Automatic Transmission > 42 Description .. 3 Power Flow 148, Electronic Control System ssn 1413 Hydraulic Control 14-18 Hydraulic Flow 1423 Lock-up System 1432 Electrical System Component Locations 439 POM Circuit TAIT Control System) von PCM Terminal Voltage/Measur ‘AIT Control System . Troubleshooting Procedures -.. ‘Symptom-to-Component Chart Electrical System .. Electrical Troubleshooting ‘Troubleshooting Floweharts .. Leck Control Salaned Vale AB Aserbiy Test . Replacement ‘Shift Control Solenoid Valve A/B sertiy Test Replacement. Linear Solenoid Assembly. Test . Replacement ... Mainshaft/Countershaft Speed Sensors Replacement . . Hydraulic System ‘Symptom-to-Component Chart Hydraulie System .. Road Test ws Stall Speed Test Fluid Level ‘Checking/Changing 1440 476 M77 77 478 1486 Pressure Testing . 1487 ‘Transmission ‘Transmission Removal 1490 Mustrated Index Transmission/Right Side Cover sss VBA Transmission Hous ‘Torque Converter Housing/Vaive Body Right Side Cover Removal .. ‘Transmission Housing Removal o Torque Converter Mousoa/aive Body Removal Valve Cape Description . Penny ut02 14-104 14106 NOT 14-108 ATE Pump Inspection Main Valve Body Disassembly /Inspection/Reessembly e110 ‘Secondary Valve Body Disassembly /Inspection/Reassembly war Regulator Valve Body Disassembly/inspection/Reassembly 14113 Servo Body Disassembly/inspection/Reassembly .. 144 Lock-up Valve Body Disassembly/Inspection/Reassembly.. a5, Mainshaft Dlsssembiy/nspecton Rasseamby nn MeAN8 Inspection . aa Countershaft Disassembly /Inspection/Reassembly weer. 1119 Disassembly/Reassembly .... 14120 Inspection 16121 One-way Cluteh Disassembly /Inspection/Reassombly ween. M123 uteh Mlustrated Index (AARA, BARA Transmission) .. 14-124 Mustrated Index (MARA Transmission} Disassombly Reassembly Differential Mlustrated Index .. Backlash Inspection Bearing Replacement... Differential Carrier Replacernent i Seal Removal Oil Seal Installation/Side Clesrance Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement ‘Countershaft Bearing Replacement Transmission Housing Bearings Mainshat/Countershaft Bearings Replacement Reverse Idler Gear Installation .... Parking Brake Stop Inspection/Adjustment Transmission Resssembly Torque Converter/Drive Plate Transmission Installation Cooler Flushing Shift Cable Removal/installation Aajustment souenenrn Shift Lever ‘Shift Indicator Panel Adjustment... ATE Cooler Hoses Connection ..Special Tools Ret. No. Tool Number Description | cry | Page Reference @ ‘O7GAB— PF50101 Mainshaft Holder 1 [ret01, 18 @ O7GAE - PG40200 Clutch Spring Compressor Bolt Assombly 1 |14-128, 191 @ (O7HAC - PKAOT0A Housing Puller 1 | 14-108 | @ O7JAD - PHE0101 Driver Attachment 1 |14-139 ® O7AD ~ PH80200 Pilot, 26x 30 mm. 1/1139 ® O7LAE - Px40100 Clutch Spring Compressor Attachment 1 /14-128, 191 ® o7PAZ 0010100 SCS Service Connector 1/1645, ® O7SAZ- 0010008 Backprobe Set 2/1446 ® O7MAJ—PvanitA | A/T Ol Pressure Hose, 2210 mm 4 |ts87 ® ‘O7MAs - PY40120 AST Oil Pressure Hose, Adapter 4 |resr ® ‘07406 - 0920400 ‘ATT Oil Pressure Gauge Set wipane! 1 |1487 @ ‘07408 - 0070300 AST Low Pressure Gauge wiparel 1 [1487 Be (07736 ~ AOTOO0A ‘Adjustable Bearing Puller, 25~ 40 mm 1 |rado, 141 @ (07748 - 0010500 ‘Attachment, 62 x 68 mm 1 |retao, 141, 142 eS (07748 - 0010600 ‘Attachment, 72 x 75 ram 1 |ratao, 142 ® (07748 0030100 Driver 40 mm LD. 1/4124, 125,197, 139 ® (07748 - 0010000 Driver 1 |14-139, 140, 141, 142 i 07367 -611501 Driver Attachment, 68 mm 1_|retas "Must be used with commercially available 3/8” ~ 16 slide hammer. “oT ° 14-2KT 4 Description 6.9; The automatic transmission is @ combination of @ 3-elemant torque converter and a dual-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 reverse. ‘Torque Converter, Goats and Clutches ‘The torque converter consists of @ pump, turbine and stator, assembled in a single unit. They are connected to the engine crankshaft so they turn together 28 a unit as the engine turns. Around the outside of the torque converter is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converter assombly serves as a flywheel while transmitting power to the transmission mainshatt ‘The transmission has two parallel shafte: the mainsheft and the countershaft. Tho mainshaft i in line with the engine crankshalt, The mainshaft includes the 1st. 2nd and 4th clutches, gears for 2nd, 4th, reverse and 1st (Srd gear is integral with the mainshaft, while the reverse gear Is integral with the 4th gear). The countershaft includes the Sed clutch, and {gears for 3rd, 2nd, dh, reverse, 1st and parking. The gears on the mainshaft are in constant mesh with those on the coun- tershaft, When certain combinations of gears in transmission are ongaged by clutches, power is transmitted from the mainshaft to the countershatt to provide 2], Bi, Bi, and [Rl positions. Eloctronie Control The electronic control aystem consists of the Powertrain Contro| Module (PCM), sensors, a linear solenoid and four solenoid valves. Shitting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard, under the front lower panel on the passengar's side. Hydrautie Control ‘The vaive bodies include the main valve body, the secondary valve body, the regulator valve body, the servo body and the lock-up valve body through the respective separator plates. They are bolted on the torque converter housing. ‘The main valve body contains the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the CPB (Clutch Pressure Beck-up) valve, the modulator valve, the serve control valve, the relief valve, and ATF pump gears. The secondary valvo tbody contains the 2-3 shift valve, the 3-4 shift valve, the 3-4 office control valve, the ath exhaust valve and the CPC (Clutch Pressure Control) valve. The regulator valve body contains the pressure regulator valve, the torque converter check valve, the cooler reli valve, and the lock-up control valve. The servo body contains the servo valve which is integrated with the reverse shift fork, and the accumulators. The lock-up valve body contains the lock-up shift valve and the lockup timing vvalva. The linear solenoid and the shift contral solenoid valve A/B are bolted on the outside of the transmission housing, and the lock-up control solenoid valve A/B is bolted on the outside of the torque converter housing. Fluid from regulator ppasees through the manual valve to the various control valvas. The clutches receive fluid from their respective feed pipes or internal hydraulic circuit Shift Control Mechanism Input from various sensors located throughout the car determines which shift control solenoid vaive the PCM will activate. Activating @ shift control solenci valve changes modulator prossure, causing a shift valve to move. This pressurizes a line to one of the clutches, engaging that clutch and its corresponding gear. The shift control solenoid valves A and B are con: trolled by the PCM. Lock-up Mechanism In Be position, in 3rd and Ath, and in [Dz position in 3rd, pressurized fluid is drained from the back of the torque converter ‘through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the rmainshaft rotates at the same as the engine crankshaft. Together with hydraulic contro, the PCM optimizes the timing of the lock-up mechanism. The lockup valves contro! the range of lock-up according to lock-up control solenoid valves A and B, and linear solenaid. When lock-up control solenoid valves A and 8 activate, the modulator pressure changes. The lock- Up control solenoid vaives A and B and the lineer solenoid are controlled by the PCM. (cont'd) 14-3Description (cont'd) Gear Selection _ The shift lever has six positions: (6) PARK, (] REVERSE, [i] NEUTRAL, i 1st through 4th g ‘gear ranges, [2] 2nd gear. ranges, (B) 1st through 3rd Position Description Tirark Front wheels locked; parking brake pawl engaged with parking gear on countershaft. All clutches released, (ireverse Reverse; reverse selector engaged with countershatt reverse gear and éth clutch locked. GMNEUTRAL | All clutches released. (by) DRIVE General driving: stars off in 1st, shifts automatically to 2nd, 3rd, then th, depending on vehicle (st through 4th}. | speed and throttle position. Downshift through 3rd, 2nd and Ist on deceleration to stop. The lock-up ‘mechanism comes into operation in © position in 3rd and 4th gear. DI DRNE Use for rapid acceleration at highway speeds and general driving; up-hill and down-hill driving; starts {ist through ra)_| off in ts, shits automatically to 2nd, then 3rd, depending on vehicle speed and throtle postion. Downshifts through 2nd to tst on deceleration to stop. The lock-up mechantism comes into operation in 3d gear. GISECOND —_| Use for engine braking or bator traction starting off on loose oF slippery surtaces; stays in 2nd ‘gear, does not shit up and down, Starting is possible only in{F) and [i] positions through the use of a slide-type, nautral-sataty switch, ‘Automatic Transaxle (A/T) Gear Position Indicator ‘The AIT gear position indicator in the instrument panel shows which gear has been selected without having to look down atthe console, Clutches Tho four-speed automatic transmission uses hydraulically-actuated clutches to engago or disengage the transmission gears. [When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This pressos the friction discs and steel plates together, locking them so they dor't slip. Power is then transmitted through the engaged clutch peck to its hub-mounted gear. Likewise, when the hydraulic pressure is bled from the clutch pack, the piston releases the friction discs and the steel plates, and they are free to slide past each other. This allows the gear to spin independently on its shaft, transmitting no power. @ st Clutch The tst clutch engages/disengages 1st gear, and is located at the end of the mainshaf, just behind the right side cove ‘The ‘st clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshatt © 2nd Clutch ‘The 2nd clutch engagesidisengages 2nd gear, and is located at the middle of the mainshatt. The 2nd clutch is joined back-to-back to the 4th clutch. The 2nd clutch is supplied hydraulic pressure through the mainshaft by a circuit connect ed to the internal hydraulic cicuit. # ard Clutch ‘The 3rd clutch engages/disengages 3:6 goar, and is located at the end of the countershatt, The 3rd cluteh is supplied hydraulic pressure by its ATF feed pipe within the countershatt 4th Clutch The 4th clutch engagesidisengages 4th gear, as well as reverse gear, and is located at the middle of the mainshaft. The 4th clutch js joined back-to-back to the 2nd clutch. The 4th clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshatt 14.4 mara eR‘One-way Clutch ‘The one-way clutch is positioned between the countershaft Sst gear and the parking gear, withthe parking gesr splined to the ‘countershatt. The 1st gear provides the outer race surface, and the parking gear provides the inner race surface, The one ‘way clutch locks up when power is tranemitted from the mainshaft Ist geer to the countershaft 1st gear. The tst clutch ‘and gears remain engaged in the Tet, 2nd, 3rd, and &th gear ranges in the Os, D5 or 2] position, However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches/gears are applied in the (4, [01 or [2] postion. ‘This is because the increased rotational speed of the gears on the countershaft overrides the locking “speed range” of the ‘one-way clutch. Thoreatter, the one-way clutch froe-wheels with the 1st clutch still engaged. 