|FFERENTIAL [4A ‘Ar breather hose ‘il level gauge Oil cherge pipe Inhibitor switch Farge sclect lever Manual shat Manuat piawe Msnuat over Roller besring Flange bolt Parking support Parking red Return spring hat Parking pow! Init pipe Outlet pipe ‘spring ving ‘Accumulator piston (N-D) 37 Oring Owing 38 Spring 28 Owing 39 Magnet 20 Accumulator piston (23) 40 Gasket 20 Spring 41 Ollpan 31 Owing 42. Datont spring 32 Accumulator piston (1-2) 44 Pipe 33 Oring 48 Tranamitsion cover 36 Spring 46 Gasket 38 Oring 47 Shim 38 Accumulator piston (4) 48 Clip. 27,17 ~20) To: 3.4 ~ 4.4 (0.35 - 0.45, 25 -3.3) TH: 12 ~14 (12-14, 9-10) Te: (AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT) [C500] 3-2a ) 5, Control Valve and Harness Routing wt Tightening torque: Nem (kg-m, ft) ‘Tt: 6 — 8 (0.6 — 0.8, 4.3 — 6.8) T2: 7-9 (0.7 — 5.1 — 6.5) + suy 2 Oil wainer 3 Transmission harness 4 Oxing 8 Duty tol, A (Line-preseure) 6 S01, assY 7. Upper valve body 8 bal 9 Upper separator plate B9214 Fig. 86 103|__3.2a {C¢00}_ __ AUTOMATIC TRANSMISSION_AND_DIFFERENTIAL {4AT]. 6. Reverse Clutch and Band Brake ( 4: selective porte Brake band Flevera clutch drum Lathe cut a og Spring Sprig Spring retainer Snap ring ek nut Brake band adjusting sow Strut Band servo piston stem Spring ‘Lathe cutseal ring ( Band vervo piston (1-2), Oxing Retainer Oring 25 Spring 26 -Retsiner 27 Cieelp 0 eat warring 29. Band servo piston (3-4) 30 Oring 310.0, servo retainer 82 Snap ring 33. Lathe cut sel ring Fig. 87 (AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] ) 7. High Clutch and Planetary Gear @ 15 Selective parts 1 High elute drum 2 Lathe ev sel cng 3 Paton 4 Lathe evt seal cing Spring etainer CP. 4 Soe ee 27 Oneavay clutch ovter race (4) 28 Overrunning luten hud as216 » Fig. 88 105 [c700)_3-2a00} __ AUTOMATIC_TRANSMISSION_AND_ DIFFERENTIAL [4A 7} —_____ 8, Forward Clutch and Low & Reverse Brake ( 1 Selective ports 1 Snap cing #2 Retalning plate 23. Drive pate 4 Delen pte 5 Dish place Soup cing #7 Retaining plate Brive pate Driven plate 10 Dish plow 11 Snap ring 3% Tirutmede toning ewe ng 2 Baleng 39. Thrust needle bearing 34 Oneenay elute inner race (1-2), 38. Soring retainer CP. 7 1 ‘ 38: Socket b 1 37 Low & revere 1 38 Lathe cut ea ing oo 8 Co tos Tightening torque: Nem (kgm, 1b) v Te 23-28 (23 2.7, 17 ~20) Fig. 89 Pre if ( 106 esAUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] [C900] 3-2a ) 9, Reduction Gear Tightoning torque: N-m (kgm, feb) Tr 93 103 (9.5 — 10.5, 69 - 76) Bozte 1073-2a_[C1000] AUTOMATIC TRANSMISSION AN TIAL [4AT] 410. Transfer and Extension S Rae 1 Snap ring 2 Prewure plate 13 Orive plate 4 Driven plate 45 Thrust needle bearing 8 Snep ring 7. Spring reainer CP 8 Lathe cut seal ting 9 Teonafer clutch piston 10 Lathe out weal ring 11 Needle beering 12. Foor drive shaft 413. Ball brerng 14 Saat ing ution sensor (40D) valve pipe -17_Duty sol. (transfer luted) 18 Gaker 19 Flaw 20 Filter 21 Gesket 22 Roller bssring 23 Extension cate 24 Bushing 28 Olt seal 26 Durt seal 27 Seal wanstor pistonAUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] {w100] 3. ) W> SERVICE PROCEDURE 1. Precaution Wheri disassembling or assembling the automatic transmission, observe the following instructions, 1) Workshop Provide a place that is clean and free from dust. Princi- pally the conventional workshop is suitable except for a dusty place. In @ workshop where grinding work, etc. which produces fine particles is done, make indepen- dent place divided by the vinyl curtain or the equivalent. 2) Worktable ‘The size of 1 x 1.5 m (40x 60 in} is large enough to work, and itis more desirable that its surface be covered with flat plate like iron plate which is not rusted too much. 3) Cleaning of exterior (1) Clean the exterior surface of transmission with steam and/or kerosene prior to disassembly, how- ever it should be noted that vinyl tape be placed on the airbreath l level gauge to prevent infiltra- tion of 1M into the transmission and also the cleaning job be done away from tho place of disas- sembly and assembly. (2) Partial cleaning will do, depending on the extent of disassembly (such as when disassembly is limited to some certain parts). 4) Disassembly, assembly and:cleaning (1) Disassemble and assemble the transmission While inspecting the parts in accordance with the Troubleshooting. (2) During job, don’t use gloves. Don't clean the arts with rags: Use chamois or nylon cloth. (3) Pay special attention to the air to be used for leaning. Get the moisture and the dust rid of the air as much as possible, Be careful notto scratch or dent any part while checking for proper operation with an air gun. 109 {4) Complete the job from cleaning to completion of assembly as continuously and sp possible in ‘order to avoid occurrence of secondary troubles caused by dust. When stopping the job unavoidably cover the parts with clean chamois or nylon cloth to keep them away from any dust. {6) Use kerosene, white gasoline or the equivalent as washing fluid. Use always new fluid for cleaning the automatic transmission parts and never reuse. The usable (6) Although the cleaning should be done by dipping into the washing fluid or blowing of the pressurized ‘washing fluid, the dipping is more desirable, (Do not immediately after the cleaning without exposure to the air for a while. Besides in case of washing rubber parts, per- form the job quickly not to dip them into the washing fluid for long time. (7) Apply the automatic transmission fluid (ATF) onto the parts immediately prior to assembly, and the specified tightening torque should be observed carefully. (8) Use vaseline if it is necessary to hold parts in the position when assembling. (9} Drain ATF and differential goar 30 that the conditions of ‘lui inspected, (10) Do not support axle drive shaft, stator shaft, input shaft or various pipes when moving transmis sion from one place to another. (11) Always discard old oil seals and bushings, and install new ones. (12) Do not reuse old pipe: Install new ones. (13) Be sure to replace parts which are damaged, worn, scratched, discolored, ete, gaskets, spring pins, etc.