Automatic Transaxle PDF

AX–1
AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM
AUTOMATIC TRANSAXLE SYSTEM

AX034–01
PRECAUTION
If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.
Author: Date: 1894

AX–2
AX035–01
OPERATION
Planetary Gear Unit 1st & Reverse Brake (B3) 2nd Brake (B2)
2nd Coast brake (B1)
O/D Direct One – Way clutch Forward
Clutch (C0) O/D Brake (B0) Clutch (C1) Direct Clutch (C2)
No.2 (F ) 2
O/D One – Way Counter One Way Clutch

Clutch (F0) Drive Gear Rear No.1 (F1) Input Shaft
Intermediate Planetary Gear Front Planetary
O/D Planetary Gear
Shaft Gear
Shift lever
Gear position C0 C1 C2 B0 B1 B2 B3 F0 F1 F2
position
P Parking
R Reverse
N Neutral
1st
2nd
D
3rd
O/D
1st
2 2nd
*3rd
1st
L
*2nd
: Operating
*: Down–shift only in the 3rd gear for the 2 position and 2nd gear for the L position no up–shift.
D00989
Author: Date: 1895

AX–3
AUTOMATIC TRANSAXLE (A140E) – VEHICLE SPEED SENSOR
VEHICLE SPEED SENSOR AX036–01
ON–VEHICLE REPAIR
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT VEHICLE SPEED SENSOR CONNEC-
TOR
3. REMOVE VEHICLE SPEED SENSOR ASSEMBLY
(a) Remove the bolt and vehicle speed sensor assembly.
Q00207
(b) Remove the clip and speedometer driven gear from ve-
Vehicle Speed Sensor hicle speed sensor.
Drive Gear (c) Remove the O–ring from vehicle speed sensor.
4. INSTALL VEHICLE SPEED SENSOR ASSEMBLY
(a) Coat a new O–ring with ATF and install it to the vehicle
speed sensor.
O–Ring Clip (b) Install the speedometer driven gear to the vehicle speed
sensor and clip.
Q04678 (c) Install the vehicle speed sensor assembly and torque the
bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
5. CONNECT VEHICLE SPEED SENSOR CONNECTOR
6. INSTALL AIR CLEANER ASSEMBLY
Author: Date: 1896

AX–4
AUTOMATIC TRANSAXLE (A140E) – PARK/NEUTRAL POSITION (PNP) SWITCH
PARK/NEUTRAL POSITION (PNP)

SWITCH AX037–01
ON–VEHICLE REPAIR
1. REMOVE CONTROL SHAFT LEVER
(a) Remove the nut and control cable.
(b) Remove the nut, washer and control shaft lever.
2. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
3. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Pry off the lock washer and remove the nut.
(b) Remove the 2 bolts and park/neutral position switch.
4. INSTALL PARK/NEUTRAL POSITION SWITCH
(a) Install the park/neutral position switch with 2 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Install a new lock plate and the nut.
(c) Bend claws on the lock plate to fix the nut.
Q10050
(d) Adjust the park/neutral position switch.
(See page DI–389)
5. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
6. INSTALL CONTROL SHAFT LEVER
(a) Install the control shaft lever, washer and nut.
(b) Install the control cable and nut.
Author: Date: 1897

AX–5
AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY
VALVE BODY ASSEMBLY AX038–01
ON–VEHICLE REPAIR
1. DRAIN TRANSAXLE FLUID
2. REMOVE OIL PAN AND GASKET

NOTICE:
Some fluid will remain in the oil pan.
Remove the oil pan bolts, and carefully remove the oil pan as-
sembly. Discard the gasket.
Q00073
3. EXAMINE PARTICLES IN PAN

Remove the magnets and use them to collect any steel chips.
Look carefully at the chips and particles in the pan and on the
magnet to anticipate what type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear
AT0103
36 (1.417) mm (in.) 4. REMOVE MANUAL VALVE BODY DETENT SPRING

AND MANUAL VALVE BODY
(a) Remove the detent spring on the manual valve body.
(b) Remove the manual valve body.
14 (0.551)
AT2711 Z10944
5. REMOVE OIL STRAINER AND OIL PIPE BRACKET

mm (in.)
(a) Remove the 3 bolts and the oil strainer.
(b) Remove the 2 bolts and oil pipe bracket.
20
(0.787) NOTICE:
50 Be careful as oil will come out of the strainer when it is re-
45 (1.969) moved.
(1.772)
AT3336
Z10940
Author: Date: 1898

AX–6
6. DISCONNECT SOLENOID CONNECTORS
AT0493 Z10941
7. REMOVE OIL PIPES

Pry up the both pipe ends with a large screwdriver and remove
the 4 pipes.
NOTICE:
Be careful not to bend or damage the pipe.
AT7868
8. REMOVE VALVE BODY

Remove the 12 bolts.
AT0399
9. REMOVE THROTTLE CABLE

(a) Disconnect the throttle cable.
(b) Remove the valve body.
10. REMOVE 2ND BRAKE APPLY GASKET
OR0038
mm (in.) 16 (0.63) 11. REMOVE SHIFT SOLENOID VALVE NO.1 AND NO.2
Shift Solenoid (a) Remove the 2 bolts and shift solenoid valve No.1.
Valve No.1 (b) Remove the bolt and shift solenoid valve No.2.
(c) Remove the 2 O–rings from the shift solenoid valve No.1
and No.2.
Shift Solenoid
16 (0.63) Valve No.2
AT3008 Z19291
Author: Date: 1899

AX–7
12. INSTALL SHIFT SOLENOID VALVE NO.1 AND NO.2

(a) Coat 2 new O–rings with ATF.
(b) Install the 2 O–rings to the shift solenoid valve No.1 and
No.2.
(c) Install the shift valve No.1 with the 2 bolts.
(d) Install the shift valve No.2 with the bolt.
13. INSTALL NEW 2ND BRAKE APPLY GASKET
14. INSTALL VALVE BODY

(a) While holding the cam down by your hand, slip the cable
end into the slot.
NOTICE:
Do not entangle the solenoid wire.
OR0038
B C (b) Install the valve body with the 12 bolts.

