SUBARU

Technical Service Information Taare Fig. 274 2) Remove the connector of line pressure control solencid Line pressure: valve, 'N range (with engine idling): 2,205 kPa (23.5 kg/em?, 334 psid a. Before measuring the line pressure, ensure the engine is warmed up completely. b. After measuring the line pressure, connect the connector of ine pressure control solenoid valve. ADJUSTMENT PROCEDURE 1) Drain ATF. 2) Remove the oil pan and oil strainer. 2) Loosen the lock nut on the pressure regulator valve guide, ‘and turn the bolt in or out to adjust the line pressure as re- auired. ‘Adjustment: ‘One rotation of bolt changes line 98 kPa (1 kg/em?, 14 psil. sure by Low line pressure is produced whi vehicle is stopped, (Solenoi idling the engine or when Nn") Loossening the bolt one complete rotation increases line pressure by 98 kPa (1 kg/em?, 14 pail Tightening the bolt one complete rotation decreases line pres: sure by 98 kPa (1 kg/em?, 14 psi 3). Shift the selector lever to the N range while idli engine, and measure the line pressure. 9 the When either of the switches operate beyond the specified range, problems listed in the following chart will occur. Type of switch Problem Cause Vehicle “creeps” during idle ‘Switeh turns ON before pedal is depressed 3mm (0.12 in) (There is no free play between ‘Accelerator switch switch and pedal.) CClutch is engaged abruptly, or clutch is | Switch turns ON when pedal is depressed at not engaged in low-speed operation. least 7 mm (0.28 in) Shock is felt when clutch is engaged. ‘Switch turns ON before pedal is depressed 16 mm (0.63 in). Throtle-position switch Clutch tends to slip during accele ‘Switch turns ON when pedal is depressed at tion in low-speed range least 24 mm (0.94 in). Ensure the carburetor throttle valve fully closes when the accelerator switch operates within the specified range.INDEX SERVICES .....08 seeeeeneeeneraneee ADJUSTMENTS .. see IN CAR TESTS ... POWER FLOW ... see eeeeeeeeees OPERATION .... errr ey TROUBLE SHOOTING ... SPECIFICATIONS . COMPONENT PARTS .. TEARDOWN AND ASSEMBLY .eevssseeveseeeees 48 AUTOMATIC TRANSMISSION SERVICE GROUPP4ATSG Technical Service Information SERVICE PROCEDURE General Ri ai ea When disassembling or assembling the automatic transmission, ‘observe the following instructions. 1) Workshop Provide 3 place that is clean and free from dust. Principally the conventional workshop is suitable except for a dusty place. Ina workshop where grinding work, etc. which produces fine particles is done, make independent place divided by the vinyl curtain or the equivalent 21 Worktable ‘The size of 1 x 1.5 m (40 x 60 in) is large enough to work, and it is more desirable that its surface be covered with fat plate like iron plate which is not rusted too much. 3) Cleaning of exterior (1) Clean the exterior surface of transmission with steam and/or kerosene prior to disassembly, however it should be noted that vinyl tape be placed on the airbreather or oll level gauge to prevent infiltration of the steam into the transmission and also the cleaning job be done away from the place of disassembly and assembly. (2) Partial cleaning will do, depending on the extent of disassembly (such as when disassembly is limited to some certain parts) 4) Disassembly, assembly and cleaning (1) Disassemble and assemble the transmission while Inspecting the parts in accordance with the Trouble shooting. (2) During job, don’t use gloves. Don't clean the parts with rags: Use chamais or nylon cloth. (3) Pay special attention to the air to be used for cleaning Get the moisture and the dust rid of the air as much as possible. Be careful not to scratch or dent any part while checking for proper operation with an air gun, (4) Complete the job from cleaning to completion of ‘assembly as continuously and speedily as possible in order to avoid occurrence of secondary troubles caused by dust. When stopping the job unavoidably cover the parts with clean chamois or nylon cloth to keep them away from any dust. (5) Use kerosene, white gasoline or the equivalent as washing fluid Use always new fluid for cleaning the automatic transmis. sion parts and never reuse. The used fluid is usable in isassemble and assemble work of engine and manual 4 (6) Although the cleaning should be done by dipping into the washing fluid or blowing of the pressurized washing {uid, the dipping is more desirable. (Do not rub with a brush.) Assemble the parts immediately after the cleaning without exposure to the air for a while, Besides in case of washing rubber parts, perform the job quickly not to dip them into the washing fluid for long time. (7) Apply the automatic transmission fluid (ATF) onto the parts immediately prior to assembly, and the speci tightening torque should be observed carefully (8) Use vaseline if it is necessary to hold parts in the Position when assembling, (8) Drain ATF and differential gear oil into a saucer so that the conditions of fluid and oil can be inspected. (10) Do not support axle drive shatt, stator shaft, input shaft or various pipes when moving transmission from one place to another (11) Always discard old oil seals and bushings, and install (12) Do not reuse old pipes, gaskets, plugs (1/8"), spring pins, ete Install new ones. (13) Be sure to replace parts which are damaged, worn, scratched, discolored, ete SECTIONS THAT CAN BE DETACHED/ SSeS 2WO Fig. 50 Section A Yes Section 8 Yes Section C YesTechnical Service Information ‘The level of ATF varies with fluid temperature. Pay attention ‘awo to the fluid temperature when checking il level. A change in the ATF level by oil temperature is shown in the following figure. 2) Ensure the vehicle is level. After selecting all positions (P, R,N, 0, 2, 1), set the selector lever in “Prange. Measure fluid level with the engine idling ‘After running, idle the engine for one or two minutes before measurement. 3) If the fluid level i below the center between high and low marks, add the recommended ATF until the fluid level is found within the specified range (above the center between hhigh and low marks). When the transmission is hot, the level should be above the center of upper and lower marks, and Fig. 51 when it is cold, the level should be found below the center of these two marks, Section D Yes Roch Deno) Use care not to exceed the upper limit level, pheric temperature of O°C (92°F): More than 25 minutes 5 Time for temperature rise to 30°C (86°F) with atmospheric On-Car Service ‘temperature of 0°C (32°F): Approx. 8 minutes By running the veicle ADJUSTMENTS Time for temperature rise to 60°C (140°F) with atmospheric temperature of 0°C (32°F): More than 10 minutes 3) Method for checking fluid level upon delivery oF at ATE LEVEL pete mpeeion nen vey 1) Raise the ATF temperature to 60 to 80°C (140 to 176°F). Check fluid level after a warm-up run of approx. 10 minutes. (This temperature may be attained by running a distance of | During this warm-up period, the automatic ‘transmission 5to 10k (3 to 6 mie) functions can aso be checked serum a] 8 g can i ad ver ewer | = at — ae" see wos} |S iauep Eterm: 700 = 790 0m ' 2] (0.39)] “cou” tower gt | 2 al | vel 30 a9 806070 8090 100 (86) (108) (122) 1140) (186) 1176) (94) (aHZICFD Automatic tranemission tig temperature Fig. 52 AUTOMATIC TRANSMISSION SERVICE GROUP 5DIFFERENTIAL GEAR OIL LEVEL 1) Ensure the vehicle is level. Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level. Check whether the oil level is between the upper and lower marks. If it is below the lower limit mark, add oil until the level reaches the upper mark, The difference in level between upper and ower marks corresponds to O.4¢ (0.8 US pt, 0.7 Imp pt) 2 OIL LEAKAGE CHECK POINTS It is difficult to accurately determine the precise position of 4 oil leak, since the surrounding area also becomes wet with cil. The places where oil seals and gaskets are used are as follows: Jointing portion of the case ‘Transmission ease and final reduction case jointing portion Final ceduction eate and converter housing jointing portion ‘Transmission case and transmission cover (or intermediate case) jointing portion Intermediate case and extension case jointing portion Converter housing ‘© Engine crankshaft ol seal ‘© Torque converter impeller sleeve oil seal ‘¢ ATF pipe connector Final reduction case Final reduction cate and governor cover Axle shaft oil seal (O-ring on the outside diameter of axle shaft ol seal holder Differential oil filler port Differential oil drain plug Speedometer cable mounting portion Governor test plug Air breather Automatic transmission case Mating surface of oil pan and transmission case O-ring on the outer diameter of servo piston cover ‘Test plug (Servo connecting side and servo release side) Oit supply pipe connections ATF pipe connector Vacuum diaphragm location Downshitt solenoid location O-ring on the outer diameter of servo adjusting screw Oil pan drain plug Governor pressure and line pressure checking blind plugs (steet ball) Technical Service Information Intermediate case © Test plugs (two plugs for line pressure, and plugs on forward clutch, reverse clutch, and transfer clutch) ‘© Blind plug (steel ball) Extension ‘© Rear drive shatt oil seal ‘© Transfer solenoid location @ Thermoswitch location The points listed above should be checked for fluid teak. Checking method is as follows: (© Place the vehicle in the pit, and check whether the leaking oil ig ATF or not. The ATF is wine red in color, and can be discriminated easily from engine oil and gear oil Wipe clean the leaking oil and dust from a suspecteble area, Using @ noninflammable organic solvent such as carbon tetrachloride. Run the engine to raise the fluid temperature, and set the selector lever to "D" in order to increase the fluid pressure ‘and quiekly detect a leaking point. ENGINE IDLING SPEED Excessively low engine idling rpm will lead to rough engine ‘operation and excessively high idling rpm will lead to a sudden shift shock or creeping when shifting from N to D or R. {ling rpm for automatic transmission cars (N or P range 800100 rpm (Except SPFI) 700100 rpm (SPFI) KICKDOWN SWITCH AND DOWNSHIFT SOLENOID Set the ignition switch to ON, pedal to see whether the solenoid functions or not. kickdown occurs, or if the shift point occurs with the throttle half open, check the kickdown switch, downshift solenoid and associated wires. If kickdown failure occurs infrequent may be due to malfunction of the solenoid contaminated with dirt. Wash the inside of solenoid while moving the push rod. ‘After washing, carefully check the operation of the solenoid. ind fully depress the accelerator If no Before removing or installing the solenoid, drain approx. 22 (2.1 US qt, 1.8 Imp qt) of ATF. INTAKE MANIFOLD VACUUM PRESSURE Check whether pressure is over -60.0 KPa (-450 mmHg, =17.72 inl) at idling speed of engine, and whether pressure decreases in proportion to increase of engine speed when ‘accelerator pedal is depressed. CREEPING ‘Check whether car exhibits a certain amount of creeping when brought to a temporary stop with selector lever in " or “R position. AUTOMATIC TRANSMISSION SERVICE GROUP 6ATSG Technical Service Information MANUAL LINKAGE Adjustment of the manual linkage, like the inspection of fluid level, ig an important operation in the automatic transmission service. Remember that improper adjustment may lead to 2 damaged transmission. Push button To me ~ Indicator. He na top ie if? Operation incicated by solid arrow mark “© must be done while pressing the push button. ‘© Operation incieated by white arrow mark ‘may be done without presing the button. Fig. 53 © Inspection = Adjustment 1) While pressing the release button, move the selector lever If the manual valve detent position is not aligned with the from the “P to "1" range; a click will be hi position. This clicking sound is caused by 2 detent of the 1) Set the selector lever to “N" ‘manual valve in the transmission, and it indicates the correct 2) Loosen the adjusting nut of the linkage rod. rd in each guide plate groove position, perform the adjustment as follows. selector lever position. Check to see that the indicator needle 3) Set the detent position so the selector arm is aligned with is aligned to this position, and also see that itis aligned with the groove of the guide plate when the release button and range of 2 6 mm (0.24 in} dia, boss] the “"N" locating mark of the transmission case (within the selector lever are released. 2). Confirm that the selector lever cannot be moved into “R’* from “N" when pushed lightly, without first pressing the release button. 3) Confirm that the engine can only be started in “P" and 'N" ranges. 4) Confirm that the backup lamp will light only when the selector lever is moved to the “R range. 5} Place the vehicle on a slope, and set the selector lever to "and check whether the vehicle is locked property. Fig. 54 AUTOMATIC TRANSMISSION SERVICE GROUP. 74) Adjust the rod so that the “N" mark of the guide plate is aligned correctly with this detent position 5) If the indicator needle is not aligned with the guide plate ‘marking, remove the console box, loosen the four indicator mounting screws and adjust the position of the indicator ASSY. VACUUM DIAPHRAGM AND VACUUM HOSE A loose or disconnected vacuum hose will result in rough ‘engine idling and an abrupt shifting shock even with light ‘acceleration. In such a case, check the vacuum hose for cracks fF check the vacuum hose joint. Excessively large shift shocks and the emission of white exhaust smoke while running may indicate a broken vacuum diaphragm. If such symptoms occur, loosen the two bolts securing the vacuum pipe (at governor cover and at the engine and transmission jointing), and turn the vacuum pipe upward around the bracket of the diaphragm joint until the bracket comes free from the bolts. Pull the vacuum hose and vacuum pipe out toward you and drain approx. 22 (2.1 US at, 1.8 Imp qt) of ATF. Remove the vacuum diaphragm by rotating by hand. ‘Be sure to remove the vacuum diaphragm when the trans- ‘mission is cold. (To avoid a burn.) b. Also take out the diaphragm rod. GOVERNOR VALVE 1f automatic shitting is not performed normally while running in the O range, or if acceleration is possible only up to 50 to 60 kevfa (31 t0 37 MPH) in the D range, itis often attributable to malfunctioning of the governor valve. Such malfunctioning may be caused by sticking of the valve ‘due to clogged dirt, burrs or nicks on the valve body, etc. Fig. 55 Technical Service Information = Disassembly 1) Remove the three governor cover mounting bolts from the right side of the final reduction case, and remove the governor cover by turning it slightly in order to avoid inter ference from the vacuum pipe bracket. 2) Pull the governor valve out while carefully turning clock: 3) Remove the E-clip @ snap ring © then remove the valve ®. spring @ and other parts from the body ©. 4} Remove two bolts @ securing the shaft @ and body © and disassemble them. Be sure to perform the steps 3) and 4) after pulling the governor valve out from the final reduction case, = Checking Check the governor valve and body visually and by feeling with a finger for burrs and dents, and repair as necessary. If the sliding surface of the body or valve is defective, replace the ‘governor body ASSY with @ new one, = Correcting 1) To correct the governor valve and governor valve 2, lightly apply 2 fine grained oil stone to the burred edge as shown in the figure, and rotate the valve one or two turns. Check whether or not the burrs have been removed by feeling with a finger Repeat this operation until the burrs are no longer felt. a. Note that the finishing of the end face is not chamferring, but it is light deburring. A sharp edge having no burrs is desirable, bb, Replace the valve ASSY if flaws and dents are noted on the sliding surface. AUTOMATIC TRANSMISSION SERVICE GROUP 8Technical Service Information keep ol stone tinea, 60" - 90" ‘correct snese areas, Fig, 56 2) Burrs and nicks at the edge of the valve body groove should be removed by using a small standard screwdriver. 3) Clean the repaired parts in clean lamp oil or white gasoline, Fit the governor valve and governor valve 2 into the valve body, and check for smooth sliding of these parts by lightly pressing them to the inside of the valve body while rotating, Fig, 57 IH the governor valve checks out to operate normally, the seal ting of governor sleeve must be checked. = Reassembling 1) Reassemble the governor valve components by referring to the figure shown above. Pay attention to the orientation of the weight. 2). Confirm that there is no foreign matter in the oil passage of the governor shaft, and tighten the shaft to the governor body after washing, Tightening torque 9-11 Nem (0.9 ~ 1.1 kgm, 6.5 — 8.0 feb) When tightening, fix the flange of the shaft, and be careful not to damage the nylon gear of the shaft. 3] When assembling the governor valve to the final reduction case, itis unnecessary to dry out the governor valve. However, the governor valve should be assembled after confirming that the seal ring is normal , use special care not to damage the seal ring, Je the case. When assembli and the lip of the ol sea installed 4) Before assembling the governor cover, replace the gasket (governor cover) and confirm that the washer is included, Tightening torque 14 — 17 Nem (1.4 — 1.7 kgm, 10 ~ 12 fetb) BRAKE BAND If the following abnormal shifting conditions are noted in road test, the brake band must be adjusted Shift state and adjustment 1) The 2nd gear state can be achieved but: © the engine rpm increase excessively shifting up from 2 to 3. © a shift delay (over 0.7 sec) accompanies at kickdown from 3102. If any of these problems occurs, it is attributable to excessive clearance between the reverse clutch drum and brake band: Tighten the adjust screw by turning it clockwi 2). The 2nd gear state can be achieved, but © the shitting shock is too small at shifting up from 1 to 2 © a braking phenomenon is noted when shifting up from 2 to 3 Hf any of these phenomena excessively small brake band clearance: screw by turning it counterclockwise. 3) When accelerating, direct shift up from Tst to 3rd occurs: Excessively large clearance. When shitting up from 2nd to 3rd, tire slip occurs Excessively small clearance, noted, it is attributable to Loosen the adjust AUTOMATIC TRANSMISSION SERVICE GROUP 9Technical Service Information 4) Loosen the pitching stopper (to a postion just before it comes off 5) Disconnect the 4WD selector solenoid harness. (Keep the disconnected harness suspended.) “Teanatersolencid connector Fig. 58 1m Adjustment of the adjusting screw Fig. 59 1). Using a socket wrench, immobilize the end of the 10 mm screw projecting on the left side of the transmission case, and loosen the nut with a double-end wrench. 6) Remove the uppercover. [This is necessary for removing In the case of occurrence of problems 1) and 2) mentioned the exhaust pipe (FI.] Previously, perform the adjustment by loosening or tightening 7) Remove the exhaust pipe (F). the nut within a range of 3/4 turn from this state. 8) Remove the intermediate side cable clamp. 9) Drain the torque converter oil (one liter) Too! No. Tool Name (The oil will not come aut of the case when the valve is removed, if one liter of oil has been drained. Measure the drained amount so that the amount to be added after complet: mn pescenerecee: ing the inspection can be easly determined.) Bo not loosen excessively; otherwise, the band strut on the 10) Remove the rear crossmember. (To ensure safety, support eeceeeeeare ne the oil pan with a transmission jack.) 11) Remove the side cable from the body clip. (Move it downward as far as posible.) Previously, perform the adjustment as follows: * Push the transmission to the left. (Insert a piece of wood Adjusting procedure: Tighten adjust screw to 9 Nim (0.9 kg-m, 12! Push the Racer ae means Ge oe between the clearance thus achieved.) aus, fo turns 13) Remove the solenoid valve. 398603610 Socket wrench 2) In case of the occurrence of problem 3) mentioned ‘Do not tighten the adjusting screw with an excessively large torque. Solenoid valve 3) With the adjusting screw immobilized, tighten the lock nut to 26 ¢ 2 Nem (2.7 * 0.2 kgm, 20 + 1.4 fib) torque, TRANSFER SOLENOID I the 4WD pilot lamp on the instrument panel remains off even when the 4WD pushbutton switch has been depressed ‘check the transter solenoid and wiring If the 4WD mode is not achieved with the lamp illuminated, ‘the solenoid may be malfunctioning. Check the solenoid and ‘wansfer valve as follows Fig. 60 = Removal 1). Open the hood. 2) Disconnect the battery ground cable. = Installation 3) Remove the spair tire Reverse the sequence of removal procedure. AUTOMATIC TRANSMISSION SERVICE GROUP 10TRANSFER SECTION Disassembly 1) Completely drain the AFT. 2) Remove the transfer solenoid. Refer to the Removal and Installation of the Transfer Solenoid for details 3) Remove the temperature switch harness from the clamp, 4) Remove the eight 8mm bolts and extract the transfer section and extension ASSY at a unit from the intermediate 4. Be careful not to drop the internal component parts. b, Place a container to collect the remaining oil. Fig. 67 5) Separate the clamp from the pipe at the bent position and disconnect the transfer pipe from the valve body and inter mediate case, Fig. 62 Remove the two 6 mm bolts securing the valve body. ansfer valve from the 6 7) Remove the Elip and remove the body, Be careful not to lose the coil spring Technical Service Information = Inspection ‘© Visually check all peripheries to ensure they are tree from burrs, dirt, metal chips, ete. © Cleaning all parts by washing them and install them in the valve body. Ensure these parts move smoothly without binding. © If the valve body or the frictional surface of the valve is, faulty, replace with @ new one. = Assembly 1). To assemble the transfer valve parts, refer to the following figure. ie wG 2 & ‘ 2 Fig. 63 2) Attach the valve body to the intermediate case and tighten with the two 6 mm bolts ‘Tightening torque: 6 ~8 Nem (0.6 — 0.8 kgm, 4.3 ~ 5.8 fb) a. Do not forget to install the plate. b, Pay attention to the direction of the valve body. © Do not forget to install the clamp. 3) Insert the transfer pipe into the intermediate case and tighten the clamp by bending ‘Always use a new pipe and clamp, 4) To assemble the transfer unit, reverse the order of dis: assembly. Be sure to install the rear drive shaft seal ring. 5) Replenish ATF and check the level CONTROL VALVE = Disassembly 1). Raise the vehicle with a jack and drain ATF. 2). Disconnect the vacuum hose, and remove the downshift solenoid and vacuum diaphragm. AUTOMATIC TRANSMISSION SERVICE GROUP arATSG Technical Service Information ‘Also remove the diaphragm rod together with the vacuum 7 id Fig. 66 Fig. 64 1 Inspection Refer to the Control Vaive ASSY section, © Assembly 3) Remove the converter oil pan. Be sure to place a container 4)" insrait the control valve ASSY. under the oil pan to collect ATF remaining in the oil pan. 4) Disconnect the servo pipes Be sure to tighten the bolts equally — one at a time — using a torque wrench. Tightening torque: 6-8 Nem (0.6 — 0.8 kgm, 4.3 ~5.8 trib) 2). Connect the servo pipes ‘Always install new servo pipes. ey, | E serve pine Fig. 65 5) Remove the six 6 mm bolts (shown by the arrow) and detach the control valve ASSY, & Bacar notte drop the mana ve Fig. 67 b Be careful not to damage the 0 Be careful not to allow dust or dirt from geting into the valve ASSY. 3} Align the mating surfaces of the converter oil pan and converter to ensure no clearance exists at any point. The gasket should not be used at this point. 4) Wipe any oil from the mating surfaces and install the converter oil pan with the gasket in place. AUTOMATIC TRANSMISSION SERVICE GROUP. 12Always use a new gasket. Tightening torque 3.4 — 4.4 Nem (0.35 — 0.45 kgm, 2.5 — 3.3 fulb) Drain plug tightening tora 25 Nem (2.5 kgrm, 18 ftlb) 5) Using the Diaphragm Rod Gauge Set, check the length of ‘the diaphragm rod is within specifications and, if the length is correct, install the vacuum diaphragm. 66) Install the downshift solenoid and connect the vacuum hose Do not forget to install the O-ring. 7) Replenish ATF and check the oil level. The amount of ATF to be replenished is approximately 4 liters (4.2 US at, 35 Imp at). Various Tests STALL TESTS AND INTERPRETATION OF TEST RESULTS ‘The stall testis of extreme importance in diagnosing the con: dition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in all shift ranges except the P and N ranges. Purposes of the stall test 1) To check the operation of the automatic transmission clutch and brake band. 2). To check the operation of the torque converter. 3) To check engine performance Technical Service Information Test methods Prior to the stall tests, check to ensure the carburetor throttle valve opens fully, and that the levels of engine oil, cooling water and ATF are correct. Set the select lever in the P range and idle the engine at 1,200 rpm for several minutes until the ATF reaches approximately 60°C (140°F). 1). Install an engine tachometer at a location visible from the driver's compartment and mark the stall speed range on the tachometer scale ‘Stall speed (at sea level: ‘Non-TURBO 2,250 ~ 2,550 rpm TURBO 2,650 — 2,950 rpm. 2). Place the wheel chocks at the front and rear of all wheels, land engage the parking brake. 3) Move the manual linkage to ensure it operates properly, and shift the select lever to the D range. 4) While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle. 5) When the engine speed is stabilized, read that speed ‘quickly and release the accelerator pedal 66). Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute 7) Record the stall speed. 8). Perform the stall tests with the select lever in the 2, 1 and R ranges. a Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle 1 stall speed reading). Failure to follow this instruction causes the engine oil and ATF to deteriorate and the clutch and brake band to be adversely affected. Be sure to cool down the engine for at least one minute after cach stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. b. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. AUTOMATIC TRANSMISSION SERVICE GROUP 13Technical Service Information Interpretation of stall test results ae Assessment Cause Remarks (at sea level) Higher than Slinpage of automatic trans © Low line pressure (lf stall "1: Brake band slippage can: 2,580 rom mmission clutch, brake band, speed is higher than speci not be judged by stall (Non-TURBO) | etc. fied range at any shift posi tests; however, if i lips, or (Further stall tests are not tion) engine speed is higher than 2,950 rpm necessary.) © One-way clutch slippage. specified rpm while car is (TURBO) (if stall speed is higher than, being driven in the 2 range. specified range only inthe | *2: Slippage of reverse clutch/ D range.) low & reverse brake can be '¢ 71: Brake band slippage judged by road tests. (if stall speed is higher If engine compression can than specified ange bbe used a a brake with only in the 2 range.) select lever in the 1 range, © °2: Stippage of low & reverse clutch is sipping; if | reverse brake or reverse it cannot be used, low & brake reverse brake is slipping, (if stall speed is higher than specified range only in the R range.) © Control members are © One-way clutch can be good order in the D, 2.1 ‘checked for condition by (Non-TURBO) and R ranges. road tests."* or ‘© Engine in good order. 2,850 ~ 2,950 ‘om (TURBO) Lower than ‘© Throttle not fully opened, 2,250 rpm © Erroneous engine operation (Non-TURBO} for one-way cluteh slippage or | 2,650 rpm (TURBO) i ** Road test ‘© Acceleration is not properly | One-way clutch slippage *3: Abnormal temperature made up to 50 km/h "3: One-way clutch jamming tise occurs. (31 MPH), Erroneous engine operation. © Car speed does not attain more than 80 km/h (60 MPH). © Operation is not proper at all car speeds. AUTOMATIC TRANSMISSION SERVICE GROUP 14ROAD TEST Road tests should be conducted to properly diagnose the condition of the automatic transmission. ‘Speed change characteristics ‘The standard speed change characteristics are indicated in the following table. Technical Service Information Non-TURBO TURBO Take manifold premure intake manifold presure shite | car speed kv MPH i yr sed keh (MPH KPa (meg, inl) " Pa i, i) cr | cece 57.284 (95.5525) 8, | e074 57.7425) Kiekdown 104.726 (65.1231) Kickdown 2,=0, | ates 70330) 40-67 440-487 (oo~80,118-197 [| 0,—0, | 96915 (602-307 {950 350, 1299 -12.781| 0, =0, | toa.9e6 (64.6431) 0,0, | 46524 209:25) p= 0, | sea iza125) D.=0, | 17.082 081.2) Di, | ron? (11.2602) fo =o, | 470:3(79281.9) ae D,—o, | eBors a7ae1.8) 283 (200,747 D0, | 190g ina 010.01 [o,-0, | s40:3 (21.1219) 0, | 17027 0621.2) 0,0, | 1652 0380.2) Full hromte Ful hvorle +25 wap gt 8 125 ae7t}S 40-67 as022Sze67y8) | | ano—487 neh 43°? 26.7") (90-50, 1.18- 1.971 oes (290 — 350, 12.99 - 13:78) = inimare ‘annum nowt wom ve0*?3 ane!) nimum thor 450, 15.75 ~ 177 275 28649) 87.3 19-600 aon +25 «og tt 8 (400 — 450, 15.75 -17.72) een ah 43°75 26.7°15) “1693 %0 17.72) Shift characteristics Pay careful attention to ensure the shift is made smoothly at the proper car speed at which shifting begins. 1) Shifting shocks are encountered or smooth shifting does rot occur. 