake the

counter drive gear nut
SS-09-71A

(6) Fix the counter drive gear with parking lock

pawl.
SS-01-52A
19. INSTALL PLANETARY GEAR

(1) Install the planetary gear to the transaxle
housing.
SS-09-30A
(2) Coat the planetary carrier thrust washer with

petroleum jelly and install it onto the
planetary gear.
SS-09-31A
20. INSTALL NO.2 ONE-WAY CLUTCH

(1) Install the No.2 one-way clutch to the
transaxle.
SS-09-32A
(2) Check that the planetary gear turns freely

counterclockwise and locks clockwise.
Freely Lock
SS-09-33A

(3) Install the anti-rattle clip in the place shown

in the illustration (the space between the
No.2 one-way clutch outer race and
transaxle case), push the anti-rattle clip in
until you hear the "click".
SS-09-34A
21. CHECK 2ND BRAKE PISTON RETURN

SPRING
length of thee spring together with spring
seat.
SS-09-35A

2ND BRAKE
(1) Check to see if the sliding surface of the disc,
plate and flange are worn or burnt.
CAUTION: If the lining of the disc is peeling off or
discolored, or even if a part of the
groove is defaced, replace all discs.
SS-09-36A Before assembling new discs, soak
them in ATF for at least 15 minutes.
23. INSTALL 2ND BRAKE
F
(1) Install the flange, 2 discs and 2 plates.
P
(2) Install the 2nd brake return spring.
D
SS-09-37A

to the 2nd brake piston.
SS-01-48A

(4) Install the 2nd brake piston into the 2nd

brake clutch cylinder.
CAUTION: Be careful not to damage to “O”
rings.
SS-09-38A
(5) Install the 2nd brake.
SS-09-39A
(6) Place SST on the 2nd brake and compress

the piston return spring with a press.
(7) Using a screwdriver, install thee snap ring.
SST
SS-01-83A
24. INSTALL FRONT PLANETARY SUN GEAR

(1) Coat the thrust bearing race with petroleum
jelly and install it onto the front planetary sun
gear.
SS-09-40A
(2) Install the front planetary sun gear to the

transaxle case.
SS-01-46A

25. INSTALL REAR PLANETARY SUN GEAR

AND ONE-WAY CLUTCH ASSEMBLY
(1) Install the thrust washer and one-way clutch
assembly to the rear planetary sun gear.
SS-01-45A

jelly and install it onto the rear planetary sun
gear and one-way clutch assembly.
CAUTION: Check the direction on the bearing.
SS-09-41A
(3) Install the rear planetary sun gear and one-

way clutch assembly to the transaxle case.
SS-01-42A
26. INSTALL FORWARD CLUTCH HUB

jelly and install it onto the transaxle case.
CAUTION: Check the direction of race.
SS-09-42A
(2) Coat the thrust needle roller bearing with

petroleum jelly and install it onto the forward
clutch hub.
CAUTION: Check the direction of bearing.
SS-09-43A

(3) Install the forward clutch hub to the transaxle

case.
SS-01-40A

jelly and install it onto the forward clutch
hub.
SS-09-44A
27. INSTALL FORWARD & REVERSE CLUTCH

ASSEMBLY
(1) Install the thrust bearing race and thrust
needle roller bearing to the forward &
reverse clutch assembly.
SS-01-39A
(2) Install the forward & reverse clutch assembly

to the transaxle case.
SS-09-45A


O/D & 2ND COAST BRAKE
disc, plate and flange are worn or burnt.
CAUTION: If the lining of the disc is peeling off
or discolored, or even if a part of the
printed mark is defaced, replace all
SS-09-16A discs. Before assembly new discs,
soak them in ATF for at least 15
minutes.
29. INSTALL O/D & 2ND COAST BRAKE

FLANGE, DISC AND PLATE
(1) Using a screwdriver, install the snap ring to
the transaxle case.
SS-09-46A
P (2) Install the flange, 2 discs and 2 plates to the

transaxle case.
(3) Clean the connected part the transaxle case
F
and transaxle rear cover.
D SS-09-70A
(4) As shown in the illustration, place a straight

edge on the transaxle case and measure the
A
distance between the 2nd coast & o/d brake
flange and straight edge using vernier
calipers. (Dimension A)
SS-09-47A