A HINT:
B Temporarily install the 12 bolts first, then tighten the 12 bolts.
A Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
Bolt length:
B
Bolt A: 20 mm (0.79 in.)
D Bolt B: 25 mm (0.98 in.)
C Bolt C: 36 mm (1.42 in.)
AT0492 Z10942 Bolt D: 50 mm (1.97 in.)
15. INSTALL OIL PIPES

Using a plastic hammer, install the 4 pipes into the positions in-
dicated in the illustration.
NOTICE:
Be careful not to bend or damage the pipes.
AT7870
Shift Solenoid Valve No.1 16. CONNECT SOLENOID CONNECTORS

Connect the black wire harness to shift solenoid valve No.2 and
Shift Solenoid Valve No.2
white wire harness to shift solenoid valve No.1.
White
AT0493 Black Z10941
Author: Date: 1900

AX–8
mm (in.) 17. INSTALL OIL STRAINER AND OIL PIPE BRACKET

(a) Install the 2 bolts and oil pipe bracket.
20
(0.78)
(b) Install the 3 bolts and oil strainer.
50 Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
45 (1.969)
(1.772)
AT3336 Z10940
36 (1.417) mm (in.) 18. INSTALL MANUAL VALVE BODY DETENT SPRING

AND MANUAL VALVE BODY
(a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Temporarily install the 4 bolts first. Then, tighten them with
a torque wrench.
14 (0.551) Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
AT2711 Z10944 (d) Place the detent spring on the manual valve body and
temporarily install the 2 bolts first.
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
19. INSTALL MAGNETS IN OIL PAN

NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
Magnets
AT2368 Z10945
20. INSTALL OIL PAN AND GASKET

Install a new gasket and oil pan with the 15 bolts.
21. FILL FLUID AND CHECK FLUID LEVEL
(See page DI–389)
Q00073
Author: Date: 1901

AX–9
AUTOMATIC TRANSAXLE (A140E) – THROTTLE CABLE
THROTTLE CABLE AX039–01
ON–VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE
(a) Disconnect the cable from the throttle linkage.
(b) Disconnect the cable from the cable clamps in the engine
compartment.
(See page AX–4)
3. REMOVE VALVE BODY (See page AX–5)
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
Q10052
5. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR

PAINT MARK ON INNER CABLE
HINT:
New cable does not have a staked cable stopper.
(a) Bend the cable to ensure a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until a slight resistance is felt,
and hold it there.
200 mm (c) Stake the stopper, 0.8 – 1.5 mm (0.031 – 0.059 in.) from
0.8 – 1.5 mm(0.031 – 0.059 in.) (7.87 in.)
the end of the outer cable.
(d) Install a new O–ring to the throttle cable.
(e) Push in the throttle cable and install the retaining bolt.
6. INSTALL VALVE BODY (See page AX–5)
Q10339 7. INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX–4)
8. CONNECT THROTTLE CABLE
9. FILL FLUID AND CHECK FLUID LEVEL
(See page DI–389)
10. ADJUST THROTTLE CABLE (See page DI–389)
Author: Date: 1902

AX–10
AUTOMATIC TRANSAXLE (A140E) – SHIFT SOLENOID VALVE SL
SHIFT SOLENOID VALVE SL AX03A–01
ON–VEHICLE REPAIR
(See page AX–4)
2. DISCONNECT SHIFT SOLENOID VALVE SL CONNEC-
TOR
3. REMOVE SHIFT SOLENOID VALVE SL
Q10051
(a) Remove the 2 bolts and shift solenoid valve SL.
(b) Remove the 2 O–rings from the shift solenoid valve SL.
4. INSTALL SHIFT SOLENOID VALVE SL
(a) Coat 2 new O–rings with ATF and install them to the shift
solenoid valve SL.
(b) Install the shift solenoid valve SL and 2 bolts.
5. CONNECT SHIFT SOLENOID VALVE SL CONNECTOR
(See page AX–4)
Author: Date: 1903

AX–11
AUTOMATIC TRANSAXLE (A140E) – DIFFERENTIAL OIL SEAL
DIFFERENTIAL OIL SEAL AX03B–01
SST ON–VEHICLE REPAIR

1. REMOVE LH AND RH DRIVE SHAFTS
(See page SA–17)
2. REMOVE SIDE GEAR SHAFT OIL SEAL
Using SST, drive out the oil seals on both sides.
SST 09308–00010
Q00394
3. INSTALL SIDE GEAR SHAFT OIL SEAL

(a) Using SST, drive in a new oil seal.
SST 09350–32014 (09351–32130, 09351–32150)
Oil seal depth:
LH: 2.7 ± 0.5 mm (0.106 ± 0.020 in.)
RH: 0 ± 0.5 mm (0 ± 0.020 in.)
SST (b) Coat the lip of oil seal with MP grease.
4. INSTALL LH AND RH DRIVE SHAFTS
Q00247 (See page SA–24)
5. CHECK TRANSAXLE FLUID LEVEL
(See page DI–389)
Author: Date: 1904

AX–12
AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made)
SHIFT LOCK SYSTEM (TMC Made)

AX03C–01
LOCATION
Shift Lock Override Cover
Shift Lock Override Button
Stop Light Switch
Key Interlock Solenoid
Shift Lock
Control Unit Assembly
D00760
Author: Date: 1905

AX–13
AX03D–01
5 (IG) INSPECTION
1 (ACC) 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY
4 (KLS+) Using a voltmeter, measure the voltage at each terminal.
HINT:
3 (E) Do not disconnect the shift lock control unit assembly connec-
tor.
2 (STP)
Wire Harness Side D00758
Terminal Measuring Condition Voltage (V)

1 – 3 (ACC – E) Ignition switch ACC 10 – 14
5 – 3 (IG – E) Ignition switch ON 10 – 14
2 – 3 (STP – E) Depressing brake pedal 10 – 14
(1) Ignition switch ACC and P position 0
4 – 3 (KLS+ – E) (2) Ignition switch ACC and except P position 7.5 – 11
(3) Ignition switch ACC and except P position (After approx. 1 second) 6 – 9.5
1 (KLS+)
2. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure resistance between termi-
nals.
2 (E) Standard resistance: 12.5 – 16.5 Ω
If resistance value is not as specified, replace the solenoid.
Q09456
(c) Apply battery positive voltage between terminals. Check

1 (KLS+)
that an operation noise can be heard from the solenoid.
If the solenoid does not operate, replace the solenoid.
2 (E)
Q09457
Author: Date: 1906

AX–14
AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made)
SHIFT LOCK SYSTEM (TMMK Made)

AX03E–01
LOCATION
Stop Light Switch
Key Interlock Solenoid Shift Lock Solenoid
Shift Lock Control ECU Shift Lock Control Switch

D00759
Author: Date: 1907

AX–15
AX03F–01
3 (IG) 1 (ACC) INSPECTION

6 (STP) Back Side 1. INSPECT SHIFT LOCK CONTROL ECU
A 1 (P) Using a voltmeter, measure voltage at each terminal.
4 (KLS+)
5 (SLS–) HINT:
4 (P2)
Do not disconnect the ECU connector.
B
3 (P1)
2 (SLS+) Front Side Q09459