2) Shifting occurs slowly in response to the condition of the engine throttle. ‘The above two problems are due to incorrect throttle pressure fr other factors involved in throttle pressure. Checking for shift patterns 1) In the D range, shitting should be made as Dy > 3 > Oy smoothly and vice versa; it should not be made in the R range 2). Kick down should activate properly 3) When the select lever is shifted from the D range to the 2 or 1 range, shifting should be made as D3-*2 (13) 1h. Engine compression can be utilized as a brake at 1p and 1, 4). Shifting should not occur while the select lever is at the range, AUTOMATIC TRANSMISSION SERVICE GROUP. 15'5) With the shift lever in the 2 range, the 2nd gear is engaged and 2nd speed is maintained. 6) The select lever should be locked when placed in the P range. ln road tests, if any abnormality is noticed in the 2 range, itis necessary to adjust the brake band. If by inspection the brake band is in good order, check the servo piston for any sign of oil leakage from the se. Check for the 4WD function With the car in the 4WD mode, turn the vehicle in a circle while lightly depressing the accelerator pedal, and then shift the vehicle into the FWO mode. When the vehicle is shifted into the FWD mode, a light shock should be fel. Whenever the transfer clutch facing is replaced with a new one, the above test should be conducted, for the run-in purpose, ‘wo to three times with the vehicle set in the 4WD mode and with the steering wheel fully turned. LINE PRESSURE TEST If the clutch or the brake band shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked, © Excessive shocks during upshifting or shifting takes place at 4 higher point than under normal ciccumstances, may be due to the line pressure being too high. © Stippage or inability to operate the car may, in most cates, be due to loss of oil pressure for the operation of the clutch, brake band or control valve. 1) Line pressure measurement (under no load) a. Before measuring line pressure, jackup front wheels (frontwheetdrive model) or all weels (4-wheel drive model). b. Maintain temperature of ATF at approximately 80°C (176°F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes with shift lever in “N” or “P.”) 2) Line pressure measurement (under heavy load) 4. Before measuring line pressure, apply both foot and parking brakes with all wheels chocked (Same as for “stall” test conditions). bb. Measure line pressure for § to 10 seconds. Before measuring it again, idle the engine for 2-5 minutes. ©. Before measuring line pressure, always shift the lever "not from "1" to “2. d. Maintain the temperature of ATF at approximately 80°C (176°F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 rmimutes with the shift lever in “N” or “P. Technical Service Information Measuring the line pressure 1) Temporarity attach the Oil Pressure Gauge ASSY to 2 suitable place in the driver's compartment, remove the blind plug located in front of the toeboard and pass the hose of the Gauge ASSY to the engine compartment. \\ LAT i vo vt 1 Pressute gauge hose 2. Hole i toe Board (blank cap hole) 3. Brake pedal Fig. 68 Tool No. Tool Name 398573600 Oil pressure gauge ASSY 2). Using the socket wrench (7), remove the pressure check plug from transmission cover (or intermediate case). 3) Attach an oil pressure adapter to the pressure check plug hole in transmission cover (or interm Fig. 69 Fig. 70 16Technical Service Information 2). Car in the 4WD mode rea celtane If an abnormality occurs in the AWD operation, check the line pressure in the transfer clutch oil circuit to determine the 498897000 Oil pressure adapter cause of the problem: 498597000 Socket wrench (7) 4) Connect the oil pressure adapter and the tip end of the Symptom ccceacle ca ears Pressure difference be- | @ Transfer pipe 5) Run the engine and check the line pressures with the ee aio a WDE tdi! ‘engine at a minimum-throttle and fullthrottle operations. pscaan mena ieee nee more than 29 kPa ing not in- Engine at idle | (0.3 kg/cm’, 4 psi). stalled (1,500 rpm) in Neutral | Pressure difference be- | @ Solenoid or , sn 4WD and FWD | transfer valve Line pressure in each select range coionmosesis, | operative Refer to the "SERVICE DATA”. less than 29 kPa (0.3 kg/cm’, 4 psi. Interpretation of line pressure 1). Car in the FWD (front-wheel drive) mode ‘Symptom Probable cause Low ‘© Oit pump worn or clear ance improperly adjusted © Leakage in oil pressure circuit. GOVERNOR PRESSURE TEST Engine at idle © Pressure reguiotor valve | 44 th | 18 governor valve operation is questionable as a result of {500 em inoperative, road tests, conduct the governor pressure test. High @ Leakage atvacoum how] 1 Remove the test plug from the right side of the final for vacuum diaphragm | ‘eduction case and, in its place, install the Adapter. fr diaphragm too long. o- Presaure regulator ve Toate, | cae jamming s9a803600 | ‘Adapter Pressure will | @ If pressure fails to rise not rise. ‘even though vacuum pressure drops, check to see if diaphragm rod was not installed. Engine at full throttle Pressure rises | @ In most cases problems butdoes not | may be due to jamming } enter speci of vacuum throttle | fied range. | valve, pressure regulator | valve or pressure regula tor plug, Change of the diaphragm rod by one rank or (0.5 mm (0.020 in)] causes the line pressure to change approximately 29 kPa (0.3 kg/em2, 4 psi) Fig, 74 AUTOMATIC TRANSMISSION SERVICE GROUP VvATSG Technical Service Information Mechanical Operation ‘The component units used in the SUBARU automatic trans mission operate as shown in the following table, transmitting ower corresponding with the driving condition in each selector position. | Forward C, | Reverse Cz 8, 8 eluteh Cy a an 7 ° N Neutral ~~ it 2.821 ° Oo D and 1.559 ° 2 ° ad 1.000 fe} fo} == a tae | oO] 3 : [ase zen | 0 ° NOTE: O-marked units operate in each corresponding gear. downshift valve @. The oil then travels to the torque con: verter ag torque converter oil 14, and, on the way to the Hydraulic Control Circuits 1) N Range converter, part of the oil is supplied to the forward and ee ae ee eee pump shaft, Since the oil pump is rotating at the same pressurized oil, called line pressure 7, is delivered to the manual valve @), vacuum throttle valve ©) , and solenoia AUTOMATIC TRANSMISSION SERVICE GROUP 182) 4-wheel Drive (4WD) If the pushbutton on the selector lever is set to the 4WO. position from the FWD position, the transfer valve opens the Circuit to the transfer clutch as the solenoid is activated, and, {at the same time, the green 4WD pilot lamp illuminates on the meter panel The line pressure, led through; transfer pipe — intermediate ‘case ~ rear drive shaft, connects the transfer clutch (hydraulic clutch) ‘The power is branched to the front and to the rear on the front hypoid pinion. The power branched to the rear from the shaft end of the pinion is led through; transfer drive shaft transfer gear — transfer clutch ~ rear drive shatt > propeller shaft + cear differential, and transmitted to the rear wheels, ‘These characteristics have been established as being necessary 0 transmit the power from the engine to the rear wheels. If an excessive brake torque is created on the front and rear wheels in a tight cornering operation, the transfer clutch acts a8 @ torque limitter (that is, the clutch slips), and weakens the braking torque, and also protects the driving members. The ‘torque limiting function is more effective when the line pres sure is lower (that is, when the throttle opening is smaller]. Technical Service Information a) ae ‘ 1! pumo| Laveen ( i ff & to oT EY 1 7 1 oi ' cad 1 Solenoid i L \ 7 te pressure] kisaion ff Troomeemer Porton ! inanetay Hs ones cue } rant vie | 15 a ine peste! < There presnre Fig. 27 Hydraulic circuit in 40D mode Control fave Front hypeld pinion “Teanser drive shat 0 pure Rear ceive shaft “Teangterctuten Extension ese Fig. 28 Transmission of power in 40D mode AUTOMATIC TRANSMISSION SERVICE GROUP 19@4ATSG Technical Service Information MECHANISM AND FUNCTION Cross Sectional View Pawo] oo Fig. 1Technical Service Information Speedometer gear Govecnor valve Rieduction rive gar Planetary gear Low & reverse brake ‘center shaft Connecting shell Forward cloteh Brake band O11 pump suter ll ‘Turbine ‘Control valve Reduction driven gear i eee ___ \ Lovie pinion | Diterenti | i L Fig.2 AUTOMATIC TRANSMISSION SERVICE GROUP 211, Torque Converter The torque converter 1s a kind of clutch that tansmits dnving power thiough oil. It works as an automatic clutch at starting ang serves co multp. ly the torque at the preliminary step before the power flows into the trans: rmussion (when starting). Ie is composed of three parts, an impeller, turbine and stator, as illus trated in the figure, The impeller is dutectly connected :0 the engine and the turbine is connected to the ‘rans: AAs the torque converter is filed with oil the rotation of the impeller (engine) causes rotation of the turbine (Griven shaft), so that the torque con: verter works as an automatic clutch at starting, Further, when the driven shaft (turbine) rotates slowly compared to the engine (impeller) rotation as when the car is starting, the converter multiples the engine torque and thereby the torque transmitted to the ttansmussion. This torque multiplying action is achieved by the stator, based fon the following mechanism: 1). First, mpeller rotation throws oil away radially by cencnfugal force, which goes into the turbine from the ‘outer side and flows along the vanes, giving the turbine a torque of the same digection as that af the impeller The figure illustrates a pattern of oil flow in the mechanism 2) Now, without the stater, the oil coming out of the turbine would flow in the direction as .adicated by P in the figure, hindering the impeller rotation. This is an effect of what 1s called uid coupling, in which the torque looked on the impeller is the same as that exerted on the curbine based on the principle of the action jon (turbine) 3). Thete is a stator, however, which reverses the st of the oil flow coming out of the turbine. as indicated by Q in the figure, helping che impeller rotation and thereby reducing the torque load on the impeller. Technical Service Information Driving nate L Oneeway clutch 2 Suter 3 Turbine 4 pels Fig. 12:12 Fig 1243 AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information 4) Therefore, less impeller torque is required in the torque converter with the stator, than in the fluid coupling, to give the same torque to the turbine, This means that the turbine (driven shaft) torque is high compared with the engine torque, which is the transmission torque multiplication ef fect of the torque converter, In reversing the direction of the oil flow 2 the stator is given torque ina direction reverse to that of the impeller and turbine rotations, so the stator must be fixed to the case. However, a5 the speed of turbine increases approaching. the impeller speed, the oil coming out, of the turbine exerts torque on the stator not in its lock direction but in the reverse direction, that is, in the same direction as the impeller and turbine rotations. This inversion point is called coupling point. Then, if the stator is still kept locked, the stator becomes an obstacle to the power transmission reducing the efficiency This is why the stator is fixed on the case with a one-way clutch so that itis allowed to freely rotate when its locking power transmission. Performance curves of such torque Fig. 12:14 converters ae illustrated in the figure Torgue convener range Fiyid eouoting range i Etliclency ‘The torque multiplication range with stator stationary is called torque converter range and that with stator rotating is called fluid coupling range In this coupling range, the stator is rotating and the torque converter functions as only the fluid coupling, thereby the torque is not multiplied. ‘The state where only impeller rotates with turbine stalled is called stall state Torque ratio, speed ratio and ef: ficiency in the figure are expressed by the following formulas. Torque of turbine shaft (output shaft) Torque ratio= Torque of impeller shaft (input shaft) RPM of turbine shaft (output shaft) ee (ihe vehicle is standing sil), where RPM of impeller shaft (input shaft) Noreen ain iseconer oes value, This maximum torque ratio Output horse power is called stall torque ratio and this Input horse power * | engine speed is called stall speed. AUTOMATIC TRANSMISSION SERVICE GROUP8) Automatic Transmission Fluid Passages Technical Service Information i | AL i u 1 Toit ecooter (14) 12 Low & reverse brake pressure B 2 13 Discharge hole of ol pump (7) 3. Govemor feed presure (1) 14 Governor premute (15) Py 46 Govemor prewure (15) 1S. Servo release” pressure (10) as 5 Drain 16 * pressure 3) 6 6 Govemor presrure impaction hole 17. Reverse clutch pretute n 1 Au breater 18 Forward cluten preture (1) cy 4 Drin 19 Torque converter presure and lubrication (14) 29 9) Governor feed presure (1) 20. Suetion ole of od pump 30 10 Governor preaure (13) 21. Reverse eltch pretrare (11) 3 n 2 Fig. 12.32 Fluid pasages in tranemission cases Governor feed preszure (1) Forward clutch presse (1) 24 1 Panesar gear 2 One-way dutch 3. Revere clutch 5 6 Lowand reverse bake 7 Olt cooler 8 Torgue convener Torque converter arenure and lubreation (14) Discharge hoe of oi pump (7) ‘Revere clutch peenue (11) Forward clutch pressure (1) ‘To rear lubneavon (14) Dischare hole of of pump To oraue converter (14) Line presureingpection hole ‘Suction hale of od pump Reverse clutch pressure inspection holeTechnical Service Information 2) P (Parking) Range the axle shaft connected to the planetary output gear is mechanically With the transmission in the P locked. range, the clutches are functionally in the same condition as in the N range. But, in the locked condition as shown in the figure, the parking pawl is ‘meshed with the parking gear t0 that Free Low & reverse brake 3) R (Reverse) Range Forward clutch The reverse clutch and the low & Lertedstred reverse brake are engaged when the WH transmission is in the R range. The power flow is from the turbine shaft, 4 ja through the reverse clutch, and from the connecting shell tothe reverse sun T sear, As the planetary carer is held stationary by the low & reverse brake, a the reverse sun gear turns clockwise This causes the output ring gear to tum counterclockwise at a reduced speed providing a gear ratio of 2.166 tol Brake band Onmway ctuten Fig. 12-38 Power flow in R (reverse) range AUTOMATIC TRANSMISSION SERVICE GROUP 254) D (1st gear) Range When the transmission is in the D (ist gear) range, the forward clutch is engaged and power from the turbine shaft is transmitted to the forward sun sear. The planetary carrier is locked to the transmission case through the one: way clutch outer race, one-way clutch and center support. The planetary gear system in this range provides a ratio of 2.600 to 1 Since the planetary cartier tends to tum clockwise when the car is coast: ing, the one-way clutch is released and runs idle. In this condition, no reverse rive is transmitted to the engine so that the engine brake will not be applied. 5) D (2nd gear), 2 and 1 (2nd gesr), Range When the transmission is in the D nd gear) range, the forward clutch is engaged and power from the turbine shaft is transmitted to the forward sun gett. Also, the brake band is applied to hold stationary the reverse clutch drum interlocked with the reverse sun sear and connecting shell The power also flows in the same manner with the transmission in the 2 and 1 (nd gear) range. With the reverse sun gear held stationary, the planetary cartier rotates clockwise as the pinions circle around the reverse sun gear. Thus, the oneway clutch outer race runs idle and s geat ratio of 1.505 to 1 is obtained in this gear Position. AUTOMATIC TRANSMISSION SERVICE GROUP 26 Technical Service Information Low & reverse bra \ Forward clutch Oneway clutch Brake band Low & ravers brake Forward clutch Pare ten L my in — Brake bend Onenay clutch6) D (3rd gear) Range With the transmission in the D (3rd sett) range, the forward clutch and the reverse clutch are engaged. Although oil pressure is applied to the servo piston on both the “apply” and “release” sides, the brake band is released as the servo piston is released by the combined releasing force which consists of the retum spring force and the thrust caused by oil pressure acting fon the annular surfaces of the servo piston which are different in area ‘The power transmitted from the turbine shaft to the forward clutch drum is divided into two streams; one is transmitted from the forward clutch to the forward sun gear and the other from the reverse clutch to the reverse sun gear through the connecting shel, Since the forward sun gear and the reverse sun gear make the same rota. tion, the planetary-gear system turns as a unit and the ouput ring gear also tums in the same direction at the same speed. Hence, there is no gear reduction in the transmission and a gear ratio of 1 to 1 is achieved. 9) 1 Range When the transmission is in the 1 (ist gear) range, the forward clutch is engaged and the planetary carrier is locked by the low & reverse brake. ‘The planetary-gear system is in the same operating condition as in the D (ist gear) range, except that instead of the oneway clutch, the low & reverse brake is applied to hold the planetary cartier stationary, so that engine braking can be used. Technical Service Information Low & revere beaks Forward clutch Revere clutch 7) D Range Kickdown While operating at speeds below approximately 80 0 90 kim/h (50 10 56 MPH), a kick “3rd to 2nd” downshift can be accomplished by fully depressing the accelerator. ‘A kick “3rd to 1st” of “2nd to Ist" downshift can be accomplished below approximately 37 to 47 km/h (23 t0 29 MPH). Uy Onewnay ciuren Dr*ke bend 8) 2 Range [Regarding the mechanical operation of this range, refer to Item 5) “D 2nd ‘gear), 2 and 1 (2nd gear) range”. Low & revere brake Forwars clutch oe ct 5 Lo Oneway elten AUTOMATIC TRANSMISSION SERVICE GROUP 27ATSG] Technical Service Information TROUBLESHOOTING Many tcoubles of the automatic transmission may be corrected by performing the basic inspection and adjustment procedures. Before starting the regular troubleshooting operation, carry ‘out the following preliminary inspection. NECESSARY TEST GAUGES 1) Tachometer (It is desirable to be able to read to 50 rpm.) 2) Vacuum gauge (It is used for measuring intake manifold vacuum.) 3) Oil pressure gauge [0 to 2,452 kPa (0 to 25 kg/em?, 0 to 356 psi range] Set above gauges so that the driver can see them, PRELIMINARY INSPECTION 1) Confirm thet the engine tune-up has been completed, heck the idling speed and idling boost. W engine is out of adjustment, check also the stall speed. 2). Check that the linkage between the accelerator pedal and the carburetor is functioning properly. (Check the full opened and fully closed positions.) TROUBLESHOOTING 3} Ensure that the vacuum pipe is not disconnected. 4) See that no fluid is leaking from the ATF cooler circula tion pipe. Check that the kickdown switch functions at the normal 5) pedal position, 6) Check that the electrical circuits of the kickdown solenoid, transfer solenoid and inhibitor switch are functioning property. 7) Confirm that the manual linkage adjustment has been completed, 8). See that no fluid is leaking out of the transmission. 9) See that the ATF level and differential oil level are normal ‘After completing the above listed operations, perform checks fon the items listed in 4, according to the Troubleshooting chart. Chattering of transfer clutch © If considerable chattering is felt in the transfer clutch when making a turn in 4WD mode, replace two to three liters of transmission oil with the recommended ATF. ee eet | as Large shock when shifting GJ i Gx wi on or aetraton rn 0 wo \ ar wil not run sp, or acrleration is very poor nA. (Gar fans in "D", eo ke Car wi trun in any ange of ane ‘Sip i fle when starting n FWD O range, (Gar unein “1 range) 6s ns Sip fet when staring in 4WD mode, (Car runs in FWD mode) ° Cr a een nN 7 ik Low maximum speed, © poor accleration ne mah Cari braked iter etn "A" L mv No shift from tat 2nd [Ke mux mr TN sit tom 2nd to 3rd re be Shi points too high from 1-2 and 2.3, cs 1 Sui occur Wom 1103 ceems | me Lage ook when shitng 12 Ted 7m 28ATSG Technical Service Information Large noise when running in FWD rd gear Toa create | evek tem Sere momma lace stig oi mga erwin ohn nino oO |g gy ~ Eee a a PG enealaee Seem eee aie toe Eircom he sake whe rig How koma Large noise when running in 4WD 3rd gear. AUTOMATIC TRANSMISSION SERVICE GROUP 29INSPECTION ITEMS Inspection items with automatic transmission mounted on vehicle Oil pressure check Stall speed Control valve Governor valve Brake band adjustment Servo pipe Inspection of fluid by draining ‘Vacuum diaphragm Governor gear xSZErACTO Inspection item with automatic transmission detached from vehicle Transfer vaive, transfer pipe, rear drive shaft seal ring Technical Service ee Information Transfer clutch Drive pinion rear oil seal Torque converter one-way clutch Forward clutch Reverse clutch Planetary gear ‘Transfer gear Brake band and band support Low & reverse brake Oi pump Leak from hydraulic circuit Power train one-way clutch Parking linkage Hypoid gear Reduction gear Stator shaft and reduction drive gear oil seals and O-rings, and governor shaft oil seal AUTOMATIC TRANSMISSION SERVICE GROUP 30ATSG Technical Service Information Fluid PassagesAir breather hole Rear portion lubricating hole Forward clutch pressure Fig. 35 To torque converter Out pump outlet port Line presure inspection hole Forward clutch pressure it pum iniet Bort Revers clutch presure inspection hole Fig. 36 Technical Service Information Automatic Transmission Fluid (ATF) Cooling System This system consists of an oil cooler builtin the radiator, pipes ‘and hotes to circulate oll between the torque converter and oll cooler. Heated oil circulating through the torque converter returns to the oil cooler and is cooled by coolant, thereby being maintained at an adequate temperature, © Oil cooler Radiation capacity has been improved by 20% [1.221 to 1.454 KW/C (1,050 to 1,250 kcal/hn"C, 4,166 to 4,960 BTUM*C!]. This is caused by changing cooler type. (Double eylinder type to laminate type) AUTOMATIC TRANSMISSION SERVICE GROUP 32Technical Service Information ‘Automatic Transmission (continued) (6.3 ~ 6.8 US gt, 5.3 - 5.6 Imp qt} 2w0 awo Non-TURBO TURBO Non-TURBO ‘TURBO —) a ‘Automatic shift control over 3 forward speeds bared on intake-manifold fe eee vacuum and output shatt speed. 8 ‘Automatic wansmission fluid (ATF) g Lines DEXRON I $ 68-728 E | Fluic capacity G0 848 (7.2 -7.6 US qt, 6.0 ~ 6.3 Imp at) (including transfer section) Lubrication system Forced feed lubrieation with oll pump 32 38| on Automatic transmission fluid (above-mentioned) Bgl cooting system Liquid cooled cl cooler incorporated in radiator éF| | _tanater gear E 0.989 142748) @ | Transfer clutch e ‘Hydraulie multi-ise clutch | eontrot methoa 7 Hydraulic remote conte! : The sme Automatic warsminion uid a ae ~ used in Automatic transmission Tet reduction gear ratio 0.974 38/38) OO ,—Ur—“i‘—iees—S——r—r——C™—=C=s=Ssts i gear ratio Rear drive - 3.900 (39/10) 3.700 (37/10) © Governor gear ratio 7980 (72710) 3 Speedometer gear ratio 3.090 (34/11) 2.909 (32/11) 3.181 (35/11) 2.909 (32/11) E [Lubricating oit API GLS 2 Front drive 420(13 US qt, 1.1 imp ae) . Oil capacity Rear drive e 08 (08 US at 07 inp al Non-TURBO ; 45.822 KW (39.400 keal/h, 156,339 BTU/N) 3 | ciation capacity es TURBO 56.522 kW (48,600 kea/n, 192,845 BTU/n) ee ES AUTOMATIC TRANSMISSION SERVICE GROUP 33Technical Service Information Service Data SERVICE STANDARD VALUE Standard value Measuring location 1 Nonturso | TURBO Except SPF 8002100 rpm _ 7002100 om ck two turns after Idling speed (N or P position) jurning screw Brake band adjusting screw tightening it to the torque of 9 Nem (0.9 kgm, 6.5 felb) ‘Axial clearance between governor cover and governor body (0.2 ~ 0.8 mm (0.008 — 0.031 in) ] | Thickness 1.6 mm (0.063 in) Facing 4 (Forward eluteh) Number 3 (Reverse clutch) ‘Thiekness 2.0 mm (0.079 in} Steel plate 4 (Forward clutch) Forward/Reverse cluteh Number 3 (Reverse clutch) Thickness 1.8 mm (0.071 in) Dish plate Warping 1.2 mm (0.047 in) Forward clutch 1.0 — 1.2 mm (0.039 ~ 0.047 in} ‘Clutch clearance Reverse clutch 1.6 ~ 1.8 mm (0.063 - 0.071 in} 5 2.3 mm (0.091 in}... NSK Warner 6 «Thickness Facing* 2.4 mm (0.094 in)... DAIKIN RM Low and reverse brake | Number 5 dlutch Thickness 2.3 mm (0,091 in} Steel plate Number 5 Clutch clearance 0.7 = 1.0 mm (0.028 — 0.038 in) Thickness 2.9 mm (0.114 in} Facing T Number 3 I 4 ‘Transfer clutch 5 Thickness 1.8 mm (0.071 in) Steel plate Number 2 3 Clutch clearance (0.4 — 0.8 mm (0.016 — 0.031 in) Clearance between inner/outer gear and transmission cover 0.02 — 0.04 mm (0.0008 — 0.0016 in) E | clearance between cresent and tooth tip of outer (0.14 — 0.21 mm (0.0055 ~ 0.0083 in) & | _Radial clearance between outer gear and oll pump carrier (0.05 — 0.20 mm (0.0020 — 0.0078 in) Clearance between seal ring and groove 0.04 — 0.16 mm (0.0016 — 0.0063 in} Clearance between planetary carrier and planetary pinion washer 0.15 ~ 0.60 mm (0.0089 — 0.0236 in} * Always use the same manufacturer's parts as a set (5 pcs.). AUTOMATIC TRANSMISSION SERVICE GROUP 34Technical Service Information ‘Measuring location Standard value Clearance between manual plate and spacer O.1-O3mm (0.004 ~ 0.012 in) (Clearance between rear shaft and intermediate case (0.05 0.3mm (0.0020 — 0.0118 in) Total axial end play (0.25 —0.50 mm (0.0098 — 0.0197 in) End play Reverse clutch drum end play (0.50 —0.80 mm (0.0197 ~ 0.0316 in) Fun-out at the tip of reduction drive gear shaft (0.08 mm or less (0.0031 in or less) 1.23 —1.62Nm Starting frietion torque of drive pinion lesz eseeine asia) oo rom he ial edston eae fae to he nd fee fe rewueICN | 9.6 A9.8mm (0.772 ~0:780in) Fun-out of converter drive plate surface 0.5 mm or less (0.020 in or less) AUTOMATIC SHIFT CHARACTERISTICS Non- TURBO. owas (100, 398 267 ‘200, 787) ’ : i i i 400 (000, 13.810 533 (ado, 15.75) lemon ica) «0 7% 190130320 cy 0) (aor (30) (ao) (so) oO) Viele speed km/h (MPH) Fig. 7 AUTOMATIC TRANSMISSION SERVICE GROUP 35TURBO Technical Service Information 533 (400, 15, a 400 (200, 12.811 267 ‘200, 77 133 (09, 3.949 010.00 a1 Cr00, -3 94 267 (209, -7.87 Intake manifold pressure KPs (mma, nba 409 (300, 11.811 52.3 (400, -15.75) 50 10 19010 (2) (ao) 0) (oO) Venice speee km/h (MPH kalem, Governor prawure Fig. 38 LINE PRESSURE pressure characteristics ew. range 2nd noid range | rk Oe Minimum enor Vehicle weed Fig. 39 0 range | AUTOMATIC TRANSMISSION SERVICE GROUP 36Line pressure in each range Non-TURBO Line pressure under light load Technical Service Information Intake manifold pressure psid Range | Engine speed cpm Se eee Line pressure KPa (kg/em R 1.500250 164.0 (480, 18.90), 447 — 599 165 — 5.5, 64 — 78) N 1500850 66.7 (500, 18.69) 314412 (32 ~ 42, 46 - 60) Ds 1.50050 58.7 (440, 17.32) 314-412 (132-42, 46 — 60) 2 1.500250 64.0 (480, 18.90) 785 — 885 (6.0 9.0, 14 — 128) 1 1.50050 64.0 (480, 18.90) 314-412 132-42, 46 - 60) Line pressure under heavy load Intake manifold pressure Line pressure under light load Range Engine speed rpm es aeetctal Line pressure kPa (kg/em?, psi) R “Stall” rpm 6.7 (50, 1.97) 1,373 — 1,569 (14.0 — 16.0, 199 ~ 228) Dy “Stall” rpm 6.7 (80, 1.97) 883 — 1,079 (9.0 ~ 11.0, 128 - 156) 2 “Stall” rpm 6.7 (50, 1.97) 1,030 — 1,226 (10.5 ~ 12.5, 149 ~ 178) 1 “stall” pm 6.7 (50, 1.97) £883 - 1,079 (9.0 ~ 11.0, 128 ~ 156) TURBO Intake manifold pressure Range | Engine speed pm dapat latent Line pressure kPa (kg/em?, psi) R 11500250 64.0 (480, 18.90) 441 — 539 (4.5 ~ 5.5, 64 — 78) N 11500850 66.7 (500, 19.69) 314 ~ 412 (3.2 - 4.2, 46 — 60) Ds 1.500850 58.7 (440, 17.32) 314 ~ 412 (3.2 ~ 4.2, 46 ~ 60) 2 1.500280 64.0 (480, 18.90) 657 ~ 755 (6.7 ~ 7.7. 95 — 109) 1 1.500850 64.0 (480, 18.90) 314-412 (32-42, 46 - 60) Line pressure under heavy load Ttake manifold pressure Range | Engine speed rpm Geaareteny Line pressure kPa (xg/em?, pi) R “Stall” cpm 50.7 (380, 14.96) 1,814 ~ 2,010 (185 — 20.5, 263 ~ 292) Dd Stall” rpm 50.7 (380, 14.96) 1,324 ~ 1,520 (13.5 ~ 15.5, 192 ~ 220) 2 “Stall” ppm 50.7 (380, 14.96) 1,824 — 1,520 (13.5 ~ 18.5, 192-220) 1 “Stall” rom 50.7 (380, 14.96) 1,824 — 1,520 (13. — 155, 192 ~ 220) 1a. Line pressures in each of D, 2 and R ranges will change in steps at certain points (where pressure modifier valve functions) and these points are called “Cutdown point”, throttle, The line pressure during idling of the engine corresponds to the oil pressure before cutdown operation with the minimum AUTOMATIC TRANSMISSION SERVICE GROUP 37Technical Service Information LOCATION AND DIMENSION OF ADJUSTING PARTS GC ShSEG (Ay | Fig. 40 MA 444 444 4Technical Service Information BACKLASH Forward sun gear 0.18 —0.22 mm to Short pinion | (0.0059 — 0.0087 in) Reverse sun gear 0.15 — 0.22 mm to Long pinion | (0.0059 ~ 0.0087 in) Planetary gear ‘Short pinion to 0.15 —0.22mm Long pinion (0.0059 — 0.0087 in) ‘Long pinion to eaten Planetary output | 9.6671 — 0.0098 in) gear 0.05 = 0.12 mm 1st reduction gears a) 0.13 - 0.18 mm 2nd reduction gears feet acti 0.30 - 0.81 mm eoeanaionee (0.0118 — 0.0319 in) 0.30 — 0.81 mm emeneeaees (0.0118 — 0.0319 in) 0.051 — 0.125 mm Ve (0.0020 — 0.0049 in} L ATF COOLING SYSTEM Chip bene Camo Fig. 49 AUTOMATIC TRANSMISSION SERVICE GROUP 39ATSG] Technical Service Information COMPONENT PARTS TORQUE CONVERTER & HOUSING AND GAUGE & PIPING SYSTEM ATE oil gouge CP a 2 Oil gauge CP fi 2 Hose 4 Vacuum pipe CP 5 Vacuum nore 6 Bolt & washer ASSY 7. Oil supply pipe CP ‘Tightening torque N- 8 O-ving Th: 23-26 (2, 2: 45-53 (4, 73: 6-8 (06 -0.8,4.3-5.8) Ta: 142 — 17.2 (1.45 — 1.75, 105 ~ 12.7) B Stator shat gasket 8 Stator matt CP Fig, 41 40ATSG Technical Service Information FINAL REDUCTION CASE AND DIFFERENTIAL GEAR * Selective parts a, : ae @ Final reduction cate (it seat 122 x 40 x 10 mt Newale bearing (22 x 28 x 12 mm) Needle Dearing (45 x 55 x 20 mm) Converter housing gasket Bote Oi 491 holder tock plate 10 Oil crain gasket 11 Ollarain pug 13. Speedometer driven gear 20. Parking bal soring 21. Springretainer 22 al 23. Parking actuator support Fig. 42 Ball retaining plate Bor Bot ‘Oxygen sensor navnes clin Earth cord Governor cover Governor cover gasket Washer Governor boay Governor anatt Governor arven gear Spring pin Bok fort Governor snat seeve Governor Seal ring Tightening torque N+ 4-17 (1 . (0. 