(5) As shown in the illustration, place a straight

edge on the o/d brake piston and measure
the distance between the transaxle rear
B cover and straight edge using vernier
calipers, (Dimension B)
(6) Calculate the piston stroke value using the
following formula. Select flange which
SS-09-48A satisfies the piston stroke value and install it.
Piston stroke = Dimension A - Dimension B
30. INSTALL TRANSAXLE REAR COVER

(1) Install new 4 apply gaskets to the transaxle
rear cover.
SS-01-36A
(2) Coat the thrust needle roller bearing with

petroleum jelly and install it onto the forward
& reverse clutch assembly.
(3) Remove any packing material and be careful
not to get oil on the contacting surfaces on
the transaxle rear cover on transaxle case.
SS-09-49A
(4) Apply FIPG to the transaxle rear cover.
SS-09-50A

(5) Install the transaxle rear cover to the

transaxle case with the 9 bolts.
TT = 19.6-29.4 N.m (200-300 kgf.cm)
SS-01-35A
31. INSTALL COUNTER DRIVEN GEAR

ASSEMBLY
SS-01-34A
32. INSTALL DIFFERENTIAL GEAR

ASSEMBLY
SS-01-29A
33. INSTALL DIRECT CLUTCH HUB

(1) Install the direct clutch hub to the transaxle
case.
SS-09-51A
34. INSTALL DIRECT CLUTCH

(1) Install thee thrust bearing race and thrust
needle roller bearing to the transaxle case.
SS-09-52A

(2) Install the direct clutch assembly to the

transaxle case.
SS-01-31A
35. INSTALL NEW APPLY GASKET
SS-01-30A
36. INSTALL OIL PUMP

(1) Install the thrust needle roller bearing to the
transaxle case.
CAUTION: Check the direction of the bearing.
(2) Place the oil pump through the input shaft,
and align the bolt holes of the oil pump with
the transaxle case.
SS-09-53A
(3) Install the 6 bolts.

TT = 19.6-29.4 N.m (200-300 kgf.cm)
SS-01-28A
37. MEASURE INPUT SHAFT END PLAY

(1) Measure the end play in axial direction.
End Play 0.3-0.9 mm
SS-01-27A

38. CHECK INPUT SHAFT ROTATION

(1) Make sure that the input shaft rotates
smoothly.
SS-09-54A
39. INSTALL TRANSAXLE HOUSING

(1) Remove any packing material and be careful
not to get oil on the contacting surfaces of
the transaxle housing or transaxle case.
(2) Apply FIPG to the transaxle housing.
SS-09-55A
(3) Install the transaxle housing to the transaxle

case with the 16 bolts.
TT = 23.5-35.5 N.m (240-360 kgf.cm)
HINT: Apply seal packing or equivalent to the 3
bolts indicated by arrows.
SS-09-67A
40. INSTALL TRANSAXLE WIRE

(1) Coat a new “O” ring with ATF install it to the
transaxle wire.
SS-01-25A
(2) Install the transaxle wire the to the transaxle

case with the 1 bolt.
TT = 3.9-6.9 N.m (40-70 kgf.cm)
SS-01-24A

41. INSTALL ACCUMULATOR PISTON AND

SPRING
(1) Coat new 6 “O” rings with ATF and install
them to the pistons.
B1 Acum. (2) Coat the 3 springs and 3 accumulator
pistons with ATF, install them to the holes.
SPRING
PART NAME
Free (mm) Outer (mm) Color
C1 Acum. C2 Acum. 57.20 17.50 Light Green
C1 Acum. 54.70 17.20 Blue
B1 Acum. 47.13 16.00 Pink
C2 Acum.
SS-09-56A
42. INSTALL APPLY GASKET

(1) Coat a new apply gasket with ATF, install it
to the transaxle case.
SS-01-17A
43. INSTALL BRAKE DRUM GASKET

(1) Coat a new brake drum gasket with ATF,
install it to the transaxle case.
SS-01-16A
44. INSTALL CHECK VALVE

(1) Install the spring and check valve.
SS-01-15A

45. INSTALL VALVE BODY ASSEMBLY

(1) Connect the manual valve control rod to the
manual valve lever as shown in the
illustration.
SS-09-57A
20 mm (2) Install the transaxle wire connectors and

40 mm
harness to the valve body assembly with the
28 mm
14 bolts.
TT = 9.8-11.8 N.m (100-120 kgf.cm)
CAUTION: When installing the valve body to
28 mm the transaxle case, do not let each
20 mm
of accumulator pistons B1, C1 and
49 mm 36 mm SS-09-69A
C2 incline. When installing the valve
body to the transaxle case, do not
hold the solenoids.
(3) Connect the 5 connectors.