A, 1 – A, 5 (ACC – E) Ignition switch ACC 10 – 14
A, 3 – A, 5 (IG – E) Ignition switch ON 10 – 14
A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14
A, 4 – A, 5 (KLS+ – E) (2) Ignition switch ACC and except P position 7.5 – 11
(1) Ignition switch ON and P position 0
B, 2 – B, 5 (SLS+ – SLS–) (2) Depress brake pedal 8 – 13.5
(3) Except P position 0
(1) Ignition switch ON, P position and depressing brake pedal 0
B, 3 – B, 1 (P1 – P)
(2) Shift except P position under conditions above 9 – 13.5
(1) Ignition switch ACC, P position 9 – 13.5

B, 4 – B, 1 (P2 – P)
(2) Shift except P position under conditions above 0
2. INSPECT SHIFT LOCK SOLENOID

5 (SLS–)
nals.
Standard resistance: 29 – 35 Ω
2 (SLS+)
Q09460

5 (SLS–)
that operation noise can be heard from the solenoid.
2 (SLS+)
Q09461
Author: Date: 1908

AX–16
1 (KLS+) 3. INSPECT KEY INTERLOCK SOLENOID

nals.
Q09456
1 (KLS+)
2 (E)
Q09457
3 (P1) 4 (P2) 4. INSPECT SHIFT LOCK CONTROL SWITCH

1 (P)
Inspect that there is continuity between each terminal.
Shift position Tester connection Specified value
P position (Release
1 – 3 (P – P1) Continuity
button is not pushed)
P position (Release 1 – 3 (P – P1)
Continuity
button is pushed) 1 – 4 (P – P2)
R, N, D, 2, L position 1 – 4 (P – P2) Continuity

Q09464
If continuity is not as specified, replace the switch.
Author: Date: 1909

AX–17
AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT
AUTOMATIC TRANSAXLE UNIT

AX03G–01
COMPONENTS
14 (145, 10)
Air Cleaner Assembly
Engine Hood
14 (145, 10)
Starter
Hold Down Clamp
Cruise Control Actuator
RH Drive Shaft
66 (670, 48) 42 (430, 31)
Torque Converter
39 (400, 29) Manifold Stay
Clutch
Snap Ring
Stiffener
32 (330, 24)
Plate
Battery
27 (280, 20)
TMMK
x6 39 (400, 29) Battery Tray
42 (430, 31) 39 (400, 29)

TMC
42 (430, 31) LH Drive Shaft
Stiffener Plate 66 (670, 48)
Clip Snap Ring
42 (430, 31)
Shift Control Cable
Exhaust
66 (670, 48)
15 (150, 11) Manifold Stay
Plug for Line Pressure Test
19 (195, 14)
No.1 Exhaust Pipe Support Bracket
Rear End Plate
25 (250, 18)
Oil Pan Insulator
N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
Q10053
Author: Date: 1910

AX–18
RH Fender Apron seal RR Engine Mounting Stabilizer Bar

TMC Made : 80 (820, 59) 19 (195, 14)
TMMK Made :
Green Color Bolt : 66 (670, 48)
Silver Color Bolt : 44 (450, 32)
RH Rear
10 (100, 7)
Lower Brace LH Engine Mounting
64 (650, 47)
39 (400, 29)
Steering Return Pipe
FR Engine Mounting
Stabilizer Bar Link
RH Front Lower Brace 181 (1,850, 134)
LH Rear Lower Brace
66 (670, 48)
32 (330, 24)
Front Suspension
36 (370, 27)
Member
181 (1,850, 134)
TMC Made : 80 (820, 59)
TMMK Made :
LH Front
127 (1,300, 94)
Green Color Bolt : 66 (670, 48) Lower Brace 80 (820, 59)
Silver Color Bolt : 44 (450, 32) 36 (370, 27) 181 (1,850, 134)
Front Exhaust Pipe 56 (570, 41)
Gasket
62 (630, 46)
Gasket
LH Fender Apron Seal
Exhaust Pipe No.1 Support Bracket
Tie Rod End
33 (330, 24) 49 (500, 36)
Exhaust Pipe
LH Fender Liner Cotter Pin
Clamp
33 (330, 24)
294 (3,000, 217)

Lock Nut Cap
Center Engine Under Cover
LH Fender Liner
Engine Under Cover

Non–reusable part
Q10054
Author: Date: 1911

AX–19
AX03H–01
REMOVAL
1. REMOVE BATTERY
3. DISCONNECT THROTTLE CABLE
4. w/ CRUISE CONTROL:
REMOVE CRUISE CONTROL ACTUATOR
(a) Disconnect the connector.
(b) Remove the 3 bolts and disconnect cruise control actua-
tor with the bracket.
Q10055
5. DISCONNECT OIL COOLER HOSE

TOR
CONNECTOR
8. DISCONNECT SHIFT SOLENOID VALVE NO.1 AND
NO.2 CONNECTOR
9. DISCONNECT SHIFT SOLENOID VALVE SL CONNEC-
Q00211 TOR
10. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS

Torque:
TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf)
TMMK made:
Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf)
Silver color bolt: 44 N·m (450 kgf·cm, 32 ft·lbf)
Q10056
11. DISCONNECT 2 GROUND CABLES

12. REMOVE STARTER
(a) Disconnect the connector and remove the nut.
(b) Remove the 2 bolts, shift cable clamp and starter.
13. REMOVE 3 TRANSAXLE–TO–ENGINE BOLTS
Q10057
Author: Date: 1912

AX–20
14. REMOVE EXHAUST MANIFOLD STAY

Remove the 2 bolts and exhaust manifold stay.
15. REMOVE TRANSAXLE–TO–ENGINE BOLT
16. REMOVE ENGINE HOOD
(a) Disconnect the washer pipe.
(b) Remove the 4 bolts and engine hood.
Q10058 Torque: 14 N·m (145 kgf·cm, 10 ft·lbf)
17. RAISE AND SUPPORT VEHICLE SECURELY
18. REMOVE FRONT WHEELS
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
19. REMOVE ENGINE UNDER COVER AND CENTER EN-
GINE UNDER COVER
20. DISCONNECT SHIFT CONTROL CABLE

(a) Remove the nut and disconnect the shift control cable
from the park/neutral position switch.
(b) Remove the clip and disconnect the shift control cable
from the bracket.
Q10059
21. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND

GASKET
HINT:
At the time of installation, please refer to the following item.
Replace the used gasket with a new gasket.
22. DRAIN DIFFERENTIAL FLUID
23. REMOVE LH AND RH FENDER APRON SEALS
24. REMOVE LH AND RH DRIVE SHAFTS
Q00251 (See page SA–17)
Author: Date: 1913