8-110, 23 — 26 (2. 87 ~67 (5. Oilseat LH ‘Axle drive sna lr beating 10 "2 13. Pinion & crown gear set (Non-4WO) 14 Olsen (RH) 1 Oving 16 Pinion & crown gear st (WD AT) AUTOMATIC TRANSMISSION SERVICE GROUP. aTechnical Service Information TRANSMISSION CASE AND CONTROL VALVE + Selective parts Tightening torque Nem (kgm, ft1b) Th: 23~26 (23-27, 17-20) 2: 8-10 (0.8 ~1.0,58 ~7.2) Ta: 6-8 (06~08,43-58) 1 Transmission cave CP Control valve ASSY 2 Gott 16x36 « 18 mm} 3. Stud bolt 18 x47 x 12 mm) 3. Bolt 16x 40 x 16 mm) 4 Stenight pin (8 18 mm) 20 Rut 4 Bolt (6 x25 x 16 mm) 5 Plug (18 i) 21 Manual pate 5 Gasket 6 Parking ever pin 22, Manual shaft spacer 1 Oil pan cP 27 Transmission cover gasket (€WO AT) 23. Washer (15.2 + 26 x 0.2 mm) 7 Oi grain gasket 8. Vacuum eiapnragm ASSY 24 Parking lever 8 Oi drain plug 8 Bolt & washer "9 Diaphragm roa 25. Oring GO mm) 10 O-ing (22 mm) 26. Oust se! 10 Onitice 11. Servoappty pice 11 Downshattrolenoid ASSY 27. Selector rm 12 Parking paw shatt 28 Washer 12 Servorelease pipe 12 Clip 29 Spring warner 14 Transmission eae sakes 14ND AT) 30 Bowt 31 Bott 18 ci 16 Parking paw! Fig. 43 AUTOMATIC TRANSMISSION SERVICE GROUP 42Technical Service Information SHAFT & REDUCTION GEAR “Selective parts Tightening tora n T2113 011 ume aeive anatt Turbine output erate ection drive gear unit Bal bearing Snap ring Reduction driven gear Drive pinion shim Drive pinion spacer Taper roller bering Lock washer Leek mut Bott Snap ring (IN-80) Oit set ving Oil seat holder Washer Spring washer Snap ring Speedmeter drive gear at Ci pump shaft bushing Soring in Fig. 44 AUTOMATIC TRANSMISSION SERVICE GROUP 434 ATSG Technical Service Information PLANETARY GEAR AND LOW & REVERSE BRAKE Selective parts, Tightening torque N-m (kg-m, ft-lb) Tr 21-23 (21-23, 15-17) Fig. 45 AUTOMATIC TRANSMISSION SERVICE GROUP 44ATSG Technical Service Information FORWARD CLUTCH & REVERSE CLUTCH sSerecive part Connecting sell Lock washer “Thrust bearing utch hub Forward clutch ASSY Snap ringTechnical Service Information BAND SERVO & OIL PUMP “Selective pars ‘© Aajusing rake bane Tighten adjusting crew toa torque o! 9 Nim (0.9 kam, 65400, than turn i back to Tighten tock nut to secure the aojustment. 1 Oi pump assy 2. Transmission cover CP 23. Intermediate cave *4 Oil pum inner ger 5 Ong "5 Oil pump outer gear 7 Bott 8 Needle bearing 9 Oi pume earner bushing 10 Seal ving 11 Searing 12 Band serve cio 13 Snap ring 14 Oving 15 Servopiston cover, 18 Seat ring 17. Serverpiston CP 38 Seat ving 18 Servo retuen toring 20 Brake band str 21 Brake band ASSY 22. Brake band agjutt srew 23 O-ing +26 Thrust masher s27 Thrust bearing 28 Oil pump drive shaft 2 28 Snap ring UInner! 30. Snap ring (Outer) 31 Serve piston roo 32 Ong 33. Accumulator piston 34 Accumulator soring 35. Accumulator supporter Fig. 47 AUTOMATIC TRANSMISSION SERVICE GROUP 46TSG Technical Service Information EXTENSION CASE +1 wasner Seal rng 2 2 alt bearing 5 Traneer riven gear UN Snap ring (IN 98.5), 17 Pressure pate (F) 8 Orwen plate 3 9 Drive pate 3 10 Pressure pate (R} 11 Teanstereluteh drum 32. Rear dive shalt, 13. Ball bearing 14 Extension ease CP 15. Needie bearing 16 Oilseat 17 Dust cover 18 Transfer cluten solenoid Gasket “Temperature switch ASSY Non-TURBO Teansler clutch valve ASSY tio Transter valve body 19 20 2 2 2 2% 2s 25 2 Fs 29. Transfer cluteh valve 30 Plate 31 Extention gorket 32 Plug 233 Intermediate cate CP 34 ousting 35. Swasght pia D6. Transfer dive shaft 37 Clemp 38. Snap ring {OUT 301, 39. Ball bearing 40 Thrust plate 441 Tranter drive gear 42 Burning 43 Clip 48 Weaner 45. Spring washer 46 Bolt 47 Bearing 46 washer Tightening torque Nem (kgm, ftb) Fig. 48 AUTOMATIC TRANSMISSION SERVICE GROUP a7Technical Service Information 2). Install the Gauge ASSY in a suitable location in the driver's compartment and pass the gauge hose to the engine compartment and attach the Adapter to the hose end, 5)" Warm up the engine by ing for Seeral mites nt the oll reaches Its operating temperature. While the ea is being eS driven tothe 2 range ana check ihe govern presure nee ee ‘Standard governor pressure 4 _Jme Forward clutch pressure Governor pressure KPa (kg/em?, psil [Vehicle speed km/h (MPH) | Non-TURBO ‘TURBO ‘Under | 010,0) 010, 0) 10(6) Fine 139,3829.4 163.8429.4 40125) | (1.42203, 20.2843) | (1.67203, 23.7249) 20 (60 346.2249.0 394.2249.0 (353405, 50.247.1) | (4,0220.5, 57.287.1) {For reference] Locations of other oil pressure check holes. Walt ly Bane art p> ZF : Torque Converter Leander apply disassemble it. Far? REMOVAL 1) Remove oil pan drain plug and drain the ATF. Check the volume and state (color, smell, etc.) of the ATF. 2) Take out the torque converter ASSY from conv housing taking care of the following, (1) Prepare the appropriate saucer under converter housing to receive the ATF which pours out from the torque converter ASSY, turbine shaft and/or oil pump drive shaft 1 Line pressure (2) When taking out torque converter, turbine shaft and 2. Revere clutch presure oil pump drive shaft may come out together. 3 Forward clutch presure In this case take them out straight and gradually not to Fig bend them AUTOMATIC TRANSMISSION SERVICE GROUP 48INSPECTION 1) Check the oneway clutch funtion of stator with the spline of stator shaft engaged into stator and replace if efective. Ik is normal that when turning stator shaft counterclockwise ‘one-way clutch is engaged, and when clockwise, the clutch is released. 2) Check for the exterior damage, oil leakage, bend and depression, and replace if detective 3) Completely take off the rust on the pilot and/or sleeve of 4) If the ATF is soiled or excessively deteriorated, wash the interior of torque converter as follows. (1) Take off the remained ATF in torque converter. (2) Pour 05% (05USat, 0.4 Impat) of gasoline (unleaded gasoline or kerosene) (3) Blow in the compressed air to wash the interior and then drain the gasoline. (4) Pour 0.58 (0.5 US at, 0.4 Imp atl of ATF. (5) Blow in the compressed air and drain the ATF. INSTALLATION Install torque converter straight onto shaft while turning it slowly. Extension Case (4WD) REMOVAL 1) Remove the rear engine mourt (rubber cushion) and place the transfer unit on a work bench with the oil pan facing down, 2} Remove the solenoid from the transfer unit by turning it by hand, 2, Be sure to remove the solenoid first. bi, Ensure that the harness is detached from the clamp before separating the transfer unit from the engine, Remove the O-ring together with the harness. Technical Service Information Fig. 75 3) Remove the temperature switch with a wrench. Ensure that the harness is detached from the clamp in advance. Temperature switch Fig, 76 4) Remove the extension ASSY. To do this, remove the eight 8mm bolts and extract the transfer section together with the extension ASSY. 1 Place a container to receive ATF remaining in the exten- son, b, Be careful not to drop the rear drive gear thrust plate and transfer drive gear ASSY. c. Remove the washer from the bear of the intermediate case, 4. Do not place the opening of the extension ASSY down, as this may cause the rear shaft ASSY to drop. bore on the upper side AUTOMATIC TRANSMISSION SERVICE GROUP 49Technical Service Information 61. Drive the ball bearing (9072 x 12) out, using REMOVER DISASSEMBLY {#997170001 1) Remove the washer from the upper surface of the inter: ‘mediate case atthe bearing bore location. 2) Remove the rear shatt ASSY from the extension case. \ Bea Remover Be careful not to damage the oil seal located at the rear of the = [14997170001 extension. 3) Remove the seal ring ‘ 4) Using REMOVERS (899864100) and (499717000), drive fut the ball bearing (20 x 52x 15), washer (20x38 x 4), = transfer driven gear UN, bearing and washer. Fig. 79 | Gea UN is] (Transfer dive) Remover (499717000), 7) Disassemble the transfer clutch ASSY. Pry off the snap ring (inner: 98.5) and remove the front pressure plate, drive plates, driven plates and rear pressure plate. Fig. 77 j po 5) Remove drum AY using REMOVER (499717000). Fig. 80 rom REMOVER When removing needle bearing from extension case, use PULLER ASSY (499707200). Fig, 78 AUTOMATIC TRANSMISSION SERVICE GROUP 50INSPECTION Wash the disassembled parts and check for the following 1) Bearings Replace any bearing if (1) The balls, outer race or inner race are damaged or rusted. (2), Various parts of the bearing are worn excessively. i). The bearing does not spin smoothly or is noisy even after being lubricated with gear oi (4) Other abnormalities are noticed. 2) Transfer gear Backlash: (0.051 ~ 0.125 mm (0.0020 — 0.0049 in) Replace the transfer gear if (1). The surface is chipped, worn or otherwise damaged. (2) The roller surface is worn of otherwise damaged. (3) The bore of the transfer driven gear UN or the end face is damaged. 3) Rear drive shaft Repair or replace if the sliding surtace of the transfer driven gear UN is excessively damaged 4) Plates UNG and 3 Replace if plates or surfaces are worn” or damaged ‘+ If the measured clutch clearance during disassembly exceeds 1.3 mm (0.051 in). ‘© Always replace plates UN3 together with the pressure plate and adjacent steol plates. 5) Extension oll seal (35 x 50 x 11) Replace the oil seal if the sealing lip is deformed, hardened, worn or otherwise damaged, 6) Rear drive shaft seal ring Replace if the seal ring is worn or otherwise damaged, Technical Service Information ASSEMBLY 1) Transfer clutch ASSY Apply a coat of recommended ATF to all parts and assemble all parts in the order of disassembly, (1) Assemble the bearing (30 x 72 x 19) and drum ASSY to the rear shaft (2) Install the rear pressure plate, plates 3, plates UNS. and front pressure plate. INSTALLER (899874100) INSTALLER, (398179700) Fig. 81 a. Use a suitable INSTALLER when driving the drum into place, Special tool: INSTALLER 899874100 Special tool: INSTALLER 49927000 Special tool: INSTALLER 398177700 Direct compressed air into the oil hole to ensure that the piston moves properly. care Fig. 82 AUTOMATIC TRANSMISSION SERVICE GROUP 51& Pay attention to the directions of the front and rear pressure plates. b, Always use recommended ATF to coat parts with oil. Front side ew side Fig. 83 (3) After parts have been assembled, meature the clear- lance between the outer snap ring (98.5) and front pressure plate and select a suitable pressure plate to ensure the Clearance is within specifications. Transfer clutch clearance: 0.4 — 0.8 mm (0.016 — 0.031 in) ‘Available front pressure plates Part No Plate thickness 1447677000 47 mm (0.185 in) 447677001 5.0 mm (0.197 in) ‘447677002 5.3 mm (0.209 in} 447677003 5.6 mm (0.220 in} 1447677004 5.9 mm (0.232 in) Fig. 84 Technical Service Information Direct compressed air through the oil hole to move the drum ‘two to three times. 2) Using the installer, install washer, bearing, transfer drive gear UN, washer (20 x 38 x 4) and ball bearing (20 x 62 x 15). Special tool: INSTALLER, 398177700 ‘SNAP RING PRESS 899754102 Special tool: Before installing, apply # coat of recommended ATF to the sliding surfaces of transfer drive gear UN and rear drive shaft. Paes (90754102) INSTALLER (998177700), Fig. 85 3) Install the seal ring onto the rear drive shaft 44) Install the rear shaft ASSY in the extension case. a. Be careful not to damage the bushing and oil seal near the ‘ear end of the rear drive shaft. b, After the rear shaft ASSY has been installed, do not place ‘the opening of the case down as this may cause the rear shaft ASSY to drop. 5). Select a suitable washer (42 x 51 x t) so that the clearance between the rear shaft ASSY and intermediate case is with specifications Standard clearance between rear shaft ASSY and intermediate case: (00.3 mm (0 ~ 0.012 in) AUTOMATIC Cee ey SERVICE GROUPATSG Technical Service Information ols described in item (1) above, (2) Using the sam (1) Meature dimension “m’” (shown in the figure) using measure dimension “M DEPTH GAUGE (498147001) and LOW & REVERSE BRAKE GAUGE (398643600). -—-ss Low & reverse brake gauge Fig. 86 (3) The thickness (t} of the washer (42 x51 x t) can be determined by the following equation: t= (M+ 0.2) (000.3) =m Select suitable washers (up to three pieces) from the table ‘on the right to obtain the specified thickness. Part No. Thickness 803242010 (0.2 men (0.008 in) 1803242011 0.8 mm (0.020 in} 6) Install the rear drive gear thrust plate and transfer drive ‘gear CP onto the intermediate case. When installing the thrust plate, be sure to align the notch in the plate withthe mounting bot. AUTOMATIC TRANSMISSION SERVICE GROUPINSTALLATION 1) Install the extension ASSY. Using the selected washer in the intermediate case, install the extension ASSY and tighten the eight 8mm bolts to the specified torque. Tightaning torque: 25 Nem (2.5 kgrm, 18 ftlb) a Tighten the clip (one place) for the transfer solenoid harness with one of the eight bolts. bi. Be sure to install the seal ring. 2) Install the transfer solencia. ‘Attach the O-ring to the bore in the extension case and install the transfer solenoid. ‘Always install the solenoid securely with your hand—not by any tool. 3) Install the temperature switch. Install the temperature switch with the gasket in place and tighten to the specified torque ‘Tightening torque: 18 Nem (1.8 kg-m, 13 feb) ‘Always use a new gasket. 4), Fasten the harnesses with clamps. 5} Install the rear engine mount rubber cushion and tighten ‘the two 8 mm bolts to the specified torque Tightening torque: 25 Nem (2.5 kg-m, 18 flb) Technical Service Information Transmission Case REMOVAL 1) Remove the extention ASSY, (4WO) 2) Drain AFT. (AFT should be drained when the transmis sion is dismounted from the vehicle.) 3) Carefully pull the turbine output shaft and oil pump drive shaft straight out, If they are hard to remove by hand, wrap their splines with 2 cloth of vinyl tape and extract them using pliers. Be careful not to damage the splines. When removing pin for oil pump drive shaft bushing, use REMOVER (OIL PUMP SHAFT) (498797000). 4) Disconnect the oil cooler pipe from the transmission case 5) Remove the lead wire clips. ‘To do this, remove the nuts which secure the transmission case to the final reduction case, and remove the downshift solenoid, ‘wansfer solenoid and temperature switch lead wire clips 6) Remove the vacuum pipe and ground lead wire. To do this, remove the bolts which retain the governor cover ‘and disconnect the vacuum pipe and ground lead wire. 7) Remove the oil supply pipe. Disconnect the oil supply pipe trom the transmission case Ensure that ATF is drain out before disconnecting the pipe ‘Be careful not to Lose the O-ring located at the end of the pipe. 8). Drain the differential gear oil completely. 9) Also drain ATF remaining in the transmission case and place the transmission on a bench with the housing down, as shown in the figure. Fig. 68 a. The automatic transmission and the differential sections are ‘not separated from each other under normal circumstances. AUTOMATIC TRANSMISSION SERVICE GROUP 54fb, However, if the two must be separated, follow the disassembly procedure of the final reduction case section to separate the two, and place the automatic transmission section on STAND (399933610). DISASSEMBLY Remove the converter oil pan. Remove the downshift solenoid and vacuum diaphragm v 2) 1. Also remove the diaphragm rod, 'b, Remove each O-ring at the same time. 3} Remove the servo apply pipe and servo release pipe. 4) Remove the control valve ASSY. 5) Remove the transfer valve To remove, separate the bending portion of the transfer pipe slip from the transfer pipe, disconnect the pipe and remove ‘the two bolts which secure the transfer clutch body. For disassembly, inspection and inspection of the transfer valve, refer to the instructions under the heading “On-Car Service” Fig. 89 ‘Always install new transfer pipe and its clip during each ASSY. 6) Remove the oil pump ASSY. (1) Tighten the adjusting screw until the reverse clutch is lightly held by the brake band, (2) Remove bolts which secure transmission cover (intermediate case) and, using a plastic hammer, lightly tap the Periphery of the case until the oil pump ASSY is removed. Technical Service Information Fig. 90 a. Be careful not to lose the thrust washer located at the end of the oil pump carrier. b. There are six needle thrust bearings, three thrust washers and three toothed thrust washers in the removal steps until 16). Be careful not to lose these parts during disassembly. 7) Move the transfer drive shaft upward and remove transfer coupling from the rear spline of the drive pinion. Then, extract, the transfer drive shatt as shown in the figure below. Fig. 91 8) Remove the band servo piston CP with PLIER (398663600) 9) Remove the strut band 10) Remove the brake band ASSY, reverse clutch ASSY and forward clutch ASSY. 11) Remove the connecting shell 12) Remove the center support ASSY by using two 6 mm bolts. 13) Remove the planetary input gear and planetary input gear 2. 14) Remove the planetary gear ASSY and low & reverse brake plates. 15) Remove retaining plate 2 AUTOMATIC TRANSMISSION SERVICE GROUP 55Technical Service Information 16) Remove the planetary ouput gear. Perform steps 17), 18) and 20) below, if needed. 17) Remove the selector arm. 18) Remove the manual plate and parking rod. 19) Remove the transmission case. (1) Wrap a vinyl tape around the rear splines of the drive pinion to prevent damage to the cil sel. (2) Remove the nuts securing the transmission case to the final & reduction case, and separate the transmission case Fin 88 Ear Vom dT Fig. 92 Fig. 94 20) Remove the parking paw, parking pawl shaft and parking shaft support plate. When installing the oil seal, use ORIVE PINION OIL SEAL INSTALLER (499247000). a. Pay attention to the direct b. Before installing the oil se INSPECTION perohery. ¢. Tilting of the oil seal should be kept to a minimum. 1) Transmission cate and transmission cover (intermediate case Too! Na Tool Name (1) Replace transmission case and/or transmission cover 7 Oil sea! puller (intermediate case) if cracks, damage, etc. are noticed. seecroo 2 (2) Repair ifthe mounting surtace is dented or gouged 499247000 Drive pinion oil seal installer () Check the drive pinion oil seal (21 x 33 x6.5) and oil seal breather for scratches at the passage location and, if necessary, replace. To remove the oil seal, always use OIL SEAL PULLER (398308700) and drive the ol seal out as shown in the figure. AUTOMATIC TRANSMISSION SERVICE GROUP. 56Re (Gantss) Technical Service Information ASSEMBLY | To assemble, reverse the order of disassembly. 11 Installation of parking paw and parking paw shaft Install parking rod support plate, parking paw! return soring and parking paw! to cate in that order and retain with clip after inserting parking paw! shaft trom the front side 2)- Installation of parking rod and parking lever Connect parking tod and parking lever and retain with clip —-—— After hanging parking rod on the notched portion of parking shaft support plate with its cam portion potitioned atthe back of parking pawi, install parking lever to parking lever pin and - retain with clip ee 3) Connect the transmission case and final reduction case. install ORIVE PINION OIL SEAL GUIDE (499257100) onto the splines of the drive pinion rear end and secure the tran mission care to the final reduction case withthe eight 8 mm INSTALLER (499247000) Tightening torque: 25 Nem (2.5 kg-m, 18 feb) a. Be careful not to damage the sealing ip of the oil seal b. Apply a thin coat of ATF to the guide in advance. Fig, 96 I | DRIVE PINION. Lon seat cuioe (499257100) 2) Low & reverse brake and brake band, If facing is excessively worn or otherwise damaged, replace the brake and/or brake band, 3). Gaskets, O-rings and seal rings. (1) Instat new gaskets during each ASSY. (2) If the O-ring and seal ring are folded, eracked or otherwise damaged, replace. Fig. 7 (3) Check for tightness of the two straight pins (8 x 18) driven into the transmission case used for alignment with the differential. If found loose, remove the two using a 4) Checking the operation of one-way clutch wooden or plastic hammer and install new ones. Make certain that the clutch turns clockwise only, as viewed ‘rom the front side with the planetary carrier ASSY assembled Before installing the straight pins, apply @ coat of Lock Tite 4 the center support. to their mating surfaces and drive them into the transmission 5) installation of the planetary gear ASSY case 9 mm (0.35 in). 8). Selection of retaining plate 2 ‘This is for determining the proper retaining plate 2 so that the clearance between piston 2 and driven plate is within specifi cations. Putting the component parts on BASE (499687100) as shown in the figure, select a proper retaining plate 2 so that "Hi within specifications. H = 82.35 — 82.55 mm (3.2421 ~ 3.2500 in} AUTOMATIC TRANSMISSION SERVICE GROUP 57Technical Service Information ‘When installing the center support, screw the 6 mm bolts in the center support, and then install it into the transmission case while turning the center support gradually. b. The center support is engaged with the transmission case by splines at one position. When installing the center support, be careful not to damage the one way clutch and bushing by the end of the center support. «. Install the snap ring (134 mm) with its open ends positioned sideward or upward. 4. If difficulty is encountered in installing the center support, loosen the bolt that fixes the transmission case to stand. 8} Measuring the clearance between piston 2 and driven plate ‘After assembly, measure the clearance between piston 2 and driven plate, The clearance should be within the specifications. Low & reverse brake clearance: 0.7 — 1.0 mm (0.028 — 0.039 in) 1 Driven pate 6 Retaining plate 2 2 Drive plate Scene 8} Checking the operation of low & reverse brake 3. Depth gwuge 8 Center support Apply air into the oil hole in low & reverse brake to see that 4 GAUGE (398643600) 9 Snao ring the piston moves properly 5 Soap ing 10 BASE (499687100) 10) Installation of connecting shell, lock washer, thrust beer ing, washer and clutch hub Install connecting shell and clutch hub as an ASSY to the spline of reverse sun gear and forward sun gear. Fig. 98 11} Installation of forward clutch ASSY and reverse clutch Assy Install forward clutch ASSY and reverse clutch ASSY in that order. Make certain that the thickness of thrust bearing which is Retaining plate 2 installed between forward clutch ASSY and clutch hub is Part No Thickness 4.0 mm (0.187 in 12} Installation of brake band '31667AA080 7.8 mm (0.307 in) Match the projected portions of the brake band with the notches in the transmission case to install the brake band. 316678090 8.0 mm (0.315 in} TeSTRATOO Seas Wan handing he brake band be cael not to open open 31667AA110 8.4 mm (0.331 in) Too much opening causes separation and damage of the facing Sieszeai2y 8.6 mm (0.339 in) 13) Measure the total end play in the axial direction, Deter- arena aa enaeeial mine the thickness of the washer (21 x 31.2 x t) to be used at the oil pump earrier end. The total end play should be within 31867AA140 8.0 mm (0.354 in) specifications 31667AA150 9.2 mm (0.362 in} Soaparae 3166748160 9.4 mm (0.370 in} oe eee 3166788170 9.6 mm (0.378 in) (1) Measure dimension “L", as shown, using DEPTH GAUGE (498147001) and LOW & REVERSE BRAKE 71. Installation of low & reverse brake parts GAUGE (398643600). Install snap ring, retaining plate 2, drive plate, driven plates, center support ASSY and snap ring into casein that order. When measuring dimension “L”, ensure that the thrust bearing Quantity of drive plates 5 (20 x 35 x 2.8) is not installed. Quantity of driven plates 2... 2... 5 AUTOMATIC TRANSMISSION SERVICE GROUP 58Brake band Tranamanon eae Forward clutch panic (11 pump carrier Toul end ploy Reverie clutch end pisy Fig, 99 cause (3986436001 Low & revere brake gue Fig. 100 (2) Using the same tools as those in (1) above, measure dimension “e”. Technical Service Information Special too! ‘GAUGE *3986¢3600) brake gauge Fig. 101 (3) Determine thickness T by the following equation and select the suitable thrust bearing (20 x 35 x t) from those listed in table. T= (L +04) - (0.25 100.50) -£ PartNo. Thiekness 806520030 | «3.8 mm (0.150in). 806520080 4.0 mm (0.187 in) 806520050 4.2 mm (0.165 in) 806520060 4.4 un (0.173 in} 1806520070 4.6 mm (0.181 in) 1206520080 4.8 mm (0.189 in) 806520090 5.0 rom (0.187 in) 14) Measure the end play of the reverse clutch drum. Select a suitable thrust front clutch washer so that the end play between the reverse clutch drum and oll pump carrier is within specifications AUTOMATIC TRANSMISSION SERVICE GROUP 59Technical Service Information jrse clutch end play: 0.5 — 0.8 mm (0.020 ~ 0.031 in} (1) Measure dimension “"M", as shown, using DEPTH GAUGE (498147001) and LOW & REVERSE BRAKE GAUGE (398643600), (2) Using the same tools as in (1) above, measure dimen: LOW & REVERSE BRAKE GAUGE (398643600), Fig. 102 (3) Thickness t of the thrust front clutch washer to be used can be determined by the following equation. t= (M+0.4) ~ (0.5 10.0.8) ~m Select @ suitable washer from those listed in the table below. Washer Part No, I Thickness '31828x0100 1.9 mm (0.075 in} 31528x0101 2.1 mm (0.083 in) 31528x0102 2.3 mm (0.091 in) 3128x0103 2.5 mm (0.098 in) 31528x0104 2.7 mm (0.106 in) 31528x0105 1.5 mm (0.059 in) 31528X0106 1.7 mm (0.067 in) 15) Installing the transfer drive shaft. Secure the transfer coupling to the transfer drive shaft with the spring pin and engage the shaft with the drive pinion at the splines. ‘Always use a new spring pin. | Teanster drive shatt Fig. 103 16) Assembling the oil pump ASSY. Assemble the thrust bearing (20 x 35 x 2.8) to the forward clutch. Apply vaseline to the washers which have been selected in steps 13) and 14) and affix them to the oil pump carrier Install the oil pump ASSY, being careful not to drop the washers. Before installing the oil pump ASSY, ensure that the mating surfaces of transmission cover (intermediate) and transmission case gaskets are clean from oil Tightening torque of case mounting bolts: 23 ~ 26 Nem (2.3 ~ 2.7 kam, 17 ~ 20 feb) 17) Assembling the band servo piston and servo piston cover, With the band servo piston assembled to the servo piston cover, insert the transmission case into place, using the piston rod as 2 guide, and attach the servo piston cover with the inner snap ring AUTOMATIC TRANSMISSION SERVICE GROUP 60Technical Service Information ¢ the O-ring located at the periph ‘ery of the servo piston cover. b. Be sure to install the servo return spring on the piston in advance, paying attention to its orientation, Fig. 105 21) Assemble the vacuum diaphragm ASSY. Fig, 104 (1) Attach the ROD DIAPHRAGM GAUGE SET to the transmission case and screw it in until it butts up against the throttle valve. (2) Read the scale of the ROD DIAPHRAGM GAUGE where it aligns with the end face of the holder, and select a suitable diaphragm rod from those listed in the following 18) Adjusting the brake band ASSY. table Install the brake band strut correctly. Tighten the brake band adjusting screw to 2 torque of 9 N:m (0.9 kg-m, 6.5 ftb) and backoff the screw two rotations. Then tighten the lock nut (10 x 8) to 26 + 2 Nem (2.7 £ 0.2 kg-m, 20 # 1.4 ft) Transmission cI Seale 3 Do not tighten both the adjusting screw and lock nut to more thn ther pected torque sting : i } 10) oasation of mao pee Aust the clewance between anual plate and space by liner ae shim (s} until it is within 0.3 mm (0.012 in), and install manual valve ‘Holder oad Tighten nut to the specified torque. Torque: ; 34 — 44 Nem (3.5 — 45 kgm, 25 — 33 ft) ae 20) Installation of control valve ASSY. Adjust the groove (D to the manval plate pin @. and install | Gauge ean to transmission case, tneestion ene Torque (Valve body attaching bol 1 __[ stesexros | 34001300) | pew 05 «1200 6 ~ 8 Nem (06 ~ 0.8 kgm, 4.3 ~5.8 felb) z Berween Fe 3065 ~ 31.05 cerwaen | siosaxros | 34sirase) | 20682108 31.18 — 3188 3 | siesoxtor | as ce) | Sus a 288 Beoween 3168 — 3205 resaxror | 35511 Sands | 992% (1998) | za6n — 126101 5 | srosexro0 | 36017417) [anow 9205 112618) AUTOMATIC TRANSMISSION SERVICE GROUP 61Technical Serv Install the vacuum disphragm together with the selected rod Do not forget to install the O-ring. 22) Assembling the downshitt solenoid ASSY. Install the downshift solenoid ASSY in the bore on the front side of the transmission case turning it by hand. Do not forget to install the O-ring. 23) Assembling the servo apply pipe and servo release pipe. Lightly drive the pipes into their proper positions. Ensure that ‘the pipes’ height (at points where the pipes are supported by the oil pan) does not exceed 41 mm (1.61 in) as measured from the mating surface of the converter oll pan Fig, 107 4. Be careful not to deform or bend the b. Install new pipes at each ASSY. 24) Installing the converter oi pan Before installing the oil pan, be sure to clean the oil from the mating surface of the oil pan and gasket. Install a new gasket at each ASSY. Tightening torque of converter oil pan: 3.4 = 4.4 Nem (0.35 — 0.45 kg-m, 25 — 3.3 fib) INSTALLATION 1) Install the oil supply pipe. 2). Install the vacuum pipe and ground lead wire and clip them. 3) Connect the oil cooler pipe. 4) Insta the turbine output shatt and oil pump drive shaft. 