| —3-2a_{wW2at} —_AUTOMA: 2. On-Car Service ‘A: INSPECTION 1, ATF LEVEL 1) Raise ATF temperature to 60 to 80°C (140 to 176°F) from 40 to 80°C (104 to 140°F) (when cold) by driving a distance of 6 to 10 km (3 to 6 miles). ‘The tovel of ATF varies with fluid temperature, Pay ‘attention to the fluid temperature when checking oll level. 2) Ensure the vehicle is level. After selecting all posi- tions (P, R, N, D, 3, 2, 1), set the selector leveler in “P” range, Measure fluid level with the engine idling, ‘After running, idle the engine for one or two minutes before measurement. 3) If the fluid level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found within the specified range (above the center between upper and lower marks). When the ‘transmission is hot, the level should be above the cen- ter of upper and lower marks, and when it is cold, the level should be found below the center of these two marks. ‘8. Use care not to exceed the upper limit level. b. ATF lovel varies with temperature, Remember that the addition of fluid to the upper limit mark when the ‘transmission is cold will rsutt in the overfiling of fluid, 4) Fluid temperatura rising speed By idling the engine Time for rising temperature to 60°C (140°F} with atmospheric temperature of 0°C (32°F): More than 25 minutes (Reference) Time for temperature rise to 30°C (86*F) with atmo. spheric temperature of 0°C (32°F): Approx. 8 minutes # By running the vehicle for temperature rise to 60°C (140°F) with atmo- spheric temperature of 0°C (32°F): More than 10 min- utes |} 8} Method for checking fluid tevel upon delivery or at periodic inspection. ‘Check fluid level after a warm-up run of approx. 10 min. tutes. During the warm-up period, the automatic trans- mission functions can also be checked. 2, DIFFERENTIAL GEAR OIL LEVEL 1) Ensure the vehicle Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level. 2) Check whether the oil level is between the upper (F) and lower (L) marks. if itis below the tower limit mark, ‘add oil until the level reaches the upper mark. FRANSMISSION-AND- /FFERENTIAL_[4AT} 3. OIL LEAKAGE ( Itis difficult to accurately determine the precise position of a oil leak, since the surrounding area also becomes ‘wet with oi, The places where oll seals and gaskets are used are as follows: (Jointing portion of the case) © Transmission case and oll pump housing jointing portion ‘© Converter case and oil pump housing jointing portion @ Transmission case and transmission cover jointing portion (FWD) © Transmission case and extension case jointing por- tion (4W0) Converter housin SEngine crenkahent oll seal © Torque converter impeller sleeve oil seal ATF cooler pipe connector © Torque converter ( Converter case Converter ce * Axle shett oll seal © O-ring on the outside diameter of axle shaft oil seal holder ‘ O-ring on the differential oil gauge © Differential oil drain plug ‘* Speedometer cable mounting portion * Location of steel balls imp housing Si-pump houeng (Defective casting) © O-ring on the test plugs. © Checking blind plugs © Differential gear breather Automatic transmission case ‘Transmission case ‘© Mating surface of oil pan © O-ring on the test plugs ( © Checking blind plugs (steel balls) * Oil supply pipe connector ‘© ATF cooler pipe connector and gasket © Oil pan drain plug * O-ring on the transmission harness holder © O.ting on the oil pump plugs = © ATE breather © Shift lever oll seal Extension case ‘© Extension case (Defective casting) ‘© O-ring on the revolution sensor ‘© Rear drive shaft oil seal © Checking blind plugs (stee! ball) © O-ring on the testing ‘Transmission cover ismission cover (Defective casting) The point listed above should be checked for fluid leak. Checking method is as follows: ( ive casting) 110AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] 1) Place the vehicle in the pit, and check whether the 19 oil is ATF or not. The ATF is wine red in color, can be discriminated easily from engine oll and gear oil, 2) Wips clean the leaking oll end dust from a suspect- able area, using a noninflammable organic solvent such as carbon tetrachloride. 3) Run the engine to raise the fluid temperature, and set the selector lever to “D” in order to increase the fluid pressure and quickly detect a leaking point. Also check for fluid leaks while shifting select lever to “R", "2", and —", ; ADJUSTMENT 1, BRAKE BAND If the following abnormal shifting conditions are noted in a road test, the brake band must be adjusted. Improper brake band cleerances and their symptoms Cloarence [Problem 1 Too wide [Upahit from 1at dirty to Srd gear occurs. 2. Wide '* Engine rpm ineroasee abruptly whilo Lupshiting from tet to 2nd gear or 3rd to Ath ge ‘6 Time tag of at east one sacond occurs during kickdowrn operation from 3rd 10 2nd gear. 3. Small “Braking” symptom oocure while upshifting from 2nd to 2rd goer, ‘Too emall Upshifte from 2nd to 4th gear and down- shits from 4th to 2nd goar occur repeatedly 3.591 Fig. 92 [W2B2] 3-2a Lock nut Clearance, Cescanee erases, ‘deerones. ‘Adjusting serew Bs.532| Fig. 93 © Adjustment of the adjusting screw 1) Using @ socket wrench, immobilize the end of the 10 mm screw projecting on the left side of the transmis- sion case, and loosen the nut with a double-end wrench, In the case of occurrence of problems 1) and 2) men- tioned previously, perform the adjustment by loosening or tightening the nut within a range of 3/4 turn from this py Do not loosen excessively; otherwise, the bend strut on the servo piston will drop off. 2) In case of the occurrence of problems 1 and 4 men- tioned previously, perform the adjustment as follows: Adjusting procedure: Tighten adjusting screw to 9 Nem (0.9 kg-m, 6.5 ft-lb) torque, then back off three turns. Do not tighten the adjusting screw with an excessively large torque. 3) With the adjusting screw immobilized, tighten the lock nut to 25 — 28 Nem (2.6 — 2.9 kg-m, 18 — 21 ft-Ib) torque. 