2NDELUTCH ATH CLUTCH ast CLUTCH (MAINSHAFT ‘COUNTERSHAFT ‘ONE-WAY CLUTCH PARKING GEAR couNTERSHAFT 1ST GEAR aA CLUTCH OUTSIDE OF ONE-WAY euuren The sprage engage! INSIDE OF ONE-WAY disengage outside quwTcH land inside of the ‘Splined with countor ‘one-way elute shat - Lockine conomon, oveR-FIDING {LOCKING SPEED CONDITION 14-5Description Power Flow Prat ToROUE ] 181 GEAR 2N0 GEAR | 3RO GEAR | aH | REVERSE | PARKING posmons. |CONVERTER] circ | ciuTcH | cluTcH | Gean | clutcH | SEAR | GEAR @ [6 x x x x x x | o- il o CPB Valve - Line Pressure (S]-» 1-2 Shift Valve — Line Pressure (5}-+ 2-3 Shift Valve ~ 2nd Clutch Pressure (20) -* 2nd Clutch ‘The hydraulic pressure also flows to the 1st clutch. However, no power is transmitted because of tha one-way clutch. NOTE: When used, “left” or “right” indicates direction on the hydraulic circuit. (cont'd) 14-27Description Hydraulic Flow (cont'd) 3. ard Go {As the speed of the vehicle reaches the proscribed value, shift control solenoid valve & is tuned OFF by means of the PCM, Shift contro! solenoid valve A remains ON. The modulator pressure (6) flows to the right end of the 1-2 shift valve and the left end of the 2-3 shift valve. The 2-3 shift valve is moved to the right side by the modulator pressure (6B). The 2.3 shift valve covers the port to stop line pressure (5} to the 2nd clutch and uncovers to the 3-é shift valve as the 2-3 shift valve is moved to the right side. The line pressure (6) becomes the 3rd clutch pressure (30) at the 3-4 shift valve, Tha 3rd clutch pressure (30) is applied to the 3rd clutch, and the Grd clutch is engaged. Fluid flows by way of: ~ Line pressure (4) > CPB Valve — Line Pressure (5) > 1-2 Shitt Valve ~ Line Pressure (5) ~ 2-3 Shift Valve “Line Pressure (61> 3-4 Shift Valve ~ 3rd Clutch Pressure (90) + 3rd Clutch The hydraulic pressure also flows to the 1st clutch, However, no power is transmitted because of the one-way clutch asin 2nd gear. NOTE: When used, “left” or “right” indicates direction on the hydraulic circuit.eo 4 4. th Gear ((0« Position) ‘As the speed of the vehicle reaches the prescribed value, shift control solenoid valve A is turned OFF by means of the PCM. Shift control solenoid valve B remains OFF. The modulator prossure (6) flows to the laft end of the 1-2 shift valve and the left end of the 3-4 shift valve. The modulator pressure {6A} in the left end of the 1-2 shift vaive equals the modulator pressure (6B) in the right end of the 1-2 shift valve, the 1-2 shift valve remaing at left side by the ten sion of the valve spring. ‘The 3-4 shift valve is moved to the right side by the modulator pressure (BA). The 3-4 shift valve covers the port to the 3rd clutch and uncovers the port to the 4th clutch as this valve is moved to the right side. The Ath clutch pressure (41) from the 3-4 shift valve becomes the sth clutch pressure (40) at the manual valve. The 4th clutch pressure (40) i¢ applied to the ath clutch, and the 4th clutoh ie engaged, Fluid flows by way of = Line pressure (4) + CPB Valve - — Line Pressure (6) > 3-4 Shitt Valve ~ 4th Clutch Pressure (41) -» Manual Valv 4th Clutch 1e Pressure (5) > 1-2 Shift Valve ~ Line Pressure (5) > 2-3 Shift Valve th Clutch Pressure (40) The hydraulic pressure also flows to the Ist clutch. However, no power is transmitted because of the one-way clutch a in 2nd and 3rd gear NOTE: When used, “lett” or “right" indicates direction on the hydraulic circuit cont'd) 14-29Description Hydraulic Flow (cont'd) [BH Position in i] position. The line pressure (1) changes to the 192s to the line prossure 3!) at the 1-2 shift valve fe (Reverse range position) and uncovers the port to ‘The flow of fluid through the torque converter circuit is the same Tine pressure (3) and flows to the 1-2 shift valve. The line pressure ( land flows to the servo valve. The servo valve is moved to the right aliow line pressure (2°) to the manual valve, The line pressure (3! from the 1-2 shift valve flows through the servo valve to the manual valve and changes the 4th clutch pressure (40). The 4th clutch pressure (40) is applied to the 4th clutch, and the Ath clutch is engaged, Reverse Inhibitor Control ‘When the ffl position is selected while the vehicle is moving forward at speeds over 6 mph (10 krrvh, the PCM outputs the {st speed signal to shift control solenoid valves A and B; shit control solenoid valve A is turned OFF, shift control solenoid valve B is turned ON. The 1-2 shift valve is moved to the right side and covers the port to stop line pressure (3') to the servo valve. The line pressure (3) is not applied to the servo valve, and the ath clutch pressure (40) is not applied to the ‘th cluteh, as @ result, power is not transmitted to the reverse direction. NOTE: When used, “left” or “right” indicates direction on the hydrautic circuit 14-30Bo: P) Position ‘The flow of fluid through the torque converter circuit is the same as in IN] position. The line pressure (1} changes to the line presgure (3) and flows to the 1-2 shift valve. The line pressure {3} changes to the line pressure (3) at the 1-2 shift valve ‘and flows to the servo valve. The serva valve is maved to the right side (Reverse range position| and uncovers the port to allow line pressure (3") to the manual valve as in [Rl position. The line pressure 3") from the servo valve is intercepted by the manual valve. However, hydraulic pressure is not supplied to the clutches. and the power is not transmitted. NOTE: When used, “left” or “right” indicates direction on the hydraulic clcuit 14-31Description Lock-up System Lockup Clutch 1. Operation (clutch on) With the lock up cluteh on, the fluid in the ehamber between the torque converter cover and the lock-up piston is drained off, and the converter fluid exerts pressure through the piston against the torque converter cover. As a result the convert er turbine is locked to the converter cover. The effect is to bypass the converter, thereby placing the vehicle in direct drive. | Power flow LOCK. UP PISTON DAMPER SPRING ‘TURBINE The power flows by way of A a Tonave conventen—.| naine cover’ Drive pate 4 Torque converter cover + Lock up piston + Damper spring + Turbine 4 Mainshatt MAINSHAFT 2. Operation {clutch off With the lock-up clutch of, the fluid flows in the reverse of “clutch on.” As a result, the lock-up piston moves away from the converter cover, and the torque converter lock-up is reloased, Power flow ‘TURBINE ‘TORQUE CONVERTER Engine cover + Drive plate + Torque converter cover + Pump. + Turbine ‘ Mainshaft To ATF cooler MAINSHAFT: 14-32Eo TORQUE CONVERTER. Lock uP CONTROL, valve In [Bs position, in ard and éth, and Bi position in 3rd, pressurized fluid is drained from the back of the toraue ‘converter through @ fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft cotates at the same speed as the engine crankshaft. Together with the hydraulic, control, the PCM optimized the timing of the lock-up, system, Under certain conditions, the lock-up clutch is applied during deceleration, in 3rd and ath gear. The lock-up system controls the range of lock-up accord: 19 to lock-up control solenoid valves A and B, and the ingar solenoid. When lock-up control solenoid valves A and 8 activate, modulator pressure changes. Lock-up. contro} solenoid valves A and B and the finear solenoid fre mounted on the outside of the torque converter housing, snd are controlled by the PCM. Lock-up Conditions/Lock-up Control Solenoid Valves/ Linear Solenoid Pressure Leckup Cont! | Linear Lock-up Solenoid Valve | solenoid Condtins A B ure “Lock-up OFF OFF OFF High “scan, a ay operation Lockup Hat | on | Ouyoveration | oy lockup. ful” | ON | ON Wish Tock Duty operation suri on Low |[Toraue CONVERTER 9 OFF == ON teow 1 |L-+-moouLaTon PRESSURE curr vawel [—— + unean SoLENOIO PRESSURE are srmainen . . ye SRY CD IN rr ron J (cont'd) 14-33Description Lock-up System (cont'd) No Lock-up_ ‘© Lock-up Control Solenoid Valve A: OFF ‘© Lock: up Contro! Solenoid Valve B: OFF = ‘© Unear Solencia Pressure: High The pressurized fluid regulated by the modulator works ‘on both ends of the lock-up shift valve. Under this condi tion, the pressures working on both ends of the lock-up shift valve are equal, the lock-up shift valve is moved to the right side by the tension of the valve spring alone, The fluid from the ATF pump will flow through the left side of the lock-up cluteh to the torque converter; that i, the lock-up clutch isin OFF condition. NOTE: When used, “Ieft” and “right” indicates direction fon the hydraulic eiruit. Lock.uP conTROL VALVE ci Lock.uP CONTROL SOLENOID VALVE |“ woexur Ak olf fe fe SHIFT VALVE | oraue conventén] fi sours Leen MODULATOR PRESSURE - reuervatve| fe Lock uP mime | EP VALVE >» | REGULATOR . o- S| | vatve — . LINEAR SOLENOID PRESSURE | COOLER RELIEF VALVE [ATE STRAINER ner ATF PUMPBO; Holf Lock-up + Lock-up Contral Solenoid Vaive A: ON © Lock-up Control Solenoid Vaive 8: Duty Operation OFF = ON ‘© Linear Solenoid Pressure: Low ‘The PCM switches the solenoid valve A on to release the \ ‘modulator pressure in the (eft cavity of the lock-up shift } valve. The modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force: thus the lock-up shift valve is moved to the left side The line pressure is then separated into the two pas TORQUE CONVERTER ‘sages to the torque converter: “Torque Converter Inner Pressu \. side to engage lock-up clutch tors into right Torque Converter Back Pressure: enters into left side Lock.UP CONTROL, to disengage lock-up clutch 4 VALVE The back pressure (F2) is rogulated by the lock-up con: ‘tol valve, whereas the position of the lock-up timing valve is determined by the linear solenoid pressure and LocK-uecontaoL tension of the valve spring. Also the position ofthe lock- SOLENOID VALVE” up control valve is dotermined by the back pressure of the lock-up control valve, torque converter pressure reg: Ulated by the torque converter check valve, and modula- tor pressure determined by the lockup control solenoid ‘valve 8. The PCM switches the lock-up control solenoid ‘valve B on and off rapidly (duty operation) under certain conditions to regulate the back pressure (F2) to lock the torque converter properly cue a SHIFT VALVE A 8 NOTE: Whon used, “left” and “right” indicates direction Tonove convent] othe hydoute cel CHECK VALVE .