5) Pour ATF and differentia! gear oil. 66) Install the extension ASSY (4WO). ice Information The transmission section contains many small parts which a similar in configuration and are machined accurately. Before assembling and/or installing these parts, place them in neat ‘order so that they may be assembled properly to their proper positions. Be sure to check the operation of parts. Reverse Clutch 1 snap ring 6 Sap ring 2. Retaining plate 7. Spring retainer 3 rive ate 8 Coil spring 4 Deven pate 9 Cheek bal 5 Dish pate —_____ Fig, 108 DISASSEMBLY Pry off the snap ring (@ with a screwdriver, and comove the retaining plate @, drive plates @), driven plates @, and dish plate @). Using CLUTCH "SPRING COMPRESSOR (398673600) and PLIERS (399893600), pry off the snap fing © from the cot spring retainer ©) Remove the coil spring retainer @) and coil springs @). Apply 4ir into the el hole to remove the piston AUTOMATIC TRANSMISSION SERVICE GROUP 62+ PLIERS (299899600) 2 COMPRESSOR 1398673600) Fig. 109 Fig. 110 INSPECTION 1) Replace the clutch drive plate if the facing is worn or damaged, 2). Replace defective parts if snap ring is worn, return spring is fatiqued or broken or spring retainer is deformed ASSEMBLY To assemble, reverse the disassembling procedure, applying the ATF onto all the parts, 1). Install the driven plates to the clutch drum. Be sure to align the driven plate missing tooth portion with the oil hole in the clutch drum. Fig, 112 2) Check the clearance between the snap ring (and retaining plate @) to ensure that itis within the specifications. If itis not, change the retaining plate with a proper one Reverse clutch clearance: 1.60 — 1.80 mm (0.0630 — 0.0709 in) 1 Revers clutch drum 7 Snap ting 2 O«ing 8 Dun plate 2 Late cut sea ing 9 Driven pine 4 Reverse clteh paton 10 Drive plate 5 Retin or 11 Retaining lave & Spring retainer 32 Snap ring foo 2. Retaining plate Fig. 117 Fig. 113 AUTOMATIC TRANSMISSION SERVICE GROUP 63Technical Service Information in seven different sizes as Forward Clutch PartNo. Thickness 318672900 5.0 mm (0.197 inl 318672001 5.2 mm (0.206 in} 31867%2902 54 mm (0.213 in) 315672903 5.6 mm (0.220 in} 31967x2004 | 5.8mm (0228 in) '31567%2905 6.0 mm (0.236 in} 315672906 6.2 mm (0.244 in} 3}, Install the reverse clutch ASSY to the oll pump carrer. Aoply air into the oil hole to see that the reverse clutch moves properly as shown in the figure Forward clutch drum 6 Driven plate Piston Dish piate Snap ring Coil spring retainer Retaining plate Coit sorng Drive plate Fig, 195 Fi ti4 DISASSEMBLY 1) Using the same disassembling procedure as that for the reverse clutch, remove the snap ring @), retaining plate @, drive plates (), driven plates © and dish plate @). Remove the snap ring from the coil spring retainer ®) 1 PLIERS (29989600), 2. COMPRESSOR (298673600) Fig. 116 AUTOMATIC TRANSMISSION SERVICE GROUP 64Technical Service Information 7 Drive te piston out by applying air intn she oi hoe. 1), After assembly, check the clearance between the nap ring © and retaining piate @ to see that it is within the specifi: 1 Snap ing 2. Ressining plate Fig. 117 Fig. 119 Forward clutch clearance: 1.00 ~ 1.20 mm (0.0394 ~ 0,0472 in) 2] Install the forward and reverse clutch assemblies tthe oil pump carrier. Apply ir into the oll hole to see that the forward clutch moves propery. 1 Forward euteh drum 8. Sorin einer 2 Waser 9 Sop ing 3 Tout bearing 10. Oined pate 4% Oring 11 Driven plate Lathe cut sok ing 12. rive plate & Fomardeuteh paton 13 Retaining plate Fig. 120 Fig, 118 Center Support ‘center support CP INSPECTION ate a ig “Thrust sring ving Refer to the topic under the reverse clutch previously described, ing ASSEMBLY Low tsomronnsia ‘To assemble forward clutch, reverse the order of disassembly. Be sure to apply the ATF to all parts when assembling, Fig, 121 AUTOMATIC TRANSMISSION SERVICE GROUP 65Technical Service Information DISASSEMBLY INSPECTION 1) Replace tow & reverse return spring if it is fatigued. 2) Check seal ring and Orting for damage. If necessary, replace 3) Replace other parts which are worn or damaged. 1). Use the following tools to remove the snap ring from the center support. ASSEMBLY To assemble the center support ASSY, reverse the order of disassembly. Be sure to apply the ATF onto all parts when assembling 4 PLIERS (299893600) For center support ASSY, use the same tools as those used 2 COMPRESSOR (398673600) during disassembly, and be careful not to damage the seal ring 3. SEAT (499627000) during ASSY. Fig. 122 Oil Pump a oe ee ee DISASSEMBLY Remove the bolts and disassemble the oil pump carrier and transmission cover (intermediate case. Remove the inner and outer gears from the oil pump carrier. 1 Sea ving 7 Low & Reverse retuen spring 2 Oil pump carrier 2. Canter apport @ Snap ring 3 Outer geat 2 Piston 9 Driven plate 4 Inner ger 4 Lathe cus eal ring 10 Drive plate 5 Oil pump drive shaft It 5 O-ring 11 Retaining plate L_ Boe 6 Thrust sorng ring 12 Snap ring ar] Fig, 123 When disassembling the oil pump, note the positions of the side faces of inner gear and outer gear so that they may be installed with their side faces facing the same way. AUTOMATIC TRANSMISSION SERVICE GROUP 66ae ATSG Technical Service Information 2). Installation of needle bearing and bushing INSPECTION 1 Whe natn he mie eae oer beige INSTALLER and 1) Check the inner and outer gear tooth faces for damage or (898863600) as shown in the figure. wear. If necessary, replace. Replace the O-ring and seal rings if they are damaged means? go mstssase ° [ieee eee (2) When installing the bushing and remaining needle roller bearing, use INSTALLER (399543600), as shown 2) Check the bushing and two needle roller bearings (15 x in the Figure. 21x 12mm) located in the oil pump carrier. If they are damaged, replace. 3) Replace oil pump carrier and/or transmission cover if the contacting surface with inner gear or outer gear is damaged. 4) Replace oil pump shaft 2 if the shaft portion or contacting surface with inner gear is damaged, REMOVAL INSTALLATION 1) Removal of needle bearing and bushing Set up the oil pump carrier as shown in the figure, and drive Fig 728 ‘ut the bushing and two roller bearings at one time with NEEDLE BEARING REMOVER 2 (399903600) INSTALLER (999543600) "pump carrier yoo ry BONEEDLE BEARING Gomme) MEASUREMENT Neeate bearings To check clearances, use GAUGE (398643600) and THICKNESS GAUGE (499667000), 1) Gearance between inner/outer gear and transmission cover (intermediate case) Bushing ‘Standard clearance: 0.02 ~ 0.04 mm (0.0008 — 0.0016 in) Replace the gears as 2 set if the clearance exceeds 0.08 mm Fig, 126 (0.0031 in} AUTOMATIC TRANSMISSION SERVICE GROUPATSG Technical Service Information = If the clearance exceeds 0.25 mm (0.0098 in), replace the oer | sranexoroa | araeexoros | araesxor0e | gearsasa set. Owe | srae7xor00 | a1se7xo101 | srae7xo102 over tee | ig—sso9 | 1599-1596 | 1508-1597 res | 6299 — 0.6285) | 10.6295 — 0.6291) | 106291 — 06287) | Fig. 131 4) Clearance between seat ring and groove Fig. 123 Standard clearance: (0.04 — 0.16 mm (0.0016 — 0.0063 in) 2). Clearance between cresent and tooth tip of outer gear. ‘Standard clearance: Sealing qp-—Clearance (0.14 — 0.21 mm (0.0055 — 0.0083 in) Replace the gears at a set if the clearance exceeds 0.25 mm (0.0098 in}, Fig. 132 woe ASSEMBLY 1). Place the oil pump carrer as shown in the figure, set the 3). Radia clearance between outer gear and oil pump carrier. inner and outer gears properly, and insert the eil pump drive shaft I into the oil pump carir. 0.05 — 0.20 mm (0.0020 — 0.0079 in) AUTOMATIC TRANSMISSION SERVICE GROUP 68Fig. 133, the inner and outer gears, be sure that the faces of the gears face as before disassembly, 'b, Apply the ATF to the side faces of the gears. 2) Apply the ATF to the O-ring located on the periphery of the oil pump carrier When installing the transmission cover, be sure to align the bolt holes. Then, tighten the cover with the bolts. Torque: 68 Nem (0.6 — 0.8 kg-m, 4.3 — 5.8 ftlb) Fig. 134 When inserting the oil pump cartier into the cover, press gradually so as not to damage the O-ring. '. After installing the oi! pump to the transmission case, fit the oil pump drive shaft to the oil pump drive shaft II and then check that the oil pump gears can easily be rotated with hand, & When assembling the intermediate case and oil pump carrier, pay attention to the assembling direction of the O-ring. Technical Service Information Planetary Gear 1 Thrust bearing 8 Outer race 2 Needle bearing 2 B01 3. Spacer 30 Theust washer I (Rear) 4 11 Thrust washer (Front) 5 12 Planetary pinion pin 6 7 Long pinion Fig, 135 DISASSEMBLY Remove the bolts securing the oneway clutch outer race to the planetary carrier. Push the pinion pin out toward the one-way clutch side, and etach the short pinions, tong pinions, thrust washers, thrust washer Ils, needle roller bearings, spacers, and thrust bearing Remove the one-way clutch from the outer race. INSPECTION Check gear faces for damage. Check the needle bearings and thrust washers for damage. If necessary, replace. Check the one-way clutch. sprag for wear or damage. If necessary, replace, Check the bushing at the oneway clutch outer race for wear or damage. If necessary, replace. AUTOMATIC TRANSMISSION SERVICE GROUP. 69Check the planetary carrier-to-thrust washer clearance to see that i is within the specifications Standard clearance: (0.15 ~ 0.60 mm (0.0059 ~ 0.0236 in) I the clearance exceeds 0.70 mm (0.0276 in), replace. Af 1 carrier 2 Thrust warner 2 Fig. 136 ASSEMBLY 1) Install thrust bearing to planetary carrier 2) To assemble the planetary gear, reverse the order of disassembly. Pay particular attention to see that the installed parts face properly 3) When installing the one-way clutch on the outer race, push the T bar with finger to insert the one-way clutch until 2 snap is felt on the finger. Secure the one-way clutch retainer in the outer race. Torque: 14 — 16 Nem (1.4 — 1.6 kgm, 10 — 12 feb) Control Valve The control valve is composed of parts which are accurately machined to a high degree and should be handled carefully during disassembly and assembly. As these parts are similar in shape, they should be arranged in neat order on a table after disassembly $0 that they can be easily installed to their original positions. Spring:loaded parts should be also handled carefully, as springs may jump out of place when the parts are dis assembled oF removed, Extreme care should be taken s0 at ‘ot to drop valves on the floor. Before assembling, the parts and valves should be dipped in a container filled with the ATF. Technical Service Information Make sure that the valves are clean and free from any foreign material before assembly. Torque specifications should also be observed, If clutch seizure, brake band burning, or oil contamination is encountered, disassemble the control valve ASSY for inspection, When reassembling, flush all parts. DISASSEMBLY 1) Oil strainer Remove the bolts and nut securing the oil strainer, and detach the oil strainer. The aut is marked " QB” and the bolt is marked ( §) in the figure Fig, 137 Do not use a cross-head screwdriver. 2) Valve bodies and plate Remove the bolts, and separate the lower valve body, plate and upper valve body. 2 Spinner nance Fig. 138 AUTOMATIC ee SERVICE GROUPST TETSU 3) Manual valve fe plate, be careful not to lose the following parts located in the lower valve body: Orifice check valve, spring, throttie relief spring and steel bal Technical Service Information Fig, 139 4) 1-2 shift and 2.3 shift valves and pressure modifier valve, Do not use a cross-head screwdriver. Secone lock vaive, ‘Second lock spring Side plate (ineiading plug an spring seat) 5) Pressure regulating valve and second lock valve. Fig, 142 Solenoid downahite valve Throw back-up soring Solenoid downshift spring Throtle beckup valve Fig. 143 6) Solenoid downshaft valve, throttle back-up valve, 3-2 timing valve and vacuum throttle valve 3:2 Timing valve 3.2 Timing spring Side pate Fig, 140 1 Sie pate Siaeinees ®. Replace the control valve ASSY as a set if excessive defect is 423 mitt alos @—f Re found in the following parts. 5 23mm wring © Seized valves 6 Prewure moder wring OTP © Fatigued valve spring or check valve 2 2Saiane © Damaged oil strainer a © Leaky plate Valve body with damaged oil passages Fig, 141 © Valve body with damaged threads AUTOMATIC TRANSMISSION SERVICE GROUP 71Description of springs in valves Technical Service Information Specified length Fig. 148 va woeae | Nefeot | Stee | fxs | sted | Scat Pressure regulator } 1.2 (0.047) | 10.5 (0.413) 13.0 43.0 (1.693) | 23.5 (0.925) | 27.5 (2.8, 6.2) pews | Novtuneo |o# (ors) | soars | 50 | 185(0726)| 90 (0354) | 1.0101,0.2 modifier | TURBO (05 (0.020) | 8.0 (0.315) 55 | 17.7 (0.697) | 9.0 (0.354) | 2.0 (0.2, 0.4) 12 ait 0.7 028) | 6310268 | 125 _|32.0.1.260) | 160 (0.630) | 10.79 (1.10, 243), Tmrottie | Nom-TuRBO | 0.8 (0.031) | 6.510.256) | 14.0 | 36.0 (1.417) | 18.8 (0.740) | 18.85 (1.92, 4.23) backup | TURBO 1.0 (0.039) | 6.310.248) | 11.0 | 25.8 (1.016) | 18.8 (0.740) | 25.50 (2.60, 5.73) Second lock Jo.ss (0.022) | 5.0 (0.197) | 16.0 Yass 319} | 21.0 (0.827) | 5.88 (0.60, 1.32) relief ‘TURBO 1.0 (0.039) | 5.5 (0.217) 13.0 25.0 (0.984) | 19.0 (0.748) | 27.95 (2.85, 6.28) timing ‘TURBO oa (oosn | s5(0.217 | 170 | 38.8 (1.528) | 27.0 (1.069) | 17.06 (1.74, 2.84) AUTOMATIC TRANSMISSION SERVICE GROUP 72Manual vive Second lock spring "sleeve Spring seat sure 9 s90i9g Pretsre rapulting valve 3-2 Timing vive ‘Vacuum throm valve 3.2 Timing soring Throtle backup spring Solenoid downthitt valve ‘Throttle backup valve Solenaid downshift soring Presture modilier spring 2.3 Shitt plug Pressure modifier valve 2.3 Shite spring 2.3 Shift vale 17 Shite valve 13-2 Shite epeing tl Fig. 145 ASSEMBLY To atsemble the control valve ASSY, reverse the order of = disstembly. Observe the fllowing instrctions fees When assembling minor parts, such as valve springs, and valves, mone” ee refer to the general exploded view and detailed description of relief valve! ‘Orifice check valve valve springs, in figure before. Apply the ATF to all valves when installing. When tightening parts, be sure to observe the specified torques Do not force valves into place, but lightly push them into place with hand 1) Be sure to install the side plates: Torque (Side plate attaching serew eaiee 25-34N. 0.35 kg-m, 1.8 — 2.5 ft 2) Install the orifice check valves, spring, throttle relief spring and steel ball to the lower valve body. 3). Assemble the upper and lower valve bodies. Do not misplace the check valve and relief valve, Lightening bolts to combine the upper and lower them in position by two reamer bolts at B-marks AUTOMATIC TRANSMISSION SERVICE GROUP 73Technical Service Information Torque (Control valve bolt: 2.5 — 3.4 Nem (0.25 ~ 0.35 kgm, 1.8 — 2.5 ft-lb) Torque (Reamer bolt): 3.4 — 4.4 Nem (0.35 — 0.45 kg-m, 25 — 3.3 fb) Fig, 147 4) Install the oil strainer. Torque (Oil strainer bolt): 3=4 Nem (0.3 — 0.4 kgm, 2.2 ~ 2.9 ftb) After completing ASSY of control valve ASSY, wrap it in paper to prevent dust from accumulating on it. Final Reduction Case REMOVAL 1) Remove extension ASSY. (4WO) 2) Remove oil pan and control valve. (4WD) 3) Wrap vinyl tape around the spline portions of the drive pinion rear end in order not to damage the oil seal. (WD) 4) Separate the transmission case section from the final reduction cate section, 5) Place the final reduction ASSY with gasket on STAND (499937000). Then secure them with the two appropriste bolts and nurs. STAND (490937000) Fig. 148 6) Remove the 10 bolts combining the final reduction case and the converter housing. A small amount of oil will flow ‘out when separating the cases. Place a container to receive the oll 7) Remove the bolts securing the governor cover, and detach the governor body ASSY ax shown in the figure. 1 Governor body ASSY 2 Bole 3. Governor sleeve 4 Gasket 5 Governor cover Fig. 149 ‘When pulling out governor ASSY, turn it to the right slowly. 8) Parking actuator. 9) Remove the 3 bolts securing reduction gear oil seal holder. 10) Pry out the snap rings from the axle drive shafts in the differential case. 11) Remove the lock plates, and detach the axle shaft ol seal holders and the axle drive shafts ac an ASSY. Wrap vinyl tape over the shaft splines to avoid damaging the oil seal. 12) Move the differential ASSY to one side, and take it out of ‘the final reduction ease. AUTOMATIC TRANSMISSION SERVICE GROUP 74‘2. Do not confuse the right roller bearing (37x72x18.25 mm) with the left one. b. Remove oil level gauge before removing differential ASSY. 413) Drive pinion. (1) Pur SHAFT (398653600) into the reduction drive ‘gear, and engage it with STOPPER (398781600) to securely lock the reduction drive gear (2) Remove the drive pinion lock nut with SOCKET WRENCH (35 mm) (499987100), ‘The staking may be left as it is. 1 STOPPER (2987816001 2 SHAFT (298652600) 3 SOCKET WRENCH (4999871001 Fig, 150 (3) Remove final reduction case from Stand, and press out drive pinion. Pay attention to the reduction drive gear ‘end which protrudes from the mating surface (4) Press out the reduction driven gear and bearing cetainer as an ASSY from the transmission side by pressing the driven gear with an appropriate size of steel rod or Pipe. During this operation, pay attention to keep the reduction riven gear free from interfering with the case. 10) Speedometer driven gear. (1) Remove the snap ring from the end of the speed: lometer shaft, and detach the driven gear and steel ball (2) Remove the snap ring from the speedometer shaft 11) Reduction drive gear 12) Stator shaft INSPECTION Wash all parts and carefully inspect them as follows: 1) Cases Replace if cracked or damaged Repair if a mating surface is scored or seized Replace seized or cocked bushings. Technical Service Information 2) Gaskets, oil seals, O-rings Replace gaskets at every removal. Replace O-rings if the sealing lips are folded, torn of deformed. Replace oil seals if getting loose of spring, deformation of lip or any other abnormality are recognized 3) Bearings Check bearings for damaged roller face and abnormal wear. I necessary, replace bearings as an ASSY. Replace bearings which show abnormal color on the roller face. 4) Gears If damage or abnormality are recognized on the tooth surface of hypoid gear, differential gear, reduction gear and governor gear, replace them with new ones. Check the gears carefully, because worn tooth surface of abnormal tooth contact, which is difficult to find on external ‘appearance, will become a cause of gear noise. INSTALLATION 1) When final reduction components are disassembled, assemble ther properly. 2) Press thrust bearing retainer with front bearing cup preset in it and reduction driven gear into final reduction case by Using INSTALLER (499427000) and HANOLE (498477000). 4. Be sure to align the projection of retainer flange with the groove of case. 1, Press the retainer until the end surface of retainer flange reaches that of case. Contact this trace lately ANOLE (498477000) INSTALLER (499427000) “Thrust bearing retainer Fig, 151 3). Install the transmission case's front gasket and reduction ‘rive gear on the final reduction case, and snugly tighten the 8 mm bolts at three places. AUTOMATIC TRANSMISSION SERVICE GROUP 15Do not forget to install the “0” ring on the periphery of the holder. 4) Using REDUCTION BEARING —_ INSTALLER (499247200), press the holder into the bore in the final reduction case. Be careful not to damage the gasket. REDUCTION BEARING ] INSTALLER (499247200) Fig. 152 5). Secure the final reduction case to the Differential Stand with two bolts {tightening torque: 10 Nom (1.0 kg-m, 7 feb!) land tighten the three holder retaining bolts to the specified torque. Tightening torque of holder: 25 Nem (2.5 kgm, 18 ftb) Fig, 153 6) Install speedometer driven gear 7). Make certain that the run-out at the tip of reduction drive ‘gear shaft is within specifications by turning it with SHAFT (398653600) and HANDLE (899924100), Run-out (Reduction drive gear shaft): (0 ~ 0.08 mm (0 ~ 0.0031 in} Technical Service Information PULLER 1999573600) Fig. 154 Use PULLER (399523600) as an attachment. 8). Preload adjustment of drive pinion bearings (11 Install the front bearing cone, SPACER (399913604), ‘and rear bearing cone in this order onto MASTER 2 (499917400) in final reduction case as shown in the figure, Using SOCKET WRENCH (499987100) tighten HOLDER (399913603) with an open end wrench put inside the case to lock as shown in the figure. Reduction eer Taper roller spacen. Retainer bearing” (399913608) HOLOER (399913603) MASTER 2 (499917400) Fig, 155 1 HOLDER (299913603) 2 SOCKET WRENCH (299084103), 3 STAND (399833610) Fig, 156 AUTOMATIC TRANSMISSION SERVICE GROUP 76Technical Servic: (2) Attach PULLEY (498567000) on the hexagonal head of HOLDER, and tighten HOLDER $0 that the tension of the spring balance reads 29 to 39N (3 to 4kg, 7 to 9 1b) to give the specified preload. Fig, 157 & Don’t tighten HOLDER excessively. b. The torque to give the specified preload is approximately 10 to 12 Nem (1.0 to 1.2 kgm, 7 to 9 fb), . The starting friction torque of the drive pinion is 1.23 to 1.62 Nem (12.5 to 16.5 kg-em, 10.9 to 14.3 inh). (3) Measure the maximum clearance between SPACER and the rear bearing which is preloaded (that is, with the tool installed) by sliding SPACER in the axial direction to the extremes with the help of MAGNET BASE (498247001) attached DIAL GAUGE (498247100) as shown in the figure. e Information t= 10+h+ [2H x0.001] +0.07 nit: mm 1 : Thickness of shim plus spacer to be installed H. Number stamped on SPACER (399813604) hs Movement of SPACER (399913604) in axial direc tion (dial gauge reading) Drive pinion spacer Part No. t 3145648000 | __9.600 mm (0.3780 in) 31454AA010 | __9.625 mm (0.9789 in} 31454AA020 {9.650 mm (0.3799 in} 31454AA030 9.675 mm (0.3809 in} 314548040 9.700 mm (0.3819 in} 31454AA050 9.725 mm (0.3829 in} 314540060 9.750 mm (0.3839 in} ‘31454AA070 9.775 mm (0.3848 in} Drive pinion shim Part No. t '31451AA000 0.6 mm (0.024 in) 31451AA010 0.8 mm (0.031 in) '31451AA020 1.0 mam (0.039 in) 31451AA030 1.2mm (0.047 in} 31451Aaoeo | 1.4 mm (0.056 in) 1 SPACER (999913608) 2 HOLDER (999913603) 3 MASTER 2 (499917400), Fig. 158 (4) Select a combination of @ shim and a spacer from ‘those in the following table, ‘Thickness of shim plus spacer to be installed should be determined by the following formula. 1a If the shim and spacer which are installed are thinner than the thickness calculated by the formula, the preload will be seater than what is indicated by the spring balance, Uf the selected thickness is thicker than the calculated one, the preload will be smaller than the reading on the spring balance. b. DIAL GAUGE should be fixed firmly as shown in the previous figure. . The selected shim and spacer should be installed after adjusting the pinion height. 9). Adjustment of drive pinion height (1) Drive pinion height adjustment is made by shir) inserted between the front bearing cone and the back face of the pinion gear. With the devices for preload measurement installed and tightened at deteribed in “t", set MASTER (399913601) and GAUGE (398643600) fo measure the clearance N AUTOMATIC TRANSMISSION SERVICE GROUP 7between MASTER and GAUGE using THICKNESS GAUGE (499667000) as shown in the following figures. 1 GauGe (398643600! 2 MASTER (399913601) 3 THICKNESS GAUGE {498667000! Fig. 159 Technical Service Information TEN+ [£6 x0.001) + [2 x0.001) Unit: mm T Shim thickness IN: Measurement by thickness gauge G: Figure on GAUGE (398643600) L: Figure on MASTER 2 (499917400) (3) Select shim(s) from those in the table. ‘Shim 2 Part No. t 31453000 (0.10 mm (0.0059 in) 31453AA010 (0.175 mm (0.0069 in) 31453AA020 (0.200 mm (0.0079 in} 31453AA030 (0.225 mm (0.0089 in) 31453AA040 (0.250 mm (0.0098 in) '31453AA050 (0.275 mm (0.0108 in) 31453 A060 (0.300 mm (0.0118 ind 31453AA070 (0.500 mm (0.0197 in} HOLOEA (399913603) MASTER 2 (499917400) “Taper roller bearing Cae (Sitterentiat& reduction) eduction driven gear GAUGE (398643600) 6 MASTER (999913603) 7 Taper roller bearing 8 Reduction drive goer 9 SPACER (399913608) 10 Fig. 160 ‘& When inserting MASTER into the hole of the final reduc tion case be careful not to damage the hole surface. Damaged surface must be reconditioned with oil stone, etc. since it can result in oil leakage from the periphery of the axle shaft oil seal holder. b. Applying oil around MASTER makes its setting easier. (2) Thickness of adjusting shim(s) (1 to 3 pieces) to be installed can be obtained by the following formula, 10) Installation of drive pinion. (1) Install the shim(s) selected in the drive pinion height adjustment to the drive pinion, and press the front bearing cone (the same one as used in the preload adjustment previously described) into drive pinion using INSTALLER, (899580100) and INSTALLER (899874100). 1 INSTALLER (899580100) 2 INSTALLER (899874100) Fig. 161 INSTALLER. Do not press the bearing retainer wit (2) Install the drive pinion with the reduction driven gear in place and install the shim and spacer determined during the preload adjustment, and the rear bearing cone onto ‘the drive pinion. AUTOMATIC TBA SMIS SION SERVICE GROUP(3) Install the lock washer and lock nut Using SHAFT (398653600), STOPPER (398781600), and SOCKET WRENCH (499987100), tighten the nut to specification as shown in the figure and stake the lock nut. Torque (Lock nut): 198 Nem (12 kgm, 87 feb) 1 SOCKET WRENCH 1499987100) 2 SHAFT (398653600) 3. STOPPER (398781600) Fig. 162 11) Recheck of preload (1) Recheck the preload by attaching (498567000) to the lock nut as shown in the figure. PULLEY i" the reading of the spring balance is not within 29 to 39 N (3 to 4kg, 7 t0 9b) select another shim and spacer combination. Shim Shim + Specer PULLEY (998563600) Soring balance Fig, 163 (2) When rechecking the preload by using SOCKET WRENCH (499987100) and beam type torque wrench, observe whether the starting friction torque is within the following range. Technical Service Information Toru 1.23 = 1.62 Nem (12.5 ~ 16.5 kg-em, 10.9 ~ 14.3 intb) Before measuring preload, insert SHAFT (398653600) into the splined end of the reduction drive gear, and install HANDLE (899924100) to give the shaft 2 or 3 turns. ‘After rechecking the preload, stake the lock nut at two points. 12) Installation of differential ASSY. (1) Insert the differential ASSY without axle shaft into final reduction case Pay attention not to damage the axle shaft oil seal holder bores in final reduction case. (2) Install the Fight and left axle shafts and secure with the snap rings. Check the clearance between the differential pinion shaft and the axle drive shaft to see that it is within the specifications Specified clearance: 0 — 0.2 mm (0 — 0.008 in) Two snap rings are available for the adjustment of the ‘above clearance. ‘Snap ring Part No. Thickness 1805026010 | 1.00 — 1.10 mm (0.0394 — 0.0433 in} (031526000 | 1.15 ~ 1.25 mm (0.0853 — 0.0492 in} (3) Install axle shaft oll seal holder with WRENCH (399780111). a. Pay attention to the R and L marks of the oil seal. 'b, Remove the O-rings on the axle shaft oil seal holders. WRENCH (399780111) Fig. 164 AUTOMATIC TRANSMISSION SERVICE GROUP 79HANDLE (899924100) and SHAFT (4) Install (898653600) to the reduction drive gear, and turn the ‘gear several times, and screw in the holder on the crown ear side until it lightly bottoms. Repeat this operation several times to locate the proper position. (8) ‘Screw in the other holder until it bottoms. (6) Attach oil seal holder lock plate and back off holder fon the crown gear side approx. 1.5 notches, and tighten holder on the opposite side. (7) Temporarily tighten the lock plate on the crown gear side. (8) Screw in the holder opposite the crown gear by 0.6 to 1 notch, and tighten the lock plate temporarily. 