2. INHIBITOR SWITCH = The inhibitor switch allows the back-up lights to turn on when the select lever is in the R range and the starter motor to start when the lever is in the N or P range, It also monitors the input signal electronically controlled for each range and turns on the corresponding range light on the instrument panel. When light operation, driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linka tic properly, check the in Teal No. 360803610 m1q ATIC TRANSMISSION AND DIFFERENTIAL [4AT}————___ (Inspection) ( 1) Disconnect cable end from select lever. Continuity 2) Disconnect inhibitor switch connector. a oat not 3) Check continuity in inhibitor switch circuits with at select lever moved to each position, N ea continuity fe not Pm] 4[3]2]+]e]7]e|s|alulole ee SE} 0 || er| val ve} & fowl even) & [os Fig. 95 (Adjustment) 1) Loosen the three inhibitor switch securing bolts, 2) Shift the select lever to the N range. 3) Insert STOPPER PIN (499267300) as vertical as pos- Bible into the holes in the inhibitor switch lever end tanton switch body. Signal santo AT conto unit en coment | ecu 4) Tighten the three inhi Also check that continuity in ignition circuit does not ‘exist when selector lever is in R, 3, 2 and 1 ranges, An erorren on tener) Fig. 94 4) Check if there is continuity at equal points when the Fa ag select lever is turned 1.5° in both directions from the N it pa 5) Repeat the above checks. If the inhibitor switch is, | —Ihthere is continuity in one direction and the continuity determined to be “faulty; replace it: mo in the other or if there is continuity at unequal points, 3, SENSOR (in transmission) dluet the inhibitor ewitch. 1) Check each sensor, solenoid and ground system for short circuits. 2AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT]___ (w2b2) ’ © Standard values Ee Part are Taal ST FWD rx. 600 ‘Vehicle speed sensor 1 @-@ ‘owt aw 9-8 ‘Approx. 600 100 — [ATF tempecsture sensor 0-8 weston Duay solaneld A {Line-pressure soteno'd) 0-08 Approx. 3 Duy solenoid 8 aaa {Lock-up solenoid @-08 ‘Approx. 12 shit oinoid 1 5-00 ‘Approx 25 Shit eolenoid? O-00 ‘Approx. 25 Shift solenoid 3 O-O®© ‘ADpIOK. 26 Duay solenoid € (4W0 oni) {Transfer clutch solenotd) @-00 iL Approx. 12 10 different from the standard value indicated above. If port is faulty, its resistance valve wi i 9 i $ ' i 1 ® ' @ ‘ o 1 a t |e ‘ oF ee i “ | frsae|___ [tock sro ' i one) — fer ' g of 4 [cht sotnoia 1 \ i 1 eet | of a sie wieotd2 ‘ 1 H os | foam 1 —oF— 1 [ere {sn sine \ ee 1 a \ a \ 9 1 otrcass [oom | : , L J Bss7eR Fig. 97 2) Check vehicle speed sensor 2. (3) Drive vehicle at approximately 10 krivh (6 MPH). (1) Disconnect 16-pin multiple connector from trans- (Judgement) mission. ® Vehicle speed sensor is in good order if circuit tester (2) Connect tester to connector receptacle on trans- registers 1 volt, AC. ssion. @ Resistance between connectors: Approx. 500 ohms: 113Fig. 98 (C: REMOVAL AND INSTALLATION 1, SHIFT SOLENOID, DUTY SOLENOID AND VALVE BODY 1) Removal (1) Clean transmission exterior. (2) Drain ATF completely. Tighten ATF drain plug after draining ATF. Tightening torque: 23 — 26 Nem (2.3 —2.7 kg-m, 17 — 20 ft-tb) (3) Remove oil pan and gasket. Drain oil into a container. (4) Disconnect solenoid valve connectors. Remove connectors from clips and disconnect con- nectors at § places, For © Sol. 3 {shied Sol, 3 (anit) For Duty Sol. 8 For ATF temp. Bs-205| Fig. 99 {6) Remove oil strainer. Disconnect oil pipe by removing the two bolts, and remove four bolts and oil strainer, Fig. 100 Be careful because oil flows from oil strainer, {6) Remove control valve body. Remove 8 long bolts (Black) and 11 short bolts (Yel- low). Be careful because cil flows from valve body. @ smortasvoon stp Waser bettie Fig. 107 114 ‘TIC TRANSMISSION AND DIFFERENTIAL [4AT}AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] (w2c1]_3-2a (7) Remove shift solenoids 1, 2, and 3, and dutysole- (3) Install valve body. old A. a Tightening torque: 8 Nem (0.8 kg-m, 5.8 ft-lb) 8. Secure accumulator springs using vaseline. b, Align manual valve connections. 6. Tighten duty solenoid B (lock-up) bracket and two bolts (also used to tighten valve body). Fig. 102 2) Installation ) (1) install duty solenoid B (lock-up). ‘Tighten bolts shown by solid arrows. The two bolts. and brackets shown by arrows “ XX “ must be tight- ened later. Beast Fig, 105 (4) Install oil strainer. Also install oil pipe and harness connector bracket. Tightening torque: 7 — 9 Nem (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) Fig. 108 (2) Install solenoid valves. Shift solenoids, 1,-2-and-3, and-duty solenoid A (line Pressure), Fig. 106 (8) Connect harness connectors at 5 places. Connect connectors of same color, and secure con- nectors to valve body using clips. 15’ }-2a_{wec2}___ AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT} 2, DUTY SOLENOID C AND TRANSFER VALVE ( BODY 1) Removal (1) Remove pitching stopper. (2) Reise car and drain ATF. (3) Remove front exhaust pipe. Disconnect ©, sensor connector, and remove exhaust pipe. (4) Remove propelier shaft. Before removing propeller shaft, scribe alignment marks on propeller sheft and rear differential coupling. 83233] (6) Remove rear crossmember. Fig. 107 © Support transmission using a transmission jack and (6) Install oil pan & gasket. raise slightly. LO) Installolipan @ gasket, w Remove bolts and nuts as shown in Figure, Tightening torque: 3.4 — 4.4 Nem (0.35 — 0.45 kg-m, 2.5 — 3.3 ft-lb) Fig. 110 (6) Remove vehicle spead sensor 1. Fig. 108 LUppo" love | Lower level Fig. 117 1514 Fig. 109 116AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] ) Remove extension & gasket. Remove gear select cable nut. ‘© Move gear select cable so that extension bolts can be removed. Fig. 112 ) “e Remove bolts. Remove extension and disconnect duty solenoid C connector. ‘8. Use a container to catch oil flowing from extension. b. Do not force extension back before disconnecting solenoid connector. Otherwise, harness may be dam- aged. Fig. 113 (8) Remove duty solenoid C & transfer valve body from # Remove transfer clutch drum. Iw2c2]_3-2a Fig. 114 ‘© Remove clamp which secures pipe. © Remove bolts. Bo26t Fig. 115 2) Installation (1) Install duty solenoid C & transfer valve body. © Install duty solenoid C & transfer valve body, © Install pipe and clamp. Tightening torque: 7 — 9 Nem (0.7 — 0.9 kg-m, 5.1 — 6.5 ft © Install clutch drum, Duty solenoid © ‘(Transter) 9.242 Fig. 116 17(2) install extension. '® Connect connector. © Tighten 11 bolts. Tightening torque: 23 — 26 Nem (2.3 — 2.7 kg-m, 17 — 20 ft-lb) © Install gear select cable. 