+~ MODULATOR PRESSURE RELIEF VALVE Lock.uP TIMING VALVE REGULATOR vaLve LINEAR SOLENOID PRESSURE w{L_!) COOLER RELIEF VALVE ‘ATE PUMP (cont'd) 14-35Description Lock-up System (cont'd) Full Lock-up ‘# Lock-up Control Solenoid Valve A: ON '¢ Lock-up Control Solenoid Valve 8: ON ‘© Linear Solenoid Pressure: High When the vehicle speed further increases, the linear solenoid pressure is increased to high in accordance with the lineer solenoid controlled by the PCM. The lock-up timing valve overcomes the spring force land moves to the left side. Also, this valve closes the fluid port leading to the loft sida of the lock-up contro! valve. TORQUE CONVERTER Under this condition, the modulator pressure in the left side of the lock-up control valve had already been a released by the lock-up control solenoid valve B; the lock-up control vaive is moved to the left side. As this Lock. uP CONTROL, takes place, the torque converter back pressure is T . VALVE released fully, causing the lock-up clutch to be engaged t fully. Lock-ue contro. NOTE: When used, “let* and “right" indicates direction SOLENOW VALE’ onthe hydraulic ecu, Tonave cowventén . ronvgseuenn — [MODULATOR PRESSURE = revervauve| FE tockur rman | fr | Late ksh. | necuiaror ‘ valve = offs tome 14-36 -¢- LINEAR SOLENOID PRESSURE wo!) COOLER REL VaLve A |Z \ J aresmmamen C17, %BO Deceleration Lock-up_ ‘© Lock-up Control Solenoid Valve A: ON © Lock-up Control Solenoid Vaive B: Duty Operation \ ‘The PCM switches solenoid valve B on and off rapidly NOTE: When used, “left” and “right” indicates direction ‘onthe hydraulic circuit LOCK.U CONTROL ete Lookur covreo, a Se ts AT] [Feo Fema coment peasant won bene woouatonmessne SLL seers] LOCK-UP TIMING i waite » | REGULATOR . 4) uneansoisnoo ressune nL") COOLER RELIEF VALVE JES e Cc wremaee 7 q SLY ater 14-37Component Locations ~~ PowERTRAIN CONTROL, ~ MODULE fPoM) "AUTOMATIC TRANSAXLE (A/T) (GEAR POSITION SWnTCH ‘COUNTERSHAFT ‘SPEED SENSOR LOCK-UP CONTROL, SOLENOID VALVE ASSEMBLY MAINSHAFT ‘SPEED SENSOR ‘SHIFT CONTAOL ‘SOLENOID VALVE ‘ASSEMBLY 14-39PCM Circuit Diagram (A/T Control System) {NOER-HO0D RISERELAY 8OX UNDER pasa no.1308Ai b RIBERA Box ono roma oaace MARCY Sure L wero. vee yeu ak cre wi rar Jn ronment ron vem AUN le ed a Fe Bont | fe Ld aap b_ ake : [ wae wom usd ky a }- axle —}-—~ semy ——|__ vn wr omic fe om 1 omnes ate as “ wow + ss jm ez Pa ei EA 14-40ri evolu REDIaKK crweLK A AUYEL GaNrwéT SERVICE CHECK CORMECTOR. d or od RW ico fice eae YL GAN BRE Br ( \ BLUyeL cauwer Bg MANstary SRIDShdon She Sacon PON Terme aeatons va ola vu TEE UP CONTROL Shlagevatve | Sono Va ‘SseMa asseweuy - a tot 14-41PCM Terminal Voltage/Measuring Conditions A/T Control System ee The PCM terminal voltage and measuring conditions are shown for the connector terminals that relate to the A/T control system. The other PCM terminal voltage and measuring conditions are described in section 11 res rete mea rem concron Aa Teil] Ba oxi Tein non aria ae eae mason a p62 | Grom ron comecron iin TenbsTibe] Bea Venn anemia B83 ‘SHA Shift control solenoid valve A In 2nd gear and 3rd gear in Til, [Bi position, ‘control and in [2 [Fl position: Battery volta: sa May Fr X 14-42Bo PCM CONNECTOR B (25) (cont'd) Terminal Number | Signal Description ‘Measuring Conditions/Terminal Voltage en SHB | Shift control solenoid valve B In Tet gear and 2nd goar in i, contrat {and in 2) position: Battery voltage {in 3rd gear and 4th gear in (0), [8 position: 0 V position, Bre SLU | intend conor Wien ignition switch is ON Ul, brake pedel Sopressed and accelerator padal releases: OV Be DéINO | Ba Indicator ight contrat When ignition switch ie rat tuned ON Battery voltage fortwo seconds im B® poston: Betery voltage Bi TNMSG | Mainshaft speed sensor ground | Always: OV Bie NM | Mainshaft speed sensor signal | Depending on engine speed: Pulsing signel input When engine i topped: 0V Bie ‘ATPR_| AMT gear postion switch (&) Inf position: OV positon signal input In other than] postion: Batery voltage BIT ATP2 AIT gear position switch [2] posi- In [2] position: 0 V thon signal input In other then postion: Battry voltage Siew a = [Nerusea B22 NCSG@_| Courtershattspeed sensor around | Aways: OV Ba NG | Countershat speed sensor signal | Depending on vehicle epeed Pulsing signal input When vehicles stopped: 0 ; d Be 'ATPD4 | A/T gear position switchs pos | In Bi position: 0V tion signal input Inotherthan 8 poston: B25 ATP.NP | A/T gear position switch [P] and InP) and [8] positions: OV {8 position signais input In other than [Pj and {NJ positions: Battery voltage POM CONNECTOR € (71) Terminal Number] Signal Doseription ‘Measuring Gonditons/Terminal Vokage — crt0 66 ‘see section 11 - cr SES | Service check signet With ignition swith ON ti) and sores check connector open: 5V With ignition switch ON (ll) and service check connector connected with special tool: OV cw | ~ see section 11 = C10 aU | Back-up power system ‘Always battery voltage eit t0 C31 ~ see section 11 ~ PCM CONNECTOR D (16P) Terminal Number | Signal Description ‘Measuring Conditions /Terminal Voltage Dito de _ see section 11 ca ‘STOP SW | Brake switch signal input Brake pedal depressed: Battery voltage Brake pedat released: 0V pao “exe econ 11= io 14-43Troubleshooting Procedures Checking the Diagnostic Trouble Code (DTC) ‘with an OBD Il Scan too! or Honda PGM Tester When the PCM senses en abnormality in the input or output systems, the ‘i indicator light in the gouge assembly will ‘link. When the 16P Data Link Connector (DLC) (located under the dash on the driver's side) is connected to the OBD fi ‘Scan Tool or Honds PGM Tester as shown, the scan too! or tester will indicate the Diagnostic Trouble Code [OTC) when the ignition switch is turned ON. When the (Bl ingicator ight hes been reported on, connect the OBD i! Scan Tool conforming to SAE J1978 or Honda PGM Tester to the DLC (16°). Turn the ignition witch ON (Ih, and observe the DTC on the screen of the OBD li Sean Tool or Honda PGM Tester. After determining the DTC, refer to the electrical system Symptom-to-Component Chart on pages 14-48 and 14-49, NOTE: See the OBD II Scan Too! or Honda PGM Tester user's menual for specific instruction, oxo scan 001 _ (~| DATA LINK CONNECTOR (16) 14-44no Checking the Diagnostic Trouble Code (DTC) ‘with the Service Check Connector and Special Too! When the PCM senses an abnormality in the input or output systems, the [8 indicator light inthe gauge assembly wil blink. When the Service Check Connector (located under the dash on the passenger side) is connected with the special tool os shown, the Bs indicator light will blink the Diagnostic Trouble Cade (DTC! when the ignition switch is turned ON (\). ‘When the ‘Bj indicator ight has been reported on, connect the Service Check Connector with the special tool, ‘Then turn ON (ll) the ignition switch and observe the (indicator light. GAUGE ASSEMBLY SeRviCe CHECK (CONNECTOR (2?) a7PAZ- 0010100 Codes 1 through 8 are indicated by individual short blinks. Codes 10 and above are indicated by a series of long and short blinks, One tong blink equals 10 short blinks. Add the long and short blinks together to determine the code. After deter: mining the code, refer to the electrical systems Symptom-to Component Chart on pages 14-48 and 14-49, Short blink once) IU swore: snes | aoe tong blink or (cont'd) 14.45Troubleshooting Procedures (cont'd) 1. Remove the kick pane! onthe passenger's side (see section 201. 2, Remove the PCM, and turn the PCM over. 28Nm (1.0 kgm, 7.2 tt tok PANEL, 3. Inspect the circuit on the PCM according to the troubleshooting flowchart with the special tools and a digital multime: ‘eras shown. How to Use the Backprobe Set Connect the backprobe adapters to the stacking patch cords, and connect the cords to @ multimeter. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it comes in contact with the terminal end of the wire. BACKPROBE ADAPTER. BACKPROBE SET ‘07520010008 (ewo required) | STACKING PATCH CORD DIGITAL MULTIMETER (Commercially available) ks “akin = 32-003 or equivalent 14-46oi ‘PCM Reset Procedure 1. Turn the ignition switch oft 2. Remove the BACK UP fuse {7.5 A) from the under;hood fusesrelay box for 10 seconds to reset the PCM. NOTE: ‘© Disconnecting the BACK UP fuse also cancels the radio preset stations and clock seting. Mai presets before removing the fuse so you can reset them. '* The PCM memory can also be cleared by using the OBD Il Scan Too! or Honda PGM Tester. note of the radio BACK UP (75 A) FUSE ‘UNER.HOOD FUSE/RELAY 80X ‘© Fina Procedure NOTE: This procedure must be done aftr any troubleshooting. 1. Tum the ignition witch OFF. Reset the PCM. 3. Disconnect the OBO il Scan Tool or Honda PGM Tester from the Data Link Connector, or remove the special too! from the Service Check Connector. 4. Turn the ignition switch ON (I), and set the radio presets and clock setting, 14.47Symptom-to-Component Chart Electrical System Diagnostic . Trouble Cod | nator Symptom Possible Cause Rater to ne code Light 09 Tr T= Locksup click does not ngage. | » Disconnected loacup contra solenoid + Lockup clutch does not aisen- | "valve A connector Pinks eae + Shr or pen feck up cont! 180 solenoid valve A wire + Fauity lockup contol solenoid valve A * Lock up clutch does not engege. | » Disconnected lock-up control solenoid valve B connector Pre | atts «Short open nck. ona vase solenoid valve 8 wire + Fauity lockup control solenoid valve 8 P708 + Fails to shift other than 2nd— Ath | « Shortin AT gear position switch wire Blinks | gears. + Faulty A goar position switch 1458 + Lock-up clutch does not engage. + Fails to shift other than 2nd ard | « Disconnected A/T gear position switch P7068 ~ Ath gears connector | OFF | Lock-up clutch does not engage. | + Open in A/T gear positon switch wire 58 + Faulty AT goar position switch + Fails to shift between Tst= 4th, |» Disconnected shift contro! solenoid poss (or 2nd ~31d gear only) | valve A connector vs + Fails to shift (stuck 4th gear.» Short or open in shi control solenoid | 14-58 valve A wire Faulty shift control solenoid valve A + Fall to shift (stuckin tet oF th |» Disconnected shit cantol solenoid | sears). valve B connector 7078 atk -Shonor open eit contol sctenod | 1460 | valve 8 wire + Faulty shift control solenoid valve B “ Lock-up clutch does not engage. | « Disconnected countershettspoed sen por20 | s0r connector oe | Blinks + Short or open in countershaft speed | 14.62 + Faulty countershaft speed sensor (OTCH*: The DTCs in parenthese nected with the special oo! (SCS serviea connector), 14.48 are the number of the [Bd indicator light blinks when the service check connector is con-Dagranie we Troublecade |B lnstor sympom Posie Caute Rate (ore) font ea Te br nase “AHPC dens otnpeam | = Disoeed maaht oan or rons [oF roi |r -Shoeropnin rina smote: | 1468 Blinks + Faulty mainshaft speed sensor “Tianariesn shard when)» Diconnesad nea solenoid omnes ure Shing ck inain gear | “Sharer openin ines slenls re (16) Blinks + Lock-up clutch does not engage. | - Faulty linear solenoid 1486 + Diconneted or oosed PG terminal Forde) ogg [= \nokup Sit done ov engage. | + Fal ockup conto este ‘ees “or | ~Fito shi eben tt= 2nd > Fey shit conlaytom tare 2nd ty dnd aed ed voraa "tsi a= ay OFF Ath oF 2nd ~ 3rd - 4th gears only). 