(4) Install the ATF temperature sensor with
clamp and 3 bolts.
CAUTION: Make sure that the transaxle wire
does not come out from the oil pan
installation surface.
SS-01-13A
46. INSTALL OIL STRAINER

(1) Install a new gasket to the oil strainer.
SS-01-12A

(2) Install the oil strainer to the valve body with

the 3 bolts.
TT = 7.8-11.8 N.m (80-120 kgf.cm)
SS-01-11A
47. INSTALL OIL PAN

(1) Install the 2 magnets in the oil pan.
SS-09-58A
(2) Install a new gasket to the oil pan and install

them to the transaxle case with the 18 bolts.
TT = 6.0-7.9 N.m (60-80 kgf.cm)
SS-01-09A
48. INSTALL INPUT SPEED SENSOR AND

NO.1 BREATHER PLUG
(1) Install the No.1 breather plug.
(2) Install the input speed sensor with the 1 bolt.
TT = 3.9-6.9 N.m (40-70 kgf.cm)
SS-01-07A
49. INSTALL VEHICLE SPEED SENSOR

(1) Install the vehicle speed sensor to the
transaxle case with the 1 bolt.
TT = 5.9-8.8 N.m (60-90 kgf.cm)
SS-01-82A

50. INSTALL BRACKET

(1) Install the bracket to the transaxle case with
the 1 bolt.
TT = 19.6-29.4 N.m (200-300 kgf.cm)
SS-01-80A
51. INSTALL SCREW PLUG

(1) Coat a new “O” ring with ATF, install it to the
screw plug.
(2) Install the screw plug to the transaxle case.
TT = 5.9-8.8 N.m (60-90 kgf.cm)
SS-01-06A
52. INSTALL UNION

(1) Coat new 2 “O” rings with ATF, install them
to the unions.
(2) Install the 2 unions to the transaxle case.
TT = 19.6-29.4 N.m (200-300 kgf.cm)
SS-01-05A
53. INSTALL NEUTRAL START SWITCH

(1) Install the neutral start switch onto the
manual valve lever shaft and temporarily
install the 2 adjusting bolts.
(2) Install a new lock washer and nuts.
TT = 4.3-6.5 N.m (44-66 kgf.cm)
SS-09-59A
(3) Temporarily install the control lever.
SS-09-60A

(4) Remove control lever.

(5) Set the SST and inspect that SST pointer
align neutral basic line.
(6) Align the groove with neutral basic line.
(7) Tighten the 2 bolts.
TT = 4.3-6.5 N.m (44-66 kgf.cm)
SST
SS-09-73A
Neutral basic line
SST pointer
SST
SS-09-74A
(8) Using a screwdriver, stake the nut with the

lock washer.
SS-09-63A
(9) Install the control lever, washer and nut.

TT = 9.8-14.7 N.m (100-150 kgf.cm)
SS-09-64A
Transaxle Housing 54. INSTALL TORQUE CONVERTER

(1) Install the torque converter.
A (2) Check the distance of A.
A= 11.1 mm
Torque Converter
CAUTION: If the distance is out of standards,
adjust within standartds again.
SS-09-72A

SERVICE SPECIFICATIONS [ RM-87 ]
SERVICE SPECIFICATIONS
GENERAL
A/T TYPE 81-40LE
BASE A/T 30510-81C008
1st 2.875
2nd 1.568
3rd 1.000
GEAR RATIO 4th 0.697
Reverse 2.300
Counter 1.019
Differential 3.750
ATF TYPE Esso JWS-3309: ISU DEXRON Ⅲ = 1:1
VOLUME ATF 5.6L (75 degree C)
CLUTCH & BRAKE

