Re4ro1a PDF

Technical Service Information
INTRODUCTION
NISSAN RE4R01A
The RE4R01A Transmission is currently found in Nisan Pathfinders, 300ZX, 240SX, Mazda MPV’s, B2200,
and B2600 vehicles. Also the Infinity J30, M30 and Subaru Legacy vehicles have similar units. This rear wheel
drive, automatic four speed transmission has a computer system that controls the shift timing and shift feel as
well as the torque converter clutch. This manual covers the procedures necessary to diagnosis, repair ans
overhaul the RE4R01A transmission. There are also some basic electrical checks and self diagnosis routines
included in this manual.
We wish to thank Nissan Motor Company

for the information and illustrations
that have made this booklet possible.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2006
WAYNE COLONNA JIM DIAL

PRESIDENT TECHNICAL CONSULTANT
DALE ENGLAND ED KRUSE

FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT
PETER LUBAN GREGORY LIPNICK
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JON GLATSTEIN DAVID CHALKER
JERRY GOTT ROLAND ALVAREZ
GERALD CAMPBELL MIKE SOUZA
AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107 AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
1
NISSAN RE4R01A
INDEX
SYMPTOM CHART................................................................................................................................. 3
OIL CHANNELS ...................................................................................................................................... 5
CONTROL SYSTEM .............................................................................................................................. 6
SELF DIAGNOSIS ................................................................................................................................... 8
APPLICATION CHART .......................................................................................................................... 14
HYDRAULIC LAYOUT .......................................................................................................................... 15
WIRING DIAGRAMS.............................................................................................................................. 16
TEAR DOWN - ASSEMBLY..................................................................................................................... 19
CONTROL VALVE ASSEMBLY............................................................................................................. 36
CLUTCH PACK........................................................................................................................................ 50
SPECIFICATIONS................................................................................................................................... 90
SPACER PLATE DIAGRAMS ................................................................................................................ 92
LINE PRESSURE ..................................................................................................................................... 93
TORQUE SPECIFICATIONS - BAND ADJUSTMENT ....................................................................... 94
REPEAT PLANETARY FAILURE ......................................................................................................... 95
SOLENOID DESCRIPTION ................................................................................................................... 102
ELECTRICAL PARTS LOCATION 300ZX ........................................................................................... 103
ELECTRICAL PARTS LOCATION 240SX ........................................................................................... 104
ELECTRICAL PARTS LOCATION PATHFINDER ............................................................................ 105
AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Copyright © ATSG 2006
2
SYMPTOM CHART
Automatic Transmission Service Group

3
SYMPTOM CHART

4
OIL CHANNEL - RE4R01A

5

6

7

4
Power shift indicator lamp Damaged Circuit
t1 = 2.5 seconds t2 = 2.0 seconds t3 = 1.0 seconds

For circuit tests refer to the Factory Manual
9

10
For circuit tests refer to the Factory Manual

11
Torque converter lock-up control
Torque converter lock-up occurs in 4th gear (O.D) only and is controlled by the automatic transmission unit after
first processing signals from the various input sensors in conjunction with its preprogrammed memory data.
The control unit then energizes a solenoid valve, retracting its plunger, thus draining piolet pressure via the
shuttle shift valve from one end of the lock-up control valve. The control valve then moves, draining TCC
pressure from the rear side of the lock-up piston.
Conditions for Lock-Up Operation

Torque converter lock-up will only occur when
all of the conditions listed are met. (Refer also to
shift schedule)

12
Shift Schedule Control

The transmission gear change points are determined by the automatic transmission control unit after
first processing signals from the various input sensors in conjunction with its preprogrammed
memory data on the basic gear change points. The control unit then, either energizes or de-energizes
shift solenoid “A” and/or “B”, thus applying or releasing pilot pressure to shift valves “A” and/or
“B”.
Relationship of Shift Solenoid to Gear Selection
NOTE: Gear selection is also rlevant to manual valve position.
Shift Solenoid Operation

The shift solenoid preforms a simple on/off
function. When energized (on), its plunger
protrudes blocking the drain on the pilot pressure
line. When de-energized (off), the plunger retracts
opening the drain on the pilot pressure line.
Shift Valves “A” and “B” Operation

Pilot pressure, when applied to the shift valve due
to the operation of the solenoid valve, acts on the
end of the shift valve, overcomes the opposing
spring pressure at the other end causing the valve
to move.

13

14
RE4RO1A Hydraulics

15
WIRING DIAGRAM

16
WIRING DIAGRAM Continued

17
CIRCUIT DIAGRAM FOR PINPOINT TEST

18
BEARING, WASHER AND SNAP RING LOCATION

19
DISASSEMBLY
1. Remove torque converter by holding it
firmly and turning while straight out.
2. Check torque converter one-way clutch.

a. Insert tool into spline of one-way clutch inner
race.
b. Hook bearing support unitized with one-way
clutch outer race with suitable wire.
c. Check that one-way clutch inner race rotates only
clockwise with the tool while holding bearing
support with wire.
3. Remove inhibitor switch from the trans.
4. Remove oil pan.

a. Drain ATF from rear extension.
b. Drain oil pan by placing wooden blocks under bell
housing and rear extension.
c. Separate oil pan and transmission case.
NOTE: Always place oil pan straight down so that
foreign particles inside will not move.
5. Place transmission into holding fixture with the

valve body facing up.

20
6. Check oil pan and filter for accumulation of foreign

material.
! If clutch lining material is found, clutch plates may
be worn.
! If metal is found, clutch plates, bands, ect. may be
worn.
! If aluminum filings are found, bushings or cast
aluminum parts may be worn.
In above cases replace converter and check unit for
wear.
7. Remove lock-up solenoid and fluid temp sensor
connector.
! Be careful not to damage connectors.
8. Remover oil filter.

a Remove oil filter from valve body.
Then remove O-ring from filter.
b. Check oil filter for damage.
9. Remove valve body.

a. Straighten terminal clips to free terminal cords
then remove terminal clips.