13) Measurement of backlash between crown gear and drive pinion. Turn HANDLE (899924100) several times, and attach MAGNET BASE (498247001) with DIAL GAUGE {498247 100) to STAND. Check the hypoid gear backlash to see if it is within the specifications. Backlash between crown gear and drive pinion: 0.10 ~ 0.18 mm (0.0039 — 0,0071 in) 14) Crown gear tooth contact patterns. Apply a coat of Prussian biue over the three of four tooth faces of the erown gear, move the gear in forward and back- ward directions to obtain gear contact patterns. Refer to the figure for various gear contact patterns. Technical Service Information {f proper gear contact patterns are not obtained, readjust. If correct adjustment has been made, loosen the holder until the Crring groove is appeared, then fit the O-ring into the groove and tighten in the holder to the position where the holder has been tightened to. Place the lock plate on the holder and tighten it to the specified torque. Perform the same job with the opposite axle shaft oil seal holder, Torque (Lock plate: 22 = 27 Nem (2.2 ~ 28 kgm, 16 ~ 20 fttb) 15) Installation of governor ASSY. (1) Apaly a coat of vaseline to needle bearing for governor shaft and the sealing lip of oil seal. Install governor ASSY. When installing the governor valve, be careful not to damage the seal ring and oil seal lip inside of the final reduction case. (2) Install gasket and governor cover with the mating surface of governor cover clean. Tighten cover attaching bolts to the specified torqui Torque: 14 — 17 Nem (1.4 — 1.7 kgom, 10 — 12 fttb) ‘Before installing the cover, attach the washer to the governor cover with vaseline. ', Replace the gasket with new one at every disassembly. AUTOMATIC TRANSMISSION SERVICE GROUPPe ATSG Technical Service Information ‘Crown Gear Tooth Contact Pattern Checking item Contact pattern Corrective action Correct tooth contact, Tooth contact pattern slightly shifted toward toe under no-load (When loaded, contact pattern moves toward heel.) Face contact Backlash is too large > ‘This may cause noise and chipping at_| Increase thickness of drive pinion hight tooth ends. adjusting shim in order to bring drive pinion close to crown gear. Flank contact Backlash is too small ro EN This may cause noise and stepped wear | Reduce thickness of drive pinion hight con surfaces. adjusting shim in order to move drive pinion away from crown 9 Adjust as for flank contact. € Toe contact (inside end contact) 4 Contact area is small. This may cause chipping at toe ends. Heel contact Contact area is small Adjust as for face contact. (Qutside end contact) ‘This may cause chipping at heel ends x Fig, 165 As 16) Installation of stator shats, 17) Mating of final reduetion cate and converter housing. Install the stator shaft to the converter housing with the gasket (1) Clean the mating surface. in place and with the flange of the shatt facing upward. (2) Apply a coat of differential gear oil on the reduction drive gear shaft before mating the cases to facilitate the insertion of the reduction drive gear shaft into the stator Torque: 23 — 26 Nem (2.3 ~ 2.7 kgm, 17 ~ 20 feb) shaft oll sea. (3). Replace the gasket with new one. AUTOMATIC TRANSMISSION SERVICE GROUP 81Torqu 23 — 26 Nem (2.3 —2.7 kgm, 17 ~ 20 ft-lb) 18) Installation of parking actuator. Install the actuator with the spacer on final reduction case. Torque: B= 11.Nm (0. = 1.1 kgm, 5.8 ~ 8.0 felb) When separating the final reduction case from STAND, be ‘careful not to damage the gasket. 19) Set the final reduction case section with converter housing downward. 20) Clean the mating surfaces of the cases. 21) After putting GUIDE (499257100) on the spline portion Of drive pinion rear end, join the transmission case section to the final reduction case section. Also install transfer drive shaft. Torque: 23 ~ 26 Nem (2.3 — 2.7 kgm, 17 ~ 20 feb) & Be careful that the parking rod and parking actuator engages properly and the sealing lip is not damaged when assembling the cases. b. Engagement of the reduction drive gear and planetary output gear will be completed easly by giving a slow and staccato turn to the axle drive shaft. Apply a thin coat of ATF to GUIDE beforehand. 2) Install the following parts to the transmission case. (1) Control valve (2) Vacuum diaphragm ASSY (3) Down shift solenoid valve (4) Servo apply pipe and servo release pipe (8) Oil pan 23) Install the turbine shaft and oil pump drive shaft to the transmission, with the oil supply ports positioned as shown in the figure The turbine shaft and pump drive shaft must be installed from the front of the transmission, Install the torque converter ASSY onto the stator shaft, turbine shaft and pump drive shaft. Technical Service Information it pump drive shat Toll pune wooty por) € 0 A \ it supply port it supply port ee Fig. 166 ‘Take care not to damage the ol seal in the converter housing. 24) Install vacuum pipe, oil supply pipe, ground wire and oil cooler pipe. Reduction Drive Gear Sibi td coe | DISASSEMBLY 1). After removing snap ring outer, remove speedometer drive gear and ball. Speedometer drive gear Snap cing Oo Fig. 167 2) Using a flat-bladed screwdriver, detach snap ring, AUTOMATIC TRANSMISSION SERVICE GROUP 82TSG '3)_ Press the drive gear and ball bearing (from the holder) out, Using GUIDE (498847000). Fig, 168 4). Press the oll seal out 5) Pry the snap ring off the reduction drive gear, using the special tool and remove the bearing using GUIDE (498847000) and REMOVER (499717000) Remover (499717000) Technical Service Information Fig. 170 2) Using 2 press, drive the bearing holder (incl. the bearing) = By ction ae ee INSTALLER (499247200) Remover Fig. 171 3) Install the snap ring and, using INSTALLER (499247100), GUIDE (498847000) and SPACER (499267100), drive the oil seal into holder, Fig. 169 ASSEMBLY 1). Press the bearing into the holder and install the snap ring. INSTALLER (499247100) Fig. 172 AUTOMATIC TRANSMISSION SERVICE GROUP 834. When installing the snap ring, be careful not to damage the oil seal surface. b. Always install the two oil seals with their backs facing each other. Fig. 173 44) Install the ball into the shaft hole and set the gear. Then, install snap ring outer. Governor Valve Assembly Refer to "ON-CAR SERVICE”. Differential Assembly anual Transmission and Differential”. Refer to Chapter 3: Drive Pinion Rear Bearing Cup DISASSEMBLY AND ASSEMBLY ‘Attach INSTALLER (399513600) to the end face of the bearing cup from the inside of the cate, and press it out Installer is also used when installing the bearing cup. Technical Service Information When assembling, be sure to press the bearing cup until its end surface of flange contacts the final reduction case. Drive Pinion Front Bearing Cone DISASSEMBLY AND ASSEMBLY Using REPLACER (498517000), remove drive pinion front bearing cone as shown in the figure. 1 REPLACER (498517000) Fig. 175 When assembling, press it with INSTALLER (899580100) and INSTALLER (899874100), Don’t press the bearing retainer with INSTALLER. Drive Pinion Front Bearing Cup DISASSEMBLY AND ASSEMBLY Press out drive pinion front bearing cup with DRIFT (398437700), In assembling, press the cup with INSTALLER (499427000) Until its end surface contacts thrust bearing retainer. INSTALLER (3998136001 Outer race onier QB pees (ehroet bearing) Bearing cup Fig, 174 Fig. 176 AUTOMATIC TRANSMISSION SERVICE GROUPAxle Shaft Oil Seal Holder DISASSEMBLY AND ASSEMBLY ” Bearing cup (1) Remove bearing cup from holder with PULLER (899703600) as shown in the figure. PULLER (99703600) [Axle shat ol fal noiser Fig. 177 (2) Press bearing cup into holder with INSTALLER (499427000) until its end contacts the end of holder as shown in the figure. ‘Axle shats ol + Be sure to bring both . feat holder ‘ends of holder anc Fig. 178 2) Oil seat (1) Remove oil seal from holder with REPRESSER (498107000). (2) Press oil teal into holder with INSTALLER, (399790100). Note that the right and left oil seals are different. ‘After installation of the oil seal, apply a coat of differential gear oil to the sealing lip. 85 Technical Service Information Speedometer Shaft and Oil Seal DISASSEMBLY AND ASSEMBLY Remove the snap ring from the tip of the speedometer shaft, ‘and drive the speedometer shaft out of the case by lightly applying hammer blows to it. The oil seal will be removed ‘together with the shaft. Remove a washer remaining in the case To install, install the speedometer shaft with the washer ‘the case and drive the oil seal in by applying hammer blows on PRESS (499827000). ‘Pres the ol sel until he stepped portion of pres contacts with that Of final reduction ese. Pay mention not t0 | | cto a wt in nd not to Inline it. 1 it seat 2 PRESS (499827000) 23. Final reduetion ese Fig. 179 Needle Bearing at Reduction Drive Gear DISASSEMBLY AND ASSEMBLY 1) Remove bearing from the front side using REMOVER (499867000) and HANDLE (498477000) by press. ‘Make sure to remove governor shaft beforehand. 2) Press bearing into case using REMOVER (499867000) and GUIDE (498807000) as shown in the figure. Remover 1 Final eeduetion ease 2. Needle bearing a) Fig. 180Technical Service Information Oil Seal and Needle Bearing of Governor Shaft DISASSEMBLY AND ASSEMBLY = remove the governor sleeve. = 2) Remove needle bearing and oil seal with PULLER SET (490527000) as shown in the figure 3 Fe ection en 3 imsTALten (2997926001 4 PULLER SEY 199827000 Fig. 183 i 8 5) Install governor sleeve to case and tighten bolts to the specified torque. Torque: 4-5 Nem (0.4 — 0.5 kgm, 2.9 ~ 3.6 feb) 2 to install governor sleeve into case with its drain Fig. 181 Bushing and Oil Seal in Converter Housing ie INSTALLER (209790600) w own nthe figure, DISASSEMBLY AND ASSEMBLY re 1) Remove oil seal from converter housing with thin minus screwdriver or the Manufacturer's b Pay attention not to damage the contact surface of housing. 2) Remove bushing by using REPLACER (498107000) and HANDLE (498477000) as shown in the figure. ® 1 Nanda ering 2 INSTALLER (299793600) 4 PULLER SET (499527000) Fig. 182 1 Converter housing 2 HANOLE (498477000) 3 REPLACER (4981070001 4 Bushing 4) Install oll teal with PULLER SET (499527000) and INSTALLER (399793600) as shown in the figure. Fig, 184 AUTOMATIC TRANSMISSION SERVICE GROUP 86Technical Serv 3) as shown in the figure. Press bushing into housing with REPLACER upsidedown ice Information ‘a. When pressing oil seal, be careful not to incl '. Apply the ATF around the oil seal lip. 1 Converter housing 2 HANDLE (498477000) 3 REPLACER (498107000) 4 Bushing ATF Cooling System REMOVAL Remove drain plug, and drain torque converter oil Fig, 185 4) Press oil seal into housing by using DRIFT (398437700) as shown in the figure. i Manutecre's marge \ Converter housing DRIFT (398437700) or the equivalent with 88 t0.60 mm (2.28 0 2.36 in} ‘outer diameter, Prete 0-1.5mm (00.059 m) 2) Loosen hose clamp, and disconnect hose from pipe. 3) Remove clamping screw which holds hose to side frame {and remove holddown band, 4) Remove flare nut from pipe CP on transmission, loosen Clamp which holds pipe, and disconnect pipe. INSTALLATION Tighten drain plug. Tighten pipe CP to transmission using flare nut and clamp. Secure hose to side frame using clamp. 4). Tighten hose clamp. 5) Pour the specified amount of automatic transmission fluid into tank. » 2) 3) 3 Oitseai Fig, 186 AUTOMATIC TRANSMIS: ‘After completion of installing all parts, check oil level as well as leakage at connections, etc. while idling the SION SERVICE GROUP 87Technical Service Information INTRODUCTION SUBARU - 4 SPEED This booklet contains information on the operation of the four speed Subaru automatic transaxle. Although this transaxle comes in two wheel and four wheel drive applications the transfer case is not covered. The teardown and assembly, lock-up converter system along with service and adjustment are shown in this manual. We thank Subaru for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA HOTLINE TECHNICIAN HOTLINE TECHNICIAN ED KRUSE LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161SERVICE ADJUSTMENTS ... TESTING veseuee OPERATIONS .... TROUBLESHOOTING . DISASSEMBLY ... VALVE BODY .... ASSEMBLY CONVERTER ... COMPONENTS .. SPECIFICATIONS AUTOMATIC TRANSMISSION SERVICE GROUP4 ATSGI Technica | Service Information SERVICE PROCEDURE (i) General Precaution When disassembling or assembling the automatic transmission, observe the following instructions. 1) Workshop Provide a place that is clean and free from dust. Principally the conventional workshop is suitable except for a dusty place In @ workshop where grinding work, ete. which produces fine particles is done, make independent place divided by the viny! curtain or the equivalent, 2) Worktable The size of 1 x 1.5 m (40 x 60 in} is large enough to work, and it is more desirable that its surface be covered with flat plate late which is not rusted too much. 3) Cleaning of exterior (1) Clean the exterior surface of transmission with steam and/or kerosene prior to disassembly, however it should be noted that vinyl tape be placed on the airbreather or oil level gauge to prevent infiltration of the steam into the transmission and also the cleaning job be done away from the place of disassembly and assembly. (2) Partial cleaning will do, depending on the extent of disassembly (such as when disassembly is limited to some certain part) 4) Disassembly, assembly and cleaning (1) Disassemble and assemble the transmission while Ingpeeting the parts in accordance with the Trouble shooting. (2) During job, don’t use gloves. Don’t clean the parts with rags: Use chamois or nylon cloth, (3) Pay special attention to the air to be used for cleaning Get the moisture and the dust rid of the air as much as possible Be careful not to scratch or dent any part while checking for proper operation with an air gun. 1. ATF LEVEL 1) Raise the ATF temperature to 60 to 80°C (140 to 176°F}. (This tempersture may be attained by running a dis tance of 5 to 10 km (3 10 6 miles)) ‘The level of ATF varies with fluid temperature, Pay attention to the fluid temperature when checking oil level. A change in the ATF level by oil temperature is shown in the following figure. 2) Ensure the vehicle is level. After selecting all positions (P, R, N, D, 3, 21, set the selector lever in “Prange, Measure fluid level with the engine idling a (4) Complete the job from cleaning to completion of assembly as continuously and speedily as postible in order 10 avoid occurrence of secondary troubles caused by dust. When stopping the job unavoidably cover the parts with clean chamois or nylon cloth to keep them away from any dust (5) Use kerosene, white gasoline or the equivalent as washing fluid Use always new fluid for cleaning the automatic transmis sion parts and never reuse. The used fluid is usable in disassemble and assemble work of engine and manual (6) Although the cleaning should be done by dipping into the washing fluid or blowing of the pressurized washing fluid, the dipping is more desirable. (Do not rub with 3 brush.) Assemble the parts immediately after the cleaning without exposure to the air for a while, Besides in case of washing rubber parts, perform the job quickly not to dip them into the washing fluid for long time. (7) Apply the automatic transmission fluid (ATF) onto the parts immediately prior to assembly, and the specified tightening torque should be observed carefully. (8) Use vaseline if it is necessary to hold parts in the position when assembling, (9) Drain ATF and differential gear oil into a saucer so that the conditions of fluid and oil can be inspected. (20) Do not support axle drive shaft, stator shaft, input shaft or various pipes when moving transmission from one place to another (11) Always discard old oil seals and bushings, and install, (12) Do not reuse old pipes, gaskets, plugs (1/8°), spring pins, ete Install new ones. (13) Be sure 0 replace parts which are damaged, worn, scratched, discolored, ete. ‘After running, idle the engine for one or two minutes before measurement. 3). If the fluid level is below the center between high and [ow marks, add the recommended ATF until the fluid level is found within the specified range (above the center between high and low marks). When the transmission is hot, the le should be above the center of upper and lower marks, and ‘when it i cold, the level should be found below the center of these two marks. Use care not to exceed the upper limit level.ATSG Technical Service Information SECTIONS THAT CAN BE DETACHED/ASSEMBLED 7 if i | Section D .. YES Section € .. YES Section F VES AUTOMATIC TRANSMISSION SERVICE GROUP 54 aATsc Technical Service Information INSPECTION AND ADJUSTMENT On-Car Service = ATE level 1) ATF level varies with temperature as shown in figure Remember that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of tia 2). Fluid temperature rising speed ‘© By idling the engine Time for rising temperature to 60°C (140°F) with atmos: pheric temperature of 0°C (32°F): More than 25 minutes (Reference) Time for temperature rise to 30°C (86°F) with atmospheric temperature of O°C (32°F) “Approx. 8 minutes © By running the vehicle Time for temperature rise to 60°C 1140°F) with atmos pheric temperature of 0°C (32°F): More than 10 minutes 3) Method for checking fluid level upon delivery or at periodic inspection. Check fluid level after # warm-up run of approx. 10 minutes. During the warm-up period, the automatic transmission functions can also be checked Fig, 27 2, DIFFERENTIAL GEAR OIL LEVEL 1) Ensure the vehicle Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level. 2). Check whether the oil level it between the upper (F) and lower (L) marks. If it is Below the lower limit mark, add oil until the level reaches the upper mark. The difference in level between upper and lower marks corresponds to 0.20 (0.4 US pt, 0.4 Imp pt) Fig. 278 “Thread portion F>~ 031 supply opening (Tapered toc Fig. 279 3, OIL LEAKAGE CHECK POINTS It is difficult to accurately determine the precise position of a il leak, since the surrounding area also becomes wet with cil. The places where oil seals and gaskets are used are as follows ‘Jointing portion of the case> ‘© Transmission case and cil pump housing jointing portion © Converter case and oil pump housing jointing portion © Transmission case and transmission cover jointing portion wo} © Transmission case and extension eate jointing portion (wo) Converter housing © Engine crankshatt oil seal '# Torque converter impeller sleeve oil seal ‘* ATF cooler pipe connector © Torque converterConverter cate Arle shat oi 3 (ing on the ouside diameter of axie shaft oil ssl holder Oring on the eitterentiat ol gouge Differentiate drain plug Speedometer cable mounting portion Location of see! ball il pump housing © Oil pump housing (Defective casting) © Oring on the test plugs © Checking blind plugs (© Differentiat gear breather ‘Automatic transmission case ‘© Transmission case (Defective casting) Mating surface of oil pan O-ring on the test plugs ‘Checking bling plugs (stel balls) it supply pipe connector ATE cooler pipe connector and gasket Oil pan drain plug (O-ring on the transmission harness holder O-ring on the oil pump plugs ATF breather Shift lever oil teal Extension case, ‘© Extension case (Defective casting) © Oring on the revolution sensor © Rear drive shaft oil sea! © Checking blind piugs (stet ball) © Oxring on the test plug ‘Transmission cover ‘© Transmission cover (Defective casting) The point listed above should be checked for fluid leak. Checking method is as follows: ‘© Place the vehicle in the pit, and check whether the leaking oll is ATF or not. The ATF is wine red in color, and can be discriminated easily from engine oil and gear oil. ‘© Wipe clean the leaking oil and dust from a suspectable ares using a nonintlammable organic solvent such as carbon tetrachloride. ‘¢ Run the engine to raise the fluid temperature, and set the selector lever to "0" in order to increase the fluid pressure and quickly detect a leaking point. Technical Service Information 4, ENGINE IDLING SPEED Excessively low engine idling rpm will lead to rough engine operation and excessively high idling rpm will lead to a sudden shift shock or creeping when shifting from N to D or R. Idling rpm for automatic transmission cars (N or P range): 800100 rem 5. BRAKE BAND If the following abnormal shifting conditions are noted in a road test, the brake band must be adjusted. 1 Shift state and adjustment 1). The 2nd gear state and 4th gear state can be achieved but: ‘© the engine rpm increase excessively shifting up from 2nd to 3rd © a shift delay (over 1 sec) accompanies at kickdown from Bed t0 2nd, |f any of these problems occurs, it is attributable to excessive Clearance between the reverse clutch drum and brake band: Tighten the adjust screw by turning it clockwise. 2) The 2nd gear state and 4th gear state can be achieved, bat: © braking phenomenon is noted when shifting up from 2nd to 3rd. If this phenomenon is noted, itis attributable to excessively small brake band clearance: Loosen the adjust screw by turning it counterclockwise. 3) When accelerating, direct shift up from Ist to 3rd occurs Gabe : « Excessively large clearance. When shifting up from 2nd to 3rd, tie slip occurs: Excessively small clearance. Fig. 280 AUTOMATIC TRANSMISSION SERVICE GROUP= Adjustment of the adjusting screw 1) Using 2 socket wrench, immobilize the end of the 10 mm screw projecting on the left side of the transmission case, and foosen the nut with a double-end wrench. In the case of occurrence of problems 1) and 2) mentioned previously, perform the adjustment by loosening or tightening the nut within @ range of 3/8 turn from this state. Too! No. 398603610 SOCKET WRENCH Do not loosen excessively; otherwise, the band strut on the servo piston will drop off. Tool Name 2) In case of the occurrence of problem 3] mentioned pre viously, perform the adjustment as follows: Adjusting procedure: Tighten adjust screw to 9 Nem (0.9 kg-m, 65 fib) torque, then back off two turns. Do not tighten the adjusting screw with an excessively large torque. 3) With the adjusting screw immobilized, tighten the lock faut to 2642 N.m (2.70.2 kgm, 201.4 ft-lb) torque, 6. SHIFT SOLENOID OR VALVE BODY When shift solenoid 1, 2 or 3s faulty, duty solenoid A or B is faulty, the hydraulic control valve is sticking or malfunction ing (failure to shift, considerable shock in shifting, ete. in ac: cordance with trouble codes, inspect the shift solenoid valve or the control valve body as required (1) Removal of shift solenoid and valve body 1 CLEAN TRANSMISSION EXTERIOR ‘To help prevent contamination, clean the exterior of the trans 2 DRAIN TRANSMISSION FLUID Remove the drain plug and drain fluid into a suitable container. 3 REMOVE OIL PAN AND GASKET cauTiol ‘Some fluid will remain in the oil pan. Be careful not to damage the filler tube and O-ring. Remove all pan bolts, and carefully remove the pan assembly. Discard the gasket. 4 DISCONNECT FIVE CONNECTORS FROM SOLENOID Technical Service Information 5 WHEN REPLACING LOCK-UP SOLENOID (Duty SOLENOID 8) (1) Remove the three bolts. (2) Remove the solencia. Be careful not to damage the O-ring when installing the solenoid. 6 REMOVE OIL STRAINER Remove the five bolts, and the oil strainer. CAUTION: Be careful as some oil will come out with the oil strainer. 7 REMOVE VALVE BODY (1), Remove the eight long length bolts and eleven short length bolts. CAUTION: Be careful as some oil will come out with oil pressure cireuits. 8 WHEN REPLACING SHIFT SOLENOID 1, 2,3 and LINE PRESSURE SOLENOID (Duty solenoid A) (a) For the shitt solenoid 1, 2,3 (1) Remove the two bolts and one nut. (2) Remove the shift solenoid 1, 2, 3. (0) For the line pressure solenoid (Duty solenoid A) (1) Remove the one bolt and one nut. Disassembly, inspection and assembly of valve body. (2) Installation is in the reverse order of removal 7. PARKING LINKAGE When problems are in the parking linkage, remove the control valve body before inspection. Before checking the parking pawl, parking actuator support, return springs, et, remove the transmission from the car. 8. INHIBITOR SWITCH ‘The inhibitor switch allows the back-up lights to turn on when the select lever is in the range and the starter motor to start when the lever is in the N or P range. It also monitors the input signal electronically controlled for each range and turns fon the corresponding range lamp on the instrument panel |When lamp operation, driving condition or starter motor oper: ation is erroneous, first check the shift linkage for improper ‘operation. If the shift linkage is functioning properly, check the inhibitor switch, AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information 9, TRANSMISSION HARNESS Separate the cable end from the range select lever, ‘The transmission harness conveys both input and output sig- : nals among the control unit, five/six (4WD) solenoids (inside The N range is the 3rd position from the oil pump housing ihe ranamission) ‘and temperature sensor. When a problem is aed manifested in accordance with trouble codes, check the harness and/or solenoids, as required. (1) Using @ circuit tester, check continuity in the On- Remove the control valve as outlined in step 6 above, Check rectors {for N, P, R, 3 and 2 ranges) at the inhibitor the condition of each solenoid and temperature sensor. If 7 O.K., check continuity in the transmission harness circuit using a circutt tester. fer to the Continuity Check chart under the heading "MECHANISM AND FUNCTION’ (2) Check if there is continuity at equal points when the 10. TRANSFER SOLENOID AND TRANSFER select lever is turned 15° in both directions from the N VALVE BODY range. It unwanted “tight-corner braking” occurs when the steering If there is continuity in one direction and no continuity in wheel is turned fully at low speed, or the trouble code reveals the other or if there is continuity at unequal points, ad- a malfunctioning transfer solenoid, or If noise is heard from just the inhibitor switch. the solenoid, check the solenoid valve for improper operation, a follows: (1) Loosen the three inhibitor switch securing bolts. (2) Shift the select lever to the N range. 1, RAISE VEHICLE AND POSITION PAN TO CATCH (3) Insert STOPPER PIN (499267300) as vertical as | ATF THAT MAY DRIP possible into the holes in the inhibitor switch lever and switch body. 2. REMOVE PROPELLER SHAFT (4) Tighten the three inhibitor switch bolts. 3. JACK UP TRANSMISSION SLIGHTLY Tightaning torque: Securely support the transmission on a transmission jack 20-25Nm Lift the transmission slightly to remove weight from the rear (0.20- 0.26 kom, 1.4- 1.9 fb) support member. 4. REMOVE REVOLUTION SENSOR 5. REMOVE REAR MOUNTING BOLTS 6 REMOVE EXTENSION. (1) Remove the eleven bolts. (2) Disconnect the transfer solenoid connector. When extracting the extension, be careful of the connector fan duty sol. ¢ in it ‘STOPPER PIN: (499267300) 7. REMOVE EXTENSION GASKET aaa 8. CLEAN AND INSPECT COMPONENT (5) Repeat the above checks, If the inhibitor switch is 11- REVOLUTION SENSOR: determined to be “faulty,” replace it. ‘When a problem exists in the revolution sensor as indicated by the corresponding trouble code, check the revolution sensor for improper operation. AUTOMATIC TRANSMISSION SERVICE GROUP 9Performance Test 5 © NECESSARY TEST GAUGES 1) Tachometer (It is desirable to be able to read to 50 pm.) 2) Vacuum gauge (It is used for measuring intake manifold vacuum.) 3). Oil pressure gauge (0 to 2,452 kPa (0 10 25 kg/em?, 010 356 psi) range] ‘Set above gauges so that the driver can see them. 1. STALL TEST The stall testis of extreme importance in diagnosing the con: dition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in all shift ranges except the P and N ranges Purposes of the stall test 1) To check the operation of the automatic transmission clutch and brake band, 2) To check the operation of the torque converter. 3) To check engine performance. Test methods Prior to the stall tests, check to ensure the throttle valve opens fully, and that the levels of engine cil, cooling water and ATF are correct. Set the select lever in the P range and idle the engine at 1,200 rpm for several minutes until the ATF reaches approximately 60°C (140°F) 1) Install an engine tachometer at a location visible from the river's compartment and mark the stall speed range on the tachometer scale Technical Service Information ‘Stall speed (at sea level): Non-TURBO 2,450 — 2,850 rpm TURBO 2,750 — 3,150 rpm 2) Place the wheel chocks at the front and rear of all wheels and engage the parking brake 3) Move the manual linkage to ensure it operates properly, and shift the select lever to the D range. 4), While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle. 5} When the engine speed is stabilized, read that speed quick ly and release the accelerator pedal 6). Shift the select lever 10 Neutral, and cool down the engine by idling it for more than one minute, 7). Record the stall speed. 8) Perform the stall tests with the select le R ranges, in the 3, 2 and 2 Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow ths instruction causes ‘the engine oil and ATF to deteriorate and the clutch and brake band to be adversely affected. Be sure to cool down the engine for at least one minute after each stall tet with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. b. If the stall speed is higher than the specified range, attempt 10 finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. AUTOMATIC TRANSMISSION SERVICE GROUP 10Technical Service Information Interpretation of stall test results Stall speed (at s23 level). Assessment Cause Remarks Higher than 2,850 pm (Non-TURBO) 3,150 rpm (TURBO) Slippage of automatic transmis sion clutch, brake band, etc. (Further stall tests are not necessary.) © Low line pressure (If stall speed is higher than specified range at any shift posi ton). © Oneway clutch slippage. (if stall speed is higher than specified range only in the D range.) «© Slippage of Forward clutch LUf stall speed is higher than. specified range in D, 3, 2, 1ST Hold range, © "1: Slippage of low & reverse brake or reverse clutch. (If stall speed is higher ‘than specified range only in the range.) “1: Slippage of reverse clutch/ low & reverse brake can be judged by road tests If engine compression can bbe used as a brake with select lever in the 1 range, reverse clutch is slipping; if it cannot be used, low & reverse brake is slipping 2,450 — 2,850 rpm (Non-TURBO) 2,780 ~ 3,150 rpm (TURBO) | | | | | ‘© Control members are in good order in the D, 3, 2 and F ranges. ‘© Engine in good order. © One-way clutch can be ‘checked for condition by road tests."