Flange Plate Disc
Clutch / Brake
(F) (P) (D)
C1 (Forward Clutch) 1 4 4
C2 (Direct Clutch) 1 2 2
C3 (Rear Clutch) 2 1 2
B1 (O/D & 2nd Coast Brake) 1 2 2
B2 (2nd Brake) 1 2 2
B3 (1st & Reverse Brake) 1 4 4
C1 ( FORWARD CLUTCH)
PART NAME SPEC.
Pack Clearance 1.30-1.50 mm
Type Th= 3.1 mm
Th= 3.2 mm
Th= 3.3 mm
Th= 3.4 mm
Th= 3.5 mm
Th= 3.6 mm
Piston Return STD

[ RM-88 ] SERVICE SPECIFICATIONS
C2 ( DIRECT CLUTCH) C3 ( REVERSE CLUTCH)

PART NAME SPEC. PART NAME SPEC.
Piston Stroke 0.40-0.70 mm Piston Stroke 0.86-1.26 mm
Pack Clearance 0.40-0.70 mm Pack Clearance 0.4-1.0 mm
Flange Thickness Th= 3.0 mm Flange Thickness Th= 3.0 mm
Type Th= 3.2 mm Type Th= 3.2 mm
Th= 3.4 mm Th= 3.4 mm
Piston Return STD Th= 3.6 mm
B1 ( O/D & 2ND COAST BRAKE) B2 ( 2ND BRAKE)

PART NAME SPEC. PART NAME SPEC.
Piston Stroke 0.65-1.05 mm Piston Stroke 0.395-1.245 mm
Pack Clearance 0.65-1.05 mm Pack Clearance 0.395-1.245 mm
Piston Return STD Piston Return STD
Spring Free Length 18.99 mm Spring Free Length 15.85 mm
B3 ( 1ST & REVERSE BRAKE)

PART NAME SPEC.
Pack Clearance 0.791-1.489 mm
Piston Return STD
OIL PUMP
PART NAME SPEC.
Body Bush STD. 38.113-38.138 mm
MAX 38.188 mm
Stator Shaft Bush STD. 18.424-18.450 mm
MAX 18.50 mm
Body Clearance STD. 0.10-0.17 mm
MAX 0.22 mm
Tip Clearance Drive STD. 0.07-0.15 mm
MAX 0.20 mm
Tip Clearance Driven STD. 0.07-0.15 mm
MAX 0.20 mm
Side Clearance of STD. 0.02-0.05 mm
Drive and Driven Gear MAX 0.10 mm

SERVICE SPECIFICATIONS [ RM-89 ]
OIL SEAL
PART NAME SPEC.
T/A Housing Oil seal in depth 2.6-3.6 mm
T/A Case Oil seal in depth 3.8-4.8 mm
Manual Shaft Oil seal in depth 0.75-1.25 mm
PLANETARY GEAR BUSHING

PART NAME SPEC.
Pla. Gear Bush Fr Mid Rr STD. 30.00-30.026 mm
Fr Mid Rr MAX 30.076 mm
Pla. FR Sun Fr Rr STD. 21.500-21.526 mm
Gear Bush Fr Rr MAX 21.576 mm
Pla. RR Sun Fr Rr STD. 21.500-21.526 mm
Gear Bush Fr Rr MAX 21.576 mm
SOLENOID
PART NAME SPEC.
S1 12-16 ohm (20 degree C)
S2 11-15 ohm (20 degree C)
ST 11-15 ohm (20 degree C)
SL 11-15 ohm (20 degree C)
T/A HOUSING - T/C BOSS DISTANCE

SPEC.
T/A Housing-T/C Distance 11.1 mm
ACCUMULATOR SPRING
SPRING
PART NAME
Free (mm) Outer (mm) Color
C2 Acum. 57.20 17.50 Light Green
C1 Acum. 54.70 17.20 Blue
B1 Acum. 47.13 16.00 Pink