AX–21
25. REMOVE EXHAUST FRONT PIPE

(a) Remove the 2 nuts and exhaust front pipe clamp.
(b) Remove the 2 bolts and exhaust pipe No.1 support brack-
et.
(c) Remove the 3 nuts.
Q10060 HINT:
Replace the used nuts with new ones.
(d) Remove the 2 bolts, nuts and front exhaust pipe.
HINT:
Replace the used nuts with new ones.
(e) Remove the 2 gaskets.
HINT:
Replace the used gaskets with new ones.
26. REMOVE FRONT SIDE ENGINE MOUNTING INSULA-
TOR BOLT
Torque:
TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf)
TMMK made:
Q00068
27. REMOVE REAR SIDE ENGINE MOUNTING NUT

(a) Remove the 2 grommets.
(b) Remove the 3 nuts.
Q08532
28. REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT

Q10061
Author: Date: 1914

AX–22
29. REMOVE STEERING GEAR HOUSING

(a) Remove the 4 bolts, LH and RH stabilizer bar brackets
and bushings.
Torque:19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Remove the front stabilizer bar. (See page SA–48)
(c) Remove the 2 steering gear housing mounting bolts and
nuts.
Q10062
30. TIE STEERING GEAR HOUSING TO REAR ENGINE

MOUNTING BRACKET BY CORD OR EQUIVALENT
31. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-
ERS
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
Q10063
32. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the 2 bolts and steering return pipe mounting
brackets.
Q06479
(b) Remove the screws and turn over the front side of the LH
and RH fender liners.
Q10041
(c) Remove the screws and turn over the rear side of LH and
RH fender liners.
Q10037
Author: Date: 1915

AX–23
Front (d) Remove the 6 bolts and 4 nuts.

Torque:
19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf)
Nut: 36 N·m (370 kgf·cm, 27 ft·lbf)
(e) Remove the front frame assembly.
33. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
Q10172
Rear
Q10064
34. REMOVE FRONT SIDE STIFFENER PLATE

TMMK made:
Remove the nut, 2 bolts and stiffener plate.
TMC : Bolt Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
TMMK : Nut TMC made:
Remove the 3 bolts and stiffener plate.
35. REMOVE REAR END PLATE
Q10065 (a) Remove the 2 bolts and No.1 exhaust pipe support brack-
et.
(b) Remove the 2 bolts and rear end plate with oil pan insula-
tor.
Author: Date: 1916

AX–24
36. REMOVE TORQUE CONVERTER CLUTCH MOUNT-

ING BOLT
Turn the crankshaft to gain access to each bolt, remove the 6
bolts with holding the crankshaft pulley set bolt by a wrench.
HINT:
First the install black colored bolt and then the 5 other bolts.
Q10066 37. REMOVE REAR SIDE STIFFENER PLATE
(a) Remove the 2 bolts and manifold stay.
(b) Remove the 4 bolts and stiffener plate.
38. REMOVE TRANSAXLE ASSEMBLY
Separate the transaxle and engine, and lower the transaxle.
Author: Date: 1917

AX–25
AX03I–01
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using a scale and a straight edge, measure to the distance from
the installed surface to the transaxle housing.
Correct distance: 13.0 mm (0.512 in.) or more
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal (See page
AT3412
AX–19).
HINT:
After installation, check and inspect items as follows.
Fluid level (See page DI–389)
Front wheel alignment (See page SA–4)
Road test of the vehicle
Engine hood (See page BO–10)
Author: Date: 1918

AX–26
AUTOMATIC TRANSAXLE (A140E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE
SST TORQUE CONVERTER CLUTCH

AND DRIVE PLATE AX03J–01
INSPECTION
1. INSPECT ONE–WAY CLUTCH
(a) Install SST into the inner race of the one–way clutch.
SST 09350–32014 (09351–32010)
(b) Install SST so that it fits in the notch of the converter hub
AT0953
and outer race of the one–way clutch.
SST 09350–32014 (09351–32020)
(c) With the torque converter clutch standing on its side,the

Hold clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
Lock the converter clutch if the clutch still fails the test.
Free
Turn
AT3306
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR
Set up a dial indicator and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Q04237
Author: Date: 1919

AX–27
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE

RUNOUT
(a) Temporarily mount the torque converter clutch to the drive
plate.
Set up a dial indicator and measure the torque converter
clutch sleeve runout.
If the runout is not within the specification, try to correct by reori-
AT4184 enting the installation of the torque converter clutch. If exces-
sive runout cannot be corrected, replace the torque converter
clutch.
HINT:
Mark the position of the torque converter clutch to ensure the
correct installation.
(b) Remove the torque converter clutch.
Author: Date: 1920

AX–1
AUTOMATIC TRANSAXLE SYSTEM

AX03L–01
PRECAUTION
If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN sec-
tion.
Author: Date: 1921

AX–2
AX03M–01
OPERATION
Planetary Gear Unit 1st and Reverse 2nd Brake (B2) 2nd Coast Brake
O/D Direct Clutch (C0) Brake (B3) (B1)
O/D Brake (B0) One–Way Clutch Forward Clutch Direct Clutch
No.2 (F2) (C1) (C2)
O/D One–Way Clutch One–Way Clutch

(F0) Counter Drive No.1 (F1) Input Shaft
Gear Rear Planetary Gear
O/D Planetary Gear Intermediate Shaft Front Planetary Gear
Shift Lever
Gear Position C0 C1 C2 B0 B1 B2 B3 F0 F1 F2
Position
P Parking
R Reverse
N Neutral
1st
2nd
D
3rd
O/D
1st
2
2nd
*3rd
1st
L
*2nd
*Down–shift only – no up–shift

: Operating
D01018
Author: Date: 1922

AX–3
AUTOMATIC TRANSAXLE (A541E) – VEHICLE SPEED SENSOR
VEHICLE SPEED SENSOR AX03N–01
ON–VEHICLE REPAIR
TOR
3. REMOVE VEHICLE SPEED SENSOR ASSEMBLY
(a) Remove the bolt and vehicle speed sensor assembly.
Q05725
(b) Remove the clip and driven gear from the vehicle speed
Vehicle Speed Sensor sensor.
(c) Remove the O–ring from the vehicle speed sensor.
Driven Gear
4. INSTALL VEHICLE SPEED SENSOR ASSEMBLY
(a) Coat a new O–ring with ATF and install it to the vehicle
speed sensor.
O–Ring (b) Install the driven gear to the vehicle speed sensor and
Clip
clip.
Q04678 (c) Install the vehicle speed sensor assembly with the bolt.
5. CONNECT VEHICLE SPEED SENSOR CONNECTOR
6. INSTALL AIR CLEANER ASSEMBLY
Author: Date: 1923

AX–4
AUTOMATIC TRANSAXLE (A541E) – DIRECT CLUTCH SPEED SENSOR
DIRECT CLUTCH SPEED SENSOR AX03O–01
ON–VEHICLE REPAIR
1. DISCONNECT DIRECT CLUTCH SPEED SENSOR
CONNECTOR
2. REMOVE DIRECT CLUTCH SPEED SENSOR
(a) Remove the bolt and direct clutch speed sensor.
Q05726
(b) Remove the O–ring from direct clutch speed sensor.