*| Lower than 2,450 rpm (Non-TURBO) 2,750 pm (TURBO) ‘© Throttle not fully opened. ‘* Erroneous engine operation fr torque converter one- way clutch slippage. ** Road test ‘© Acceleration is not properly made up to 50 km/h (31 MPH). © Car speed does not attain more than 80 krn/h (60MPH), © Operation is not proper at all car speeds, One-way clutch slippage. *3: One-way clutch jamming Erroneous engine operation. 3: Abnormal temperature rise occurs AUTOMATIC TRANSMISSION SERVICE GROUP2. TIME LAG TEST [If the shift lever is shifted while the engine is idling, there will be @ certain time elapse or lag before the shock can be felt This is used for checking the condition of the forward clutch, reverse clutch, low & reverse brake, forward oneway clutch and low one-way clutch CAUTION: (a) Perform the test at normal operation fluid temperature (50 to 80°C or 122 to 176°F). (b) Be sure to allow a one minute interval between tests. (c) Make three measurements and take the average value. Measure time lag 1) Fully apply the parking brake. 2). Start the engine. Check idling speed (A/C OFF) “°N" range: 800 rpm 3). Shift the shift lever from “N" to "OD" range. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt, Time lag: Less than 1.2 seconds 4) Insame manner, measure the time lag for ‘Time lag: Less than 1.5 seconds Ree Evaluation woe © Line pressure too low © Forward clutch worn © Low one.way clutch not operating properly 2) WENT sR © Line pressure too low (© Reverse clutch worn © Low & Rev. clutch worn time lag is longer than specified time lag is longer than specified: 3. LINE PRESSURE TEST If the clutch or the brake band shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked. © Excessive shocks during upshifting or shifting takes place at 4 higher point than under normal circumstances, may be due to the line pressure being too high © Slippage or inability to operate the car may, in most cases, bbe due to loss of oil pressure for the operation of the cluteh, brake band or control valve 1) Line pressure measurement (under no load) Before measuring line pressure, jack-up front wheels (front-wheel-drive model) or all wheels (4-wheel drive model). b. Maintain temperature of ATF at approximately 80°C (176°F) during measurement. {ATF will reach the above temperature after idling the engine for approximately 30 minutes with shift lever in “N” or “P") Technical Service Information 2) Line pressure measurement (under heavy load) 4 Before measuring line pressure, apply both foot and parking brakes with all wheels chocked (Same as for “stall” test condi ns). , Measure line pressure for 5 to 10 seconds, Before measuring it again, idle the engine for 2 to 5 minutes. , Before measuring line pressure, always shift the lever from “0” to "2", 4, Maintain the temperature of ATF at approximately 80°C (178°F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes, with the shift lever in “N” or “P”.) Measuring the line pressure 1) Temporarily attach the oll pressure gauge ASSY to a suit able place in the drivers compartment, remove the blind plug located in front of the toeboard and pass the hose of the Gauge ASSY to the engine compartment. 1 Pressure gauge hove 2. Hole in toe boss (blank cap hole) 3. Brake pedal Fig. 282 Teo! No, Tool Name 398573600 OIL PRESSURE GAUGE ASSY 498897100 | OIL PRESSURE GAUGE ADAPTER 2) Connect the oil pressure adapter and the tip end of the gauge ASSY. 3) Run the engine and check the line pressures with the engine at a minimum-throttle and full-throttle operations AUTOMATIC eee SERVICE GROUPChecking line pressure 1) Remove the line-pressure seal bolt and install the OIL. PRESSURE GAUGE ADAPTER (498897100) instead, 2). Start the engine and warm it up by driving the car for at least 10 to 15 minutes. 3) Stop the engine, Connect an oil pressure gauge to the ADAPTER, 4) Check line pressure in accordance with the following chart Technical Service Information Checking transfer clutch pressure 1) Remove the transfer clutch pressure seal bolt and install the OIL PRESSURE GAUGE ADAPTER (498897100) instead 2). Start the engine and allow it to warm up by driving the car for atleast 10 to 15 minutes. 3} Stop the engine, Connect an oil pressure gauge to the ADAPTER. 44). Check transfer clutch pressure in accordance with the following chart. < Standard line pressure > Gb mose PED Min. tine pressure | Max. line pressure Low pressure High pressure | High pressure side side fide Range {600 ~ 800 rpm Stall rpm i an = 800 rpm] Stall pm | Stall rpm > aes = ange \\|600~800.0m Stall Stall 1p a 73- R 60-70 15.2- 16.2 f 05-08 ome ° = 73-80 | N ars z o os-o8 | 73-80 ° ‘Accelerator 8 ~ 128 Fullyclosed | Fully-open | Fully-open ° 52-88 122-128 aay lyclosed \y-0per y-0p 3 52-58 122-128 2 52-58 122-128 If oil pressure is not produced or if it does not change in the AWD mode, the duty solenoid C or transfer valve assembly Accelerator |e iyclosed Oey may be malfunctioning. If oil pressure is produced in the FWD pedal mode, the problem is similar to that in the AWD mode, AUTOMATIC eae SERVICE GROUPTechnical Service Information 4. ROAD TEST ‘Speed change characteristics Road tests should be conducted to properly diagnose the con. The standard speed change characteristics are indicated in the ition of the automatic transmission, following table NON-TURBO (2WO} Throttle fully:open km/h (MPH) 192 2-3 ava | awa fase [ast | soizs | oa:zs | 144225 | 13026 | oa:25 | 40225 reel (arsi2) | (582) | (892) | teae2) | 1522) | (2582) D range manny 5625 | roses | 155225 | tasez5 | 9425 | 4525 (35:2) | 652) | (e622) | (oor) | (sata) | (aes) 3 see25 | 10825 = = oa25 | 45:25 range (522) | (6522) | (se:2)_ | (28e2) tsthold SW 5625 | 10425 | eas | 45125 oFF (52) | (6542) > 7 8:2) | (a8e2) 2 range tet hold SW 56225 | 108225 = 9225 | 50225 oN (35:2) | (6542) 7 (8:2) | (3122) Throttle fully-closed km/h (MPH) [432 278 as6 asa 3o2 | 21 T | 15:25 | s0e25 | ase25 | aozs | 15:25 | 10:25 ceeaes (922) (igs) | (zeta | (ase2) | (922) (622) O range - | rsiz5 | s0:25 | soxzs | 40225 | 20:25 | 10825 POWER (922) sea | ra | asia | trata (6#2) 3 15:25 | 30225 a a oes | 10828 range (922) (1942) (1282) (622) ‘st hold SW 1525 | rose2s an saizs | 10:25 OFF (982) (6522) (5822) (622) 2range tsthold SW 5625 | 1042s _ _ oaez5 | 50:28 oN (3512) | (6542) |_ te | ern AUTOMATIC TRANSMISSION SERVICE GROUP 14Technical Service Information TURBO (2WD & 4WO) | Throttle fully-open km/h (MPH) 1-2 243 a+4 473 372 21 7 saez5 | 99:25 | 162125 | 142425 | sat25 | 40225 NORMAL a3ez | te2e2) | (age) | eae | 5522) | (2582) D range - pean sazs | 11:25 | te5:25 | 156:25 | 100225 | 45225 | a2) | 682) | (1o3s2) | (e6=2) | (6242) (2822) . sezzs | 110825 10025 | 45225 ‘enge (722) | (e820 - = (e222) | (2822) tsthold SAW vei2s | 110225 _ roorzs | 10:25 OFF (ea | (essay 7 (6222) (622) 2range - 1 isthold SAW se:25 | 110225 _ _ 100225 | s0:25 | on (37:2) | (e822) (6222) (3122) | ‘Throttle fully-closed_ km/h (MPH) 192 243 a+4 4-3 | 352 241 vee25 | 30225 | a6sz5 | a7szs | 225 | 10:25 NORMAL (1022) (isa | (age | assay | (1282) (6:2) D range fonee reizs | sors | ssezs | aorzs | 225 | 0:25 cea) | (192) | Gata) | 2522) | (1282) (6:2) a ve:25 | 30:25 _ 2012.5 | 10826 = (1132) | (1982) iz (1282) (622) ‘sthold SW 125 | 110825 woo2s | 10:25 OFF (2) | (6822) 7 7 (6222) (#2) 2 range iahodsw | s9e25 | 110825 _ _ woo22s | s0125 ON (a722) | (e820 | ts2e2) | (ara) Shift characteristics 2). Kick down should activate properly. 3) When the select lever is shifted from the D range to the Pay careful attention to enture the shift is made smoothly at the proper car speed at which shifting begins 1). Shifting shocks are encountered or smooth shitting does not occur. 2). Shifting occurs slowly in response to the condition of the engine throttle. ‘The above two problems are due to incorrect throttle pressure OF other factors involved in throttle pressure Checking for shift patterns 1)_In the D range, shifting should be made as Dy ~ D3 > Dy ~ Dy smoothly and vice versa; it should not be made in the R range. 3 of 2 ange, shitting should be made as 3+ 2 1. Engine compression can be utilized as a brake at 2 and 1st hold range. 4). With the shift lever in the 2 range, shifting should be made a8 1+ 2-+3 smoothly. 5) When pushing 1st hold switch, shift 12013721 6) The select le range. In road tests, if any abnormality is noticed, it is necessary to adjust the brake band. If by inspection the brake band is in ‘ood order, check the servo piston for any sign of oil leakage from the seal. should be made as should be locked when placed in the P AUTOMATIC TRANSMISSION SERVICE GROUPATSG] Technical Service Information (1) Construction and operation ‘The gear train consists of two sets of planetary gears, four sets fof multi-plate clutches, one brake band, one set of multi-plate brake and two sets of one-way clutches. Broke band (Contacte at 2nd and 4th speeds.) > | |p Front planetary gear it pum Rear cte (pert whe mowing in rari} = rs ‘luton (Operates at Ord and 4th speeds.) Rese planetary gear | | [poets cu \ || | CEE \\ || \\1 \] [ rnin \ | [pi | bow & revere bake / ] / Rear rive shat T/C ast een J [Erasing sur © pesuction eer Inout shatt Front aitferentia Ame /|| L/| /| Sree pnin trent inna ge ff Rear sun gear | | © Reduction drive shat J Rea interna gene Lcrecwanie ot prerure (2) Nerange and P range Pres ‘Ail controls do not operate, just as in the N range, The parking pawl interlocked with the selector lever meshes with the parking gear to mechanically hold the output shaft stationary, thus locking the power train. 1) Neange Because both the forward clutch and reverse clutch are in the release positions, the power of the input shaft is not trans mitted to the drive pinion or the rear drive shaft (3) First speed of D or 3 range (D;, 31) ‘no power is transmitted and the engine does net provide braking action, During deceleration, the overrunning clutch is applied anc the one-way clutch (3-8) is prevented from idling: however, singe the onesway clutch (1-2) is released and is idling, reverse power is not transmitted and engine braking is not performed. ‘© When the throttle is open wide, as during acceleration in the low-speed range, the forward clutch, oneway clutch (3-4) and one-way clutch (1-2) operate to prevent the rear gear from turning in the reverse direction. ile coasting, the rear internal gear turas normally and the one-way clutch (3-4) is released and idles. Therefore, AUTOMATIC TRANSMISSION SERVICE GROUP 16(4) Second speed of D, 3, or 2 range (Dz, 32, 22) © During acceleration, the forward clutch is applied and connects the front planetary gear to the internal gear through the oneway clutch (3-4). Power is transmitted from the input shaft to the rear sun gear, turning the rear planetary carter (ie. front internal gear). ‘Also, since the band brake is applied and the front sun gear, is locked, the rear internal gear turns normally through the front planetary carrier and the forward clutch and one-way clutch (3-4) that are connected to that carrier. Thus, speed (5) Third speed of D or 3 range (Ds, 33) ‘© During acceleration, the high clutch is applied and the input shaft and front planetary carrier are connected. Further, the forward clutch and one-way clutch (3-4) operate t0 ‘connect the front planetary carrier to the rear internal gear Power is transmitted from the input shaft to the rear sun gear and rear internal gear. The rear sun gear and rear internal gear turn normally at the same speed. Therefore, the rear planetary carrer, rear sun gear and rear internal (6) D-range fourth speed (Dz) ‘During acceleration, the high clutch is applied and connects ‘the input shaft to the front planetary carrier. Also, the forward clutch is applied, but it runs idle due to the one: way clutch (3-4) and takes no part in power transmission. Power is transmitted from the input shaft to the front planetary carrier by the function of the high clutch. (7) 2-range first speed or 1st hold first speed (2,, 1st hold) © During acceleration, the forward clutch and overrunning clutch are applied and the front planetary carrier and rear internal gear are connected. Also, the low & reverse brake is applied s0 that the front planetary carrier and internal gear remain stationary. ‘The power flow is the same as in the first speed of “O”, "3 and "2" range (except for the following points) and (8) Rrange The reverse clutch is applied and power is transmitted from the input shaft through the reverse clutch to the front sun Technical Service Information increases in proportion to the rotation of the rear internal gear compared with the first speed. ‘© Since the rear internal gear turns normally while coasting, ‘the one-way clutch (3-4) is released and idles. Accordingly, reverse power is not transmitted to the engine and engine braking is not provided. ‘© During deceleration, the overrunning clutch operates to cheek idling of the one-way clutch (3-4). Reverse power is wansmitted to the engine, providing engine braking gear rotate normaly asa unit. ‘© While coasting, because the rear internal gear turns normally, the one-way clutch (3-4) idles ina released state. Thus, reverse power is not transmitted to the engine and engine braking action is not provided. © During deceleration, the overrunning clutch is applied and checks the reverse rotation of the one-way clutch (3-4. ‘Thus, reverse power is transmitted to the engine and engine braking is performed. When the front planetary earrier turns normally, because the front sun gear is held stationary by the brake band, the speed of the front internal gear increases and is delivered to the meshing reduction drive shaft in normal rotation '© While coasting, because power transmission does not go through the one-way clutch, reverse power is transmitted to the engine and engine braking is performed. ‘engine braking is performed. ‘Since the overrunning clutch is applied, the one-way clutch (3-4) is locked. + The low & reverse brake operates in place of the one- way clutch (1-2) and locks the rear internal gear. ‘© In coasting and deceleration, the idling of the oneway clutch (3-4) and oneway clutch (1-2) is checked, so that reverse power is transmitted to the engine and engine braking action is provided. gear. Also, the low & reverse brake operates to lock the front planetary cavrier, Therefore, when the front sun gear turns normally, the front internal gear slows and reverses. AUTOMATIC TRANSMISSION SERVICE GROUP uwTechnical Service Information < OPERATION OF EACH GEARSHIFT MEMBER > © @ [0 O = 5 vs OO Et lol lofo Oe Ololo iL ofo[o algae olofol [oF ‘log fol Jofofo te olololo = Ololo[o @B [ol fololo ay ofololo ofofolo . [of [ofolo ololo[o AUTOMATIC TRANSMISSION SERVICE GROUP 18ATSG Technical Service Information Sol 1 (shift) and sol. 2 (shift) If trouble occurs in either solenoid, the other one is turned OFF to attain the following gear setting to allow vehicle operation, Should trouble occur in both solenoids, the hydraulic circuit operates mechanically. shit potion * : | o fol | - jox|ae lox] - [ae] - ard x fo fae] = joxfae |x [= fae] - ¥ “o" ange | x | x [aa] - | x [aa] x | - 3d | - Bcd o fx lem [- | fae fox] - poo | = oe o feo | joxfae lex] = [ae] - ma “3 range x © | and | - JOux] aa x - | od - ord eu asia oon | ee |e x o Lo [m |= joxlaa fox] - fee] - 3 turoisowien Tx To Taw | = foxtae | x | [ae] — ee obo me |= jox|ae fox] poe] - rT eee x © | dnd | - |O-x]| 3d x - | od - od x bx fos [=| bee P| [oe [= a Duty tol. A (Line pressure) Hf duty solenoid A fails, the solenoid is turned OFF and line pressure is raised to maximum to enable vehicle operation Duty sol. 8 (Lock-up} It duty solenoid 6 fails, the solenoid is turned OFF and lock up is released. Sol, 3 (Overrunning clutch) I the overrunning clutch solenoid falls, the solenoid is turned OFF. The overrunning clutch will engage s0 that the engine ‘brake will be applied when reducing vehicle speed Duty sol. C (Transfer) When the duty solenoid C becomes inoperative, it urns OFF ‘This causes maximum oil pressure to be applied to the transfer clutch so that the power is always transmitted to rear axles (Direct-coupling 4WO) THROTTLE SENSOR The throttle sensor provides electrical signals corresponding to the throttle opening. It has the following characteristics. The throttle opening and accelerator depression speed are detected by this throttle sensor output. ovrout w os. “Throttle opening (Degree) Fig. 76 AUTOMATIC TRANSMISSION SERVICE GROUP 19PA ATSG| Technical Service Information TROUBLESHOOTING GENERAL NOTES 1). Problems in the electronic-controlied automatic transmis sion may be caused by failure of the engine, the electronic control system, the transmission proper, or by a combination fof these, These three causes must be distinguished clearly when troubleshooting, a Read the selfcdiagnostie code, (2) Preliminary inspection, (3) ‘Troubleshooting chart [4] [Gnecarservice] (5) [Performance test (6) Oftear service ka Troubleshooting for Electrical Transmission Control System 1) Self-diagnosis function is builted in this electronical con: trol system, Warning is noticed by lighting the POWER indi ator. (1) Ifa malfunction occurs in the speed sensor (No. 1 oF 2), solenoid (No. 1, 2 oF 3), duty solenoid (A, B or C), or ‘throttle sensor system, the POWER indicator will be lighted for 2 seconds, subsequently blink once every 0.25 seconds (per 0.5 seconds cycle) during 8 seconds with the ignition switeh turned to ON from OFF position. (See Fig. 1 ah] (2) If the system is operating normally (no malfunction), the POWER indicator will be turned on for 2 seconds period only with the same manner of ignition switch ‘operation. (See Fig. 1 (b).] 2) Troubleshooting should be conducted by rotating with simple, essy operations and proceeding to complicated, dif ficult operations, The most important thing in troubleshooting is to understand the customer's complaint, and distinguish between the three causes. 3) The general flow of troubleshooting is shown below: Read the trouble code on the "POWER" indicator, and perform operation according to the code. Check the following items: © Fluid tevel © Idling speed © Inhibitor switch © Shift linkoge © Tire inflation pressure © Fluid leakage, ete. See "Service Procedure”. Warning can be noticed only when the ly turned to ON. m1 025 (a) NG “ orr i 20 ky ofr 298-274 POWER indicator signal (unit: second)Technical Service Information 2) The diagnostic code can be read by the pattern of POWER Low battery voltage will cause faulty operation of the di indicator blink, according to specified operating procedure. agnosis system. Therefore, always be sure to check the battery 3) The diagnostic code (trouble code) is being memorized voltage first. in the CPU (of TCU) and is not canceled even though the ‘engine is turned off, dueing to back-up voltage. Consequently, after repair, itis necessary to turn the ignition switch off and ‘then remove the fuse or disconnect the control unit connector {for canceling the diagnostic code. /TPUT OF DIAGNOSTIC CODE START Warm up engine ‘Turn the ignition switch ON i wo) Power lah or Check POWER tghsun NOY. cru teury Fou tay ves ‘Turn the ignition switch OFF I ‘Shift into “D" range ‘Turn the 1-Hold switch ON t ‘Turn the ignition switch ON I Shift into “3 range ‘Tura the 1-Hold switch OFF i Shift into "2" range ‘Turn the 1-Hold switch ON f Depress the accelerator pedal halfway (Turn the Idle switch OFF) Thesystem | yes is operating ‘Check if POWER normal blinking (no malfunction) normaly. NO - a Trouble code ‘Once every 0.125 seconds blinking No lighting up I L L The system faulty Selfdiagnosis faulty | Range switch, Hold (Low battery voltage) witch o each circuit faulty HOW TO READ TROUBLE CODE AUTOMATIC TRANSMISSION SERVICE GROUP aiIn case of malfunction, trouble code will be observed by the specified signal of POWER indicator. The sequence of blinking shows each faulty system and the term of long segment (0.6 Technical Service Information sec) blink means its own faulty system code, (See Fig, 2.) Example: Shift solenoid No, 1 fault Shitt solenoid No. 3. Shite solenoid No. 2 Shift solenoid No. + Speed senor No.2 ‘Speed sensor No, 1 uty rolenold 8 Duty sotenoia ATE Temp. sensor | ' ' Dury solencia ore — WU Yas ba iui | Unit: ascend on f n oN oFF ore or oe os 04 een ! i fra 1 41 unit: sacons ‘Normal system Fig. 275 Faulty system AUTOMATIC ee obe Son SERVICE GROUP.Technical Service Information Blinking POWER Indicator (when the ignition switeh is turned to ON) Check diagnosis code Defective sensor i Speed sensor No.1 L-NS_-J Severed wire harness or short circuit | oK ——e Detective sensor ‘Speed sensor No. 2 NS Severed wire harness or short circuit T {o* no | Detective sensor Throttle sensor [S| Severed wire harness or short circuit oK ‘Severed solenoid or short circuit [__Shitsolencia No.1 NS. ‘Severed wire harness or short circuit oK na Severed solenoid or short circuit Shift solenoid No.2 |_“S J Severed wire harness or short circuit oK a Severed solenoid or short circuit Shift solenoid No. 3 ‘Severed wire harness or short circuit oK ‘Severed solenoid or short circuit NG Dury solenoid 8 [_NS__{ Severed wire harness or short circuit oK Severed solenoid or short circuit Ne Duty solenoid © 6 |_ Severed wire harness or short circuit oK Defective sensor ATE Temp sensor Aid ‘Severed wire harness or short circuit oK NG Severed wire harness Ignition pulse t oK Severed solenoid or short circuit Duty solenoid A ne Severed wire harness or short circuit | ox END AUTOMATIC TRANSMISSION SERVICE GROUP 23Technical Service Information Trouble Possible cause No shift @ Shife solenoid No. 1 and/or No. 2 ‘Severed or short circuit @ Speed sensor No. 1 and No. 2 ‘© Defective or severed @® Power source and grounding ‘Severed or short circuit ‘Shift point t00 high or too low @ Throttle sensor © Defective, severed or short circuit ® Speed sensor No. 1 © Defective or severed No up-shift to overdrive (after warm-up) @ Range switch © Severed or shor circuit @® ATF temp sensor © Detective or severed ® Cruise control unit © Operation unusual or short circuit No back-up {after warm-up) © Doty solenoid 8 © Severed or short circuit @ ATF temp sensor © Defective, severed or short circuit ® Ignition pulse © Severed wire harness @© idle switch © Severed or short circuit No engine braking effect at “ @ Shite solencid No. 3 © Severed or short circuit @ Theorte sensor # Detective severed oF short circuit @ Range switch Severed or short cuit Excessive shift shock @ Dury solenoid A Severed or short eitcuit ® Tarortle sensor Defective, severed or short circuit Exeessive tight corner braking © Dury solenoid c © Severed oF short cireuit ® Throttle sensor 1 Defective, severed or shor circuit @ Speed sensor No. 1 1 Detective, severed or short cireuit AUTOMATIC TRANSMISSION SERVICE GROUP« 8 3 7 g = @ aS = 5 no 3 oI z £ S 8 © Tne oeaTT vote 600 sion contrat unit (TCU! (a Fig. 276 AUTOMATIC TRANSMISSION SERVICE GROUP 25P4ATSG Technical Service Information {3} Troubleshooting Chart Reference No, —_—__—__— Probable cause ‘On-ear check Unit check ‘Symptom Starter runs in A, O or 2 range, but | 1,2,6,7,9 rot in P of N range. Transmission exterior parts: Inhibitor switch out of adjustment Noise is emitted in N or P range, 72, 65, 31 | 40 i Hoke ese emiead pan 72.358 3. Fauty convolunt et reves sioner oie eniandin Dy ng 73 e061 Sa iat alae onan Noise is emitted in Dy range, one (37, 60, 61 7. Faulty select lever 2. END formed ss etd na are 73 [Korean eer Zegna wal whe hfngtoany | 207 7 Engine stalls in P range and driving 42, 12. Faulty N-D accumulator ennoge a Fast 2h soammainor { ia roar acest Sec fon when nftog wom] 70,40 a8 ie ean see : | — 1. Comedaator 1 20. Faulty shift solenoid 1 Steck fee when mitingtomN | 79.14.70 | reser i Baas 22, Faulty shitt solenoid 3 Lengthy time lag when shifting from | 23 49,51 23. Valve sticking N to R range. 24, Faulty detent spring =] 25. Faulty manual plate Car does not move in any range 72,17, 23 64, 65,56,57, | 95, Faulty strainer seal though engine revs up. 33, 34, 36, 36, ened Parts inside extension case Engine stalls in all ranges. | | 62 26. Faulty transfer clutch a 27, Transfer valve sticking a 23 49,51 28. Transfer pilot vaive sticking though engine revs up. I 29, Faulty wansfer pipe Engine stalls in R range. | 42, 48 oe caulty cuty soleniond 31. Noisy duty solenoid C Car does not move in D or 3 range 53, 54 323, Faulty forward clutch relief ball though engine revs up. 32. Faulty overrunning clutch reliet Gar does not move in D, 3 or 2 range 41,32 a ‘though engine revs up. AUTOMATIC TRANSMISSION SERVICE GROUP 6 2TSG Technical Service Information Reference No. Symptom Probable cause Onear check | __Unit check sa = Parts inside differentia case Car does nat move in D, 3or2range | 23,3 54 oy bok cherie rive pinion broken —— _ 34. Grown gear broken Poor acceleration: 35. Axle shaft broken © High stall rom 72,23 41,51 36. Differential gear broken Low sal rpm 76, 66, 40, 37. Poor/improper contact of final Proper sal rom (Poor accelera: | 3,23 48,48 gear tion in D, 90° 2 range) 38, Faulty seal pipe ‘© Proper stall rpm (Poor acceler. | 23 46, 48, 44 38, Faulty speedometer gear tion in range) Ss Parts inside transmission No shifts er2 3.23 a 40. Oil pump seized or broken or 2253 3.23 45 foreign matter in pump 2364 3.23.16 ” 41. Forward clutch slippage + KD 3.10 42, Forward clutch sized - 43. Overrunning elutch slippage Spent 32.0 ~~ 44, Overrunning clutch seized range onl 23, 45, High clutch slippage g 5. 2or 1 range ee - 48, High clutch seized © t range only 3.23 4 ait sedaane dee Erroneous shift points 3,23, 10 a7 48, Band seized 48. Low & reverse brake spp [No lock-up operation 3.231610 | 68 50. Low & reverse brake seized 51, Reverse clutch slippage No power mode in D range 3.10 Ee ees reneey Power mode not released inO range | 3, 10 eo tence (t2) 7 54, Faulty OW.C. (34) Parking brake filure | 55. Faulty double oll seal # No braking 67 6 56. Input shaft broken {Dragging or feilure to release 67 6 57. Reduction drive shaft broken 58, Planetary gear broken Unusual select foree 59, Reduction gear broken © Considerable effort required 7,24, 28 60. Poor/improper contact of © No or light effort required 24,28 ata eae Fluid overow | 61. Poorfimproper contact of © ATF 7 reduction gear Differential oi 78 | ees Unusual changes in differential oi 36, 55 level Odor from oi supply Pipe 70 41, 43, 45,47 49,51 AUTOMATIC TRANSMISSION SERVICE GROUP arTechnical Service Information I Reference No, _ Probable cause Onearcheck” | Univcheck Absrmaiin during iting | | © Shock in 1= 2 shift [oe Other parts: | Fa76 sippegein 12am B23 1310 a7 TE © Shock In 2—~ 3 shift 3.23, 10,70, 47, 45 65. Improper installation of drive 15,76 | (8 plate © Slippage in 2~ 3 shift | 3.23,158,10 | 47.45 68, Toraue converter or OWC burned 3 Shock nd =a ai 323107, | 43 forays eo ee eee 67. horn parts in torque converter 88. Lockup facing worn Shocking =2 if | a.7310,70 | 43.47 - @ Shock in D + 3 shift 3.23, 10,70 | 43 70. Deterioration of ATF lence cement 3.23, 10, 70 eee 71. Deterioration of differential oil Shock is felt when accelerator pedal | 3,23,10,76 | 69.77 2 Ula to to aeeeeeeee | — | EE toed | | During WD operation j 7 2 Vioraton in ight corer | 70.10.81 | 29,26.27,28 | | | ee | Frome ires sp on sare, 290,311 | 29,26,27,28, | | a i * Faure ome ime2v0 neve | 3108 | 26,27, 28,29, | 30 Remember Preliminary Inspection 1) Confirm that the engine tuneup has been completed Check the idling speed and idling boost. I engine is out of adjustment, check also the stall speed, 2) Check that the linkage between the accelerator pedal and the throttle body is functioning properly. (Check the full fopened and fully-closed positions.) 3} See that no fluid is leaking from the ATF cooler circuls: tion pipe. 4) Check that the electrical circuits of inhibitor switch are functioning properly. 5) Confirm that the manual linkage adjustment has been completed. 68) See that no fluid is leaking out of the transmission, 7) See that the ATF level and differential oil level are nor mal AUTOMATIC TRANSMISSION SERVICE GROUP. 28ATSGI Technical Service Information Disassembly of Transmission 1. External Parts 1). Place the transmission unit on 2 workbench, with the oil pan facing down Be careful not to bend or damage external parts. 