3.243) Fig. 117 (4) Install rear crosemember. # Tighten bolts, Tightening torque: Crossmember to body 54 — 83 Nem (5.5 — 8.5 kgm, 40 — 61 ft-lb) Crossmember to cushion 13 — 23 Nem (1.3 — 2.3 kg-m, 9 — 17 ftlb) -*Low-and-remove transmission jack. Fig. 118 (6) Install propeller shaft. Tightening torq Nem (kg-m, ft-lb) ‘At rear differential: ( 18 — 27 (1.8 — 28, 13 — 20) ‘At center bearing: 34— 44 (38.5 — 4.8, 25 — 33) Align marks on propeller shaft and rear differential coupling. (6) Install front exhaust pipe Tightening torque: ‘Nem (kg-m, ft-lb) At engi 25 — 34 (2.5 — 3.5, 18 — 25) At hanger: 25 — 34 (2.5 — 3.6, 18 — 25) At front and rear connections: 13 — 23 (1.32.3, 9— 17) (7) Lower and remove jack. ( {8) Connect the following parts: 0, sensor connector @ Revolution sensor connector © Multi-connector {9) Install pitching stopper. Tightening torqu Nem (kg-m, ft-lb) 47 — 67 (4.8 — 6.8, 35 — 48) (Body side) 44 — 54 (4.5 — 5.5, 33 — 40) (Engine side) (10) Replenish ATF and check oil level. Check for leak 118AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] [ws82]_3-2a ) 3. Performance Test NECESSARY TEST GAUGES 41) Tachometer (It is desirable to be able to read to 50 tpm). 2) Vacuum gauge (Itis used for measuring intake man- ifold vacuum). 3) OIL PRESSURE GAUGE (498575400). 4) OIL PRESSURE ADAPTER (498897200), 5) Stop watch. B: STALL TEST 1. GENERAL ‘The stall test is of extreme importance in diagnosing the condition of the automatic transmission and the er 18, } It should be conducted to measure the engine stall ‘speeds in all shift ranges except the P and N ranges. Purposes of the stall test 41) To check the operation of the automatic transmis sion clutch. 2) To check the operation of the torque converter. 3) To check engine performance. 2, TEST METHODS Preparations before test ‘Check that throttle valve opens fully. Check that engine cil level is correct. Check that coolant level is correct. Check that ATF level is correct. 8 ‘Check that differential gear cil level is correct. Increase ATF temperature to 60 — 80°C (140 — 176*F) by idling the engine for approximately 30 minutes (With select lever set to “N" or “P”). 4) Install an engine tachometer at a location visible from the driver's compartment and mark the stall speed range on the tachometer scale, _ 2) Place the wheel chacks at the front and rear of all Wheels and engage the parking brake. 3) Move the manual linkage to ensure it operates Properly, and shift the select lever to the D range, 4) While forcibly depressing the foot brake pedal, grad- ually depress the accelerator pedal until the engine operates at full throttle, Fig. 119 5) When the engine ‘quickly and release the 6) Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute, 7) Record the stall speed. 8) Perform the stall tests with the select lever in the 3, and R ranges. ‘#2, Do not continue the stell test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open ‘throttle to stall speed reading). Feilure to follow this truction causes the engine oll and ATF to deterio- rate and the clutch and brake band to be adversely affected. Bo sure to cool down the engine for at least one minute efter each stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. b. If the stall speed is higher than the specified range, attompt to finish the stall test in a5 short a time as possible, in order to prevent the automatic transmis- sion from sustaining demege. Specifications ‘Stall speed (at sea level): 2200 ec MPFI 2,600 — 3,000 rpm 2000 ce MPF! 2,300 — 2,700 rpm 1800 ce Carburetor 2,600 — 3,000 rpm 193, EVALUATION Stall speed (atsea lovey) | Postion cause ‘© Throtto valve not fully open Loss than spect | pp | Erconeous engine operation cations 7 '# Torque converters one-way clutch slipping '@ Line pressure to0 low ‘© Forward clutch sipping '* Oneeway clutch (1 = 2) mat functioning '* One-way clutch (34) mal= functioring Line pressure too low Reverse clutch elipping Low & ravarse brake slipping Line pressure too tow Forward chch slipping Brake band slipping Donly Groater than speci fications Rony 2ony Line pressure too low ATF insutficiont RD,2 Cee C: TIME LAG TEST 1, GENERAL hifted while the engine is idling, time elapse or lag before the shock can be felt. This is used for checking the condi- tion of the forward clutch, reverse clutch, low & reverse brake, forward one-way clutch and low one-way clutch. CAUTION: {a}. Perform the test at normal operation fluid temper- ‘ature (60 to 80°C oF 140 to 176°F}. {b) Be sure to allow @ one minute interval between tests. {c) Make three measurements and take the average value, 2, TEST METHODS 1) Fully apply the parking brake, 2) Start the engine, Check idling speed (A/C-OFF) “N" range: 700% 100 rpm 3) Shift the shift lever from “N” to “D" range. Using a stop watch, measure the time it takes from shift. Ing the lever until the shock is felt, Time lag: Less than 1.2 seconds 4) In same manner, measure the time lag for “N” oR Time lag: Less than 1.5 seconds 3. EVALUATION 1) If “N" -» “D” time lag is longer than specified: © Line pressure too low 3] —_ AUTOMATIC_TRANSMISSION-AND_DIFFERENTIAL{4AT] © Forward clutch worn ‘© Low one-way clutch not operating properly 2) If "N" -» “R" time lag is longer than specified: © Line pressure too low © Reverse clutch worn © Low & Rev, brake worn © Forward one-way clutch not operating properly D: LINE PRESSURE TEST 1, GENERAL If the clutch or the brake band shows a sign of slippage ‘or shifting sensation is not correct, the line pressure should be checked, ¢ Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high. © Slippage or inability to operate the car may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake band or control valve. 