O–Ring 3. INSTALL DIRECT CLUTCH SPEED SENSOR
(a) Coat a new O–ring with ATF and install it to the direct
clutch speed sensor.
(b) Install the direct clutch speed sensor with the bolt.
Q04733
Author: Date: 1924

AX–5
PARK/NEUTRAL POSITION (PNP)

SWITCH AX03P–01
ON–VEHICLE REPAIR

CONNECTOR
Q00229

(a) Remove the clip from the shift control cable.
(b) Remove the nut and control cable.
Q06496
(c) Remove the nut, washer and transaxle control shaft lever.
(d) Using a screwdriver, pry off the lock plate.
(e) Remove the nut and lock plate.
(f) Remove the 2 bolts and pull out the park/neutral position
switch.
Q05727
3. INSTALL AND ADJUST PARK/NEUTRAL POSITION

SWITCH
(a) Temporarily install the park/neutral position switch with
the 2 bolts.
(b) Install a new lock plate and nut.
(c) Stake the nut with the lock plate.
Q04617
Author: Date: 1925

AX–6
Neutral (d) Adjust the park/neutral position switch.

Basic (See page DI–438)
Line
Groove
Z10304
(e) Install the transaxle control shaft lever and washer.

(f) Install and torque the nut.
Q04687
(g) Install the control cable and nut.

(h) Install the clip to the shift control cable.
4. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
5. TEST DRIVE VEHICLE
Q06496
Author: Date: 1926

AX–7
VALVE BODY ASSEMBLY AX03Q–02
ON–VEHICLE REPAIR
1. DRAIN ATF
Using a hexagon wrench, remove the drain plug and fluid into
the suitable container.
2. REMOVE OIL PAN AND GASKET
NOTICE:
Some fluid will remain in the oil pan.
Remove oil pan bolts, and carefully remove the pan assembly.
Discard the gasket.
AT3785
3. EXAMINE PARTICLES IN PAN

Remove the magnets and use them to collect any steel chips.
Look at the chips and particles in the pan and magnet carefully
to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear
AT0103
4. REMOVE OIL STRAINER AND APPLY PIPE BRACKET

(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as oil will come out of the strainer when it is re-
moved.
(b) Remove the 3 bolts and apply pipe bracket.
D01019
Connector 5. REMOVE OIL PIPES

Pry up both pipe ends with a large screwdriver and remove the
5 pipes.
6. DISCONNECT SOLENOID CONNECTORS
Q05728
Author: Date: 1927

AX–8
7. REMOVE DETENT SPRING AND OIL PIPE

(a) Remove the 2 bolts and detent spring.
(b) Remove the bolt.
(c) Pry up the pipe with a screwdriver and remove the pipe.
D01020
8. REMOVE MANUAL VALVE BODY

Remove the 5 bolts and manual valve body.
D01021
9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER

Remove the 2 bolts, connector clamp and pipe retainer.
D01059
10. REMOVE B3 APPLY PIPE

Pry up the pipe with a screwdriver and remove the pipe.
D01058

(a) Remove the 9 bolts.
D01023
Author: Date: 1928

AX–9
(b) Disconnect the throttle cable from the cam and remove
the valve body.
12. REMOVE 2ND BRAKE APPLY GASKET
OR0038
13. REMOVE SOLENOID VALVES

(a) Remove the 3 bolts, shift solenoid valve No.1 and No.2
with the retainer.
NOTICE:
When removing solenoid, do not use a screwdriver, etc. to
pry up the solenoid.
(b) Remove the O–rings from the shift solenoid valve No.1
and No.2.
Q05643
(c) Remove the bolt and shift solenoid valve SL.

(d) Remove the O–ring from the shift solenoid valve SL.
Q05657
(e) Remove the bolt and shift solenoid valve SLN.

(f) Remove the O–ring from the shift solenoid valve SLN.
Q05402
14. INSTALL SOLENOID VALVES

(a) Coat the 2 new O–rings with ATF and install it to the shift
solenoid valve SL.
(b) Install the shift solenoid valve SL.
(c) Install and torque the bolt.
Q05657
Author: Date: 1929

AX–10
(d) Coat the 2 new O–rings with ATF and install it to the shift
solenoid valve SLN.
(e) Install the shift solenoid valve SLN.
(f) Install and torque the bolt.
Q05402
(g) Coat the 2 new O–rings with ATF and install it to the shift
solenoid valve No.1 and No.2.
(h) Install the No.1 and No.2 solenoids.
(i) Install and torque the 3 bolts.
15. PLACE NEW 2ND BRAKE APPLY GASKET
Q05643
16. INSTALL VALVE BODY TO TRANSAXLE CASE

(a) While holding the cam down with your hand, slip the cable
end into the slot.
(b) Lower the valve body into place.
NOTICE:
Be careful not to entangle the solenoid wire.
OR0038
D (c) Install and tighten the 9 bolts.

D
A HINT:
Hand tighten the 9 bolts first, then torque with a torque wrench.
C Bolt length:
Bolt A: 30 mm (1.181 in.)
C Bolt B: 43 mm (1.693 in.)
Bolt C: 48 mm (1.890 in.)
Bolt D: 52 mm (2.047 in.)
B C D01023 Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
17. INSTALL B3 APPLY PIPE

NOTICE:
D01058
Author: Date: 1930

AX–11
B 18. INSTALL CONNECTOR CLAMP AND PIPE RETAINER

(a) Install the connector clamp and pipe retainer.
(b) Install and torque the 2 bolts.
Bolt length:
A
Bolt A: 48 mm (1.890 in.)
Bolt B: 39 mm (1.535 in.)
D01059
19. INSTALL MANUAL VALVE BODY