1468 -faltoshit ua ator ang ore voreo Any aoa eran orator: for |__| TS efminate DTC 70, rouseenocthe ober stomatranemaion prob | — |_ tom sang othe Cleat (DTC/*: The DTCs in parentheses are the number of the [Bd indicator light blinks when the service cheek connector is con: nected with the special tool (SCS service connector). NOTE: When the OBD il Scan Tool or Honda PGM Tester indicate the DTC{s) for the automatic transmission control sys- ‘tem, the scan tool of tester also indicates code P0700 simultaneously. Code PO700 means detection of some autom transmission problem on the PGM Fl control system. I the self diagnostic [Gy indicator light does not blink, perform an inspection according to the table below. Symptom Inspection’ Ret. page [Bi indicator light does not come on for two seconds after ignition switch is first turned ON it 1470 Wis on constantly (not blinking) whenever the ignition “un ‘Shift lever cannot be moved from [F] position with the brake pedal inapection vas dopressed, NOTE: Ifa customer describes the symptom for code P1706 (6, it will be necessary to recreate the symptom by test-driv- ing, then recheck the DTC. 14-49Electrical Troubleshooting Troubleshooting Flowchart — Lock-up Control Solenoid Valve A + OB Scan Tool indicates Code Pre, *Selt-disgnosis Bi indicator (Cheek for a Short to Power 1." Turn the ignition switeh OFF Disconnect the A (32P) and & (25P) connectors from the Pom, “Turn the ignition switch ON ‘Measure the vottage between the BS and A9 oF A2 tormi _——__} Is there volta vousge? 7 No ves Lockwp Control Sale. ‘A Resistonce! ition stn OFF. the. resistance Derween the B and AG ar A22 terminals, To page 14.51 14-50 Possible Cause "Disconnected lock-up control solenoid valve A connector + Short or open in lock-up control solenoid valve A wire + Faulty lock-up control solenoid valve \WIRE SIDE OF FEMALE TERMINALS. Repar short power in the wie | bbetwoen the 88 terminal and the lockup contrt solenoid valve A. ot . es ee 7 Dl lt ®) Cheek for oose POM connectors. | Wecossary,subetiute a known: 00d solenoid valve assembly oF Peat ana roeheckFrom page 1450, PCM CONNECTORS, cheek Lock up Control Solenoid acca) POLK ® Valve A fora Short Circuit { 1" Disconnect the 2P connector frp el Zee be from the lockup contol soi (Zeal ofefotap Taleo Zi7Tn fel) elo roid vaive assembly. é isis ee 2. Cheek for continuity between Vial ae 271 Ve the BS and A9 oF A22 tormi BRNreUK @ WIRE SIDE OF FEMALE TERMINALS / ves | Repair short te groundin the wire | <__ tether contnaty? between the Bs terminal and the lock contr soteoid valve A No {LoCK-UP CONTROL ‘SOLENOID CONNECTOR Measure Lock up Control Sole old Valve A Resistance st the Solenoid Connector: , s Moasure the resistance betweon the No.7 tarrinal of the lockup control soleaoid connector and body ground. TERMINAL SIDE OF MALE TERMINALS, a Sve | Check for open in the wire weve resistance 12-2507 > between the BS terminal and the . lock-up contol solenoid valve A No. Replace the lock-up control sole- ‘od valve assembly. 14-51Electrical Troubleshooting Troubleshooting Flowchart — Lock-up Control Solenoid Valve B + 080 1 Sean Too! indieatas Code i a + Sel-diagnosis Dy indicator ght Blinks twos + Short or open in lock-up control solenoid vave B wire + Faulty lockup control solenoid voheB. ‘Check for & Short to Power: 1 Turn the ignition switch OFF. 2. Disconnect the A (32P) and & (25P) connectors from the PeM, 4. Tum the ignition switch ON 4 Measure the voltage between the BA and AO oF A22 termi ale WIRE SIDE OF FEMALE TERMINALS ves [teen prem in ae —TES| Wnscessary, substitute» known- pee ease ‘goed solenoid valve assambly or NO. PH and recheck, Topege 1459 14-52Eo From page 1452 (Check Loek-up Contr! Solenoid Valve B for a Short Creu 1 Diseonnact the 2P connector 2, Check for continuity between the B4 and A9 oF A22 term: << eweminsi >| No ‘Measure Look-up Cor ‘old Valve B Resistan Solenoid Connector: stance between ‘Of the lock up control solenoid connector and body around << tothe resistance 12-75 07 No. ves, ves ‘cheek for open in the wire PCM CONNECTORS. GAN/OLK arwvoux QS ivi By ielelelZ Bal | el BRN © WIRE SIDE OF FEMALE TERMINALS Repair short to ground in the wire ‘between the B4 terminal and the Iocleap contro solanoid valve 8, Lock.uP CONTROL SOLENOID CONNECTOR ? ‘TERMINAL SIDE OF MALE TERMINALS between the Bd terminal and the lock-up control solenoid valve 14-53Electrical Troubleshooting Troubleshooting Flowchart — A/T Gear Position Switch (Short) “O80 Sean Too indiatos Code [—___rensiecnue | Paros. ‘Shor WATT gear poston swith + Seltdiagnons Di indeator Hight one Bln ve times Fatty A gear postion switch NOTE: Coge P1705 (8) is cauted when ——___|______ihe'Pcireceives two geer position | Observe the A/T Gear inputs athe same te, Inchator Terme iotion sth ON 2 Observe ihe AT gear post inoteator, and shift fo each /""Do any necator stay on 1uo_| The system is OK at this time ( Sbentne shit overs notin ‘Check the wire harness for dam \ tote postions? aoe. eM connectors wor ves san/Bix-——W i) Meanie ATPR Vorage PEEL EEA ees 7 Epstein Zils) sn ns ols a 2, Measure the voltage between eC = the B16 and AB ov AD tr srw ‘Check for short in the ve Isthere baneryvotage? > —“O | ves _ srw aux (9) Masso ATP NP Voltage: Shoat poeione other than ior voltage betwoon | AS 00 822 tori sf ‘Cheek for short in the ‘betwen the B25 terminal snd the trenw AIT gear position indicator, or a no | Martin the wires between the Tanesa bon > [AIT gear positon indicator and. < te there bene vows >| the Aft sear peation stent | ves ‘OK. check for loote ‘Measure ATP Dé Voltage: 1" Shifto all postions ot ia 2. Measure the voltage betwean the B24 end AG oF A22 term AIT gear position switch. wire is OK, check for loose POM con: ectors W necessary, substitute © known-good POM and recheck Topege 1465 14-54oft ‘Measure ATP D3 Voltage: 1" Shit al positions Be. 2. Measure the voltage between the BB and A9 oF A22 torm’ ale. ter than WIRE SIDE OF FEMALE TERMINALS Check for short in the wire between the B@ terminal and the \ NO_| A/T gest postion swatch or A/T “) gaat position indicator M wire is en (OK, check for loose PCM conn ves tors. if necessary, substitu snown-good POM and recheck ——__| oe em AP vee ees sane ae pe | 2 bane n eager False (leak eecamipterees ea is | hook toy short in the wire | ‘between the B17 terminal and the o_| A/T gear postion switch or AIT ‘gear porition indicator. H wire is ‘OK, check for loose PCM connec tors. Irnecessary, substitute @ known- good PCM and recheck. 14-55Electrical Troubleshooting Troubleshooting Flowchart — A/T Gear Position Switch (Open) + 08D i Sean Toot nates Code Possible Cause wa AT pen in AT gear poston switen | we ty APT gor postion etch Pom CONNECTORS BRN/BLK | wn (Measure ATP R Voltage: we 41. Turn the ignition switch ON {I Aa2r + 2 Sano penton” Pehl Ped Zeer Be pe) fe 3. Measure the vole batwoon Vfataletal lola Tabak] [77Tohant shalt the B18 ong AB or AZZ Terme see re eee BrN/Lx ge WIRE SIDE OF FEMALE TERMINALS |___ 5 | raps open in the wre batwoon voltage? D> AES] the 816 torminal andthe A/F gear / postion sta No sawn ——@) Masaure ATP WP Vote PEEP) Fed Vee Cy eel 27 T'Shit to orl postion elulteln lola lala] LIne =e 2. Maacure the vohage Between et eT G25 and AB oraz tom aRWraLx Repair open in the wire berwoon ‘he 825 terminal and the A/T gear 7] _asition indicator or the A/T gear 7 Position switch p———1___.._ vs Istherevologe? aN ux ‘Measure ATP Dé Vottage: 1. Shittto By position, 2. Meosute the voltage betwee B24 and AB or 822 term eaeweuer > ‘6 14.56From page 14.56 ‘Moesure ATP D3 Voltage: 1. Shift to postion. 2. Measure the voltage between the BB and AS or AZ2 termi ale, “Moasure ATP2 Voltage: 1. Shift to] position. 2. Measure the vokage between the B17 and AG oF AZ2 torr! IRE SIDE OF FEMALE TERMINALS ‘BRN/BL) -@) ae. Wy 14-57Electrical Troubleshooting Troubleshooting Flowchart — Shift Control Solenoid Valve A + 080 I Sean Too! indicates Code O73. ‘Check fora Short to Power: Pom, 3, Tum the ignition switch 0 4 Measure the ‘the 89 and AS or A22 ter lethere No 1" Turn the ignition sw'ten OFF 2. Disconnect the A (S2P) and 8 [25R) connectors from the voltage betwoon N “Measure Shift Control Solenoid Valve A Resistance: 1. Turn the ignition ewiteh OFF. 2 Measure. the re between the 83 ond AS or | __ terminals - sistance 12-250? No To page 14:59 14-58 822 ves Possible Couse * Disconnected shit control solenoid valve & connector + Short or epen in shit control sole: fat valve A wire | Faulty shift control solenoid valve A ‘PCM CONNECTORS BRNTBLK, Az) anne. Baer) 00) Banya \WIRE SIDE OF FEMALE TERMINALS [Repair short to power in the wire between the B3 terminal and the shit contra solenoid valve A a BRN/BLK, @ ne anna ‘Cheek for loose PCM connastors. Whecessary, substitute a known: {00d solenoid valve assembly or POM and recheck,From page 1458 ‘Cheek Shitt Controt Solenoid Valve Afora Short Circult: 1. Digconnect the 2P connector from the hit control solenoid valve assembiy. 12. Chock for continuity between the B9 and 89 or 22 trminals << tetherecomtinaiy? > No Massure Shift Control Solenoid ‘Valve A Resistance atthe Solenoid Connector: Measure the cosistance berween ‘the No, 1 terminal ofthe ahi com {wo solenoid connector and body round botweon the B11 termine! and No | prwreux—(@y SRW Measure Shift Contro! Solenoid 7 Oe | Volve B Resiatance: rl elle | 1° Turn tho fantion switen OFF 2 Measure. the resistance | baal | © between the B11 end Ad or L_ Azzterminas | ves Inthe resistance 12-2507 >= | No To page 14-81 14-60isk From page 14.60 Check Shift Control Solenoid Valve B for a Short Coute 1 Disconnect the 2P connector from the shi contol solenoid valve assembly 2, Check for continuty betwoon the BI? and AG oF A22 termi. nate Fetherecontinuity? No Measure Shift Control Solencid Valve & Resistance st the Solo: rnold Connector Measure the resistance between the No.2 terminal ofthe aif con trol solenoid connector and body ‘round ——__1—____. tethoresisionss 12-250? > J PEM CONNECTORS. ‘erwi/six —(G)-SRWWHT B25) ja oll Tal tern BRN/BLK ® WIRE SIDE OF FEMALE TERMINALS [SHIFT CONTROL SOLENOID ‘CONNECTOR ‘TERMINAL SIDE OF MALE TERMINALS 14-61Electrical Troubleshooting Troubleshooting Flowchart — Countershaft Speed Sensor uu + OBD Wl Scan Toot indiontes Code ossible Cause orzo, “Loose oF faulty connection + Self-diagnosis (Bd indicator botweon the PCM and car hor, Hight Binks nine timos. ess | Disconnected countershaft speed sensor connector + Short or open in countershatt speed sensor wire + Faulty countershatt speed sen- ‘Check the countershat speed sor- | ser sor instalation, ~ wc se S, [rename] Saeesrme land tec met COUNTERSHAFT SPEED SENSOR ves CONNECTOR ‘Measure Counterhatt Speed San sor Resistance at the Sensor Can sector 1! Disconnect the 2P connector fom the countershat speed peuterconnetr TERMINAL SIDE OF MALE TERMINALS & 2, Measure te resistance ofthe ountershat speed sensor L No lace the countershe {Is the resistance 40060007 >> Replace