21
b. Remove bolts “A” and “B”, and remove valve body

from transmission.
Bolt Length
“A” 37mm (1.46in)
“B” 50mm (1.97in)
c. Remove solenoid connecter.

! Be careful not to damage connector.
d. Remove manual valve from valve body.
10. Remove ware harness from wire harness from

transmission while pushing stopper..
! Be careful not to damage wire harness.
! Do not remove wire harness unless it is damaged.

22
11. Remove bell housing.

a. Remove bell housing from case.
b. Remove O-rings from bell housing.

c. Remove any traces of sealant.
! Be careful not to scratch bell housing.
12. Remove O-ring from input shaft.
13. Remove oil pump assembly.

a. Attach tool to oil pump assembly and remove it
evenly from transmission case.
b. Remove O-ring from oil pump assembly.

c. Remove traces of sealant from oil pump housing.
! Be careful not to scratch pump housing.

23
d. Remove needle bearing and thrust washer from oil

pump assembly.
14. Remove input shaft and oil pump gasket.
14. Remove brake band and band strut.

a. Loosen lock nut and remove band servo anchor
end pin from transmission case.
b. Remove brake band and band strut from case.
c. Hold brake band in a circular shape with clip.

24
16. Remove front side clutch and gear components.

a. Remove clutch pack (reverse clutch, high clutch,
and front sun gear) from transmission.
b. Remove front bearing race from clutch pack.

c. Remove rear bearing race from clutch pack.
d. Remove front planetary carrier from transmission.
e. Remove front needle bearing from front planetary

carrier.
f. Remove rear bearing from front planetary carrier.
g. Remove sun gear from transmission case.

25
17. Remove rear extension housing bolts.

a. Remove rear extension housing.
b. Remove rear extension housing gasket from
transmission case.
c. Remove oil seal from rear extension housing.

! Do not remove oil seal unless it is to be replaced.
d. Remove revolution sensor from rear extension

housing.
e. Remove O-ring from revolution sensor.
18. Remove output shaft and parking gear.

a. Remove rear snap ring from output shaft.
b. Slowly push output shaft all the way forward.

! Do not use excessive force.
c. Remove snap ring from output shaft.

26
d. Remove output shaft and parking gear as a unit from

transmission case.
e. Remove parking gear from output shaft.
f. Remove needle bearing from transmission case.
19. Remove rear side clutch and gear components.

a. Remove front internal gear.
b. Remove bearing race from internal gear.
c. Remove needle bearing from rear internal gear.

27
d. Remove rear internal gear, froward clutch hub and

overrun clutch hub as a set from transmission case.
e. Remove needle bearing from overrun clutch hub.
f. Remove overrun clutch hub from rear internal gear

and forward clutch hub.
g. Remove thrust washer from overrun clutch hub.
f. Remove froward clutch assembly from

transmission case.

428
20. Remove band servo and accumulator

components.
a. Remove band servo retainer from transmission
case.
b. Apply air pressure to feed hole until band servo

piston pops out of the case.
! Hold piston with rag while applying air to feed hole.
c. Remove return spring.
d. Remove springs from accumulator pistons “b”,

“C”, and “D”.
e. Apply air to each feed hole until piston comes out.
a
b c
! Hold piston with rag and gradually apply air to feed
hole.
Accumulator Piston ID A B C D
d Feed Hole ID a b c d
f. Remove O-ring from each piston.
21. Remove manual shaft components, If necessary.

a. Hold width across flats of manual shaft (outside
the transmission case) and remove lock nut from
shaft.

29
b. Remove retaining pin from transmission case.
c. While pushing detent spring down, remove manual

plate and parking rod from transmission case.
d. Remove manual shaft from transmission case.
e. Remove spacer and detent spring from transmission

case.
f. Remove oil seal from transmission case

30
OIL PUMP ASSEMBLY
1. Loosen bolts in numerical order and remove oil

pump cover. .
2. Remove rotor, vane rings and vanes.

! Inscribe a mark on the back of the rotor for
identification of fore/aft direction for reassembly.
Then remove rotor.
3. While pushing on cam ring remove pin.

! Be careful not to scratch oil pump housing.

31
4. While holding cam ring and spring lift out cam ring
spring.
! Be careful not to damage oil pump housing.
! Hold cam ring spring to prevent it from jumping.
5. Remove cam ring and and spring from oil pump

housing.
6. Remove pivot pin from control piston and remove

control piston assembly.
7. Remove oil seal from oil pump housing.

! Be careful not to damage oil pump housing.
INSPECTION:
Oil pump cover, rotor, vanes, control piston, slide
seals, cam ring and friction ring.
! Check for wear or damage.

32
SIDE CLEARANCES
! Measure side clearances between end of oil pump
housing and cam ring, rotor, vanes and control
piston in at least four p l a c e s a l o n g t h e i r
circumferences. Maximum clearance should be
within specifications listed below.
! Before measuring side clearance, check that friction
rings, O-ring, control piston slide seals and cam ring
springs are removed.
Cam Rings
.01 - .024 mm (.0004 - .0009 in)
Rotor, Vanes, Control Piston
.03 - .044 mm (.0012 - .0017 in)
SEALING RING CLEARANCE

! Measure clearance between sealing rings and ring
groove. If not within specs listed below then replace
oil pump assembly.
Standard Clearance
.10 - .025 mm (.0039 - .0089 in)
Wear Limit
.03 - .044 mm (.0012 - .0017 in)
OIL PUMP ASSEMBLY

1. Drive oil seal into oil pump housing.
! Apply A.T.F. to outer periphery and lip surface.
2. Install cam ring in oil pump by the following steps.

a. Install seal on control piston
! Pay attention to it’s direction - Black surface goes
toward control piston.
! Apply petroleum jelly to side of seal.
b. Install control piston on oil pump.

33
c. Install O-ring and friction rings on cam ring.

! Apply petroleum jelly to O-ring.
d. Assemble cam ring, cam ring spring and spring seat,

Install spring by pushing it against pump housing.
e. While pushing on cam ring install pivot pin.
3. Install rotor, vanes, and vane rings.