B (a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Hand tighten the 5 bolts first. Then, tighten them with a
torque wrench.
B Bolt length:
Bolt A: 22 mm (0.866 in.)
A D01021 Bolt B: 37 mm (1.457 in.)
20. INSTALL DETENT SPRING AND OIL PIPE
30 (a) Place the detent springs on the manual valve body and
(1.18)
hand tighten the 2 bolts first. Then, tighten them with a
torque wrench.
Bolt length:
Bolt A: 14 mm (0.551 in.)
Bolt B: 37 mm (1.457 in.)
B A mm (in.)
Z19257 (b) Check that the manual valve lever is touching the center
of the detent spring tip roller.
(c) Using a plastic hammer, install the pipe into the position.
NOTICE:
(d) Install and torque the bolt.
Connector 21. CONNECT SOLENOID CONNECTORS

22. INSTALL OIL PIPES
Using a plastic hammer, install the pipes into the positions.
NOTICE:
Be careful not to bend or damage the pipes.
Q05728
Author: Date: 1931

AX–12
23. INSTALL OIL STRAINER AND APPLY PIPE BRACKET

A A
(a) Install the oil strainer and apply pipe bracket.
B (b) Install and torque the 6 bolts.
Bolt length:
Bolt A: 22 mm (0.866 in.)
Bolt B: 53 mm (2.087 in.)
B
Torque:
Bolt A: 10 N·m (100 kgf·cm, 7 ft·lbf)
Z19256 Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf)
24. INSTALL MAGNETS IN PLACE

Install the 3 magnets in the indentations of the oil pan, as shown
in the illustration.
NOTICE:
Make sure that the magnet does not interfere with the oil
pipes.
AT3741
25. INSTALL OIL PAN AND GASKET

(a) Install the oil pan and a new gasket.
(b) Install and torque the 17 new bolts.
26. INSTALL AND TORQUE DRAIN PLUG
27. FILL ATF AND CHECK FLUID LEVEL
(See page DI–438)
AT3785
Author: Date: 1932

AX–13
THROTTLE CABLE AX03R–01
ON–VEHICLE REPAIR
1. REMOVE BATTERY
2. w/ Cruise Control:
Remove the 3 bolts and cruise control actuator.
Q09982
3. DISCONNECT THROTTLE CABLE FROM ENGINE

Disconnect the cable from the throttle linkage.
(See page AX–5)
(See page AX–7)
Q00225

(a) Remove the bolt and retaining plate.
(b) Pull out the cable from the transaxle case.
Q00270
7. INSTALL THROTTLE CABLE INTO TRANSAXLE

CASE
(a) Make sure to push it in all the way.
(b) Install the retaining plate and bolt.
(c) Install and torque the bolt.
8. INSTALL VALVE BODY
(See page AX–7)
Q00270
9. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR

PAINT MARK ON INNER CABLE
200 mm HINT:
(7.87 in.) New cables do not have a staked cable stopper.
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until slight resistance is felt, and
hold it there.
0.8 – 1.5 mm (0.031–0.059 in.)
Q05731 (c) Stake the stopper, 0.8–1.5 mm (0.031–0.059 in.) from the
end of outer cable.
Author: Date: 1933

AX–14
10. CONNECT THROTTLE CABLE TO ENGINE

11. ADJUST THROTTLE CABLE
(See page DI–438)
(See page AX–5)
Q00225

INSTALL CRUISE CONTROL ACTUATOR
Install the cruise control actuator with the 3 bolts.
14. INSTALL BATTERY
15. TEST DRIVE VEHICLE
Q09982
Author: Date: 1934

AX–15
AUTOMATIC TRANSAXLE (A541E) – DIFFERENTIAL OIL SEAL
DIFFERENTIAL OIL SEAL AX03S–01
SST ON–VEHICLE REPAIR

1. REMOVE FRONT DRIVE SHAFT
(See page SA–25)
2. REMOVE SIDE GEAR SHAFT OIL SEAL
Using SST, pull out the oil seal.
SST 09308–00010
Q00394
3. INSTALL LEFT SIDE GEAR SHAFT OIL SEAL

SST (a) Using SST and a hammer, drive in a new oil seal.
SST 09223–15020, 09351–32014 (09351–32130)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.)
(b) Coat the lip of the oil seal with MP grease.
Q06348
4. INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL

(a) Using SST, drive in a new oil seal.
SST 09316–60010 (09316–00010)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL FRONT DRIVE SHAFT
SST (See page SA–25)
6. CHECK TRANSAXLE FLUID LEVEL
Q00238 (See page DI–438)
Author: Date: 1935

AX–16
SHIFT LOCK SYSTEM (TMC Made)

AX03T–01
LOCATION
Stop Light Switch
Shift Lock Control Unit Assembly
D01026
Author: Date: 1936

AX–17
AX03U–02
5 (IG) INSPECTION
1 (ACC) 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY
4 (KLS+) Using a voltmeter, measure the voltage at each terminal.
HINT:
3 (E) Do not disconnect the shift lock control unit assembly connec-
tor.
2 (STP)
Wire Harness Side Q09455

1 – 3 (ACC – E) Ignition switch ACC 10 – 14
5 – 3 (IG – E) Ignition switch ON 10 – 14
2 – 3 (STP – E) Depressing brake pedal 10 – 14
4 – 3 (KLS+ – E) (2) Ignition switch ACC and except P position 7.5 – 11
1 (KLS+)
nals.
Q09456

1 (KLS+)
If the solenoid does not operated, replace the solenoid.
2 (E)
(–) (+) Q09457
Author: Date: 1937

AX–18
SHIFT LOCK SYSTEM (TMMK Made)

AX03V–01
LOCATION
Stop Light Switch

Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU

D01027
Author: Date: 1938

AX–19
AX03W–01
3 (IG) 1 (ACC) INSPECTION

6 (STP) Back Side 1. INSPECT SHIFT LOCK CONTROL ECU
A
1 (P) Using a voltmeter, measure voltage at each terminal.
5 (E) 4 (KLS+)
HINT:
4 (P2) 5 (SLS–)
Do not disconnect the ECU connector.
B
3 (P1)
2 (SLS+) Front Side
Q09459

A, 1 – A, 5 (ACC – E) Ignition switch ACC 10 – 14
A, 3 – A, 5 (IG – E) Ignition switch ON 10 – 14
A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14
A, 4 – A, 5 (KLS+ – E) (2) Ignition switch ACC and except P position 7.5 – 11
(1) Ignition switch ON and P position 0
B, 2 – B, 5 (SLS+ – SLS–) (2) Depress brake pedal 8 – 13.5
(3) Except P position 0
(1) Ignition switch ON, P position and depress brake pedal 0
B, 3 – B, 1 (P1 – P)
(2) Shift except P position under conditions above 9 – 13.5
(1) Ignition switch ACC, P position 9 – 13.5

B, 4 – B, 1 (P2 – P)
(2) Shift except P position under conditions above 0
2. INSPECT SHIFT LOCK SOLENOID