th shaft speed ves PCM CONNECTOR & 125°) Check Counteshat Speed Sansor_ | fora Short Creat 1 Disconnect the 6 (25°) con ‘ecto from the PCM, 2. Check fr continuity between o the body ground and the 823, terminal and 822 tecminel inevcaly | +t ‘yes | Repair short inthe wires berwoen, the 823 and B22 terminals {the countershaf speed sensor. No \WIRE SIDE OF FEMALE TERMINALS | yes 14-63Electrical Troubleshooting Troubleshooting Flowchart — Mainshaft Speed Sensor + QD Ut Sean Too! indieater Code Possible Couse Por, : By indicator Light indeates Code 15. Chock the mainghaft and counter shaft speed sensor instalation. + Disconnected ruainshaft speed + Short or open in mainshaft _+ Faulty mainshaft speed sensor Reinstall and recheck. ‘are the mainshaft nd countrshatt, NO \ speed sensor insta property? Yes Measure Mainshaft Speed Sensor Resistance at the Sensor Con: 1 Disconnect the 2P connector ‘rom the mainshat speed son 2, Measure the resistance ofthe rmainshet spacd censor ._No- ves Check Mainshett Speed Sensor fora Short Circuit: 1 Disconnect the 8 (25°) connee- | tor trom the PCM 2. Check for continuity between body oround and 815 termina ‘nd vo BE terminal indivi aly. <_tethare continuity? \___lithere continuity? | no. To page 1865 Replace the mainshaft speed sen- Code P0718115i on the PCM ays mean there's an electrical ‘robiem in the mainghat or countershaft Speed sensor iret: code POT 8115) may als indicate @ mechanical problem ia the IMAINSHAFT SPEED ‘SENSOR CONNECTOR fa t Ly ‘TERMINAL SIDE OF MALE TERMINALS PCM CONNECTOR & 125) WIRE SIDE OF FEMALE TERMINALS XVoi From page 1664 “Measure Mainahaft Spaed Sensor Resistance | connect the mainshatt spacd | sensor 2° connector. 2, Measure. the. resistance betwoon tho B16 and B14 tor: un the Electrical Troubleshocting Fowehart for code P0720). Check for loose PCM connectors. ves Is the resistance 400-6007 > Woecessary, substitute a known. No. ‘good PCM and recheck ‘Gheck NM Wire Continuity: 1. Disconnect the 2P connector from tho mainchat epoe sen 2. Check for continuity between | the B15 erminal andthe No terminal of the mainshatt speed sensor connector. ——_! ~_no_| Repair open in the wire between << tethers eoninuiny? the BIS terminal and the main- ———__ —— shel speed senor. ves ‘Check NMSG Wire Continuity: CChook for continuty betwaon the 81 terminal anc the No. 2 Tem: hal ofthe mainshaf speed sensor Repal opan inthe wire between the B14 terminal end the main shatt speed sensor <_ te there continuity? No ves ‘Check for loose PCM connectors necessary, substitute a known {900d POM snd rocheck PCM CONNECTOR 8 25P) RED wer WIRE SIDE OF FEMALE TERMINALS MAINSHAFT SPEED SENSOR CONNECTOR aE al Vet 14-65Electrical Troubleshooting Troubleshooting Flowchart — Linear Solenoid + 080 1 Scan Too inciostes Code Possible Couse P78. Disconnected linear sal + Selt-diagnosis (03 indicator |" connector Hat indicates Code 16. + Short or open in ina solenoid ‘wire LINEAR SOLENOID CONNECTOR « Fauty linear solenoid _ | , (ts) ‘Measute Linear Solenoid Resist ance atthe Solenoid Connector: @ "Turn the fontion switch OFF. 2: Disconnect the 2° connector TERMINAL SIDE OF MALE TERMINALS. Finear solenoid Replace the near solenoid aster by soos son > N2 approx 5.0 >| YES PCM CONNECTOR 8 (25P) (Check Linear Solenoid for a Short Gireut 1." Diaconnect the B (25P) connec tor trom ha PCM, 2. Check for continuity between the body ground and the B1 terminal and 82 terminal i vidual yes ‘Measure Linger Solenoid Resist- A Connect the Hinear solenoid |” connector. PER 2. Measure the resistance 4 between the BY and B2 termi= Tes os | UA el Teal ——_no | Repair loose terminal or open in stance approx. 5.0307 >—“° | the wires betwoon the BY and B2 rminals and the linear solenoid. Yes Se To page 1467 14-66 eeFrom page 1468 PEM CONNECTOR A (327) ‘Cheek the Ground Circuit: Check for continulty botweon the AS and A termin Brive 5 aye] Te “Repair nthe. wi et al ——__ No. | between the terminals A and 's there continuity? At and G101, > AM and Gn connector WIRE SIDE OF FEMALE TERMINALS | _ + Repair poor ground (G10, 14-67Electrical Troubleshooting Troubleshooting Flowchart — Lock-up Control System + 08D I! Scan Too! indicates Code Possible Ceune oreo, lock-up control system + Self-dlagnosis [Dd indicator ight {_feuttytockop contrat sytem _} Indlestes Code 40 (Check for Another Code: ‘Check whether the OBD I! scan tool or the [05 indicator light Indicates anotner code, /” do0e the 080 1 scan too! or the (Bs inaieator tight icieate ‘another code? Flowchart for the ‘Codes). Recheck for code POTAD (40) attr troubleshooting, No NOTE: Do not continue with this woublashoating unt the causes of any Test Line ther DTCs have been corrected, Measure the line praseure ( age 1407 and 14-88), Is the line pressure within the Repair the hydraulic system as, service lt? necessary (son page 14-88). rol ‘Solenoid Valve Assembly and Recheck 1 Replace the lock-up control solenoid valve A/B assembly {s0e page 1478) 2. Turn the ignition ewiteh OFF ang reset the PCM by remov ing the BACK UP (7 a) tose in the under-hood fuseielay box for more than 10 seconds 3. Using the scan toal, check to bbe eure that the engine cool ant temperature isin 176°F (80°C) and above 4. Drive the vehicle at $5 moh [88 teh) constantly for more than one minute 5. Recheck for code PO740 140) ¢ tne OBD I scan tool NO | ox mamama Imicawcoerror@ a —|_Theartm vox etmesie, | ves Replace the transmission and ‘torque converter. 14-68) Troubleshooting Flowchart — Shift Control System * OBD i Scan Too! indiates Code Possible Couse Faulty shift contol systern (Oheck for Another Code: Check whether the OBD It scan tool or the (BY indicator light leate anther code. form the Troubleshooting ‘08D tecen toot or 00! yes. ‘ Frowchas ingen igh flow \Laneanercoget | ta No. NOTE: De not continue with thie woubleshooting unt the causes of any ‘other DTCs have bean corrected, oat tat, 2nd, Sed and 4th Clutch Pressure: Moosure the 1st, 2nd, 3rd and &th cluten pressure (soe page 14-87 thew 1489), Replace Shift Control Solenoid Valve Assembly, Linear Solenoid ‘Assembly and Recheck: 1 Replace the shift contro! solenoid valve A/B assombly (cee pege 14-761 2, Replace the linear solencia assombly {s00 page 1477 3. Turn the ignition switch OFF and reset he PCM memory by emoving the BACK UP (75 Ab fuse in the under hood fuse! fay box for more than 10, seconds. |. Brive the vehicle at over 12 mph (20 keh) In 15. 2nd, Sed {and th gear for more then 30 seconds t 8 postion. Recheck for code PO730 (41), ‘The system is OK at this time 14.69Electrical Troubleshooting Troubleshooting Flowchart — (D. Indicator Light Does Not Come On ‘The (Bd indicator ight does not come on wen the ignition switeh is iret turned ON i (ht shoula ‘come on for about two seconds.) | check the Service Cheek Connee- ‘Make sure the special tool (SCS Service Connecto isnot sonaee tothe sore chock connector. , | _ | fine peer ool CS Senice ves [Dianne he spac ta om ( Esttatoncomasaa‘othocer, "SS | Retonn cock sonnet \ ses conto res No Chak ert YES_| Check for loose PCM connectors, necessary, substitute « known: ‘900d PCM and recheck PCM CONNECTOR A (22P) (Cheek the Ground Cireut: Turn the ignition switch OFF 2. Disconnect the A 32P1 connec tor trom tho PCM, 13. Check for continuity between the AQ terminal and body ground and the AZ2 terminal 5nd body ground (WARE SIDE OF FEMALE TERMINALS NO_| = Repair open in the wires between | | the A or AZ2 terminals and’ G01. | + Repair poor ground (G10), Is ther Topage 16-71ask From page 14.70 Mensur Voltage 1. Tom the ignition switch ON i 2. Measure the voltage betwoen terminals AS and ATT and bbotween terminals AZ2 and 2k ves ‘Measure D4 IND Votiage: 11 Tan the ignition switch OFF, 2 Connect the A132?) connector tothe PCM. 3. Connect 9 digital multtester tothe B13 and A9 or AZZ ter- 4. Turn the ignition ewiteh ON a and make sure hat he voltage {savallable fortwo seconds ves Is there voltoge? No. —— ‘Cheek for loose POM connectors. Check the A/T gear position snitch. W necessary, substitute & [known-good POM and recheck. No votiage? so | Repair open or short n the wire | betwnan the A) andor AZA tre ats, the PGM-FI main elay, fd the fusebox. | PCM CONNECTOR A (32P) yeLeuK veLsaLx WIRE SIDE OF FEMALE TERMINALS ‘Check for open in the wir | between the B13 terminal and ‘the gauge assembly. If wire is (OK, check for a feuty (Os indica: {or light bulb or a faulty assembly print circuit board "96: BLU/RED (99,98: GRN/ELK 14-71Electrical Troubleshooting Troubleshooting Flowchart — [D.| Indicator Light On Constantly 9 [Dt indator ight is on con tantly (not blinking] whenever ‘the faition smitch is ON PEM CONNECTOR 8 25h Measure D4 IND Votage stunt tion sth OFF — 2: Discanet he B PI connec [a Fre tortom ine Pe cae 2, Tumnthe ignition saiteh ON @ ic = eV & Muasue the soap tomes Me A lel the B15 terminal ond booy ‘96 BLU/nED sovnd ‘98 GRNTBLX WE S1D€ OF FEMALE TERMINALS a Fa termina and | ‘the gouge sssembly, No 1 : Measure ATP D4 Volt wetormmetgnbon 2. Cones tne 8 SP) constr Berth 7p APL oy 3, Torntheigitn swith ON th alae {Shinto ary goron ober hen Cpe & Moosure vet the BZ terminal and wosy oround No_| Check or «short to ground on the < Is there vokage? NA wie: Wie fs OK replace the AT ‘S0ar position indcatr. ves I Replace the PCM. 14 Troubleshooting Flowchart — Brake Switch Signal Inspection ofthe brake witch | ‘Measure STOP SW Votuage: 1. Turn the ignition switeh OFF. 2, Disconnect the A (32P) and D (16) connectors trom the Pow. 3. Mencure the voltage between ‘he DS and AG oF AZ2 termi nals with the brake pedat pressed. + Brake switch signal is OK. 1 Check for logae PCM connectors Wnoconsary, substitute a known- (00d PCM and recteck. -Tnapect the brake switch circuit (a0e section 23. Symptom ‘Shift ever cannot [F postion with the brake pedal PCM CONNECTORS. No. 14.73Lock-up Control Solenoid Valve A/B Assembly Test 1 2 Disconnect the 2P connector from the lock-up eon: trol solenoid valve A/B assembly. TERMINAL SIDE OF [MALE TERMINALS. Lock. uP CONTROL, SOLENOID VALVE A/B ASSEMBLY Measure the resistance between the No. 2 terminal {solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the 'No. 1 terminal (solenoid valve 8) and body ground. STANDARD: 12-25 0 Replace the lock-up control solenoid valve assem: biy ifthe resistance is out of specification, Hf the resistance is within the standard, connect the No. 1 terminal of the lock-up control solenoid valve ‘connector to the battery positive terminal. A clicking sound should be heard, Connect the No, 2 terminal to the battery positive terminal. A clicking sound should bbe heard. Replace the lockup contral solencid valve assembly fe clicking sound is hear, Replacement NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembl 1. Remove the mounting bolts and lock-up control solenoid valve A/B assembly. LOCK-UP contrat SOLENOID VALVE 121 ASSEMBLY 6x10 mm 11-2 kgtom, 8.7 Itt) FILTERIGASKET Clean the mounting eurtoce Replace rene and fuid passages, 2. Clean the mounting surface and fluid passages of the lock-up control solenoid valve assembly, and install @ new lock-up control solenoid valve A/B with a new fitor/gasket 3. Check the connector for rust, dirt or oll, and recon- ect it securely, &Shift Control Solenoid Valve A/B Assembly J Test 1. Disconnect the 2° connector from the shift control solenoid valve A/B assembly. TERMINAL SIDE OF MALE TERMINALS. our coa. See a 3 oo 2, Measure the resistance between the No. 1 terminal (solenoid valve Al of the shit control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. STANDARD: 12-250 4. Replace the shift control solenoid val the resistance is out of specification. 