! Pay attention of direction of rotor.
4. Install oil pump housing and oil pump cover.

a. Wrap masking tape around splines of oil pump
cover assembly to protect seal. Position oil pump
cover assembly in oil pump housing assembly, then
remove masking tape.
b. Tighten bolts in a criss-cross pattern

34
5. Install seal rings carefully after packing ring

grooves with petroleum jelly. Press rings down into
jelly to a close fit.
! Sealing rings come in two different diameters.
Check fit carefully in each ring groove.
! Small Diameter ring. (No Mark)
! Large Diameter ring. (Yellow Mark shown by
arrow.
! Do not spread gap of sealing ring excessively while
installing. It may deform ring.

35
VALVE BODY ASSEMBLY

36
VALVE BODY DISASSEMBLY

1. Remove solenoids.
a. Remove lock-up solenoid and side plate from lower
body.
b. Remove O-ring from solenoid.
c. Remove line pressure solenoid from upper body.

d. Remove O-rings from solenoid.
e. Remove 3-unit solenoid assembly from upper valve

body.
f. Remove O-rings from solenoids.
2. Disassemble upper and lower valve bodies.

a. Place upper valve body face down and remove
bolts, reamer bolts and spacer plate.
b. Remove lower valve body, separator plate and
gasket as a unit from the upper valve body.
! Be careful not to drop pilot filter, orifice check
valve, spring and steel valve.
c. Place lower valve body face down and remove

gasket and separator plate.
d. Remove pilot filter, orifice check valve and orifice
check spring.

37
e. Check to see that the steel check balls are properly

positioned in the upper valve body and then remove
them.
INSPECTION
LOWER AND UPPER VALVE BODIES.
! Check to see that there are pins and retainer plates in
lower valve body.
! Check to see that there are pins and retainer plates in

upper valve body.
! Be careful not to loose these parts.
! Check to see that the oil circuits are free and free
from damage.
! Check
damage.
tube brackets and tube connectors for
SEPARATOR PLATE
! Check to see that the separator plate free and free
from damage and not deformed and oil holes are
clean.

38
PILOT FILTER
! Check to make sure that the filter is not clogged or
damaged.
LOCK-UP SOLENOID
damaged.
! Resistance check should be between 10-16 Ohms.
LINE PRESSURE SOLENOID

damaged.
! Resistance check should be between 2.5-5 Ohms.
SHIFT SOLENOID ASSEMBLY

! Resistance check should be between 20-30 Ohms
on all 3 solenoids.
SHIFT SOLENOID ASSEMBLY

! Resistance check should be 300 Ohms at 175°F.

39
UPPER VALVE BODY
NOTE: Please be advised that since the RE4RO1A is found in many different vehicles. valve line
ups and configuration may be different from what appears in this manual. Care and special attention
must be taken when disassembling these valve bodies for cleaning to prevent any possibility of a
disassembly. Below is a example of several different styles of the pressure regular line-ups and
configurations.

40
1. Remove valves at parallel pins.

! Do not use a magnet.
a. Use a wire paper clip to push out pins
b. Remove parallel pins while pressing their

corresponding plugs and sleeves.
! Remove plugs slowly to prevent internal parts from
jumping out.
c. Place mating surface of valve face down, and

remove internal parts.
! If valve is hard to remove, place valve body face
down and lightly tap with a soft hammer.
! Be careful not to drop or damage valves.
2. Remove valves at retainer plate.

a. Pry out retainer plate with wire paper clip.

41
b. Remove retainer plates while holding spring.
c. Place mating surface of valve face down, and

remove internal parts.
! If valve is hard to remove, place valve body face
down and lightly tap with a soft hammer.
! Be careful not to drop or damage valves.
! 4-2 sequence valve and relay valve are located far

back in the upper valve body, if they are hard to
remove push them out with a stiff wire
! Be careful not to scratch valve surface
INSPECTION
Valve Springs
! Measure free length and outer diameter of each
valve spring, Also check for damage.
! Numbers of each valve spring listed below.
Torque converter relief valve spring

Pressure regulator valve spring
Pressure modifier valve spring
Shuttle shift valve D spring
4-2 sequence valve spring
Shift valve B spring
4-2 relay valve spring
Shift valve A spring
Overrun clutch control valve spring
Overrun clutch reducing valve spring
Shift valve S spring
Pilot valve spring
Lock-up control valve spring

42
VALVE BODY LAYOUT

43
1. Lubricate the valve body and all valves with A.T.F.

Install valves by carefully into there bores.
! Be careful not to scratch or damage valve body.
! Wrap a small screwdriver with vinyl tape and use it

to insert valves into proper position.
Pressure Regulator Valve

! If Pressure regulator plug is not centered correctly,
sleeve cannot be inserted into bore in upper body. If
this happens, use vinyl wrapped screwdriver to
center sleeve until it can be installed.
! Turn sleeve slightly while installing.
Accumulator Control Plug

! Align protrusion of accumulator control sleeve with
notch in plug.
! Align parallel pin groove in plug with parallel pin,
and install accumulator control valve.
2. Install parallel pins and retainers.

44
! While pushing plug, install parallel pin.
4-2 Sequence Valve and Relay Valve.

! Push 4-2 sequence valve and retainer valve with
wire wrapped in vinyl tape to prevent scratching of
the valve body, install parallel pins.
! Insert retainer plate while pushing spring.

45
ASSEMBLY
1. Install upper and lower valve bodies.
a. Place oil circuit of upper valve body face up and
install the steel check balls into the proper locations.
b. Install reamer bolts from bottom of upper valve

body and install gaskets.
c. Place oil circuits on lower valve body face up and

install orifice check spring, orifice check valve and
pilot filter.
c. Install lower gaskets and separator plate on lower

valve body.
d. Install and temporarily tighten support plates on
lower valve body.
e. Install and temporarily tighten support plates, fluid
temp sensor and tube brackets.