5 (SLS–)
nals.
Standard resistance: 29 – 35 Ω
2 (SLS+)
Q09460

5 (SLS–)
that operation.
If the solenoid does not operated, replace the solenoid noise
can be heard from the solenoid.
2 (SLS+)
Q09461
Author: Date: 1939

AX–20

1 (KLS+)
nals.
Q09456

1 (KLS+)
If the solenoid does not operated, replace the solenoid.
2 (E)
(–) (+) Q09457
4. INSPECT SHIFT LOCK CONTROL SWITCH

3 (P1) 4 (P2) 1 (P)
Inspect that there is continuity between at each terminal.
Shift position Tester connection Specified value
P position (Release
1 – 3 (P – P1) Continuity
button is not pushed)
P position (Release 1 – 3 (P – P1)
Continuity
button is pushed) 1 – 4 (P – P2)
R, N, D, 2, L position 1 – 4 (P – P2) Continuity

Q09464
If continuity is not as specified, replace the switch.
Author: Date: 1940

AX–21
AUTOMATIC TRANSAXLE UNIT

AX03X–01
COMPONENTS
Engine Hood
Air Cleaner
Assembly
26 (265, 19)
13 (130, 9)
w/ Cruise Control :
Cruise Control Actuator
Shift Control
RH Drive Shaft Cable Clamp
Starter
Snap Ring
39 (400, 29)
32 (330, 24) 41 (420, 30)
66 (670, 48) Hold–Down
x6 48 (490, 35) 20 (200, 15)
Clamp
Exhaust Manifold
x5 Plate
Battery
California:
Insulator
Torque Converter Clutch 34 (350, 25)
Hole Cover
Exhaust manifold Battery
Exhaust Manifold Plate
Bracket
20 (200, 14)
Shift Control Cable
Clip
California: Plug for Line
Battery Tray
Pressure Test
15 (150, 11) Snap Ring

LH Drive Shaft
34 (350, 25)
Exhaust manifold Bracket
Non–reusable part
D01057
Author: Date: 1941

AX–22
RH Fender Apron Seal Stabilizer Bar Link

Rear Side Engine
Mounting Insulator Stabilizer Bar
RH Rear Lower Brace
19 (195, 14)
36 (370, 27)
32 (330, 24)
Steering Return Pipe 80 (820, 59)
10 (100, 7) 39 (400, 29)
181 (1,850, 134)

TMC Made:
80 (820, 59)
TMMK Made: LH Fender Apron Seal
Green Color Bolt 181 (1,850, 134)
66 (670, 48) LH Rear Lower Brace
Silver Color Bolt
44 (450, 32)
Front Side Engine
Mounting Insulator
Tie Rod End
RH Front
Lower Brace Lock Cap
36 (370, 27)
49 (500, 36)
181 (1,850, 134) 48 (490, 35)
TMC Made: Grommet
80 (820, 59) LH Front
Lower Brace 80 (820, 59)
TMMK Made: Cotter Pin 294 (3,000, 217)
Green Color Bolt Exhaust Front Pipe 127 (1,300, 94)
66 (670, 48) Support Bracket
Silver Color Bolt Gasket
44 (450, 32) 62 (630, 46) Cotter
21 (210, 15) Pin
RH Fender Liner Gasket
Gasket
56 (570, 41)

62 (630, 46)
33 (330, 24)
Center Engine Under Cover

Exhaust Front Pipe Support Stay
33 (330, 24)
Engine Under Cover LH Fender Liner

Non–reusable part
Q10282
Author: Date: 1942

AX–23
AX03Y–01
REMOVAL
1. REMOVE BATTERY
3. REMOVE THROTTLE CABLE FROM THROTTLE
BODY
Q00225
(a) Disconnect the connector.
(b) Remove the 3 bolts and disconnect cruise control actua-
tor with the bracket.
Q09982
5. DISCONNECT GROUND CABLE

TOR
7. DISCONNECT DIRECT CLUTCH SPEED SENSOR
CONNECTOR
CONNECTOR
9. DISCONNECT SOLENOID CONNECTOR
Q10287
10. DISCONNECT SHIFT CONTROL CABLE

(a) Remove the nut and disconnect the shift control cable
from the park/neutral position switch.
(b) Remove the clip and disconnect the shift control cable.
Q00075
11. REMOVE 2 ENGINE MOUNTING ABSORBER BOLTS

Q10028
Author: Date: 1943

AX–24
12. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS

Torque:
TMC Made: 80 N·m (820 kgf·cm, 59 ft·lbf)
TMMK Made:
Q06478
13. REMOVE STARTER AND A/T SHIFT CABLE CLAMP

(a) Disconnect the connector and remove the nut.
(b) Remove the 2 bolts, starter and A/T shift cable clamp.
Q10286
14. REMOVE EXHAUST MANIFOLD BRACKET MOUNT-

ING BOLT
Torque:
Except California: 20 N·m (200 kgf·cm, 15 ft·lbf)
California: 34 N·m (350 kgf·cm, 25 ft·lbf)
Q06530
15. REMOVE 5 TRANSAXLE–TO–ENGINE BOLTS AND

DISCONNECT GROUND TERMINAL
16. REMOVE ENGINE HOOD
(a) Disconnect the washer pipe.
(b) Remove the 4 bolts and engine hood.
17. RAISE AND SUPPORT VEHICLE SECURELY
Q10038 18. REMOVE FRONT WHEELS
19. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND
GASKET
HINT:
Replace the used gasket with a new gasket.
20. DRAIN DIFFERENTIAL FLUID
21. REMOVE LH AND RH ENGINE SIDE COVERS
22. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA–25)
Author: Date: 1944

AX–25
23. REMOVE ENGINE UNDER FRONT COVER AND NO.4

CENTER ENGINE UNDER COVER
24. REMOVE EXHAUST FRONT PIPE

(a) Remove the 2 bolts and exhaust front pipe support stay.
HINT:
Replace the used nuts with new once.
Q10030 (c) Remove the 2 bolts and nuts.
HINT:
Replace the used nuts with new once.
(d) Remove the 2 exhaust front pipe clamp bolts and exhaust
front pipe.
(e) Remove the 3 gaskets.
HINT:
Replace the used gaskets with new once.
(f) Remove the 2 nuts, 2 bolts, exhaust front pipe support
bracket and hole cover.
Torque:
Exhaust front pipe support bracket mounting nut:
21 N·m (210 kgf·cm, 15 ft·lbf)
Hole plug mounting bolt:
Q10341
25. REMOVE FRONT SIDE ENGINE MOUNTING INSULA-