4, Ifthe cesistance is within the standard, connect the No. 1 terminal of the shift contro! solenoid valve connector tothe battery postive terminal. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal. clicking sound should be heard. Replace the shift control solenoid valve assembly if no clicking sound is h Replacement NOTE: Shift control solenoid valves A and B must be romovedireplaced as an assembly. 1, Remove the mounting bolts end shift contro! solenoid valve A/B assembly 5x10mm 2Nm CONNECTOR BRACKET (1.2 kat, 8:7 WH) FLTERIGASKET clean the mounting surtace Replace snd fui passages 2. Clean the mounting surface and fluid passages of the shift control solenoid valve assembly, and instal @ new shift control solenoid valve A/B with @ new fiter/gasket and the clamp bracket 3. Check the connector for rust, dit or ol, and recon ect it securely.Linear Solenoid Assembly Test 1. Disconnect the linear solenoid connector. LINEAR SOLENOID LINEAR SOLENOID CONNECTOR WA TERMINAL SIDE OF MALE TERMINALS. > 2. Measure the resistance between the No. 1 and the No. 2 terminals of tne linear solenaic connector, STANDARD: approx. 5 2 3. I the resistance is out of specification, replace the linear solenoid assembly. 4. Connect the No. 2 terminal of the linear solenoid con- rector to the battery positive terminal and connect the No. | terminal to the battory nogative terminal. A clicking sound should be heard. 14-76 5. not, ramove the ear solenoid assombly. 6. Check that the linear solencid fluid passage for dust ordi 7. Connect the No. 2 terminal of the linear solenoid connecter to the battery positive terminal end con: ‘oct the No, 1 terminal tothe battery negative term nal Check that the valve moves. 8, Disconnect one of the battery terminals and check ‘that the valve releases. NOTE: You can soe the valve movement through ‘the fluid passage in the mounting surface of the lin ‘ear solenoid assembly. LUNEAR SOLENOID 9. Ifthe valve binds, or moves sluggishly, or the linear Solenoid does not operate, replace the linear solenoid assembly.Mainshaft/Counter- shaft Speed Sensors 0.0; J Replacement Replacement | 1, Remove the mounting bolts and the linear solenoid 1, Remove the 6 mm bolt and the countershaft speed sccorbly. sensor from the night side cover. Cleon tne mounting surtace ex 101m snafu passooen S22 kof. coUNTERSHART 87 lott) ‘SPEED SENSOR 5x1.0mm TN (12 kgte, a7 ibte onWe Replace (MAINSHAFT SPEED NEAR SENSORWASHER 8x 1.0mm SOLENOD {D16Y7 engine) aN 1.2 kgten, ASSEMBLY amet) B® Sarees surface and fluid passage of the 2, Romove the 6 mm bolt and the mainshaft speed ar solenoid assembly and transmission housing. sensor from the transmission housing. 3 ‘2 new lingar solenoid assembly with @ new 3, Replace the O-ring with @ new one before installing the countershaft speed sensor or the mainshaft speed sensor. NOTE: Do not pinch the gasket when installing the \inear solenoid; make sure that the gasket is installed NOTE: Install the mainshaft speed sensor washer on properly in the mounting groove of the linear sole- the mainshaft speed sensor. The mainshaft speed roid ‘sensor washor is used on models with the D16Y7 engine. 4. Cheek the linear solenoid connector for rust, dist or oil, and connect it securely. 14.77Symptom-to-Component Chart Hydraulic System . 20k these tems on the eck these items on | srwrtow ‘Prounate cause ust | "tnenoTestat Engine runs, but vehicle does not move in any gear. |1.2.3,5, 6, 7, 36, 38 KURS ‘Vehicle moves in [2], [R], but not in [0s, ibs, position, 6,8, 9, 10, 30, 54 CMO Vehicle moves in 03, [Os [8 but not in 2] position. 6,11, 12,28 Gt Vehicle moves in IO, [bs [2], but not in [Al position. 4,6, 14, 16 [cto Vehicle moves ini position 10, 12,13, 14, 16,28, 23, 34,35 | C.D Excessive idle vibration, 7.2, 19, 32, 36, 45, 47, 48 BL 12.3,6,38, 4 KOR Stall rpm high in Os, [Bd position. [ 6.8, 10 CD Stall rpm high in 2] position, 612 cD ;_ Stal rpm isin sp 4 N | "Stall rpm low. 17,52, 46, 47,48 ee ‘Wo sbi 18,20, 40,48, 49 Tou Fails to shift in ©) (i position: trom tet to Sed gear | 22, 49 - _ Fails to shift in (Bs, 1] position; from 1st to 4th gear 22, 23, 48, Erratic upsifting. 112 upshit 23 upshif. 3-4 upshife se 2 upshit 2a 2:3 upshit 22,49 Stat ae - X Horsh upshift (7-2). 12, 18, 20, 29, 60, 51, 67, 58 CDE | Harsh upshift 23) 13,19, 20,24, 27, 29,50,51,87,58 | C.O.E.WL Harsh upshit (3-4). 14, 19, 20, 26, 28, 29, 50, 51,57,58 | CO.ELL Harsh downshift (21) 178,20, 24, 43, 54 57,58 ° Harsh downshift (3-2) 12,18, 20, 25, 43, 85,67, 58 CO.EH Harsh downshift (43). - 13, 19, 20, 26, 43, 56, 57, 68 CDE! Flares on 2-3 upshift. ~~} 19, 20,24, 27,51 Et Flares on 3-4 upshift 14, 19, 20, 25, 28, 51 BLN Excessive shock on 23 ups 18,18, 20,24, 27, 8, 50,61, 58 ELN Excessive shock on 3-4 upshift 14,19, 20, 26, 28, #3, 80,51, 58 [Eun Late shit from Bl position to fs or [5 postion 10.30 M Late shift from In] position ta [R) position, 4,14, 21,63 jo Noise from transmission in all shift evar positions. 2.37 [Kua Vehicle does not accelerate more than 91 mph (60 km/h. | 17 Shift lever does not operate smoothly. 6.39 P Fall to hit; stuck in sth gear. 19,48, 8 Transmission will nat shit into parking gearin[F position. 6, 18, 38 P J Stal rpm high: all cltch pressures are in specification. | 47 D.KO lock-up clutch does not disengage. 19, 44, 45,66, 47,60, 5,88 EL - Look-up clutch does not operate smoothly. | 18, 41.44, 48,46, «7,60,53,58 [| L Lock-up elutch does not engage. | 19, 41, 44,45, 48, 47, 50,51, 87,88 | EL — i ‘Vibration in all positions 38 - 14-78 Dass EEEESENSTSNSUCSSSSUOSSSUSSSUSSSOSESOSSSBo PROBABLE CAUSE 1 [teware 41 | Foraue converter check valve suk 7 | ATF pump wor or Bina, 42 Farelgn marr separator late 3 Regulator valve stuck, 43 ‘CPB vaive stuck 4 4 | Serve valve stuck. = “44__| Look-up timing valve stuck 5 “Mainshaft worn/damaged. 48 | Lock-up shift valve stuck _| | Shit cable broken/ot of asian 16 [ Lock contol valve suck 7 Final gars worndamaged. 47 | Lock up piston detective 8 ‘One-way (sprag) clutch worn/damaged. “48 __| Shift control solenoid valve A defective. 9 Ist geers wornidamaged (2 gears). co ‘Shift control solenoid valve B defective 10__[ tstetuteh detective = 50 Lookup contol solenoid valve Adefcive W ‘2nd gears worn/damaged {2 gears). | st Lock-up contral solenoid valve B defective. 12 | 2nd clutch defective. 52__| Servo control vaive stuck 7 13 [Bed elt dfective 53 | tet accumulator dfectv 14 [ah lth dtetive Si Foreign material in 2od exhaust oie is averse gore worvdamaged goal $5] Fovsign material in Sd exhoust ris, 16 Evcnsive ATE 36 Foreign material in ah oxhoust orien 7 Torque converter one-way clutch defective. '57____ Mainshaft speed sensor defective, 18 Paking mechanism defective. 58 Countershaft speed sensor defective. | |__19 Linear solenoid assembly defective. 20] CFC valve stuck = 2 41-2 shift valve stuck, __ ) 3s 2 23 shift valve stuck. 238-4 shif valve stuck Ezy 2nd accumulator defective. 25 —| Bred accumulator defect 4 26 “4th accumulator defective. - Z| 2nd otic contol valve tek 2a [3 orfesconto valve stud | 29 | Farign material in main ors, 36 —[ Farign matenolin tt oie, ST Foreign material in reverse orice, 32__| Engine output low, 30 Needle bearing wornamaged 34 [Thrust washer worndamaged 35-7 Ghtcheteorance ncorredt Drive plate defective or wanarianion Aisa as [ova pia ott son Torque conve7erhousng or anemiaion 37__| Rousing bearing wornidan " | AT erin dogged ae ont nse nd anon ora 40 ‘Modulator valve stuck. _ | feont'd) 14-79Symptom-to-Component Chart Hydraulic System (cont'd) Check these items on the ™ oy probe epairorcowony | pwogaste cause ouETO | Nowe ‘Vehicle creeps in [N] position, Ri, R2 | Vehisle does not move in Dior Bs] position [ne - ‘Transmission locks up in [R} position, 3, R11 Excessive drag in transmission. RE - KR Ercan viboon ped ba Noise: wheels moving only. RS | Main seal pops out. _ ‘RB s Varicus siting pobons Tre. PROBABLE CAUSE DUE TO IMPROPER REPAIR [Ri [improper clutch clearance. 2, | Improper gear clearance. - Z — Ra. | Parking brake lever installed upside down, Ra. | One-way (sprag) clutch installed upside down, ” ~ 5. | Reverse selector hub installed upside down. 6. | ATE pump binding. - F7.__ | Toraue converter not fully seated in ATF pump. 8. | Main seal improperly installed. RS, _| Springs improperiy installed. : 7 R10.__| Valves improperly installed Rit.__| Shift fork bolt not installed 14-80NOTES See flushing procedure, page 14-155 and 156, ‘Set idle rpm in gear to specified idle speed. If stil no good, adjust motor mounts @s outlined in engine section ofthis manual C.__| fthe large clutch piston O-ring is broken, inspect the piston groove for rough machining D. | ifthe clutch peck is seized or is excessively wor, inspect the other clutches for wear, and check the orifice | control valves, CPC valve and linear solenoid for free movement, &__| Ifthe linear solenoid is stuck, inspect the clutches forwear. ~ G. ifthe 1-2 shift vaive is stuck closed, the transmission will not upshift f stuck open, the transmission has no 1st gear. H.__| Ifthe 2nd orifice control valve is stuck, Inspect the 2nd and Srd clutch packs for wear. 1. | ifthe 34 orifice control valve i stuck, inepact the Srd and ath clutch packs for wear, a __ ] Ithe clutch pressure control valve is stuck closed, the transmission will not shift out of ist gear. K. | Improper alignmant or main valve body and torque converter housing may cause ATF pump seizure, The symptoms are mastly an rpm-related ticking noise oF a high-pitched squeak ifthe ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentia! Pinion sft both are OK and na cause forthe contamination is found, place the torque converter ‘M._| Ifthe fst clutch feed pipe guide in the right side cover ie scored by the mainshaft, inspect the ball bearing for excessive movement in the transmission housing. If OK, replace the right side cover as itis dented. The (ring under the guide is probably worn, | + Replace the mainshaft the bushing for the 4th feed pipe is loose or damaged. If the ath feed pipe is dar aged or out of round, ceplace the right side cover. + Replace the mainshaf ifthe bushing forthe 1st feed pipe is loose or damaged. If the tst feed pipe is dam. ‘aged or out of round, replace it ©. | Aworn or damaged sprag clutch is most a result of shifting the transmission in ® or Bd position whi the wheels rotate in reverse, such as rocking the vehicle in snow. P. _ | Inspeat the frame for collision damage. Inspect for damage and wear 1, Reverse selector gear teeth chamfors. 