46
f. Temporarily assemble upper and lower valve

bodies using the reamer bolts as a guide.
! Be careful not to dislocate or drop steel check balls,
orifice check spring, orifice check valve or pilot
filter.
g. Install and temporarily tighten bolts and tube

brackets in their proper locations.
BOLT LENGTH A B C D
(in) 2.76 1.97 1.30 1.06
(mm) 70 50 33 27
2. Install solenoids.
a. Attach O-ring and install lock-up solenoid and side
plates onto lover valve body.
b. Attach O-rings and install 3-unit solenoid assembly

onto upper valve body.
b. Attach O-ring and install line pressure solenoid

onto upper valve body.
3. Tighten all bolts.

47
LOWER VALVE BODY

48
1. Remove valves at parallel pins.

2. remove valves at retainer plates.
VALVE INSPECTION
! Measure free length and outer diameter of each
valve spring, Also check for damage.
! Numbers of each valve spring listed below.
! Replace valve springs if damaged or weak.

! Check sliding surfaces of valves, sleeves and plugs.
ASSEMBLY
! Install valves, for installation refer to upper valve
bosy assembly

49
DISASSEMBLY
1. Remove reverse clutch assembly from clutch pack.
2. Check operation of reverse clutch.

a. Install seal ring onto oil pump cover and install
reverse clutch. Apply compressed air to oil hole.
b. Check to see that the retaining plate moves to snap
ring.
c. If retaining ring does not move to snap ring, D-ring
or oul seal may be damaged or fluid may be leaking
at piston check ball.

50
3. Remove drive plated, driven plates, retaining plate,

dish plate and snap ring.
4. Remove snap ring from clutch drum while

compressing clutch springs.
! Do no expand snap ring excessively.
5. Remove spring retainer and return springs
6. Install seal ring onto oil pump cover and install

reverse clutch drum. While holding piston, apply
compressed air to oil hole until piston is removed.
! Do nor apply compressed air abruptly.
7. Remove D-ring and oil seal from piston.
Reverse Clutch Return Springs

UNIT: mm (in)
! Check for deformation or damage. Also measure
11.6 (0.457”)
free length and diameter.
19.69 (0.7752”)
Reverse Clutch Drive Plates

! Check facing for burns, cracks or damage.
! Measure thickness of facing
Standard Thickness 2.0mm (.079”)
Were Limit 1.8mm (.071”)
! Replace if not within limit
Reverse Clutch Dish Plate
! Check for deformation or damage.

51
REVERSE CLUTCH PISTON

! Shake piston to assure that balls are not seized.
! Apply compressed air to check ball hole opposite
the return spring to assure that there is no air
leakage.
! Also apply compressed air to oil hole on return
spring side to assure that air leaks past ball
ASSEMBLY
1. Install D-ring and oil seal on piston.
! Apply A.T.F to both sides
2. Install piston assembly by turning it slowly and

evenly.
! Apply A.T.F to inner surface of drum.
3. Install return springs and spring retainer.
4. Install snap ring while compressing clutch springs.

52
! Do not align snap ring gap with spring retainer

stopper.
5. Install drive plate, driven plates, retainer plate and

dish plate.
6. Install snap ring.
7. Measure clearance between retaining plate and

snap ring. If not within allowable limit, select
proper retaining plate.
Specified clearance:
Standard
0.5-0.8mm (0.020-0.031 in)
Allowable limit
1.2mm (0.047 in)
8. Check operation of reverse clutch.

Refer to disassembly of reverse clutch

53
HIGH CLUTCH
Service procedure for high clutch are essentially the

same as those for reverse clutch with the following
exception:
! Check operation of high clutch

54
! Removal and installation of return springs.
! Inspection of high clutch return springs.

Part number 31505-21X03
Length 22.06mm (0.8685 in)
Diameter 11.6mm (0.475 in)
! Inspection of high clutch drive plate.

Thickness of drive plate:
Standard
1.6mm (0.063 in)
Wear Limit
1.4mm (0.055 in)
! Measurement
and snap ring.
of clearance between retaining plate
Specified Clearance:
Standard
1.8-2.2mm (0.071-0.087 in)
Allowable Limit
3.0mm (0.118 in)

55
FORWARD AND OVERRUN CLUTCH

56
Service procedures for forward and overrun clutches

are essentially the same as those for the reverse clutch,
with the following exception.
! Check forward clutch operation.
! Check overrun clutch operation.
! Remove forward clutch drum.

Remove forward clutch drum from transmission
case by holding snap ring.
! Removal
pistons.
of forward clutch and overrun clutch
1. While holding overrun clutch piston, gradually
apply compressed air to oil hole.
2. Remove overrun clutch from forward clutch.

57
! Removal and installation of return springs.
! Inspection of forward clutch and overrun clutch

return springs.
Part Number 31505-41X01
Length 35.77mm (1.4083 in)
! Inspection of forward clutch drive plates.

Thickness of drive plates:
Standard
2.0mm (0.079 in)
Wear Limit
1.8mm (0.071 in)
! Inspection of overrun clutch drive plates.

Standard
2.0mm (0.079 in)
Wear Limit
1.8mm (0.071 in)
! Installation of forward clutch piston and overrun

clutch piston.
1. Install forward clutch piston by turning it slowly
and evenly.
! Apply A.T.F. to inner surface of clutch drums.

58
! Align notch in forward clutch piston with groove in

forward clutch drum.
2. Install overrun clutch by turning it slowly and

evenly.
! Apply A.T.F. to inner surface of forward clutch
piston.
! Measurement of clearance between retaining plate

and snap ring of overrun clutch.
Standard
1.0-1.4mm (0.039-0.055 in)
Allowable Limit
2.0mm (0.079 in)
! Measurement of clearance between retaining plate

and snap ring of forward clutch.
Standard
0.45-0.85mm (0.0177-0.0335 in)
Allowable Limit
1.85mm (0.0728 in)

59
LOW & REVERS BRAKE
DISASSEMBLY
1. Check operation of low/reverse brake.
a. Install seal ring onto oil pump cover and install
reverse clutch. Apply compressed air to oil holes.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring
or oil seal may be damaged or fluid may be leaking
at piston check ball.
2. Remove snap ring, low and reverse brake drive

plates, and driven plates and dish plate.