1) Line pressure measurement (under no load) @. Before measuring line pressure, jeckup front wheels (front-wheel-drive model} or all wheels (4- wheal drive model). b. Maintain temperature of ATF at approximately 60 to 80°C (140 to 176°F) during measurement. {ATE will reach the above temperature after idling the proximately 30 minutes with shift lever in 2) Line pressure measurement (under heavy load) 2. Before measuring line pressure, apply both foot end parking brakes with all wheels chocked (Same as for “stall” test conditions). 'b, Measure line pressure when select lover is in “R”, “D", "2" and “1” with engine under stall conditions. © Measure line pressure within 5 seconds after shift- ing the select lever to each position. (If line pressure needs to be measured again, allow the engine to | and then stop. Wait for at least one minute before measurement:) Soe d. Maintain the temperature of ATF at approximately 60 to 80°C (140 to 176°F) during measurement. (ATF will reach the sbove temperature efter idling the engine for approximately 30 minutes with the shift lever in "NN" or ”P".) 2, TEST METHODS 1) Temporarily attach the OIL PRESSURE GAUGE ASSY (498575400) to a suitable place in the driver's compartment, remove the blind plug located in front of the toeboard and pass the hose of the GAUGE ASSY to the engine compartment. 120AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] 1 Pressure gauge hose 2 Hole in toe board (blank cap hole! 3 Brake pedal Fig. 120 2) Remove the test plug and install OIL PRESSURE GAUGE ADAPTER (498897200) instead. Fig. 121 3) Connect OIL PRESSURE GAUGE ADAPTER (498897200) with OIL PRESSURE GAUGE ASSY (498575400). 4) Start the engine and warm it up. 5) Check line pressure in accordance with the following chart [w3e9} 3. EVALUATION Under no load: “P", “R", "D", "3", "2" and “1” Under full load: “A”, “D", "3", "2" and “1” (With engine running at stall speed) (Standard line pressure) ‘Unit: kPa (kg/em?, psi) Ti tbapaneae | Wax te poe fom [eed en0 9m [Silom fi aie a ssa ete) o—eo | aise 8 aaa tee 20 " a ‘aa 8 > thes ae re a 798 nats ae 9 fasten] eB Te a8 2 ee (11.5 — 128, aswtoer—en| S28 Tea 1 at eee, (11.5 — 128, Cee et Peco | Fabystowd | Fulropen —; TRANSFER CLUTCH PRESSURE TEST Check transfer clutch pressure in accordance with the following chart in the same manner as with line pres- sure. Under no load: “R” and “D” ranges Under heavy load: “R” and “D” ranges in 4WD-mode “R” and “D” ranges in FWD mode Fig. 122 121Unit: KPa (ka/em*, psi) wb mee FO mode Taree [gn momma [Fon pee sce [anes ee ee Oe em fro—ne R (0.6 — 0.8, (7.3— 8.0, 0 {0, Oo} Pe [fara o—n fiie— ne ° Ges foamen, ow pany [oan Seca" |Fullrctosed | Full-open | Full-open If oll pressure is not produced or if it does not change in the 4WD mode, the duty solenoid C or transfer valve ‘assembly may be malfunctioning. if oil pressure is pro- duced in the FWD mode, the problem is similar to that in the 4WD mode. [iC TRANSMISSION AND DIFFERENTIAL [4AT] 2. CHECKING FOR SHIFT PATTERNS ‘Check “kick-down" and engine brake operation. D-rango: 1st $5 2nd $ 3rd $ 4th ‘S-range: 1st $ 2nd $ 3rd $ 4th (Manual switch OFF) 2nd + 3rd $+ 4th (Manuel switch ON) 2erange: Tet $5 2nd 3rd # 4th (Manual switch OFF) 2nd $5 3rd $ 4th (Manual switch ON) ‘T-range: 1st $s 2nd $s rd S= 4th 3. CHECK FOR THE 4WD FUNCTION If “tight-corner braking” occurs when the steering wheel is fully turned at low speed: 1) Determine the applicable trouble code and check the corresponding duty solenoid C (transfer) for proper operation. 2) If the solenoid clutch pressure, 3) {f oll pressure is normal but “tight-comer braking” occurs: operating properly, check transfer F: ROAD TEST Check the transfer control valve for sticking, and the twansfer cl facing for wear. 4. GENERAL (Refer to Disassembly and Inspection of the Transmis- Road tests should be conducted to properly diagnose 10M.) the condition of the tomatic transmission, When performing test, do not exceed posted speed limit. . 122AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT} (W3F4]_3-2a 4, AUTOMATIC SHIFT CHARACTERISTICS © 1800 ce Carburetor “D” range Normal pattorn " 7 & i? 2 25 ° 30-40, 80 Bodo —ta9 eo Tag 200 (2s) 760) fez) } tga) ) at) Vehicle sosed kmh (MPH) Base7 Fig. 123 “D" range Power pattern 2nd Lock 100 1 % fi a 1 1 { 1 \ y q } 4 i i y 4] \ 020" 40 “80 8016030440 460180 00 (12) (25) (371 BO) 62) 75) a) oo) aaa) Vehicle speed km/h (MPH) 53569 Fig. 124 123RANSMISSION-AND-DIFFERENTIAL [4A 7} ™D" range Eoonamy pattern, ( chp OFF Srd Lek OM 6 Leskan OFF a Tay ds 185 285 fa) (so) cia (a2) sen PH) Fig. 125 124AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4A’ [W3F4] 3-2a D6 2000 ce mPri ‘Drange Normal pattern 3 oo OFF Sateen 2nd, Loekup ON. Ath Lockup OFF 2nd. Loekup OFF 100) 75} z g € i | ) i 25 030 40 G85 100720140160 180260 (12) (26) (37) (GO) (6278) t67) FOO) (142) (124 \Vehlete speed km/h (MPH) 29.970 Fig. 126 “'D" range Power pattorn rd, Locksup OFF. 2nd, Lock-up ON- 2nd, Lock-up OFF. 100, \ oa 40 60 BOT to 180182 (121 (25) (37) (60) (62) (75) BT) (90) 112) (124) Vehicle speed kmh (MPH) 3.071 Fig. 127| 3-2a [W3F41___ AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT} “1D range Economy pattern 3rd, Lockup OFF. rd. Lock-up ON 2nd, Lockup ON 4th Lockup OFF 2nd, Lockup OFF. 41h Lockup ON 1009 75h “Throttle opening (%) 23) ote a ao 00 saat ia) G28) (37 (60) C62) (78) toa) UhTa) (128) ‘Varies nh (MHD esera Fig. 128 © 2200 cc MPFI 7" range Normal pattern aa 29 Look? OFF veces OFF 100 jase ' 1 { @ [a x 21d Lockup ON ee ee eee am va 2 Ce VP oled ko ton 2” aon 9572 Fig. 129 126AUTOMATIC TRANSMISSION AND.DIFFERENTIAL [4AT]__[W3F4]_ 3-24 “"“D" range Power pattern 100) 7s) ‘Throtte opening (81 8 { : ‘ ! 