2. Engagement teeth chamfers of countershaft ath and reverse gear | 23. Shift fork for scutf marks in center. 4. Differential pinion shaft for wear under pinion gears. 5, Bottom of 3rd elutch for swirl marks. Replace items 1, 2, 3 and 4 if worn or damaged. If transmission makes a clicking, grinding or whirring noise, also replace mainshaft 4th gear, reverse idlor gear, and countershat éth gear in addition to 1, 2, 30°4 Ir cifferential pinion shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughly clean transmission, fush torque converter, cooler and lines, If bottom of 2rd clutch is swirled and transmission makes gear noise, replace the countershat and final driven gear. A. _| Be very careful not to damage the torque converter housing when replacing the main ball bearing. You may also damage the ATF pump when you torque down the main valve body. This will result in ATF pump seizure if not detected. Use the proper tools. 'S. | Install the main seal flush with the torque converter housing. If you push it into the torque converter housing until it bottoms out, it will Block the fluid return passage and result in damage. 14-81Road Test NOTE: Warm up the engine to normal operating temperature (the radiator fan comes on} 1. Apply parking brake and block the wheels. Start the engine, then shift to [Ot position while depressing the brake Pedal. Depress the accelerator pedal and release it suddenly, The engine should not stal, 2. Repeat same test in (5) position 3. Testrive the vehicle on a flat road in the (6 position. Check that the shift points occur at approximate speeds shown (on a flat road. Also check for abnormal noise and clutch slippage, NOTE: Throttle position sensor voltage represents the throttle opening, ‘2. Unbolt the PCM for road testing: refer to page 14-46. , Set the digital mutitester to check voltage between D1 {+) terminal and A9 (-] or A22 (-) terminal of the PCM for the throttie position sensor. STACKING PATCH: cord DIGITAL MULTIMETER (Commercially availabe) KS~ AMM 32003, or equivalent | | pow convecrons | srneux © : pocouco7W,ccofousaan lac facael Oeiehieante Chee eee AE eet Corte aise “beet A122) samen | _ B28 eva) Wn SOE OF MALE TERMINALS 14-82ist | #4 [Bi Position: D16V7 engine + Upsnite ‘Throttle Opening ‘Unit of speed ast> 2nd | and ard || ard Ath Lock-up ON Throttle postion sensor mph 9-2 zm | 21-24 voltage: 0.75 V kmh 15-19 32-37 45-62 34-39 Throttle position sensor mph 21-25 __ 10-8 59-65 62-67 voltage: 2.25 V keh 34-40 { 65-73, 95-104 99 - 108 Fully opened throttle mph 33-38 6-71 11-112 99-109 Throttle position sensor |] = voltage: 45 V ev sae | 102-115 163-190 | 159-176 Unit of speed | LockupOFF | ath—> 3rd ‘Srd-> 2nd ‘2nd 1st meh 19-72 7-20 6-9 (ard tat Throte postion sonsor = voltage: 0 V ‘eh 30-38 27-32 10~ 15 Grd 150) Fully-opened that mph 95-105 35-95 54-61 25-30 Theotle position sensor voltage: 45V ver 153-169 137-183 87-98 0-48 ) B® Position: D16¥8 engine # Upshift Throttle Opening Unitofepeed | tst>2nd | and~ard | ard ath | LockupON | Throttle position sensor mph 9-2 20-23 28-32 21-24 voltage: 0.75 V kmih 15-19 32-37 45-52 -39 Throttle position sensor mph 2-2 40-45 59-65 62-67 voltage: 225 V wh 3-40 6-73 95108 99-108 Fully opened throttle mph 2-37 62-70 96-107 96 - 108 Throttle position sensor voltage: ABV min | 82-60 100-113 185-172 153-170 Unitofepeed | LockupOFF | ath=ard | Srd~2nd | 2nd tet Fully MAINSHAFT LOCKNUT (FLANGE NUT) 21 x 1.25 mm Replace. ® CONICAL SPRING WASHER Replace. 1ST CLUTCH ASSEMBLY @ O-RINGS Replace. \(0 PARKING GEAR 4) THRUST WASHER @ ONE-WAY CLUTCH @@ THRUST NEEDLE BEARING (® COUNTERSHAFT 1ST GEAR @@ NEEDLE BEARII GD NEEDLE BEARING @ MAINSHAFT 1ST GEAR 9 COUNTERSHAFT 1ST GEAR COLLAR @ MAINSHAFT 1ST GEAR COLLAR {B O-RINGS Replace. @ ATF COOLER LINE | RIGHT SIDE COVER GASKET Replace 4 SEALING WASHERS Replace. > DOWEL PINS @ JOINT BOLT G PARKING BRAKE PAWL STOP @ ATF DIPSTICK (i LOCK WASHER Replac @ ATF COOLER LINE (2 PARKING BRAKE STOP Selective pert & JOINT BOLT 2) PARKING BRAKE LEVER @ SEALING WASHERS Replace. @ PARKING BRAKE LEVER SPRING & VEHICLE SPEED SENSOR % DRAIN PLUG © O-RING Replace 0) SEALING WASHER Replace. ® O-RING Replace. 9 COUNTERSHAFT SPEED SENSOR @ PARKING BRAKE PAWL 2) PARKING BRAKE PAWL SPRING $ PARKING BRAKE PAWL SHAFT (0 LINEAR SOLENOID ASSEMBLY BD LINEAR SOLENOID GASKET Replace. ‘TORQUE SPECIFICATIONS. Bolt/Nut No. Torque Value Size Remarks oA 12 Nem (1.2 kgm, 8.7 IDEA) 6x1.0mm 6B aN (1.4 kgm, 10 Ine) 6x1.0mm aF 22 Nem 22 kgtm, 16 lot) 8x 1.25 mm 1A 28 Nem 129 kgf, 21 lott) 2x1.25mm | Joint bolt 180 49 Nem 5.0 kgm, 36 lot A) 18x15mm | Drainplug 21M 78 Nem (8.0 kgf, 58 Joh) 21%1.25mm | Mainshaftlocknut: Left-hand threads 230 103 Nem (10.5 kgf, 75.9 IbEft] | 23x1.25mm | Countershaftlocknut: Left-hand threads 14-95Illustrated Index Transmission Housing 14-96oo) ® LOCK WASHER Replace. REVERSE SHIFT FORK ‘COUNTERSHAFT REVERSE GEAR COLLAR ‘COUNTERSHAFT REVERSE GEAR ) NEEDLE BEARING (@ REVERSE SELECTOR © REVERSE SELECTOR HUB @ COUNTERSHAFT 4TH GEAR (@ NEEDLE BEARING «th DISTANCE COLLAR, 28 mm Selective part 4 COUNTERSHAFT 2ND GEAR (@ THRUST NEEDLE BEARING (fl COUNTERSHAFT 3RD GEAR (4 NEEDLE BEARING ‘ COUNTERSHAFT SRD GEAR COLLAR (i THRUST NEEDLE BEARING ‘f SPLINED WASHER (Gi 3RO CLUTCH ASSEMBLY O-INGS Replace @@ COUNTERSHAFT @ SNAP RING @ THRUST WASHER (@ THRUST NEEDLE BEARING (2) MAINSHAFT 4TH GEAR/REVERSE GEAR NEEDLE BEARINGS ys trusrrerpizceannc {@ MAINSHAFT 4TH GEAR COLLAR 4 2ND/4TH CLUTCH ASSEMBLY OFINGS Replace THRUST WASHER, 365 x 55 mm Selective part Si THRUST NEEDLE BEARING {@ MAINSHAFT 2ND GEAR (3) NEEDLE BEARING ‘TORQUE SPECIFICATIONS. (3H THRUST NEEDLE BEARING 39 MAINSHAFT 36 SEALING RINGS, 35 mm &} SEALING RING, 29 mm. 0 NEEDLE BEARING i SETRING (at SHIFT CONTROL SOLENOID VALVE A/B ASSEMBLY @ HARNESS CLAMP BRACKET @ SHIFT CONTROL SOLENOID FILTER/GASKET Replace. @ CONNECTOR BRACKET 4 TRANSMISSION HANGER 46 BREATHER CAP ® MAINSHAFT SPEED SENSOR @ MAINSHAFT SPEED SENSOR WASHER (D16Y7 engine} @ O-RING Replace. @ SNAP RING @ MAINSHAFT TRANSMISSION HOUSING BEARING 3) COUNTERSHAFT TRANSMISSION HOUSING BEARING (@ REVERSE IDLER GEAR SHAFT HOLDER ASSEMBLY ‘69 NEEDLE BEARING @ OIL SEAL Replace. ‘9 SET RING, 80 mm Selective part 6 TRANSMISSION HOUSING SP REVERSE IDLER GEAR @ DOWEL PINS TRANSMISSION HOUSING GASKET Replace. (@® DIFFERENTIAL ASSEMBLY © OIL SEAL Replace. |W TORQUE CONVERTER HOUSING Bolt/Nut No. Torque Value ‘Size Romarks 6A 12. (1.2 kgim, 87 TOFD 6x10 mm 68 TAN (1.4 kgm, 10 bff) 6x10 mm. 108, 44 Nem (45 kgm, 33 bff) 101.25 mm 14-97Illustrated Index Torque Converter Housing/Valve Body 14-98oe} {) ATE FEED PIPE 2) ATF STRAINER 3) SERVO BODY ‘SERVO SEPARATOR PLATE ‘SECONDARY VALVE BODY 6) DOWEL PINS 7) SECONDARY SEPARATOR PLATE SERVO DETENT BASE @ ATF FEED PIPES 4@ ATF FEED PIPES @ SHAFT STOP ‘CONTROL SHAFT §@ DETENT ARM SPRING @ DETENT ARM {8 DETENT ARM SHAFT FILTER Replace, CHECK BALLS |5@ TORQUE CONVERTER CHECK VALVE SPRING \5@ TORQUE CONVERTER CHECK VALVE DOWEL PINS LOCK-UP VALVE BODY LOCKUP SEPARATOR PLATE {® REGULATOR VALVE BODY DOWEL PINS @® COOLER RELIEF VALVE SPRING @ COOLER RELIEF VALVE ® O-RING Replace, @ STATOR SHAFT ® stop SHAFT (9D ATF FEED PIPE 4 MAIN VALVE BODY ATF PUMP DRIVEN GEAR SHAFT ® ATF DRIVEN GEAR @ DOWEL Pins GS ATF PUMP DRIVE GEAR (3 MAIN SEPARATOR PLATE (SUCTION PIPE COLLAR TORQUE SPECIFICATIONS 8 ATF MAGNET 8 COUNTERSHAFT TORQUE CONVERTER HOUSING BEARING @ ATF GUIDE PLATE ‘§] TORQUE CONVERTER HOUSING \ OIL SEAL Replace, {@ MAINSHAFT TORQUE CONVERTER HOUSING BEARING @ OIL SEAL Replace, 45 LOCK-UP CONTROL SOLENOID FILTER/GASKET Replace. @ LOCK-UP CONTROL SOLENOID VALVE A/B ASSEMBLY ‘& CONNECTOR BRACKET Bolt/Nut No Torque Value ‘Size Remarks a 12 Nem (12 kgm, 87 TE) 6x10mm 14-399Right Side Cover Removal NoTE: ‘© Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed ar. ‘© Blow out all passages. © When removing the right side cover, replace the following — O-rings — Mainhatt end count | — Conical spring washers. — Right side cover gasket — Lock washer Sealing washers shaft locknuts ASSEMBLY Richt SiOE $19. B0LT cover one fIGHT SIDE asrc.urca, (MAINSHAFT. 1ST GEAR MAINSHAFT 1ST GEAR COLLAR’ MaiNsHarT ATE COOLER. tunes: SEALING WASHERS, 14.100BO) 1. Remove the 13 bolts securing the right side cover, then remove the right side cover. al tool onto the mainshatt as shown. 3. Engage the parking brake paw! with the parking gear. 4. Cut the lock tabs of the mainshaft and countershaft locknuts using a chisel as shown, then remove the locknuts and conical spring washers CAUTION: Keep all of the chiseled particies out of ‘the transmission, NOTE: ‘© Mainshaft and countershatt locknuts have left. hand threads. ‘© Always wear safety glasses. crise, Locknut Lock TAB 5. Remove the special tool from the mainshaft after removing the locknuts. 6. Remove the tst clutch and mainshatt 1st gear assem- bly and mainshatt st gear collar from the mainshatf 7. Remove the parking brake pawl, spring and shaft. 8. Remove the parking brake lever from the control shat 8. Using 2 universal two jaw puller, remove the parking gear, one-way clutch and countershaft Ist g assembly. PULLER Commercially available! PARKING GEAR 10, Remove the needle bearing and the countershaft ‘st gear collar from the countershaft 11. Remove the ATF cooler lines and ATF dipstick 14-101Transmission Housing Removal “TRANSMISSION HOUSING MOUNTING BOLTS 1a Boke [MAINSHAFT SPEED’ ‘SENSOR WASHER {(D16¥7 engine) rete ‘SUB-ASSEMBLY MAINSHAFY SPEED SENSOR TRANSMISSION MoUsiNG GASKET ‘TORQUE CONVERTER HousiNG 14-102Bo NOTE: © Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. © Blow out all passage ¢ When removing the transmission housing, replace ‘the following: = O-ring — Transmission housing gasket = Lock washer 1. Remove the mainshaft speed sensor from the trans mmission housing, 2. Remove the transmission housing mounting bolts and hanger. 