60
3. Remove low one-way cutch inner race, spring

retainer and return springs from transmission case.
4. Remove seal rings from low one-way clutch inner

race.
5. Remove needle bearing from low one-way clutch
inner race.
6. Remove low and reverse brake piston using

compressed air.
7. Remove oil seal and D-ring from piston.
INSPECTION:
Low and reverse brake snap ring and spring retainer.
! Inspection of low and reverse return springs.

Part Number 31521-21X00
Length 23.7mm (1.933 in)
! Inspection of low and reverse clutch drive plates.

! Check facing for burns, cracks or damage.
! Measure thickness of facing
Standard
2.0mm (0.079 in)
Wear Limit
1.8mm (0.071 in)

67
Low one-way cutch inner race.

! Check friction surface of inner race for wear or
damage.
! Install new seal rings onto low one-way inner race.

! Be careful nor to expand seal ring gap excessively,
! Measure seal ring-to-groove clearance.
Inspection standard:
Standard: 0.10-0.25mm (0.0039-0.0098 in)
Limit: 0.25mm (0.0098 in)
ASSEMBLY:
1. Install bearing onto one-way clutch inner race.
! Pay attention to its direction - Blace surface goes to
rear side.
! Apply Petroleum jelly to needle bearing.
2. Install oil seal and D-ring onto piston.

! Apply A.T.F. to oil seal and D-ring.
3. Install piston by rotating it slowly and evenly.

! Apply A.T.F. to inner surface of transmission case.

62
4. Install return springs, spring retainer and low one-

way clutch inner race into transmission case.
5. Install dish plate, low and reverse brake drive

plates, driven plates and retaining plate.
6. Install snap ring on transmission case.
7. Check operation of low and reverse brake clutch

piston. Refer to disassembly.
7. Measure clearance between retaining plate and

snap ring. If not within allowable limit, select
proper retaining plate.
Specified clearance:
Standard
1.1-1.5mm (0.043-0.059 in)
Allowable limit
2.5mm (0.098 in)
9. Install low one-way clutch inner race seal ring.

! Apply petroleum jelly to seal rings.
! Make sure seal rings are pressed firmly into place
and held by petroleum jelly.

63
DISASSEMBLY:
1. Remove snap ring from forward clutch drum.
2. Remove side plate from forward clutch drum.
3. Remove low one-way clutch from forward clutch

drum.

64
4. Remove snap ring from forward clutch drum.
4. Remove needle bearing from forward clutch drum.
INSPECTION:
Forward clutch drum.
! Check spline portion for wear or damage.
! Check friction surfaces of low one-way clutch or
needle bearing for wear or damage.
Needle bearing and low one-way clutch.

! Check frictional surface for wear or damage.
ASSEMBLY:
1. Install needle bearing in forward clutch drum.

65
2. Install snap ring onto forward clutch drum.
3. Install low one-way clutch onto forward clutch

drum by pushing the roller evenly.
! Install low one-way clutch with flange facing

rearward.
4. Install side plate onto forward clutch drum.

5. Install snap ring onto forward clutch drum.

66
REAR INTERNAL GEAR AND FORWARD CLUTCH HUB
DISASSEMBLY:
1. Remove rear internal gear by pushing the forward
clutch hub forward.
2. Remove thrust washer from rear internal gear.
3. Remove snap ring from forward clutch hub.

67
4. Remove end bearing.
5. Remove forward one-way clutch and end bearing as

a unit from forward clutch hub.
6. Remove snap ring from forward clutch hub.
INSPECTION:
Rear internal gear and forward clutch hub.
! Inspect gear for excessive wear, chips or cracks.
! Check frictional surfaces of forward one-way
clutch and thrust washer for wear and damage.
! Check spline for wear or damage.
Snap ring and end bearing.


68
ASSEMBLY:
1. Install snap ring onto forward clutch hub.
2. Install bearing.
3. Install forward one-wayclutch onto clutch hub.

! Install forward one-way clutch with flange facing
rearward.
4. Install end bearing.
5. Install snap ring onto forward clutch hub.
6. Install thrust washer onto rear internal gear.

! Apply petroleum jelly to thrust washer.
! Securely insert pawls of thrust washer into holes in
rear internal gear.
7. Position forward clutch hub in rear internal gear.
FREEWHEEL
8. The rear internal ring gear must freewheel
RING GEAR
clockwise And lock counter clockwise when holding
forward hub.
FREEWHEEL
HOLD
FORWARD
CLUTCH HUB

69
BAND SERVO PISTON ASSEMBLY
DISASSEMBLY:
1. Block one oil hole in the O.D. servo piston retainer
and the center hole in the O.D. band servo piston.
2. Apply compressed ait to the other oil hole in the
piston retainer to remove the O.D. band piston from
the retainer.
3. Remove D-ring from the O.D. band servo piston.
4. Remove band servo piston assembly from servo

piston retainer by pushing it forward.
5. Place piston stem end on a wooden clock. While

pushing servo piston spring retainer down, remove
E-ring.

70
6. Remove servo piston spring retainer, return spring

C and piston stem from band servo piston.
7. Remove E-ring from band servo piston.
8. Remove servo cushion spring retainer from band

servo piston.
9. Remove D-rings from band servo piston.
10.Remove O-rings from servo piston retainer.
INSPECTION:
Piston, retainers and piston stem.
! Check frictional surfaces for abnormal wear or
damage.
Return springs
! Check for deformation or damage. Measure free
length and outer diameter.
PART FREE LENGTH O.D.
SPRING A 45.6mm (1.795 in) 34.3mm (1.350 in)
SPRING B 53.8mm (2.118 in) 40.3mm (1.587 in)
SPRING C 29.0mm (1.142 in) 27.6mm (1.087 in)

71
ASSEMBLY:
1. Install O-ring onto servo piston retainer.
! Apply A.T.F. to O-rings.
! Pay attention to position of each O-ring.
2. Install servo cushion spring retainer onto band

servo piston.
3. Install E-ring onto servo cushion spring retainer.
4. Install D-rings onto band servo piston.