7 i o 34060 80 00 190140 160780200 2) 26) O62) 8) BT) ata) Hae) ‘Voice soee “kev (PH 53574 Fig. 130 “D” range Economy pattern ed voekp- #0 Loskap ie (96 "Fore x z g & oo E 25 O30 40 "0 B60 130 14a Ten 80 — 06 a @) Gn) ota) a Verilesped vn PHD B37, Fig. 137 1274. Overall Transmission ‘SECTIONS THAT CAN BE DETACHED/ ASSEMBLED [ee] <=> <= Fig. 132 128 : Adjusting direction of drive pinion i Adjusting direction of crown gear ‘Checking te ‘Contact pattern Corrective sction (Gorect tooth contact ‘Tooth contect patern aighaly shifted toward toe under notod raatlon. {When losded, contact pattern moves toward hae) Dp Face contact ‘Backash too Taree, NI ‘Thi may eause nels ond chipping at teoth an. Pas ft eocicrsentluat sjstng shim Ya order to brlag drive pinion lose to eawn gear. ‘lank contact ‘Backlash i too small IS “This may enute noite and stepped wear on urtaces, “ty puss breton pion ae tam ron gtr Tonsoni Pa Ter nk eo Une dente +h hts Conta ns at. The my ctse ching at tox eae vl connet Conacr ee a, jt fore cone, Tove end cont Sle ny ete pic el *B ys Besta retainer to the mi plate to the specified torque. 23 — 26 Nem (2.3 — 2.7 kg-m, 17 — 20 ft-lb) rk the retainer p tion and loosen it, After fitting the O-, 1d position. Thon tighten the lock 12) Install the seal pipe to the converter case, ing, screwin the Be sure to use a new seal pipe. e03t4RANSMISSION AND DIFFERENTIAL { 13) Install two oil seals to the oil seal retainer with a. Fit the seal ring after compressing, and rub vaseline t INSTALLER (499247300). into the seal ring to avoid expansion. a. Pay attention to the orientation of the oil seals. b, The “R” seal ring has a lerge diameter, while “H” 'b. Be careful not to damage the seal lips. If any dam: has small diameter. age is found, replace with a new one, 14) Attach the O-ring to the oil seal retainer with vase- line, Install the seal to the oil pump housing bore. Fig, 197 ( 17) Install the rubber seal to the converter case. Be careful not to lose the rubber seal. Laleted 2. TRANSMISSION CASE SECTION 15) Install the oll seal retainer taking care not to dam- : age the oll seal lips. Then secure with three bolts. 1) Press-fitthe roller bearing to the transmission case. 16) Apply vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings.AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4A° (w4s2) ) 3) Install the manuel plate and shaft, and secure with a 6) Install the lathe cut seal ring and lip seal to the I.D/ spring pin. 2. Be careful not to damage the oil seal lip. b, After installation, make sure of smooth movement. ©.D. of the low & reverse piston. Then install the piston into the case with a press. @. Be careful not to tilt the piston when installing. b, Be careful not to dameye the lip seal. ) Fig. 200 4) Assemble the manual lever and parking rod to the inside shaft, and secure with a nut, | —Fig--207— 5) Install the detent manual spring. Position the spring so thet its center is aligned with the center of the manual plate. Tightening torque: 5 —7 Nem (0.5 — 0.7 kg-m, 3.6 — 5.1 ft-lb) Be.s22! Fig. 202 7) Install the one-way clutch inner race. (1) Using a press, install the thrust needle bearing to ‘the inner race, 0.020) Fig. 203 Use the PULLER ASSY (398527700) when removing. (2) Install four seal rings. Apply vaseline to the groove of the inner race and to the seal ring efter installation, so that the seal ring will not expand. {3) Place the spring retainer CP on the inner race. Install the spring to the recessed portion of the pi ton. Then tighten eight socket head bolts from the rear side of the transmission case. Tightening torque: 23 — 26 Nem (2,3 — 2.7 kg-m, 17 — 20 ft-lb) Be sure to tighten evenly. 143nap ring Retaining plate Tranaission case — Lip seat ish plate 8) Install the band servo sub ASSY. 9) Press the O.D. servo retainer into position, and secure with a snap ring. Piston okt ‘Lathe ut ea rng ‘COMPRESSOR: 1498877000), 12 following operations with the transmis- set vertically on wooden blocks. 10) Installation of the low & reverse brake: | utc sing ive | Fornard cen Drive Pate ‘Orie Plate 3.326 Fig. 206 (1) Install two dish plates, driven plates, drive plates, and a retéining plate, and secure with a snap ring. ¢. Dish plate :2 (2) Apply compressed air intermittently to check for. operation,AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] Standard value: 1.1 — 1.7 mm (0.043 — 0.067 in) Allowable limit: 2.7 mm (0.106 in) Before measuring clearance, place the same thickness. of shim on both sides to provent retaining plate from tilting. © Avsilable retaining plates Part No, Thickness rm fin) SI667AAT80 6.5 (0.256) B1867AA100 6.8 (0.268), 31667AA200 724 (0.280) S1667AA210 74 (0.201), 31667AA220 7.740.308) 3166744230 8.0(0.316) 31667AA240 8.2 (0.323) 31667AA250 84 (0.331) 11) Install the thrust needle bearing to the inner race. 12) Install the forward clutch drum ASSY. (1) Install carefully while rotating the drum slowly paying spe ition not to damage the seal ring. (2) Installation is complete when the drum recedes 2.5 mm (0.098 in) from the inner race surface. 25 mm 0.088 in) [waB2]_3-2a 13) Assemble the overrunning clutch hub. . Join the thrust needle bearing® and thrust washer with vaseline, and then install them together. b, Make sure thet the splines are engaged correctly. Fig. 209 14) Install the one-way clutch outer race ASSY. Make sure the forward clutch splines are engaged cor- Fig. 210 15) Assemble the reer internal gear. (1) Join the thrust needle bearing* and—thrust ‘washer to the gear with veseline, and install the gear while rotating it. (2) Securely engage the bearing with the dog of the overrunning clutch hub. Installation is complete when the snap ring top surface of the forward clutch drum recedes epproximately 3.5, mm (0.138 in). 145Fig, 211 16) Install the rear planetary carrier. Attech the thrust needle bearing* to the inside of the carrier with vaseline. Then install the carrier while rotat- ing slowly. 