2) Remove the drain plug, and drain differential oil. Tighten the plug temporarily after draining Fig. 117 5) Remove the input shaft, Be careful not to scratch the bushing. Fig. 115 3) Remove the drain plug, and drain automatic transmission fluid (ATF), Tighten the plug temporarily after draining. PT) | bee Fig. 176 44) Extract the torque converter. Extract the torque converter horizontally. Be careful not to seratch the bushing inside the oil pump shaft. Fig. 119 29Technical Service Information 7). Disconnect the air breather hose, 10) Remove elips from the harnestes No. of hoses 4WD: 2 No. of harnesses 4WD: 3 2wo: 1 2w0: 2 (Transmission case) Fig. 120 Fig, 123 8) Remove the oil charger pipe, and remove the O-ring from the flange face. Artach the O-ring to the pipe. 2. Separation of Converter Case and Transmission Case Sections 4. Separate these cases while tapping lightly on the housing. b. Be careful not to damage the oil seal and bushing inside the | converter case by the oil pump cover, Tp Fig. 121 9} Remove the oil cooler inlet and outlet pipes. Fig. 124 Fig. 122 AUTOMATIC TRANSMISSION SERVICE GROUP 30Technical Service Information 3. Separation of Transmission Case and 2) Remove the reduction driven gear Extension Sections (4WD)/ 1)" Seagen ie sake prton, ne remove te lst Transmission Cover Sections (2WD) 1) Remove the revolution sensor. (4WD) Set the range selector lever to “P”. Fig. 125 Fig, 128 2), While pulling the extension slightly, disconnect the con: rector for the duty solenoid C (transfer) (2) Using the PULLER SET (899524100), extract the reduction driven gear. Drill two holes in the puller. Redvetion civen gear uty sl. € teranter) Fig. 126 ‘ : Sieg 9 Ua mt 3). Separate both sections. 4. Transmission Case Section Fig. 129 1) Remove the reduction drive gear ASSY. 3), Remove the parking pawl, return spring and shaft. Fig, 127 Fig. 130 AUTOMATIC TRANSMISSION SERVICE GROUP 314) Loosen the taper roller bearing mounting bolts MV Fig. 131 5) Remove the revolution sensor. (20D) ‘Keep the sensing element in the transmission case, 6) Place two wooden blocks on the workbench, and stand ‘the transmission case with its rear end facing down, areful not to scratch the rear mating surface of the ‘transmission case, b, Note that the parking rod and drive pinion protrude from the mating surface. ae i. _ F z bec ON Fig. 132 7) Remove the oil pan and gasket, Tap the corners of the oil pan when removing. Technical Service Information Fig. 133, 8) Remove the oil cooler outlet pipe, Be careful not to twist the pipe. Fig. 134 8} Disconnect the harness connectors for the solenoids and duty solenoids and the ground cord. Fig. 135 AUTOMATIC TRANSMISSION SERVICE GROUP 32Technical Service Information 12) Remove three accumulator springs. fer 413) Tighten the ceverse clutch drum lightly by turning the adjusting screw, Then remove the olf pump housing, Be careful not to lose the total end play adjusting thrust 11) Remove the control valve body. washer. aaa SSS fs Cas Z i) Z s af). SSeS Fig. 139 strut Fig. 137 AUTOMATIC TRANSMISSION SERVICE GROUP 33Technical Service Information 15) Remove the brake band and reverse clutch. 18) Take out the front sun gear. Contract the brake band with a clip. Fig, 145 Fig, 142 17) Take out the high clutch hub. 20) Take out the rear planetary carr | Ss A ronan | "7 _f fi ier and rear sun gear. Ss = vga 8 nf Gl haf SS AS) SSeS Fig. 146 AUTOMATIC TRANSMISSION SERVICE GROUP 34Technical Service Information 21) Take out the rear internal gear 24) Take out the forward clutch drum. Fig. 147 Fig. 150 25) Take out the low & reverse brake section. (1) Remove the snap ring, Then remove the retaining plate, drive plates, driven plates, and dish plates asa unit. 22) Take out the one-way clutch outer race. Fig. 151 (2) Turning the case upside down, take out the one-way Clutch inner race and spring retainer CP. Fig. 149, AUTOMATIC TRANSMISSION SERVICE GROUP 35Technical Service Information 1 the low & reverse piston by applying com: pressed air ecumaaror 1-5) qn ene a Fig. 153 28) Remove the range select lever 29} Remove the detent spring, 26) After removing the snap ring {inner}, take out the servo piston by applying compressed air from the release pressure side Hold the servo piston with a rag so that it will not be ejected with the air pressure. In this case, do not allow your finger to be pinched between the pipe and retainer. Fig. 156 30) Remove the parking rod together with the manual lever. Then remove the manual shaft by pulling off the straight pin. Be careful not to damage the lips of the press-fitted oil seal in the case 27) Apply compressed air from the operating pressure side, and take out accumulator (3-4), accumulator (1-2), accumu: lator (2:3), and accumulator (N-D) Fig. 157 AUTOMATIC TRANSMISSION SERVICE GROUP 3631) Remove the inhibitor switch T Fig. 158 32) Remove the transmission harness. Be careful not to damage the cord insulation. Technical Service Information 2) Remove te differential side retainer, Hold the differential case ASSY by hand to avoid damaging retainer mounting hole of the converter case and speedometer gears 3). Extract the axle shaft Do not reuse the circlip. “remover (499095500) ~~ 5. Converter Case Section 1). Wrap the axle-shatt serration with vinyl tape \Cinsracuen: (499247300) 4} Remove the differential case ASSY a, Remove the seal pipe if it is attached. (Reusing is not allowed.) b, Be careful not to damage the retainer mounting hole of the converter case and the speedometer gears. 5] Remove the snap ring. Then remove the speedometer driven gear. Fig, 162 AUTOMATIC TRANSMISSION SERVICE GROUP 37Technical Servic 6) Tap out the speedometer shaft to the outside of the case and remove the oil sea e Information Transfer pine Fig. 165 3) Remove duty solenoid C and the transfer valve body. a. Take out the infet filter. bb. Do not damage the O-ring, TT oooATSG] Technical Service Information 4) Using a press, remove the ball bearing [3] Disassembly, Inspection and Assembly of Each Component _~ Reduction dive shat 4. Reduction Drive Gear Assembly S “ten a DISASSEMBLY Oe 1) Take out the seal rings Be careful not to damage the seal rings. Fig. 170 Ue INSPECTION Make sure that each component is free of harmful gouges, cuts, oF dust. ASSEMBLY 1) Press-fit the ball bearing and reduction drive gear to the shaft Fig. 168 2). Take out the snap ring (out). Be careful not to damage the splines. H _-— Reduction drive gear 3) Using a press, remove the reduction drive gear all bearing edetion crive shaft Fig. 171 2} 4WO: Fit the snap ring securely in the snap ring groove | onthe shaft ZWD: Press-ft the ball bearing using a press, then fit the snap ring to the snap ring groove on the shaft, 3]. Attach two seal rings Fig. 169 To make subsequent assembly easier, apply vaseline to the 13g grooves of the shaft and to the exterior of the seal ring.2. Control Valve Body DISASSEMBLY 1) Remove the following parts from the upper valve body. (1) Solenoid ASSY (shift 1.2.3) (2) Duty solencid A tine pressure) Solenoid ASSY—_~ Solenoid2 (shit) Durty solenons A Solero tnt) Hine pressure) ge ees i (verrunning elute = Aa 3). Separate the upper valve body and lower valve body. ‘a, Do not lose the nine (9) stee! balls contained in the upper valve body. b. Do not lose an orifice and a strainer contained in the lower, valve body. ¢, Remove the upper-lower valve body tightening bolts. Then remove two reamer bolts. COMPONENTS ATTACHED TO CONTROL VALVE Technical Service Information 2) Remove the following parts from the lower valve body. (1) Duty solencia & floek-up) (2) ATF temperature sensor Duty solenoid @ (lock ue Fig. 173 During ordinary servicing, clean the control valve bodies in this condition, without further disassembly. In the event of a seized clutch or other problem, disassemble the control valve bodies further, and clean the component parts. 404aTSsG Technical Service Information CONTROL VALVE —c0-f Ma— tet om | TT “Pe f By 00> CD ame UD t= po Ie bail [em 2-0 0 oe — 8 Ut] o—o Lowen VALVE BODY Fig. 41 AUTOMATIC TRANSMISSION SERVICE GROUP aTSG Technical Service Information ASSEMBLY Reverse the disassembly sequence, paying attention to the following points: a. Be sure to properly position the steel balls, orifice and strainer. < Upper valve body > < Lower valve body > b. Tighten two reamer bolts. Then tighten the upper-lower valve body tightening bolts. Nem (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) 3. Oil Pump Assembly DISASSEMBLY I Fig. 175 11 Remove the oit seal retainer Aso remove the O-ring and oil seal (air breather) AUTOMATIC TRANSMISSION SERVICE GROUP 42ATSG Technical Servi 2) Remove the oil pump cover. Lightly tap the end of the stator shaft to remove the cover, Fig. 176 3) Remove the retainer and return spring. Then remove the rotor, two vane rings and nine vanes. ce Information 55) Remove two seal rings (R) and two seal rings (H). INSPECTION 1) Make sure that each component is free of harmful gouges, ‘cuts, and dust 2). Selection of oil pump components (rotor, vanes, control piston and cam ring) (1) Using @ micrometer, measure the height of the rotor, vanes, control piston and cam ring in at least four posi tions, (Measure the height at one place for each of the nine vanes.) a. Remove the control piston seals when b. Remove the friction ring from the cam ri ring. when measur- Fig, 17 4) Remove the cam ring and contro! piston. ‘Also remove the O-ring, friction ring, two side seals, and plain seal ( Fig. 179 (2) Using 2 depth gauge, measure the depth of the oil pump housing from the contact/sliding surface of the above-mentioned component parts in the same manner as above. Contral piston Fig. 178 Fig. 180 AUTOMATIC TRANSMISSION SERVICE GROUP 43Technical Service Information (2) Make sure that the clearances are within the specified 3) Install the return spring and retainer between the housing wear limits. If the wear limit is exceeded, select pump and cam ring, components so that the standard clearance can be Wear fimit | Standard value Rotor, control. 0.054 mm | 0.030 — 0.044 mm Seo piston, vanes (0.0021 in) | (0.0012 — 0.0017 in) ff 7 eens ! Sou eae 0.034mm | 0.010 - 0.024 mm ISK, 8 {0.0013 in} (0.0004 — 0.0009 in} Select vanes which are the same height as the rotor. Fig, 183 ASSEMBLY 1). Coat both the O-ring and friction ring with vaseline and attach to the cam ring. Then fit them into the oil pump oe 44) Install the control piston to the oil pump housing Fit the seal in the piston groove, with the ted seals facing the ‘top side. (Two side seals and one plain seal are attached.) Ms son na Ovring cam ving Fig. 181 2) Install the vane ring, rotor, vanes, and vane ring into the housing in this sequence. Fig. 184 5). Set the rotor at the center of the housing bore. Apply ATE abundantly to each rotary portion. 6) Install the ei! pump cover. Tightening torque: J 25 £2.Nem (2.5 + 0.2 kgm, 18.12 1.4 feb) Fig, 182 AUTOMATIC TRANSMISSION SERVICE GROUPATSG Technical Service Information 2). Using @ press, separate the rear roller bearing and outer race from the shatt. 1. Align both pivots with the pivot holes of the cover, and install the cover being careful not to apply undue force to the pivots. b. After assembling, turn the oil pump shaft to check for smooth rotation of the rotor. it pump cover Fig. 185 Install the oil seal retainer and seal rings (R) and (H) after adjusting the di mn backlash and tooth contact. Se Ul Front rile bearing 4. Drive Pinion Shaft EPLACER (498517000) DISASSEMBLY 1). Straighten the staked portion of the lock nut, and remove the lock nut while locking the cear spline portion of the shaft. ‘Then pull off the drive pinion collar. Remove the O-ring —~ A oo INSPECTION seat AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information ASSEMBLY s&s 1) Measure dimension “A” of the drive pinion shaft, 1 WRENCH 3 HO t499787100) | 1 HOLOER , (498937100) 5) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing, Fig, 197 Fig. 189 1 torque: 2). Using a press, force-fit the roller bearing in position. SS ace ene ae enact Do not change the relative positions of the outer race and bearing cone. Drive pinion sha Fig. 192 6) Stake the lock nut securely at two places 7)_Measure dimension "2" of the deive pinion shaft, 3) After fitting the Orring to the shaft, attach the drive inion collar to the shaft. Be careful not to damage the O: fing 4} Tighten the lock washer and lock nut Tightening torque: 113 £5 Nem (11.5 + 0.5 kgm, 832+ 3.6 felb) a, Pay attention to the 'b. When using “900 QL tation of lock washer. tighten it to 88 Nem (9 kgm, 65 fe). Fig. 193 AUTOMATIC TRANSMISSION SERVICE GROUP 46'B)_ Determine the thickness t (mm) of the drive pinion shim. 1=65+0.0125 ~ (6 - A) ‘The number of shims must be three or less. 5. Reverse Clutch DISASSEMBLY 1) Remove the snap ring, and take out the retaining plate drive plates, driven plates, and dish plate Technical Service Information 2) Using the COMPRESSOR (398673600), INSTALLER, (398177700) and PLIER (399893600), remove the snap ring and take out the spring retainer and springs. 3}. Take out the piston by applying compressed air. INSPECTION 1). Drive plate facing for wear and damage 2). Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation 3} Lip seal and lathe cut seal ring for damage '4)_ Piston check ball for operation ASSEMBLY Lip seat Revere clutch piston Lathe evt sat ring Soring Sering Spring retainer @ 8 Snap ring 9 Diamine 10. Driven plate 11 Drive pate 12 Reteining pate 33. Snap ring 18 High luten drum Fig. 194 11 Using the same special tools as those used in disassembling, assemble piston the return springs, spring retainer and snap ring, 2) Assemble the dish plate, driven plates, drive plates and Tetaining plate in that order and attach the snap ring Pay attention to the orientation of the dish plate. 3) Checking operation: ‘Apply compressed air intermittently to the oil hole, and check the reverse clutch for smooth operation. 4) Measuring clearance (Retaining plate selection). ‘Standard val 0.5 ~ 0.8 mm (0.020 — 0.031 in} Allowable limit: 1.2 mm (0.047 in) AUTOMATIC TRANSMISSION SERVICE GROUP6. High Clutch DISASSEMBLY 1) Remove the snap ring, and take out the retaining plate, drive plates, and driven plates. 2) Using the COMPRESSOR (398673600), INSTALLER (398177700), and PLIERS (399893600), remove the snap fing and take out the spring retainer CP. 3) Apply compressed air to the clutch drum to remove the piston, Technical Service Information INSPECTION 1). Drive plate facing for wear and damage 2). Snap ring for wear, return spring for setting and breakage, and spring retainer for deformation 3} Lathe eut rings (large) (small) for damage 4), Piston check ball for smooth operation ASSEMBLY High elutch drum High clutch piston Lathe et sat ring Spring retainer CP. ‘Snap ring Driven piste (Thinner) 8 Drive pate 8 Driven plate (Thicker 10 Retaining pice 11. Sasp ring 12 Thrust needle bearing 13 High cluten hub Fig. 195 1) Using the same special 1o0ls a those used in disassembling assemble the piston, spring retainer CP, and snap ring 2). Install the driven plate (thin), drive plates, driven plates, and retaining plate in that order. Then attach the snap ring. 3) Checking operation: Apply compressed air intermittently to the oil hole, and check ‘the high clutch for smooth operation, 4], Measuring clearance (Retaining plate selection) Standard value 1.8 — 2.2 mm (0.071 ~ 0.087 in) Allowable limit: 2.6 mm (0.102 in} AUTOMATIC TRANSMISSION SERVICE GROUP 48Technical Service Information 7. Forward Clutch Drum 4) Remove the retaining plate, drive plates, driven plates and dish plate, (Overrunning clutch) 5} Comoress the spring retainer, and remove the snap ring DISASSEMBLY from the forward clutch, by using SEAT (498627100), COMPRESSOR (290673600) nd SEAT (498627000) 6) Install the one-way clutch inner race to the forward clutch drum, and apply compresed air to remove the overrunning piston and forward piston 1). Remove two snap rings from the forward clutch drum: ‘Soap ring Oneway eluteh Fig. 196 Fig. 198 2) Remove the retaining plate. drive plates, driven plates and dish plates. (Forward clutch) Sinan eae eee ec ene 7) Remove the one-way clutch after taking out the snap ring. 8} Remove the needle bearing after taking out the snap ring, INSPECTION 1). Drive plate facing for wear and damage 2). Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation —} 3) ip seat ana tathe cut ring for damage Fig, 197 4) Piston and drum check ball for operation AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information ASSEMBLY Forward elute piston Lip seat Drift att Formarg elvtch um | ocean] | \ CR | vom fp [~se rine eure +t es ee | — = _ TEEN enc nin as Kane ctr ee ee mS ——s cowoen | = | oer l Fig. 199 1) Fit the forward piston and overrunning piston to the forward clutch drum ‘Align the forward piston cut-out portion with the spline of the rum, Forward elute ‘rum Overrunaing piston Fig. 200 riven plate 2). Set the springs and retainer on the piston with a press and attach the snap ring. ‘comenesson (398673600) seat, (498627000) AUTOMATIC TRANSMISSION SERVICE GROUP 50Technical Service Information the clearance is out of the specified range, select 2 proper '3) Install the ish plate, driven plates, drive plates, and retaining plate so that the standard clearance can be obtained. retaining plate, and secure with the snap ring, (Overrunning clutch) Pay attention to the orientation of the dish plate Fig. 204 Fig. 202 4) Install the dish plates, driven plates, drive plates, and retaining plate, and secure with the snap ring. (Forward clutch) Pay attention to the orientation of the dish plate, Fig. 205 9) Install the one-way clutch (1-2) and plate, and secure with ‘the snap ring Set the inner race. Make sure that the forward clutch is free in egies the clockwise direction and locked in the counterclockwise i direction, as viewed from the front of the vehicle, '5)_Install the snap ring (for front planetary carrier) 8) Check the forward clutch and overrunning clutch for = operation. | oy soa ng Set the one-way clutch inner race, nd apply compressed air | \ Oneway clutch for checking. 7) Checking clearance Z ] Sinaia ive [owas im \ | vm in ea cn | 048 = 08 bs wringer | ggg gone) | 20,007) ra? Fant AUTOMATIC TRANSMISSION SERVICE GROUP 51Technical Service Information 8. One-Way Clutch Outer Race INSPECTION DISASSEMBLY 1) check each component for harmful ets, damage, rote faults 2) Check the O-ring and lathe cut ring for damage. Remove the snap ring, Then remove the one-way clutch (3-4). INSPECTION Check the sliding surface and one-way clutch (3-8) for any harmful cuts, damage, or other faults. ASSEMBLY ASSEMBLY Assemble the one-way clutch (34), and secure with the snap fing Pay attention to the orientation of the one-way clutch (3-4). pete Sering Lathe cut seal ring Band sev piston (1-2) Late cut sal ring Confirm: Assemble the rear internal gear, and secure the outer race. Make sure that the internal gear is locked in the clockwise direction, and free to rotate in the counterclockwise direction. | aioe | Ocing Sorina new cach ae outer race eae (occ Ue ct sa ig Band seve pon (-4) Orang 0.3, eve etn Soa rng Pea interna ear Fig, 208 Fig. 207 9. Servo Piston 1) Install the band servo piston (1-2) to the cetiner, and insert stm DISASSEMBLY ting sevrey we cmprening te rng 5)” inate bard epson C2) 11 Remove the sig 4} gall the pring securely 10 te and serv piston (2) 2} emeve the band seve piston (4 31 nie comprenng te retina tom above, remove the a, Many differnt Ovings and ute eat rings ar ued. Be sro rng Then ermore he eae sigan stm fare nat to confuse them when stalin. 4 Takeout the band servo piton (12) bs Be earful not to damage Ovings and ate euros AUTOMATIC TRANSMISSION SERVICE GROUP 52Technical Service Information 10. Differential Case Assembly 3}. Pull out the straight pin and shaft, and remove the differ: DISASSEMBLY 1) Using a press, remove the taper roller bearing Be careful not to damage the speedometer drive gear. Differential cate (RH) Remover (498077000) INSPECTION Check each component for harmful cuts, damage, and other faults 2) Secure the case in a vise and remove the crown gear "hrenng bots, then parte te crown gear. case (RH) and ASSEMBLY tial ion 1) Install the washer, differential bevel gear, and diffe bevel pinion in the differential case (RH). Insert the shaft, and fit the straight pin in order to lock the Make sure that the case (RH) is stake straight pin. Ditterensial case (RH rd 2) Install the washer and differential bevel gear to the differ- | | i citer ex ts ental case (LH), Then put the case over the differential case | | yaa (RH), and connect both cases. oe | 3). Install tne crown gear and secure by tightening the bolt \ TE Standard tightening torque: 57 ~ 67 Nem (5.8 — 6.8 kg-m, 42 — 49 ft-lb) Fig. 210 4) Measurement of backlash (Selection of washer) Measure the gear backlash by inserting 2 dial gauge through the access window of the cate. Standard value: (0.13 — 0.18 mm (0.0051 — 0.0071 in) AUTOMATIC Ree SERVICE GROUPmacner aasOO\\ {5 (49827001), 5) Install the speedometer drive gear. Then force-tit the taper roller bearing with a pres. Be sure to position correctly the locking end of the speed- ‘ometer drive gear. RIFT (398487700) Fig 213 11. Transfer Clutch DISASSEMBLY 1} Remove the seal ring ‘ecareful not to damage the seal ring. Fig. 214 2). Using a press, remove the ball bearing Do not reuse the bearing Ball bearing Remover (498077000) 3) Remove the snap ring, and take out the pressure plate, dive plates, and driven plates. Sao ting Fig. 216 AUTOMATIC TRANSMISSION SERVICE GROUP 54Technical Service Information ‘COMPRESSOR (398673600) | ‘COMPRESSOR (398673600), seat (499627000) SEAT (498627000) Za ) Fig. 219 et 3) Install the driven plates, drive plates, and pressure plate, and secure with a snap ring 4) Aoply compressed sir to see ifthe assembled parts move smoothly, 5) Apply compressed air to the rear drive shaft to remove the piston, g Fig. 220 5) Check the clearance elt Standard value: 9 mm (0.008 — 0.035 in} INSPECTION meemarpit 1). Cheek the drive plate facing for wear and damage, 2) Check the sqap ring for wear, return spring for permanent set and breakage, and spring retainer for deformation. 3) Check the lathe cut ring for damage ASSEMBLY 1) Install the lathe cut seal ring to the 1.0,/0.0. of the transfer clutch piston. 2) Install the piston and spring retainer, and secure with 2 snap ring Fig, 227 AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information 6). Press-ft the ball bearing 12. Transfer Valve Body DISASSEMBLY INSTALLER (899590100) Vaive body ‘Transfer eutch valve Lo Ta ORE Ra CE soring Pilot vive Fig. 222, Fig. 224 1) Remove the plate. Then remove the spring and pilot valve together. 2) Remove the straight pin and pry out the plug with 2 screwdriver. Then extract the spring and transfer clutch valve together, 7), Coat the seal ring with vaseline, and install it in the seal ring groove of the shaft. Do not expand the seal ring excessively when installing. Be careful not to damage the valve and valve body. INSPECTION Check each component for harmful cuts, damage, or other faults, Fig. 223, ASSEMBLY ‘To assemble, ceverse the removal sequence, ‘Make sure the valve slides smoothly after assembling. AUTOMATIC TRANSMISSION SERVICE GROUP 56ATSGI Technical Service Information [4] Assembly 44) Forest the ol seal to the converter cas Transmission 1. CONVERTER CASE SECTION 1). Check the appearance of each component and clean. Make sure each partis free of harmful cuts, damage, and other faults. 2). Install the washer and snap ring to the speedometer shaft, and set the oil seal, Then force-it the shaft to the converter '5) Install the differential ASSY to the case, paying special attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the differentia side retainer contact surface). 66) Install the snap ring to the axle shaft, insert the shaft into the differential assembly, and tap it into position with plastic hammer. Fig, 225 ‘Thrust play: 3). Install the speedometer driven gear to the speedometer shaft, and secure with a snap ring whether the shaft is fully inserted, ect, replace the axle shaft. 7). Wrap vinyl tape around the splined portion of the axle shaft. 8) Install the oil seal and outer race (taper roller bearing) to ‘the differential side retainer. Then screw in the retainer after costing the threads with oil ‘Pay attention not to damage the oil seal lips. 'b. Do not confuse the RH and LH oil seals. ‘c, Keep the O-ring removed from the retainer. 9} Using the HANDLE (499787000), screw in the retainer until light contact is felt ‘Screw in the RH side slightly deeper than the LH side. AUTOMATIC TRANSMISSION SERVICE GROUP 3710) Hypoid gear backlash adjustment and tooth contact check (1) Assemble the drive pinion assembly to the oil pump housing. 1, Be careful not to bend the shims, b. Be careful not to force the pinion against the housing bore. Fig. 228 (2) Tighten four bolts to secure the roller bearing. Tightening torque: 39+ 3 Nem (4.0 + 0.3 kgm, 28.9 + 2.2 ftlb) Technical Service Information wrench (499787100) HOLDER (499837100) Fig, 230 (6) Repeat this operation several times to confirm the position where light contact is felt: ‘This is called the backlash “zero” state, (6) Screw in the RH side retainer until light contact is felt. (7) Apply the lock plate. Then serew out the LH side retainer by “three teeth” of the plate. Screw in the RH side retainer by the same amount. ‘Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 in). (8) Temporarily tighten the LH side lock plate. (9) Screw in the RH side retainer another “1.75 teeth”. ‘Then tighten the lock plate temporarily. (10) Turn the drive pinion several rotations and check to see if the backlash is within the standard value. Backlash: (0.13 — 0.18 mm (0.0051 ~ 0.0071 in) ‘After confirming that the backlash is correct, check the Fig, 229 (G) Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts. Tightening torque: 33 £3 Nom (3.4 40.3 kom, 26.6 + 2.2 ft1b) ‘8, Thoroughly remove the liquis surface beforehand. b, Use an old gasket or an aluminium washer so as not t0 damage the mating surface of the housing. gesket from the case mating (4) Turn the drive pinion several times. Then screw in the LH side retainer until light contact is felt. ‘tooth contact. MAGNET BASE (498247001) Fig. 231 AUTOMATIC TRANSMISSION SERVICE GROUP 58ATSG Technical Service Information (11) Apply red lead evenly to the surfaces of three or contact pattern. four teeth of the crown gear. Rotate the drive pinion in If tooth contact is improper, readjust the backlash or the forward and reverse directions several times. Then shim thickness. remove the oil pump housing, and check the tooth Checking item Contact pattern Corrective action Correct tooth contact Tooth contact pattern slightly shifted toward toe under no-load (When loaded, contact pattern moves toward heel.) Face contact Backlash is too large »> iy AAL | This may cause noise and chipping at | Increase thickness of drive pinion hight tooth ends, adjusting shim in order to bring drive pinion close to crown gear. Flank contact, Backlash is too small Vi) « This may cause noise and stepped wear | Reduce thickness of drive pinion hight on surfaces. adjusting shim in order to move drive pinion away from crown gear. Adjust as for flank-contact. + Toe contact (inside end contact) 4 Contact area is small. This may cause chipping at toe ends. Heel contact Contact area is small Adjust as for face contact. (Outside end contact) ‘This may cause chipping at heel ends. % Fig. 232 AUTOMATIC TRANSMISSION SERVICE GROUP 59Technical Service Information (12)1f tooth contact is correct, mark the retainer position 14) Install the oil seal retainer taking care not to damage the ‘and loosen it. After fitting the Osring, screw in the oil seal lips. Then secure with three bolts retainer to the marked position. Then tighten the lock plate to the specified torque. Make sure the O-ring is fitted correctly in position. Tightening torque: Tightening torque: 23 ~ 26 Nem (2.3 ~ 2.7 kgm, 17 — 20 feb) 7£1 Nem (0.7 £0.1 kgm, 5.1 £0.7 feb) 11) Install the seal pipe to the converter case. Be sure to use a new seal pipe. Fig, 235 15) Apply vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings. 4 Fit the seal ring after compressing, and rub vaseline into to sai ion. 12 “R” soa ring has a largo diameter, while “H” has small 12) Install two oil seals to the oll seal retainer with IN: STALLER (499247300) 4. Pay attention to the orientation of the oil seals. fh Be careful not to damage the seal lips. If any damage is found, replace with a new one. 13) Attach the O-ring to the oil seal retainer with vaseline. Install the seal to the oil pump housing bore. Fig. 236 16) Install the rubber seal to the converter case Fig 234 Be careful not to lose the rubber seal. AUTOMATIC TRANSMISSION SERVICE GROUP 60Technical Service Information ION CASE 4) Assemble the manual lever and parking rod to the inside shatt, and secure with a nut 1) Press-tt the rolier bearing to the transmission case Tightening torque: 39 +3 Nem (6.0 £ 0.3 kgm, 28.9 + 2.2 feb) oRIeT (398487700), Fig. 237 2) Using a plastic hammer, force-tt the cil seal. Fig. 240 5) Install the detent manual spring. Position the spring so that its center is aligned with the center of the manual plate, Tightening torque: 621 Nem (0.6 + 0.1 kgm, 4.3 + 0.7 feb) Fig. 238 6) Install the lathe cut seal ring and lip seal to the 1.0./0.0. of the low & reverse piston. Then install the piston into the 3) Install the manual plate and shaft, and secure with a case with press. spring pin. 4 Be careful not to tit the piston wh bh Be careful not to damage the lips ‘2. Be careful not to damage the oil seal lip. bi. After installation, make sure of smooth movement, Fig. 239 Fig, 241 AUTOMATIC TRANSMISSION SERVICE GROUP 617 Install the one-way eluteh inner race. Use the PULLEY ASSY (398527700) for removal. 