! Apply A.T.F. to D-rings.
5. Install servo piston spring retainer, return spring C

and piston stem onto band servo piston.

72
6. Place piston stem end on a wooden block. While

pushing servo piston spring retainer down, install
E-ring.
7. Install band servo piston assembly onto servo piston

retainer by pushing it inward.
8. Install D-ring on O.D. band servo piston.
9. Install O.D. band servo piston onto servo piston

retainer by pushing it forward.

73
PARKING PAWL COMPONENTS
DISASSEMBLY:
1. Slide return spring to the front of rear extension
flange.
2. Remove return spring, pawl spacer and parking

pawl from rear extension.
3. Remove parking pawl shaft from rear extension.
4. Remove parking actuator support and rod guide

from rear extension.

74
6. Place piston stem end on a wooden block. While

pushing servo piston spring retainer down, install
E-ring.
ASSEMBLY:
1. Install rod guide and parking actuator support onto
rear extension.
2. Insert parking pawl shaft into rear extension.
3. Install return spring, pawl spacer and parking pawl

onto parking rod.
4. Bend return spring upward and install it onto rear

extension.

75
ASSEMBLY:
1. Install manual shaft components.
a. Install oil seal onto manual shaft.
! Apply A.T.F. to oil seal
! Wrap threads of manual shaft with masking tape.
b. Insert manual shaft and oil seal as a unit into
transmission case.
c. Remove masking tape.
d. Push oil seal evenly and install it onto the

transmission case.
e. Align groove in shaft with drive pin hole, then drive

pin into position as shown in figure at left.
f. insert detent spring and spacer.
g. While pushing detent spring down, install manual

plate onto manual shaft.

76
h. Insert lock nut onto manual shaft.
2. Install accumulator piston.

a. Install O-rings onto accumulator piston.
A B C D
Small End 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14)
Large End 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77)
mm (in)
b. Install return spring for accumulator “A” onto

transmission case.
! Accumulator “A” free length is 43mm (1.69 in).
c. Install accumulators pistons A, B, C and D.

! Apply A.T.F. to transmission case
3. Install band servo piston.

! Install return springs onto servo piston.

77
b. Install band servo piston onto transmission case.

! Apply A.T.F. to O-ring of band servo piston and
transmission case.
c. Install gasket for band servo onto transmission
case.
d. Install band servo retainer onto transmission case.
4. Install rear side clutch and gear components.

a. Place transmission case in vertical position.
b. Slightly lift forward clutch drum assembly and

slowly rotate it clockwise intill its hub passes fully
over the clutch inner race inside transmission case.
b. Slightly lift forward clutch drum assembly and

slowly rotate it clockwise intill its hub passes fully
over the clutch inner race inside transmission case.

78
d. Install thrust washer onto front of overrun clutch

hub.
! Apply petroleum jelly to the thrust washer .
! Insert pawls of thrust washer securely into holes in
overrun clutch hub.
e. Install overrun clutch hub onto rear internal gear

assembly.
f. Install needle bearing onto rear of overrun clutch

hub.
! Apply petroleum jelly to needle bearing.
! NOTE: Later application may have a 3 piece
bearing rather than a open face bearing. Requires
shorter low sprag race.
FREEWHEEL
g. The rear internal ring gear must freewheel
RING GEAR
clockwise And lock counter clockwise when holding
forward hub.
FREEWHEEL
HOLD
FORWARD
CLUTCH HUB
h. Place transmission case into horizontal posittion.

79
I. Install rear internal gear, forward clutch hub and

overrun clutch hub as a unit into transmission case.
j. Install needle bearing onto rear internal gear.

k. Install bearing race onto rear of front internal gear.

! Apply petroleum jelly to bearing race.
! Securely engage pawls of bearing race with holes in
front internal gear.
l. Install front internal gear on transmission case.

80
ASSEMBLY:
1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case
while slightly front internal gear.
! Do not force output shaft against front of
transmission case.
b. Carefully push output shaft against front of

transmission case. Install snap ring on front of out
put shaft.
! Check to be sure output shaft cannot be removed in
rear direction.
c. Install needle bearing on transmission case.

! Pay attention to its direction, Black side goes to
front.
d. Install parking gear on transmission case.
e. Install snap ring on rear of output shaft.

! Check to be sure output shaft cannot be removed in
forward direction.

81
2. Install rear extension.
a. Install oil seal on rear extension.
! Apply A.T.F. to oil seal.
b. Install O-ring on revolution sensor.

! Apply A.T.F. to O-ring.
c. Install revolution sensor on rear extension.
d. Install rear extension gasket on transmission case.
e. Install parking rod on transmission case.
f. Install rear extension on transmission case.

82
3. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
! Pay attention to its direction.
b. Make sure needle bearing is on front of front

planetary carrier.
c. Make sure needle bearing is on rear of front
planetary carrier.
! Apply petroleum jelly to bearing.
! Pay attention to its direction, Black side goes to
front.
d. While rotating forward clutch drum clockwise,

install front planetary carrier on forward clutch
drum.
! Check that portion “A” of front planetary carrier

protrudes approximately 2mm (0.080 in) beyond
portion “B” of forward clutch assembly.
e. Make sure bearing races are on front and rear of

clutch pack.
! Apply petroleum jelly to bearing races.
! Securely engage pawls of bearing races with holes
in clutch pack.

83
f. Install clutch pack into transmission case.
4. Install brake band and break strut.

a. Install band strut on break band.
! Apply petroleum jelly to band strut.
b. Place brake band on periphery of reverse clutch

drum, and insert band strut onto end of band servo
piston stem.
c. Install anchor end bolt on transmission case. Then,

tighten anchor end bolt just enough so that reverse
clutch drum (clutch pack) will not tilt forward.
5. Install input shaft on transmission case.