9.332] Fig. 212 17) Install the rear sun gear. Install the gear with the oil hole facing up. Fig, 213 18) Install the front planetary carrier, Attach the thrust needle bearings* to both sides of the carrier with vaseline. Install the carrier carefully, while 19 with the splines of the forward clutch drum, ‘and while rotating the pinion, Fig. 214 19) Install the fro Att Fig. 215 line and install the hub by correctly engaging the splines of the front planetary carrier. Fig. 216 21) Install the high clutch ASSY, Correctly engage the high clutch hub and clutch splines, 146' }-—H AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] Fig. 217 22) Install the reverse clutch ASSY. Engage the high clutch outer spline with the reverse clutch spline and the front sun gear with the cut-out portion of the reverse clutch drum correctly when insteliing. Fig, 218 23) Install the brake band ASSY. ®. Be cereful not to damage the brake band when installing. b. Instell the strut to the band servo piston stem. Then ‘ighten it temporarily toevoid tilting the band. Fig. 219 147 (w482]_3-2aAUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] 3-2a_[waB2) 24) Adjustment of total end play and reverse clutch end play (1) Measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum “L", and the distance to the top surface of the reverse clutch drum ”M". Lm] ue Fig. 220 148AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT]__ 1452] 3-2a ) (2) Measure the distance from the oil pump housing mating surface to the top surface of the oll pump- cover with of the raverse clutch, i ' i Boa Fig, 221 (@) Equation for calculation + Reverse clutch end play Total end play Unit: mm [C= (M+ 0.4) —m Perot ea C : Clearance between oil pump housing hose and end © : Clearance between concave portion of high clutch 4. Of Teverse clutch and end of clutch drum support surface to concave portion 0.4 ; Gasket thickness |: Height from housing mating surface to upper sur- face of clutch drum support Select suitable bearing race from among those listed in 9 table so that clearance C is in the 0.25 — 1217 in) 0.8 (0.02) 1.0 0.030), 1.2 (0.087) 114 (0.088) 1.6 (0.083), 1.840.071) 2.0 0.078) M: Distance from case mating surface to upper surface of reverse clutch 0.4 : Gasket thickness SESE m:Height from housing mating surface to thrust- receiving area of reverse clutch Select suitable thrust washer from among those listed in the following table so that clearance C is in the 0.55 = 0.9 mm (0.0217 — 0.0354 in) rang Part NO. Thickness mm (ed ‘31209AA000 31299AA010 ‘312098020 312000030 ‘21209040 31209AA050 312908080 1.9 (0.075) 14925) Install the oil pump housing ASSY. (1) After completing end play adjustment, insert the bearing race* in the recess of the high clutch, Attach the thrust washer and thrust needle bearing to the oil pump cover with vaseline. {2) After correctly installing the gasket to the case ‘mating eurface, carefully install the oil pump housing ASSY. Bo careful to avoid hitting the drive pinion against the inside of the case. ‘2. Be careful not to damage the seal ring. b. Be sure to use @ new gasket. Fig. 222 {3) Install both parts with dowel pins aligned, Make sure no clearance exists at the mating surface. Any clearance suggests a damaged seal ring. (4) Secure the housing with two nuts. Tightening torque: 38 — 44 Nem (3.9 — 4.5 kg-m, 28 — 33 ft-lb) Fig. 224 2) Install the converter case ASSY to the transmission case ASSY, and secure with six bolts and four nuts. Tightening torqui ‘34 — 40 Nem (3.5 — 4.1 kg-m, 25 — 90 ft-lb) ‘When installing, be careful not to damage the con- verter case bushing and oil seal. 4, CONTROL VALVE AND OIL PAN 1) Install four accumulators with oil pans facing upward. Be careful not to confuse the springs and installation positions. 2.245] Fig. 225 © Spring spec. rit em fn) ‘Accumulator spring Freo length 12 205 (1122) 445 (1.782) a 23 2055 (0.807) 31.0 (1.220) a4 173 (0.88%) 48:7 (1.720) 3. CONVERTER CASE AND TRANSMISSION no 178 (0.70%) 285 (1437) CASE 1) Apply proper amount of liquid gasket (Three-bond #1215) to the entire converter case mating surface, Make sure that the rubber seal and seal pipe are fitted in position.:-. 2) Install and route the transmission harness. Be careful not to damage the harness. 150AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] 3) Install the control valve ASSY. (1) Set the select lever in range “2”, (2) Install the control valve by engaging the manual valve and manual lever, then tighten the 19 bolts, (W484) 3-24 @ ones aon 1108 D> io (Black) 8 poe Fig. 226 . Be careful not to pinch the herness roll the gasket. b. Tighten the control valve mounting bolts evenly. | —4}-Install the oit strainer to the control valve. Be careful ot to cut or break the O-ring, Then tighten bolts. Tightening torque: 7 —9 Nem (0.7 — 0.9 kg-m, 6.1 — 6.5 ft-lb) 151 Fig. 227 5) Secure five connectors. 89.345] 6) Install the oil cooler outlet pipe, and secure with two bolts, Tightening torque: 7 ~ 9 Nem (0,7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) Fit the pipe into position. Be careful to evoid twisting. 7) Install the oil pan. (1) Attach the magnet at the specified position, Fig. 229(2) With gasket inserted, secure the oil pan by tight- ening 20 bolts, Tightening torque: 3.4 — 4.4 Nem (0.35 — 0.45 kg-m, 2.5 — 3.3 ft-lb) Tighten the bolts evenly. Fig. 230 5. EXTENSION SECTION When installing new oil seal into extension case, press it with INSTALLER (498057300). 1) Install the filter in the extension case. Pay attention to the orientation of the filter. 2) Install the transfer clutch valve ASSY, with four bolts. nd secure Tightening torque: 7 —9 Nem (0.7 — 0.9 kg-m,5.1— 6.5 Ib) 1. Be sure to tighten the going lead with one of these bolts. b. Be sure to use @ new gasket. 3) install the pipe, and clamp securely. 4) install the transfer clutch assembly to the case. 8. Be careful not to damage the seal rings. b. Insert the clutch assembly fully into position until the bearing shoulder bottoms. 6. CONNECTION OF EACH SECTION 1) Install revolution sensor (vehicle speed sensor 1) on transmission case. [FWD only} ‘Tightening torque: 93 — 103 Nem (9.5 — 10.5 kg-m, 69 — 76 ft-tb) After tightening, stake the lock nut securely. 