TOR BOLT
Torque:
TMC Made:
TMMK Made:
Q00235
Author: Date: 1945

AX–26
26. DISCONNECT 2 OIL COOLER HOSES
Q10027
27. REMOVE REAR SIDE ENGINE MOUNTING NUT

Q10071
28. REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT

Q10034
29. REMOVE STEERING GEAR HOUSING

(a) Remove the 4 bolts, LH and RH stabilizer bar brackets
and bushings.
(b) Remove the front stabilizer bar.
(See page SA–47)
(c) Remove the 2 steering gear housing mounting bolts and
nuts.
Q10035 Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
30. SUPPORT STEERING GEAR HOUSING, AS SHOWN
Q10040
Author: Date: 1946

AX–27
31. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-

ERS
(a) Install the No.2 engine hanger in the correct direction.
Part No.:
Engine
Hanger
No.2 engine hanger: 12282–20020
Bolt: 91642–80825
(b) Attach the engine chain hoist to the engine hangers.
P19478 CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
32. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the 2 bolts and PS reservoir pipe mounting
brackets.
Q06479
(b) Remove the 4 screws and turn over the front side of the
LH and RH fender liners.
Q10041
(c) Remove the 2 screws and turn over the rear side of LH
and RH fender liners.
Q10037
Author: Date: 1947

AX–28
(d) Remove the 6 bolts and 4 nuts.

Front
Torque:
19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf)
Nut: 36 N·m (370 kgf·cm, 27 ft·lbf)
(e) Remove the front frame assembly.
Q10172
Rear
Q10064
33. SUPPORT TRANSAXLE WITH A TRANSMISSION

JACK
34. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access to each bolt, remove the 6
bolts with holding the crankshaft pulley bolt by a wrench.
HINT:
Q04660 At the time of installation, please refer to the following item.
First install black colored bolt and then the 5 other bolts.
35. REMOVE EXHAUST MANIFOLD PLATE
(a) Remove the bolt, nut and exhaust manifold plate.
Torque:
Except California: 20 N·m (200 kgf·cm, 15 ft·lbf)
California: 34 N·m (350 kgf·cm, 25 ft·lbf)
Q10036
Left and lower 36. REMOVE 3 LOWER TRANSAXLE–TO–ENGINE

BOLTS
37. REMOVE TRANSAXLE ASSEMBLY
Separate the transaxle and engine, and lower the transaxle.
Z14284
Author: Date: 1948

AX–29
AX03Z–01
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using a scale and a straight edge, measure from the installed
surface to the transaxle housing.
Correct distance: 13.7 mm (0.539 in.) or more
AT3412
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
(See page AX–23)
HINT:
After installation, check and inspect items as follows.
Fluid level. (See page DI–438)
Front wheel alignment. (See page SA–4)
Do the road test. (See page DI–438)
Hood. (See page BO–10)
Author: Date: 1949

AX–30
TORQUE CONVERTER CLUTCH

AND DRIVE PLATE AX040–01
INSPECTION
SST
1. INSPECT ONE–WAY CLUTCH
(a) Install SST into the inner race of the one–way clutch.
SST 09350–32014 (09351–32020)
AT0952
(b) Install SST so that it fits in the notch of the converter hub
SST
and outer race of the one–way clutch.
SST 09350–32014 (09351–32010)
AT0953
(c) With the torque converter clutch standing on its side,the

Hold clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
Lock Replace the converter if the clutch still fails the test.
Free
Turn
AT3306
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR
(a) Set up a dial indicator, and measure the drive plate run-
out.
(b) Check the damage of the ring gear.
If the runout is not within specification or ring gear is damaged,
replace the drive plate.
AT2821 Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
Author: Date: 1950

AX–31
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE

RUNOUT
(a) Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator and measure the torque con-
verter clutch sleeve runout.
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
AT4184 HINT:
Mark the position of the converter to ensure the correct installa-
tion.
(b) Remove the torque converter clutch.
Author: Date: 1951

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AX–1

AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM

AUTOMATIC TRANSAXLE SYSTEM

Author: Date: 1894

O/D One – Way Counter One Way Clutch

Author: Date: 1895

VEHICLE SPEED SENSOR AX036–01

Author: Date: 1896

PARK/NEUTRAL POSITION (PNP)

Author: Date: 1897

VALVE BODY ASSEMBLY AX038–01

2. REMOVE OIL PAN AND GASKET

3. EXAMINE PARTICLES IN PAN

36 (1.417) mm (in.) 4. REMOVE MANUAL VALVE BODY DETENT SPRING

5. REMOVE OIL STRAINER AND OIL PIPE BRACKET

Author: Date: 1898

6. DISCONNECT SOLENOID CONNECTORS

7. REMOVE OIL PIPES

8. REMOVE VALVE BODY

9. REMOVE THROTTLE CABLE

Author: Date: 1899

12. INSTALL SHIFT SOLENOID VALVE NO.1 AND NO.2

14. INSTALL VALVE BODY

B C (b) Install the valve body with the 12 bolts.

15. INSTALL OIL PIPES

Shift Solenoid Valve No.1 16. CONNECT SOLENOID CONNECTORS

AT0493 Black Z10941

Author: Date: 1900

mm (in.) 17. INSTALL OIL STRAINER AND OIL PIPE BRACKET

36 (1.417) mm (in.) 18. INSTALL MANUAL VALVE BODY DETENT SPRING

19. INSTALL MAGNETS IN OIL PAN

20. INSTALL OIL PAN AND GASKET

Author: Date: 1901

THROTTLE CABLE AX039–01

5. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR

Author: Date: 1902

SHIFT SOLENOID VALVE SL AX03A–01

Author: Date: 1903

DIFFERENTIAL OIL SEAL AX03B–01

SST ON–VEHICLE REPAIR

3. INSTALL SIDE GEAR SHAFT OIL SEAL

Author: Date: 1904

SHIFT LOCK SYSTEM (TMC Made)

Shift Lock Override Cover

Shift Lock Override Button

Stop Light Switch

Key Interlock Solenoid

Author: Date: 1905

Wire Harness Side D00758

Terminal Measuring Condition Voltage (V)

(c) Apply battery positive voltage between terminals. Check

Author: Date: 1906

SHIFT LOCK SYSTEM (TMMK Made)

Shift Lock Override Cover

Shift Lock Override Button

Stop Light Switch

Key Interlock Solenoid Shift Lock Solenoid

Shift Lock Control ECU Shift Lock Control Switch

Author: Date: 1907

3 (IG) 1 (ACC) INSPECTION

Terminal Measuring Condition Voltage (V)

(1) Ignition switch ACC, P position 9 – 13.5

2. INSPECT SHIFT LOCK SOLENOID