1) Using a press, install the thrust needle bearing to the INSTALLER (98497700) Fig. 242 (2) Install four seal rings ‘Apply vaseline to the groove of the inner race and to the seal ‘ing after installation, so that the seal ring will not expand. (3) Place the spring retainer CP on the inner race, Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case. Tightening torque: 25 +2.Nem (2.5 £0.2 kgm, 18.1 + 1.4 feb) Be sure to tighten evenly. Technical Service Information 8) Install the band servo sub ASSY. 9) Press the O.D. servo retainer into position, and secure with a snap ring, comPnesson: 498677000), Fig. 244 * Perform the following operations with the transmission case set vertically on wooden blocks. 10) Installation of the low & reverse brake: Fig, 243 ‘cusch soring Forward clutch Fig. 245 (1) Install two dish plates, driven pI 2 retaining plate, and secure with a snap ring, AUTOMATIC TRANSMISSION SERVICE GROUP 62 drive plates, and"= Pay attantion to the orientation of the dish plate. b. Driven plate | Non-TURBO : 4 Drive plate { TURBO: 6 © Dish plate Non-TURBO : 2 TURBO 1 (2) Apply compressed air intermittently to check for operation. Fig. 246 Fig. 247 11) Install the thrust needlle bearing to the inner race. Refer to ocation and installing direction of thrust needle bearing and washer” for the orientation of the bearing. Carefully check the orientation of all parts indicated by an asterisk * in the following pages.) 12) Install the forward clutch drum ASSY. (1) Install carefully while rotating the drum slowly paying special attention not to damage the seal ring. Technical Service Information (2) Installation it complete when the drum recedes 2.5 mm (0.098 in) from the inner race surface. 125 mm (0.098 ind Fig, 248 13) Assemble the overrunning clutch hub, 1 Join the thrust needle bearing® and thrust washer with vaseline, and then install them together. 1, Make sure that the spines are engaged correctly. 14) Install the one-way clutch outer race ASSY. Make sure the forward clutch splines are engaged correctly. Fig, 250 AUTOMATIC TRANSMISSION SERVICE GROUP 63Technical Service Information 15) Assemble the rear internal gear. (1) Join the thrust needle bearing” and thrust washer to ‘the gear with vaseline, and install the gear while rotating it (2) Securely engage the bearing with the dog of the over running clutch hub, Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 3.5 mm (0.138 in). TERR OTT ne ‘Overrunning luteh hub Fig. 253 18) Install the front planetary carrier. ‘Attach the thrust needle bearings * to both sides of the carrier with vaseline, Install the carrier carefully, white aligning with the splines of the forward clutch drum, and while rotating the pinion. ‘Thrust needle Rear interna gear bearing Forward clutch rum Fig. 251 16) Install the rear planetary carrier. ‘Attach the thrust needle bearing* to the inside of the carrier with vaseline. Then install the carrier while eotating slowly. Fig, 254 19) Install the front sun gear. Attach the thrust needle bearing® to the gear, and install the gear while turning slowly. “Thrust needle bearing Fig. 252 17) Install the rear sun gear Install the gear with the oil hole facing up. Fig. 255 AUTOMATIC TRANSMISSION SERVICE GROUP 64ATSG Technical Service Information 20) Install the high clutch hub. 22) Install the reverse clutch ASSY. ‘Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front Engage the high clutch outer spline with the reverse clutch planetary carrier. spline and the front sun gear with the cut-out portion of the reverse clutch drum correctly when installing. 21) Install the high clutch ASSY. 23) Install the brake band ASSY. Correctly engage the high clutch hub and clutch splines 4 Be careful not to damage the brake band when installing. ‘Install the strut to the band servo piston stem. Then tighten it temporarily to avoid ttting the band. Fig. 259 AUTOMATIC TRANSMISSION SERVICE GROUP 65ATSG Technical Service Information 24) Adjustment of total end play (1) Measure the distance from the transmission case ‘mating surface to the recessed portion of the high clutch drum, and the distance to the top surface of the reverse clutch drum. Fig. 260 AUTOMATIC eS SERVICE GROUP‘the distance from the oil pump housing mating surface to the top surface of the oil pump cover Fig. 267 (3) Equation for calculation Unit: mm T=(L+0.4) —2- (0.25 10 0.58) T: Thickness of bearing race Li Depth of the recess of high clutch drum from case mating surface 2: Height of top surface of the cil pump cover with ‘needle bearing from the mating surface of the housing 0.4: Thickness of gasket 0.25 t0 0.55: Total end play standard value t= (M +04) ~m — (0.55 100.9) ti Thickness of thrust wesaer M: Depth of top surface of reverse clutch drum from case mating surface im: Height of reverse clutch thrust surface from housing ‘mating surface. 0.4: Thickness of gasket 0.85 t0 0.9: Total end play standard value 25) Install the oll pump housing ASSY. (1) After completing end play adjustment, insert the bearing race” in the recess of the high clutch. Attach the ‘thrust washer to the oil pump cover with vaseline. Technical Service Information With needle bearing, and to the thrust surface of the reverse clutch. ASSY. Be careful to avoid hitting the drive pinion (2) After correctly installing the gasket to the case mating surface, carefully install the oil pump housing ASSY. Be careful to avoid hitting the drive pinion against the inside of the case 4, Be careful not to damage the seal ring. b. Be sure to use a new gasket. AUTOMATIC TRANSMISSION SERVICE GROUP 67ATSG Technical Service Information (3) Install both parts with dowel pins aligned. Make sure 2) _Install the converter case ASSY to the transmission case no clearance exists at the mating surface, ASSY, and secure with six bolts and four nuts. Any cle nce suggests a damaged seal ring. Sa 33 £3.Nem (3.6 + 0.3 kgm, 24.6 +22 fri} (4). Secure the housing with two nuts. Tnening trea When installing, be careful not to damage the converter case 39.23 Nem (3.4 20.3 kom, 24.6 #22 fulb) ee 4, INSTALLATION OF CONTROL VALVE AND OIL PAN 1). Install four accumulators. Be careful not to confuse the springs and installation positions. Fig. 263 3. CONNECTION OF CONVERTER CASE o AND TRANSMISSION CASE Accumaato piston (29) 1) Apply proper amount of liquid gasket (The #1215) to the entire converter case mating surface, rong | A=nmUIOBtton INO! 6 Fig, 265 Make sure that the rubber seal and seal pipe are fited in position, 2). Install and route the transmission harness. Be careful not to damage the harness. eee 3) Install the control valve ASSY. (1) Set th Fig. 264 AUTOMATIC TRANSMISSION SERVICE GROUP 68ATSG Technical Service Information (2) Install the control valve by engaging the manual valve ‘and manual lever, then tighten the 18 bolts. Tightening torque: 821 Nem (0.8 £ 0.1 kg-m, 5.8 +07 feb) aS SS U; Fig. 267 15) Secure five connectors Fig. 268 6) Install the oil cooler outlet pipe, and secure with two Fig, 266 bolts. Tightening torque: 8 1Nem (0.8 40.1 kgm, 5.8 £0.7 ftib) Fit the pipe into position. Be careful to avoid twisting. ee 1 the gk. 7) Install the oll pan. eee tamess roll the gasket 1) Attach the magnet at the specified position. ‘i. Tighten the control valve mounting bolts evenly. Eee te eve eee 44). Install the oil strainer to the control valve. Be careful not to cut or break the O-ring. Then tighten bolts. Tightening torque: 821 Nem (0.8 + 0.1 kgm, 5.8 20.7 felb) Fig. 269 AUTOMATIC TRANSMISSION SERVICE GROUP 6(2) With gasket inserted, secure the oil pan by tightening 20 bolts. Tightening torqui £0.5 Nem (0.6 + 0.05 kgm, 2.9 + 0.4 fb) Tighten the bolts evenly, 5. EXTENSION CASE 11. Install the filter in the extension case. Pay attention to the orientation of the filter. 2) Install the transfer clutch valve ASSY, and secure with four bolts. Tightening torque 841 Nem (0.8 40.1 kgm, 8.8 £07 ftib) Be sure to tighton the going lead with ane of these bolts. i, Be sure to use a new gasket, 3) Install the pipe, and clamp securely. 4) Install the transfer clutch assembly to the case. Be careful not to damage the seal rings. ‘Insert the clutch assembly fully into position until the beating shoulder bottoms. Technical Service Information 6. CONNECTION BETWEEN EXTENSION CASE AND TRANSMISSION CASE 1). Install the revolution sensor to the transmission case with fone bolt. (2WO model only) Tightening torque 7 £1/Nom (0.7 £0.1 kgm, §.1 + 0.7 feb) 2) Install the reduction driven gear. 3) Install the parking pawl and thaft, set the select lever in the “P” range and tighten the drive pinion lock nut. Tightening torque: 98 £5 Nem (10+ 0.5 kgm, 72.3 + 3.6 fib) After tightening, stake the lock nut securely. 4) Install the reduction drive gear ASSY. Insert the ASSY fully into position until the bearing shoulder bottoms. 5) Adjustment of extention end play: (1) Measure the distance from the transmission case mating surface to the reduction drive gear end surface. 2WD model: Measure the distance from the transmission case ‘mating surface to the bearing end face. AUTOMATIC TRANSMISSION SERVICE GROUP 70Rear drive shaft ; eis 40m foge# 18) i GAUGE Fig. 74 (2) Measure the distance from the extension case mating surface to the rear drive shaft end face. ‘2WD model: Measure the distance from the cover case mating surface to the bearing mounting surface. (3) Calculation equation: Unit (mm) T=(L +04) ~£ ~ (0.05 100.25) Te Thickness of thrust bearing {2WD model: Thickness of Al washer) Li Distance of rear drive shaft end face from extension case mating surface (2WD model: Depth of bearing mounting face from cover case mating surface) 2: Height of reduction drive gear end surface {from transmission case mating surface (2WD model: Height of bearing end face from transmission case mating surface) 0.4: Thickness of gasket 0.05 to 0.25: Standard value of end play 6) Installation of extension case 4WD, cover case 2WD and 4WD model: (1) Attach the selected thrust needle bearin surface of reduction drive gear with vaselin (2) Set the parking return spring. (3) Remove the transfer clutch from the extension case. ‘Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub. * to the end Be sure to engage the spline teeth correctly. (4) With gasket inserted between them, install the extension case to the transmission case. (Be sure to use a new gasket.) 1 After inserting the extension case halfway, connect the connectar for duty sal. C. Be careful not to jam the cord in ‘the case, b. Be careful not to damage the rear drive shaft seal ri AUTOMATIC TRANSMISSION SERVICE GROUP n(5) Tighten bolts to secure the case. Tightening torque: 25 2 Nem (2.5 £ 0.2 kgm, 18.1 + 1.4 ftb) ‘2WD mode: (1) Attach the selected aluminum washer to the cover cate with vaseline. (2) Set the parking return spring, (3) With gasket inserted between them, install the cover case to the transmission case. 1, Be sure to use a new gasket. b Install the case while ensuring proper alignment of the bearing, parking shaft, and reduction driven gear. (4) Tighten bolts to secure the case Tightening torque: 25 + 2.Nem (2.5 +0.2 kgm, 18.1 + 1.4 fb) az ” INSTALLATION OF EXTERIOR PARTS. Install the revolution sensor. (8WD only) Tightoning torque: 71 Nem (0.7 £0.1 kgm, 5.1 £0.7 ftlb) 2) Installation and adjustment of inhibitor switch: (1) Install the inhibitor switch to the transmission case Fit the projecting portion of the switch in the recessed Portion of the case, and tighten three bolts temporarily (2) Insert the range selector lever into the shaft, and tighten the nut, Tightening torque: 39 +3 Num (4.0£ 0.3 kom, 28.9 + 2.2 fb) Fig. 272 Technical Service Information (3) With the selector lever set to “N" adjust the inhibitor switch so that the hole of range selector lever is aligned with the inhibitor switch hole. STOPPER PIN: (499267300), Fig. 273 (4) With hole aligned, tighten three bolts to secure the inhibitor switeh. Tightening torqy 3.4 £ 0.8 Nam (0:35 + 0.06 kgm, 2.5 + 0.4 feb) Clip the following cords and harness: (1) Transmission harness (2) Inhibitor switch cord {8) Revolution sensor cord (4WD only) Install the oil cooler outlet pipe Tightening torque 30.9 £ 3.4 Nem (3.18 + 0.38 kg-m, 22.8 + 2.5 fb) 5) Install the oil cooler inlet pipe. Tightening torque: 252 Nem (2.50.2 kgm, 18.1 + 1.4 ft) ‘Be sure to use a new aluminum washer. 6) Install the oil charge pipe. stoning torque: 30.9 £ 3.4 Nem (3.15 + 0.35 kgm, 22.8 + 2.5 fib) Be careful not to damage the O- 7) Adjustment of brake band: (1) After tightening the brake band adjusting screw to 9.N.m (0.9 kgem, 6.5 ft-lb) torque, back it off three turns. ‘Then secure with a fock nut. Lock nut tightening torus 25 — 28 Nm (2.5 — 29 kgm, 18 — 21 feb) AUTOMATIC TRANSMISSION SERVICE GROUP 72Technical Servi When tightoning the lock nut, be careful not to turn the adjusting serow. ce Information (2) Holding the torque converter assembly by hand, carefully install it to the converter case, Be careful not to damage the bushing. Also, to avoid undue contact, 8) Install the pitching stopper. between the oil pump shaft bushing and stator shaft portion of the oil pump cover. Tightaning torque (3) Rotate the shatt lightly by hand to engage the splines 3923 Nem (4.0 0.3 kom, 28.9 + 2.2 ft4b) securely. 13) Add oil: 9) Tighten the drain plugs. Specified quantity £ (US qt, Imp gt) Tightening torque: itt. Diff. 13-18 (14-16, 1.1-1.3) 44 £3 Nom (6.5 40.3 kgm, 32.5 #22 felb) ATF ATE 2WD: 9.3 — 9.6 (9.8 ~ 10.1, 82-84) 2522.Nem (2520.2 komm, 18.1 + 1.4 ftb) 4WD: 9.5 — 9.8 (10.0 — 10.4, 8.4 — 8.6) 10) Install the ‘After adding oil, insert the oil level gauge into the oil inlet. 11) Insert the input shaft while turning lightly by hand. Be careful not to damage the bushing. 12) Install the torque converter assembly. (1) Install the oil pump shaft to the torque converter. Make sure the clip fits securely in its groove. AUTOMATIC TRANSMISSION SERVICE GROUP 73ATSG] Technical Service Information MECHANISM AND FUNCTION 1) Cross Sectional ViewFig. 3 This newly-designed transmission is an_electronically- controlled, 4-speed fully.automatic transmission for FF vehicles. It fully utilizes the latest electronics technology. In this automatic transmission, various control operations such a5 gear shifting, engine brake application, locking-up operation, slection of proper gear shift timing, etc. are controlled accurately by a microcomputer according to vehicle operating conditions indicated as throttle opening signal, vehicle speed signal, engine rpm signal, drive range signal, etc, This trans- mmission also features a new function a drive pattern automatic- selection. This function automatically selects an optimum riving pattern for the vehicle, It ranges between a normal pattern, suitable for ordinary economy driving, and a power pattern suitable for driving uphill or accelerating, correspond ing to accelerator pedal depression < FEATURES > 1) One-way clutches and accumulators and a fully electronic control system have been used for drastic reduction of shock g during shifting. 2) A hydraulic lockup-type torque converter and a variable capacity oil pump have been employed to improve driving performance and fuel economy. 3). Selt-diagnosis and fail-safe functions are used to improve serviceability and reliability, 4) A push-pull cable is used in the control system to improve quietness. This transmission is SUBARU's unique, electronic controlled Multi-Plate-Transfer (MP.T) system, full-time, 4WD automatic transmission. Its design is based on the above: mentioned electronically-controlled, 4-speed fully-2utomatic ‘transmission for 2WD. This transmission is equipped with a transfer hydraulic control system, including a duty solenoid ‘and hydraulic multislate clutch in the transfer section on the rear of the transmission, ‘The transmission control unit stores optimum transfer clutch torque [duty ratio) data corresponding to various vehicle ‘operating conditions. As signals are sent from various sensors indicating actual operating conditions (car speed, throttle ‘opening angle, range position, wheel slip, etc.), the control unit selects the optimum duty ratio for current conditions It, then, controls the torque of the transfer clutch (hydraulic, rmultiplate clutch) by activating the duty solenoid to control hydraulic pressure. This system allows the transfer clutch torque t0 be finely controlled corresponding to the various vehicle operating conditions, in contrast to the conventional WD automatic transmission where transfer clutch torque is controlled only by vehicle speed and throttle angle. < FEATURES > In addition to the features of the 2WD automatic transmission, ‘the AWD automatic transmission has the following features: 1). It permits transfer clutch capacity to be finely controlled by an electronic system. This eliminates the tight-corner ‘braking phenomenon which occurs when the steering wheel is turned fully at low speeds, 2) It permits optimum distribution of rear wheel driving power corresponding to engine output and gear position. 3). It facilitates non-slip control. This improves the ability to ‘get off bad roads or slippery surfaces at low speeds. 4) The “1st hold” range improves driving performance. AUTOMATIC TRANSMISSION SERVICE GROUP 75Technical Service Information Electronic Control System Schematic Fig 6 AUTOMATIC TRANSMISSION SERVICE GROUP 76Technical Servi 4) Construction and Features of Each Component 4-1 Torque Converter ‘Torque converer Fig. 7 ‘The newly developed torque converter is designed to match a wide range of engine designs from large to small displacement. ‘The 0.0. and width of fluid passages, and the vane shape have been modified to improve starting acceleration and reduce fuel ‘consumption, The torque converter also has an electronically controlled, built-in hydraulic lock-up clutch system that pre- vents slip loss during medium to high speed operation. In addition, clutch engagement shock is minimized through transient control of the actuating hydraulic pressure. The lock-up clutch uses torsional dampers arranged on its per pphery. It also uses @ wave spring and friction washer in combi- ration to minimize vibration and noise of the driveline. Curent production New 4a Bees Symmetric, Felement Tsrage. 2ohese torque | Symmetric, element, Toe converter eoupting | Tatage, Z-phase toraue (wuitm nyeraute lockup | converter coupling | euren) (0.0.01 uid £246 mm (9.69 in) dia, | 296 mm 19.29 n) ia. 2 0, | 296 mm 19.29 n) Wath of ue (66 mm (2.60 0 76 mm (2980) mame On) 15m ‘Oneway elute Sorague toe Serague wpe Suilworqueravo | 24-28 20-21 286 288 Oi capacity (2.0.USet, 25 imo at | (3.0 USat, 25 Imp at) AUTOMATIC TRANSMI. ce Information Construction and Function 1) CONSTRUCTION ‘© The torque converter is composed of impeller, turbine, stator, and lock-up clutch, It is filled with oil; thecefore it ‘must not be disassembled. ‘The impeller is directly coupled to the crankshaft via 2 drive plate. A sleeve for driving the oll pump, which isthe source of the hydraulic pressure for the automatic trans mission, is welded to the rear of the impeller. The turbine transmits multiplied engine torque in the torque converter range, unmultiplied engine torque in the ‘coupling range, or engine torque itself directly through the lock-up clutch to the automatic transmission via the input shaft spline fitted to the internal spline of the turbine hub. The stator incorporates @ Sprague type one-way clutch. The stator is splinesfitted to the oil pump cover via the inner race of the one-way clutch, and secured to the torque converter case 2) FUNCTION Rotating direction Fig. 8 Function of torque converter When the impeller rotates, centrifugal force pushes out oil ‘which then enters the turbine. The oil flows along the turbine blade and exerts force on the blade, This causes the turbine to rotate and power is transmitted to the input shaft. If turbine speed is below impeller speed, the oil leaving the turbine flows in the direction impeding impeller rotation (ain Fig. 8). This direction is then changed by the stator so that the oil will assist impeller rotation (b in Fig. 8). With this setion, the torque is multiplied. ‘The stator is subject to reverse torque when it changes the direction of oil flow, hence it must be secured to the casing ‘As turbine speed increases and approaches impeller speed, the cil from the turbine begins to push directly on the back of ‘the stator blade. (This changeover point is called the “coupling point”) If the stator is stil fixed under this condition, the ol flow will be impeded by the stator. To avoid this, the stator is mounted to the case via a one-way clutch 40 that it can rotate freely in the same direction as the impeller and turbine, ISSION SERVICE GROUP 7TSG Technical Service Information 3) PERFORMANCE The performance curve of the torque converter is shown in Fig. 9. The torque ratio, speed ratio, and efficiency respec: TTeraue converter range _ Coupling an caption rn tively are represented by the following equations. Turbine shaft (output shaft) torque 255. orque ratio= Toraue 38°0 Trmpeier shaft (input shaft) torque 20 100 ‘Turbine shatt (output shat) speed Speed ratio = Twibine shatt (ourput shaft) speed Impeller shaft (input shaft) Torave ratio Efficiency 1%) 3. a urput horse-power Efficiency = QutButherse-power 199 (5 10 5 Y * “input horse;power * 100 (%) etticieney ‘The torque multiplication range with stator fixed is called the | “torque converter range”, The range in which the stator =r 5 | rotates together with the impeller and turbine is called the {__0 Sperdro9§ _4.0 ___} coupling range". In this coupling range, the torque converter oe ‘unetions similarly to the fluid coupling, and the torque is not multiplied, When the speed ratio it zero (0), that is, the condition in which the impeller shaft (engine side) alone rotates and the turbine shaft does not rotate, is called the ‘stall point” (the vehicle is at a standstill). At this stall p. the torque ratio of the input shaft and impeller shaft is maximum. The torque ratio at this point is called the torque ratio", and the engine speed is called the stall speed, ‘Change in torque converter design “ew one Cad Fluid passage wieth Unit mm in sae) passage 0.0. Fh Fig. 10 Change in torque converter design AUTOMATIC TRANSMISSION SERVICE GROUP 78TSG Tock-up Clutch System 7 fy Lock-up eluteh Torsional damper Friction washer & wave spring Drive plate erat Technical Service Information Ampeler cover Impaler Turbine stator One-way clutch Input heft Fig. 17 ‘The control unit controls the 50 Hz duty control (pulse width modulation) solenoid by changing its on/off time ratio. The lock-up control valve actuated by this solenoid switches the cil passages, and controls the hydraulic pressure applied to the lock-up cluteh, Pulse Width Modulation Fig. 12 The duty control solenoid is operated by voltage pulses; and the percentage modul indicate its performance, This percentage modul called the duty ratio, which is represented by the following expression. Duty ratio = 100 (4) = x 100 (4) ‘The repetition period A is defined as follows: Period A= ON time + OFF time Pulse width modulation means variation of duty ratio while keeping period A constant. AUTOMATIC TRANSMISSION SERVICE GROUP 79Technical Service Information Content of lock-up control Control content Remarks Lock-up control Lockup on Duty ratio 95% Lock-up off Duty ratio 5% © Lockup on/off characteristics are set for (1) Normal control | each range, gear position and pattern by one throttle opening and vehicle speed. ‘© Fuel consumption, power performance . and shift characteristics are taken into | i account, i‘ 2 Range | Mode Purpose Normal | Lower fuel consumption | ‘owl D Power | Higher performance Fig. 13 3 | Power | Same as above Lock-up non-operation condition elec cos eee VATE temperature 40°C (104°F) or 2) Ist speed, N, R. 3} During gear shifting. 4) When throttle is fully closed. If cruise control is set, or if V> 140 km/h, lock-up operates even when throttle is fully closed. 5) Rapid accelerator pedal depression, (2) Smooth | When switching from lock-up off to lock-up, | No transient contral when lock-up is off control | the duty ratio is first set to 25% and then gradually changed to 95% for smooth lock- up operation. AUTOMATIC TRANSMISSION SERVICE GROUP 80Technical Service Information Operation Lock-up eluten Leck wy ere in a x BT Fe coor Torque converter a REG. pressure [= 2 Leck-up control vave Venice speed [ T toe en [Range anal AIT control unit Leck-up duty presure pilot presure Plunger uty tolenoid {lock-up} bon Fig. 14 The lockup control valve is pushed downward by torque converter REG pressure and pilot pressure. It is pushed upward by lock-up duty pressure and spring force, (1) DURING LOCK-UP OPERATION Oil pretsure at the lock-up control duty solenoid valve is drained (duty ratio 95%) by a signal from the automatic trans mission control unit so that no lockup duty pressure is developed and the lock-up control valve remains in condition (A), As a result, hydraulic oll flows into the lock-up apply circuit, On the other hand, the lock-up release circuit drains. This causes a pressure differential across the lock-up piston. The piston is then forced again: the impeller cover and turned {as an integral unit with the cover. Thus, power from the engine is directly transmitted to the transmission input shaft. That is, the transmission is directly coupled to the engine, (2) DURING NON-LOCK-UP OPERATION In this mode, the lock-up control duty solenoid is driven at 2 5% duty ratio, This causes the lock-up duty pressure (pilot pressure) to be generated, With this pressure, the lock-up ‘control valve it set to condition (B), and hydraulic oil flows AUTOMATIC TRANSMISSI 81 into the lock-up release circuit. On the other hand, the lock-up apply circuit is connected to the oil cooler in the radiator. Accordingly, the relationship between “lock-up release pres sure lock-up apply pressure" is established. As a result, the lock-up piston is foreed to separate from the impeller cover, ‘and power is transmitted from impeller to turbine to input shaft, as with an ordinary torque converter coupling (3) DURING SMOOTH CONTROL When the lock-up clutch is operated, the duty ratio of the lock-up contral duty solenoid does not increase directly to 95%. Instead, it is first modulated to a preset value, then smoothly changed to 95%, This operation allows lock-up duty pressure to be changed smoothly, achieving shockless engagement of the lock-up clutch. NON-LOCK-UP OPERATION DURING “4ST SPEED", “N' and “R” In this mode of operation, pilot pressure is generated, and the lockup control valve is set to condition (B) where lock-up is inoperative. (4) ION SERVICE GROUPTechnical Service Information Transfer and Extension Selective parte ‘Snap rng +2 Pressure plate Drive plate Driven pate 5: Thrust needle betring 16 Pilot vave pipe 17 Duty sol C lranster) 18 Gastar 18 Plate 20 Filter 21 Gasket 22 Roller bearing Tightening torque: Nem (kam, feb) o Wi 721107 203,84 207) ales 72 021(08201,5820.7) selene 13: 2521 (2504, 181207) 38 buna Ta: 13£1(1.3£0.1, 9440.7) Fig. 113 ee emceeTechnical Service Information 5 8 Reduetion crive pear 7 Snap ring 8 Drive pinion shaft Reduction riven gear 10 Lock washer 12. ecueton crv gar ~. PPPS \ 2S “\y Tightening torque: Nem (kg-m, ft-lb) T; 9825 (10405, 72.3436) Fig, 112 AUTOMATIC TRANSMISSION SERVICE GROUP 83Technical Service Information Forward Clutch and Low & Reverse Brake & 1 Shaping : plate 4 Driven 5 Dish plate 6 Snap ring °7 Retaining pate 8 Orie pate 9 Driven plate 10 Olsh plow 18 Lathe eut mal ring 20. Forward eluteh rum U---- SS 21 Needle bearing 22 Snap rng 23 Oneway clutch (1-2) 33. Thst needle bearing 34 Oneonay clutch inner race (1-21 235. Soring reainer 36 Socket bolt 37 Low & revere piston 38 Lathe cut salting 39 Upset Tightening torque: Nem (kg- T: 222(28¢ Fig. 111 eaten ee AUTOMATIC TRANSMISSION SERVICE GROUP 84TSG Technical Service Information High Clutch and Planetary Gear + Selective ports running euten Pub Fig. 110 AUTOMATIC TRANSMISSION SERVICE GROUP 85Technical Service Information °. Duty tot A (Line ratte) Sol. Assy Upper vale bady Batt peer separator plate 10 Lower epparator plate 11 Lower vlve Dagy 12 Dutysal. 8 (Locks! 13 Pipe 14 Revolution sensor (20V0) Tightening torque: N-m (kgm, 1b) Ti: 721(0.7£0.1,8.120.7) 72 841(08£0.1,5820.7) Fig. 108 AUTOMATIC TRANSMISSION SERVICE GROUPATSG Technical Service Information Reverse Clutch and Band Brake > Selective parts 1 Brake band 2 verse clutch gram 33. Lathe cut sa ring Tightening torque: _N-m (kg-m, fb) T: 25-28 (25-29, 18421) Fig. 109 AUTOMATIC TRANSMISSION SERVICE GROUP 86Technical Service Information Control Valve and Harness Louting = > S& 2 om | 1 lip 2 Clip 3. Transmission harness 4 Oring 5. Duty sol. A (Lineeessure) 6 7 8 3 Upper separator plate 30. Lower seporator plate 11 Lower valve baay 12 DurysolB (Lock-vol 13 Pipe 14 Revolution sentor (20! g! | Sp—~e Sea Sa _ 4 Tr7sto7 2018107 Vi [=] 1oss0188:0.) Fig, 108 AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information ion Cover and Control Device Transmission Case, Transmi: Selective parts ‘ie raatner nose ange select lever Manual shaft Manual piace ‘Snap ring Plug ving Olt seal Releat valve ioe Roller bearing “Transmission cover (200) Parking support Parking rod Return soring hate Parking paw! Inlet pipe Outlet pipe ‘Soring Owing ‘Aceumulator piston (N-D? ving Oving ‘Accumulator piston (23) ‘Spring Oring ‘Accumulator diton (12) Oning Spring Oning Accumulate piston (34) oving Spring Tightening torque: Nem (kg-m, Fb) Ti: 3.42 0.5 (0.35 + 0.05, 25 + 0.6) Tz: 39 £3(4.020.3, 28.9222) TH 30.92 2.4 (3.15 + 0.35, 22.825) Ta 61 (0.6 £0.1, 4340.7) Ts: 25+2(25+0.2, 18.12 1.4) To: 3.90.5 (0.4 + 0.05, 2.9 0.4) Fig. 107 AUTOMATIC TRANSMISSION SERVICE GROUP 88

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