4) Install the reduction drive gear ASSY, Insert it fully into position until the bearing shoulder bottoms, 5) Measurement and adjustment of extension end play (1) Measure distance L from end of extension case and rear drive shaft, (On FWD models, measure dis- tance from end of case to point at bearing location. 18mm {0.59'n} 83.061 Fig. 231 L = Measured value — 15 (2) Measure the distance “¢” from the transmission case mating surface to the reduction drive gear end surface, (On FWD models, measure distance from end of case to end of bearing.) 16+ 35 mm (080+ 1.38 in) Tightening torque: 6 —8 Nem (0.6 — 0.8 kg-m, 4.3 — 6.8 ft-Ib) 2) Install the reduction driven ge 3) Install the parking pawl and shaft, set the select lever in the “P” range and tighten the drive pinion lock nut. Fig. 232 152and transmission cat AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] €= Measured value — 50 (3) Calculation equation: Unit: (mm) [wab7]_3-2a (6) Tighten bolts to secure the case. Tightening torque: 23 — 26 Nom (2.3 — 2.7 kg-m, 17 — 20 ft-lb) T=(L+ 04)—€ T jearance between end of reduction drive gear ind end of rear drive shaft. (Clearance between ‘end of reduction drive gear and end of bearing on FWD model) stance from end of extension case to end of rear drive shaft. (Distance from end of case to point at bearing location) 0.4 Gasket thickness € : Height from end of transmission case to end of reduction drive gear. (Height from end of case to end of bearing on FWD models) Select suitable thrust needle bearing from among those listed in the following table to adjust clearance in the 0.50 — 0.2 mm (0.0197 — 0.0079 in) range. © 4WD: Thrust needle bearing Ls WD model: (1) Attach selected shim to cover case using vase- line. (2) Set the parking return spring. (8) After positioning gasket, assemble cover case ‘and transmission case. While aligning beerings, parking shaft, reduction driven gear, etc. essemble the two cases. (4) Tighten bolts. Tightening torqu 23 — 26 Nem (2.3 — 2.7 kg-m, 17 — 20 ft-Ib) 7. EXTERNAL PARTS 4) Install the revolution sensor. (4WD only) PartNo, Thickness mr "306535020 3.8 (0.159) 1806535030 4.0 (0.187) 1906595040 4.2 (0.108) 1806595050 44 (0.173) ‘906835060 4 (0.181) 908595070 480.189) 208635000 5.0 (0.197) ® FWD: Reduction gear shim Part No. 312864000 Thickness mm (in) 0.16 (0.0059) Select from one to five shims so that clearance is within specifications, 6) Installation of extension case 4WD, cover case FWD 4WD model: (1) Attach the selected thrust needle bearing’ to the end-surface of reduction drive gear with vaseline. (2) Set the parking return spring. (8) Remove the transfer clutch from the extension ca Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub. Be sure to engage the spline teeth correctly. {4) With gasket inserted between them, install the extension case to the transmission case. (Be sure to use a new gasket.) 8. After inserting the extension case halfway, connect the connector for duty sol. C, Be careful not to jam the cord in the case, b. Be careful not to damage the rear drive shaft seal ring. Tightening torque: 6 — 8 Nem (0.6 — 0.8 kg-m, 4.3 — 5.8 ft-lb) 2) Installation and adjustment of inhibitor switch: (1) Install the inhibitor switch to the transmission ‘case. Fit the projecting portion of the switch in the recessed portion of the case, and tighten three bolts ‘temporarily, {2) Insert the range select lever into the shaft, and tighten the nut, Tightening torque: 36 — 42 Nem (3.7 — 4.3 kg-m, 27 — 31 ft-lb) 153Fig. 233 (3) With the selector lever set to “N” adjust the inhib- itor switch so that the hole of range select lever Is aligned with the inhibitor switch hole, Ensure that gauge movas properly. Fig. 234 {4) With hole aligned, tighten three bolts to secure the inhibitor switeh. Tightening torque: 2.9 — 3.9 Nem (0.30 — 0.40 kg-m, 2.2 — 2.9 ft-lb) 3) Clip the following cords and harness: (1) Transmission hamess {2)-Inhibitor-switch-cord-~ — (8) Revolution sensor cord (4WD only) 4) Install the oil cooler outlet pipe. 5) Install the oil cooler inlet pipe. Tightening tore 23 — 26 Nem (2.3 — 2.7 kg-m, 17 — 20 ft-tb) Be sure to use a new aluminum washer. 6) Install the oil charge pipe. Tightening torque: Nem (kg ‘UPPER 34 — 40 (3.5 — 4.1, 25 — 30) LOWER 5.9 — 6.9 (0.60 — 0.70, 4.3 — 5.1) \ ft-lb) Be careful not to damage the O-ring. 7) Adjustment of brake band: (1) After tightening the brake band adjusting screw to 9 Nem (0.9 kg-m, 6.5 ft-lb) torque, back it off three turns, Then secure with a lock nut. Tightening torque: 25 — 28 Nem (2.5 — 2.9 kg-m, 18 ~ 21 ft-lb) ‘When tightening the lock nut, be careful not to turn the adjusting screw. 8) Install the pitching stopper bracket. Tightening torque: 36 — 42 Nem (3.7 — 4.3 kg-m, 27 — 31 ft-lb) 9) Tighten the drain plugs. Tightening torque: Nem (kgm, ft-lb) Dit. 41 —47 (4.2 — 4.8, 30 —35) ATE 23 — 26 (23 —27, 17 —20) 10) Install the air breather hose. 11} Insert the input shaft while turning lightly by hand. ( 3078AUTOMATIC TRANSMISSION AND DIFFERENTIAL [4AT] 12) Install the torque converter assembly. (1) Install the oil pump shaft to the torque converter. ‘Make sure the clip fits securely in its groove. (2) Holding the torque converter assembly by hand, carefully install it to the converter case. Be careful not |. Also, to avoid undue contact, imp shaft bushing and stator shaft Portion of the oil pump cover. (G) Rotate the shaft lightly by hand to engage the splines securely. 18) Add ol Specified quantity ¢ (US qt, Imp at) Diff. 1.31.5 (1.4— 1.6, 1.1 — 1.3) ATF 8.3 — 8.6 (8.8 — 9.1, 7.3— 7.6) After adding oil, insert the oil level gauge into the oil inlet, 5. Reduction Drive Gear Assem- bly ‘A: DISASSEMBLY 1) Take out the seal rings. Be careful not to damage the al rings. 2-258] Fig. 236 [W560] _3-2a 2) Take out the snap ring (out). Be careful not to damage the splines. 3) Using a press, remove the reduction drive g Fig. 237 Fig. 238 B: INSPECTION Make sure that each component is free of harmful gouges, cuts, or dust. ate tee 156