[ RM-90 ] SERVICE SPECIFICATIONS
TIGHTENING TORQUE
PART NAME TT (Tightening Torque)
Vehicle Speed Sensor 1 M8-25 5.9-8.8 N.m (60-90 kgf.cm)
Neutral Start Switch 2 M6-20 4.3-6.5 N.m (44-66 kgf.cm)
Neutral Start Switch Nut 1 --- 9.8-14.7 N.m (100-150 kgf.cm)
Input Speed Sensor 1 M6-16 3.9-6.9 N.m (40-70 kgf.cm)
Union 2 1/2-20UNF 19.6-29.4 N.m (200-300 kgf.cm)
Screw Plug 1 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm)
Oil Pan 18 M6-14.5 6.0-7.9 N.m (60-80 kgf.cm)
Oil Strainer 3 M6-12 7.8-11.8 N.m (80-120 kgf.cm)
Transaxle Wire 1 M6-16 3.9-6.9 N.m (40-70 kgf.cm)
T/A Housing - T/A Case 16 M8-60 23.5-35.5 N.m (240-360 kgf.cm)
Oil Pump - T/A Case 6 M8-20 19.6-29.4 N.m (200-300 kgf.cm)
T/A Case - T/A Rear Cover 9 M8-25 19.6-29.4 N.m (200-300 kgf.cm)
Parking Lock Pawl Bracket 2 M6-16 5.9-8.8 N.m (60-90 kgf.cm)
Manual Detent Spring 1 M6-16 7.8-11.8 N.m (80-120 kgf.cm)
No.1 Transaxle Case Plate 1 M6-12 7.8-11.8 N.m (80-120 kgf.cm)
Oil Reservoir Lock Plate 3 M6-12 3.9-6.9 N.m (40-70 kgf.cm)
Oil Apply Pipe Clamp 1 M6-12 3.9-6.9 N.m (40-70 kgf.cm)
Screw Plug - Rear Cover 4 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm)
T/A Housing - Bracket 1 M8-16 19.6-29.4 N.m (200-300 kgf.cm)
Stator Shaft - Oil Pump Body 8 M6-16.7 7.8-11.8 N.m (80-120 kgf.cm)
2 M6-20
Solenoid - Lower Valve Body 5 10.0-12.0 N.m (100-200 kgf.cm)
3 M6-49
1 M6-49
1 M6-36
Valve Body 14 6 M6-20 9.8-11.8 N.m (100-120 kgf.cm)
5 M6-28
1 M6-40


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[ RM-1 ]

This REPAIR MANUAL covers Disassembly, Inspection and Assembly

Automotic Transmission Engine Type REF No.

QUALITY ASSURANCE DEPT.

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

ASSY ............................................................ Assembly

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

SLT ........................ Throttle Pressure Control Solenoid

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

FOREWORD ........................................................................................ RM-1

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

The new automatic transmission AW 81-40LE is an electronically controlled

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

Solenoid Clutch Brake 1 Way Clutch

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

1. Most repair operations begin with an overview illustration.

GENERAL REPAIR INSTRUCTIONS

1. During disassembly, keep parts in order to facilitate reassembly.

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

REMOVAL OF COMPONENT PARTS

Breather Hose No.1 Breather Plug

Non Reusable Part

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

Torque Converter "O" ring

Gasket Oil Seal

Non Reusable Part "O" ring SS-01-01A

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

Apply Gasket Transaxle Rear

1st & Reverse

Non Reusable Part

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

Counter Driven Gear

Differential Gear Oil Seal

Direct Clutch Hub

Non Reusable Part

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

SEPARATE EXTERNAL PARTS

4. REMOVE SCREW PLUG

6. REMOVE INPUT SPEED SENSOR AND NO.1

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

7. PLACE TRANSAXLE ON WOODEN

8. REMOVE OIL PAN AND GASKET

9. EXAMINE PARTICLES IN PAN

(2) Remove the gasket from the oil strainer.

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

11. REMOVE VALVE BODY ASSEMBLY

(3) Support the valve body assembly and

12. REMOVE CHECK VALVE

13. REMOVE BRAKE DRUM GASKET

14. REMOVE APPLY GASKET

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

15. REMOVE ACCUMULATOR SPRING AND

(3) Remove the 2 “O” rings from the C2

(4) Apply compressed air (4.0 kgf/cm2) to the oil

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

(7) Apply compressed air (4.0 kgf/cm2) to the

(8) Remove the 2 “O” rings from the B1

16. REMOVE TRANSAXLE WIRE

(3) Remove the “O” ring from the transaxle wire.

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)

17. REMOVE VEHICLE SPEED SENSOR