! Pay attention to its direction - O-ring groove side is
front.
! 6. Install gasket on transmission case.

84
1. Adjust total end play.

Total end play “T”
0.25 - 0.55mm (0.0089 - 0.0217 in)
a. With needle bearing installed, Place J34291-1

(bridge). J34291-2 (legs) and the J34291-5
(gauging cylinder) onto oil pump. The long ends of
the legs should be placed firmly on machined
surface of oil pump assembly and gauging cylinder
should rest on top of the needle bearing. Lock
gauging cylinder in place with set screw.
b. Install J34291-23 (gauging plunger) into gauging

cylinder.
c. With original bearing race installed inside reverse

clutch drum, place shim selecting guage with its
legs on machined surface of transmission case (no
gasket) and allow gauging plunger to rest on
bearing race. Lock gauging plunger in place with set
screw.
d. Remove tool and use feeler gauge to measure gap

between gauging cylinder and gauging plunger.
This measurement should give exact total end play.
Total end play “T”
0.25 - 0.55mm (0.0089 - 0.0217 in)
! If end play is out of specification, decrease or
increase thickness of oil pump cover bearing race as
necessary.

85
2. Adjust reverse clutch end play.

Reverse clutch end play “T”
0.55 - 0.90mm (0.0217 - 0.0354 in)
a. Place J34291-1 (bridge). J34291-2 (legs) and the

J34291-5 (gauging cylinder) on machined surface
of transmission case (no gasket) and allow gauging
cylinder to rest on front thrust surface of reverse
clutch drum. Lock cylinder in place with set screw.
b. Install J34291-23 (gauging plunger) into gauging

cylinder.
c. With original thrust washer installed on oil pump,

place shim setting gauge legs onto machined
surface of oil pump assembly and allow gauging
plunger to rest on thrust washer. Lock plunger in
place with set screw.
d. Use feeler gauge to measure gap between gauging

plunger and gauging cylinder. This measurment
should give you exact reverse clutch drum play.
Reverse clutch drum end play “T”.
0.55 - 0.99mm (0.0217 - 0.0354 in)
! If end play is out of specification, decrease or
increase thickness of oil pump thrust washer as
necessary.

86
7. Install oil pump assembly.
a. Install needle bearing on oil pump assembly.
! Apply petroleum jelly to the needle bearing.
b. Install selected thrust washer on oil pump
assembly.
! Apply petroleum jelly to thrust washer.
c. Carefully install seal rings into grooves and press

them into the petroleum jelly so that they are a tight
fit.
d. Install O-ring on oil pump assembly.

! Apply petroleum jelly to O-ring.
e. Apply petroleum jelly to mating surface of

transmission case and oil pump assembly.
f. Install oil pump assembly.

! Install two converter housing securing bolts in bolt
holes in oil pump assembly as guides.

87
! Insert oil pump assembly to the specified position in

transmission, as shown to the left.
8. Install O-ring on input shaft.

! Apply A.T.F. to O-ring
9. Install converter to housing. Install O-ring on

converter housing.
Apply recommended sealant Part # KP610-00250

to outer periphery of bolt holes in converter
housing.
! Do not apply too much sealant.
Apply recommended sealant Part # KP610-00250 to

sealing surfaces of bolts that secure front of converter
housing.

88
Install manual valve in control valve.

! Apply A.T.F. to manual valve.
Place control valve assembly on transmission case.

Connect solenoid connector for upper body. Install
connector clip.

connector clip.

connector clip.
Install oil pan gasket on transmission case. Install

oil pan and bracket on transmission case.

89
SPECIFICATIONS AND ADJUSTMENTS

90
SPECIFICATIONS AND ADJUSTMENTS

91

92
LINE PRESSURE CHECKS

93
TORQUE SPECIFICATION CHART
CLUTCH PACK CLEARANCE AND BAND ADJUSTMENT CHART
GEAR RATIOS FOR PATHFINDER, 240SX, & 300ZX TWIN TURBO

94
NISSAN RE4RO1A/3A
PLANETARY FAILURE DUE TO LACK OF LUBE
COMPLAINT: Before or after overhaul, vehicle equipped with an RE4RO1A exhibits planetary
gear train failure, due to lack of lubrication.
CAUSE: The cause may be one of the following.

1. Inadequate cooler flow.
2. Excessive output shaft to case bushing clearance.
3. Excessive clearance between the output shaft bushing and turbine shaft.
4. Forward clutch rings leaking on the low sprag inner race.
5. Internal leak on the turbine shaft.
6. Cooler relief check-ball capsule and spring leaking at the back of the case.
7. Bushing not removed from the front sun gear.
CORRECTION: 1. Insure that the vehicle has sufficient cooler flow. Minimum cooler flow must
be no less than 1 quart per 20 seconds when the vehicle is "HOT".
Warm vehicle until operating temperature is over 160 degrees. Raise and securely
support vehicle on a lift (For safety concerns, do not attempt this test on the
ground). Once operating temperature has been reached, shut motor off.
Disconnect the "Rear" cooler line from the transmission and place the end of the
line into a bucket or suitable apparatus to keep oil from spilling or splashing. Have
a helper get into the vehicle and start the engine. Apply the parking brake then hold
the brake pedal and move the selector lever into the D position. While holding the
brake pedal on, allow the vehicle to idle in drive. IMPORTANT: Visually check
the rear cooler line fitting at the transmission. THERE MUST BE NO OIL
COMING FROM THE CASE. If there is oil coming from the case, the most likely
cause is a leak at the forward clutch rings on the low sprag inner race. Count for
approximately 20 seconds then move the selector lever back to park and shut the
motor off. Measure the amount of oil in the container. There must be a minimum of
1 quart of oil in the container. If less oil flowed from the radiator, disconnect the
front cooler line and repeat the test. If the test still shows insufficient cooler flow,
the problem is most likely a restriction in the valve body. If cooler flow is now
sufficient the problem is a plugged radiator. Repair or replace the radiator as
necessary (Refer to Figure 1 for information on replacement cooler element).
Inspect the case bushings in the back of the case for wear (Refer to Figure 2). If
2. needed insert the output shaft into the case and check for excessive play from side
to side. If side to side movement is excessive replace the case bushings. Using
compressed air and a blow gun, direct air pressure into the different lube holes in
the output shaft and make sure there is no debris blocking the holes and that air
passes through the holes freely.

95
CORRECTION: (Continued)
3. Inspect the output shaft bushing where turbine shaft rides (Refer to Figure 3).
Insert the turbine shaft into the output shaft and move the turbine shaft from side to
side. If excess movement is detected, replace the output shaft bushing.
4. Inspect the forward clutch sealing rings that are installed on the low sprag inner
race (Refer to Figure 4). Make sure there are no cuts or nicks in the rings. Carefully
remove the ring from the inner race and bore fit the rings in the drum.
IMPORTANT: There must be no more than .003’‘ end gap between the butt ends
of the rings. Replace the rings, or the low sprag inner race if necessary.
5. Inspect the turbine shaft for cracks and blow a small amount of compressed air
approx. 30 psi. Into either end of the turbine shaft (Refer to Figure 5).
IMPORTANT: No air must pass completely through the shaft from one end to the
other. The shaft is blocked in the middle to separate converter release oil and lube
oil. If this shaft leaks, all lube will be drained when lock-up is engaged.
Remove the cooler relief check-ball capsule and spring from the back of the
6. transmission case (Refer to Figure 6). Install a solid cup plug or tap the case and
thread in a pipe plug. Note, late model cases (after 1994) had the check-ball
capsule and spring eliminated from the factory.
Remove bushing from the front sun gear and leave it out (Refer to Figure 7). This
7. will allow more lube to pass through the sun gear to the front planetary. Note, if a
new front sun gear shell is purchased from the factory, no bushing will be installed
in the sun gear. Do not install a bushing into a new sun gear shell.

96
Most Nissan vehicles have what is known as a fin type cooler. This type cooler becomes easily restricted causing
poor cooler flow resulting in lack of lubrication to the planetary gear train. Cooler line flushing machines cannot
sufficiently flush this type of cooler. The spiral cooler shown in Figure 1 below is a replacement cooler. This
cooler may be installed instead of replacing the entire radiator.
This cooler is available from Nissan the part number is 21606-15V25.
Spiral Cooler
Part Number 21606-15V25
Figure 1

97
Inspect case bushings

for wear. Replace the
bushings if necessary.
Use compressed air to blow air into

these passages make sure these lube
journals are free from debris. Air
should pass freely throughout the
shaft.
Figure 2

98
Inspect this bushing closely for wear or

damage. All gear train lube for the front of
the transmission must pass through this
bushing. Insert turbine shaft into bushing
to determine amount of side clearance.
Figure 3
Nissan Part Number

31525-41X00
Inspect these rings for nicks and cuts. Also

bore fit the rings in the Forward Drum.
End gap between the butt ends of the rings
must be less than .003". Rings with
excessive gap must be replaced.
Figure 4

99
Air blown into this side

of the shaft should not
exit the other end of
this shaft.
Converter Air blown into this side

Lube to Exhaust of the shaft should not
Front Planets exit the other end of
this shaft.
Figure 5
If there is a bushing installed

in this sun gear, remove it
and leave it out. New shells
from the dealer come without
bushings installed.
Figure 6

100
Remove this cup plug, ball and

spring from the case. Replace with
a solid cup plug or thread the hole
and install a pipe plug.
Figure 7

101
RE4RO1A
HARNESS CONNECTOR PIN DESCRIPTION

102
A/T ELECTRICAL PARTS LOCATION
300 ZX

103
240 SX

104
PATHFINDER

105
PATHFINDER CONT’D

106

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Technical Service Information

We wish to thank Nissan Motor Company

The information and part numbers contained in this booklet have

Copyright © ATSG 2006

WAYNE COLONNA JIM DIAL

DALE ENGLAND ED KRUSE

AUTOMATIC TRANSMISSION SERVICE GROUP

AUTOMATIC TRANSMISSION SERVICE GROUP

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

Power shift indicator lamp Damaged Circuit

t1 = 2.5 seconds t2 = 2.0 seconds t3 = 1.0 seconds

Automatic Transmission Service Group

For circuit tests refer to the Factory Manual

Torque converter lock-up control

Conditions for Lock-Up Operation

Automatic Transmission Service Group

Shift Schedule Control

Relationship of Shift Solenoid to Gear Selection

NOTE: Gear selection is also rlevant to manual valve position.

Shift Solenoid Operation

Shift Valves “A” and “B” Operation

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

Automatic Transmission Service Group

WIRING DIAGRAM Continued

Automatic Transmission Service Group

CIRCUIT DIAGRAM FOR PINPOINT TEST

Automatic Transmission Service Group

BEARING, WASHER AND SNAP RING LOCATION

Automatic Transmission Service Group

2. Check torque converter one-way clutch.

3. Remove inhibitor switch from the trans.

4. Remove oil pan.

5. Place transmission into holding fixture with the

Automatic Transmission Service Group

6. Check oil pan and filter for accumulation of foreign

8. Remover oil filter.

b. Check oil filter for damage.

9. Remove valve body.

Automatic Transmission Service Group

b. Remove bolts “A” and “B”, and remove valve body

c. Remove solenoid connecter.

d. Remove manual valve from valve body.

10. Remove ware harness from wire harness from

Automatic Transmission Service Group

11. Remove bell housing.

b. Remove O-rings from bell housing.

12. Remove O-ring from input shaft.

13. Remove oil pump assembly.

b. Remove O-ring from oil pump assembly.

Automatic Transmission Service Group

d. Remove needle bearing and thrust washer from oil

14. Remove input shaft and oil pump gasket.

14. Remove brake band and band strut.

b. Remove brake band and band strut from case.

c. Hold brake band in a circular shape with clip.

Automatic Transmission Service Group