3. Align the spring pin on the control shaft with the transmission housing groove by turning the control shat ‘SPRING Pint CONTROL SHAFT HOUSING PULLER ‘O7HAC= PKAGTOA 4, Install the special tool on the transmission housing, then remove the housing 3s shown. CAUTION: Make sure the mainshaft speed sensor has been removed from the transmission housing before removing the transmission housing from the ‘torque converter housing. B 8 Remove the countershaft reverse gear with the col: lar and needle bearing, Remove the lock bolt securing the shift fork, then Femove the fork with the reverse selector from the ‘countershatt. Remove the countershatt sub-assembly and the ‘mainshatt sub-assembly together. MaINSHAFT ANATOLY CCOUNTERSHAFT SUB-ASSEMELY Remove the differenti converter housing, assembly from the torqueTorque Converter Housing/Valve Body Removal 6x1.0mm 7Bowe ATE FEED PRE Books. (MAIN VALVE. BODY 3 Bois “SECONDARY VALVE OY ‘ATF PUP DRIVER ‘GEAR SHAFT ATF PUMP DRIVEN GEAR” [MAIN SEPARATOR- PLATE ‘DOWEL PIN ‘SECONDARY ‘SEPARATOR PLATE ‘TORQUE CONVERTER, HOUSING 14-104.O) NOTE: © Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed ai ‘© Blow out al passages. ‘© When removing the valve body, replace the O-ring. Remove the ATF feed pipes from the servo body, secondary valve body and main valve body. 2. Remove the ATF strai (wo bots. er and servo detent base 3, Remove the servo body and servo separator plate {seven bolts). Remove the secondary valve body, shaft stop and secondary separator plate (three bolts). Ramove the lock-up valve body and separator plate {seven bores) ‘8. Remove the regulator valve body (one bolt 7. Remove the stator shaft and stop shaft 8. Remove the detent spring from the detent arm, then remove the control shaft from the torque converter housing, 19 Remove the detent arm and detent arm shaft from ‘the main valve body. 10. Romove the main valve body (five bolt). NOTE: Do not let the eight check balls fall out of the main valve body when removing the main valve body, 111. Remove the ATF pump driven gesr shaft then remove the ATF pump gears. 12, Remove the main separator plate and two dowel pins. 42, Clean the inlet opening of the ATF strainer thor- ‘oughly with compressed air, then check that itis in {goad condition, and the inlet opaning is not clogged. ae INLET OPENING 14, Test the filter by pouring clean ATF fluid through the inlet opening, Replace the ATF strainer if itis clogged or damaged. NOTE: The ATF strainer can be reused if itis not cloggedValve Caps Description # Caps with one projected tip and one flat end are installed with the flat end toward the inside of the valve body, © Caps with a projected tip on each and are installed with the smaller tip toward the inside of the valve body. The smal tip is spring guide. of vatve body. 8 ‘Toward inside of valve body. ‘© Caps with one projected tip and hollow and are installed with the tip toward the inside of the valve body. The tip is @ spring guide, Toward outside of valve body. 14-106 ‘© Caps with hollow ends are installed with the hollow lend away from the inside of the vaive body. ‘© Caps with notched ends are installed with the notch toward the inside of the valve body. ‘© Caps with flat ends and a hole through the center ate installed with the smaller hole toward the inside of the valve body. Toward outside of valve body. Toward inside of valve body. ‘© Caps with flat ends and @ groove around the cap are Installed with the grooved side toward the outside of the valve body. ‘Toward outside of valve body. Groove S ‘Toward inside of valve body.Valve Body eo Repair NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. You may use this procedure to froe the valves in the valve bodies 1. Soak a sheet of 8600 abrasive paper in ATF for about 30 minutes. 2. Carefully tap the valve body so the sticking valve drops out ofits bore. CAUTION: It may be necessary to use a small sorewdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver. 3. Inspect the valve for any scuff marks. Use the ATF- ‘soaked #600 paper to polish off any burrs that are ‘on the valve, then wash the velve in solvent and dry itwith compressed air 4. Roll up half a shoot of ATE-soaked paper, and insert itin the valve bore of the sticking valve. ‘Twist the paper slightly, so that it uaralls and fits the bore tightly, then polish the bore by twisting the paper as you push tin and out. CAUTION: The valve body is aluminum and doesn’t require much polishing to remove any burrs. Remove the #600 paper and thoroughly wash the ‘emtire valve body in solvent, then dry it with com pressed ar. oar the valve with ATE, then drop it into its bore, It should drop to the bottom of the bore under its ‘own weight. not, repeat step 4, then retest. VALVE ‘VALVE BODY Remove the valve, then thoroughly clean it and the valve body with solvent. Dry all parts with com: presead ai, then reassemble using ATF as a lubri= 14-107Valve Assembly NoTE: Coat all parts with ATF before assembly. '# Install the valve, valve spring and cap in the valve body and secure with the roller, ROLLER, VALVE BODY sPaING: 14-108 ‘© Sot the spring in the valve and install it in the valve body. Push the spring in with a screwdriver, then install the spring seat ‘SPRING SEAT ‘SPRING. 4 Insta the valve, spring and cap in the valve body. Push the cap, then install the clip.ATF Pump 4 1 Inspection Install the ATF pump gears and ATF pump driven ‘gear shaft in the main valve body. Nore: ‘© Lubricate all parts with ATF during inspection. ‘Install the ATF pump driven gear with its grooved ‘and chamfered side facing up as shown, [ATE PUMP ORIVEN GEAR. [ATE PUMP DRIVE Grooved and chamfered sde GEAR fecing up. ATE PUMP DRIVEN ‘main VALVE BODY ATE PUME OF 2 Measure the side clearance of the ATF pump. and driven gears, ATE Pump Gears Side (Radial) Clearance: Standard (New): [ATE Pump Drive Gear (0.108 ~ 0.1325 mn (0.004 ~ 0.005 in} ATE Pump Driven Gear (0.05 - 0.0625 men (0.0014 - 0.0025 in) ‘main vauve 60oY ATE PUMP DRIVEN GEAR ‘ATE PUMP. Inspect teeth for wear and damage DRIVE GEAR Inpect oth for woar and damage Remove the ATF pump driven gear shaft. Measure the thrust clearance of the ATF pump driven gear- to-valve body. ATE Pump Drive/Driven Gear Thrust (Axial) Clearance: ‘Standard (New): 0.03 - 0.05 mm (0,001 ~ 0.002 in} ‘Serview Limit: 0.07 mm (0.003 in) ‘STRAIGHT EDGE ATRPUMP, DRIVEN GEAR 14-109Main Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. Replace the valve body as an assembly if any parts are worn or damaged. Check all valves for free movement. If any fall to slide freely, see Valve Body Repair on page 14-107. Coat all parts with ATF during assembly. CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls 12 SHIFT VALVE ore vave vaive car cuP » ,2ND ORIFICE CONTROL VALVE comma sear : JZ Pe i“ " & \ v4 AST ACCUMULATOR CHOKE 5 \ 6% ooutaton wave neuer vatve ‘MAIN VALVE BODY Inspect for wear, seratches sna seoring SERVO CONTROL VALVE VALVE CAP 14-110CHECK BALL MAIN VALVE BODY (Sectional view! SPRING SPECIFICATIONS nit: mm tnt Standard (New) No. Springs Wire Dia, op. Free Length | No. of Coils @ | Reliet vaive spring 1.4 (0.083) esa) | 97.1(1.461) 184 ® | Moduiator valve spring 1.4 (0.055) 9.4 (0.374) '35.0(1.378) 109 @ | CPB vaive spring 09 (0.035) | 8.140.322) 97.2 (1.858) 183 @ | 1-2shitt valve spring 0.9 (0.035), 7.8 0.302), 41.3 (1.628) 163 © | and orifice control valve spring 0.7 (0.028), 6.6 (0.262), 34.8(1370) 220 © | Servo control valve spring 1.0 (0.039), 8.110.322), 52.1 2.051) 208 14.111Secondary Valve Body Disassembly/Inspection/Reassembly NoTE: ‘© Clean all pants thoroughly in solvent or carburetor cleaner, and dry with compressed ait. Blow out all passages. ‘© Replace the secondary valve body kit, P/N 27700 ~ PAR ~ 205 (The secondary valve body kit includes the linear solenoid assembly) if any parts are worn or damaged. © Cheet © Coat | parts with ATF during assembly '¢ The CPC valve is installed in the secondary valve body, held in place by the lock bolt VALVE CAP VALVE CAP cur valves for free movernent. f any fal to slide freely, 2.3 SHIFT VALVE Valve Body Repair on page 14-107. 4 SHIT VALVE smuennaust vaive Looe aout | ERUTION. Bo not move. SECONDARY VALVE BODY Inapect fo weer, sates and rc 3-4 ORIFICE CONTROL vaLvE Le SPRING SEAT vauve seve noun ‘SPRING SPECIFICATIONS ni: mm in Pecan tena Springs , Wire Die oo. FreeLength | No.of Colle ! 34 shi valve spring dain | 7630 | s70(2200 268 2.3 hit valve spring asics) | 76020 | s70(2240) 288 ‘th exhaust valve spring ogiacs | 61020 | ae4i.439) tas 34 onion contol valve soring o7ioo) | 661026 | a.5\1476) 26 & Xé 4 Regulator Valve Body 0.0) Disassembly/inspection/Reassembly Note: ‘© Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. ‘© Replace the vaive body as an assembly if any parts are worn or damaged. ‘© Check ail vaives for frae movement If any fail to slide freely, see Valve Body Repair on page 14-107, 1. Hold the regulator spring cap in place while removing the stop bolt. Once the stop bolt is removed, cap slowiy fase the spring CAUTION: The regulator spring eap can pop out when the stop bolt is removed. 2, Reasserbly is the raverse order of the disassembly procedure, parte with ATF during assembly. ‘¢ Align the hole in the reguletor spring cap with the hole in the valve body, then press the spring cap into the valve body, and tighten the stop bott ‘Yana va ° R [REGULATOR SPRING CAP STOP BOLT Bx10mm 12am (1.2 kgf, 8.7 Ht) [REGULATOR VALVE BODY é Ro Trepect for wear, cfatehes * and soring REGULATOR VALVE LOCK-UP CONTROL VALVE ‘COOLER RELIEF a “TOROUE CONVERTER CHECK VALVE" vavesune rouse son secomcaTions Waa: Stare We { ‘Springs. —_ wWisda [OB | Fetogin | Woot Sorreston spine een | ssn festa | ts Ecole rit ave sa Seam | “sts Sens | a2 see secavesoing | tomas | axwasy | sear | tr Uaskipcowolvae svg soma | esose | senae | vs 14-113Servo Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. © Replace the valve body as an assembly if any parts are worn or damaged, ‘© Coat all parts with ATF during assembly. © Repla the O-rings. ‘SERVO BODY oo Inspect for west, sertches and scoring o-nING Replace. 2ND ACCUMULATOR. « 2 PISTON, 8 O-RING —_ > Replce, 3A 1ST ACCUMULATOR PISTON omen 8 nar nna 6 SRO ACCUMULATOR PISTON {18 ACCUMULATOR PISTON vanversaet SNAP AGS Fork SHAFT onine Reptece. SPRING SPECIFICATIONS Uni: eum tnd Standard (New) No. Springs — - Wire Dia, OD. FreeLength | No.of oils @ | 1st accumulator spr | 2.1 0.083) 16.0 (0.636) 89.1 (3.508) 162 @ | ath accumutator spring A 2600102) | 17.0(0676 | 97.01.4251 2 {| 4th accumulator spring 8 | 2300039 | to200402) | stez0s | 128 4 @ | 34d accumulator spring A 2810110) | 175(0698) | 99.912.516) 158 4} © | rd accumulator spring 8 2210087) «| stor2a0) | a5.10.982) 24 © | 2nd eceumulator spring C 2210087) | 14810576) | 68.0(2877) 139 ) 2d accumulator spring A 2.400.098) | 28.011.182) | 39.0(1.836) 28 © | 2nd accumulator spring 8 1.5 (0.069), 9.010.358) | 20.7 0818), 61 14.114Lock-up Valve Body 6.0) J Disassembly/inspection/Reassembly NOTE: ‘© Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. ‘Replace the valve body as an assembly if any parts are warn or damaged. ‘© Cheek all valves for froe movement. If any fall to slide freely, see Valve Body Repair on page 14-107. ‘© Coat all parts with ATF during assembly, ROLLER Lock.UP VALVE BODY Inspoet for weer, serotchoe ALVE CAP 4 anoscommg Loc Ta vat @ ON eae SPRING SPECIFICATIONS Unit mm tnd ‘Standard (New) | No. Springs | ) | Wire Dia op Free Length | _ No.of Cols D | Lock-up shift valve spring 0.9 (0.035) 7.610.302) | 73.7 (12.902) 320 2 | Look up timing valve spring agi) | ats) | 80713177 68Mainshaft Disassembly/Inspection/Reassembly NOTE: © Lubricate ‘* Inspect the thrust needle bearings and the needle bearings for galling and rough movement. ‘© Before installing the O-rings. wrap the shaft splines with tape to prevent damaging the O-rings. © Locknut has left-hand theeads. |! parts with ATF during reassembly. LOCKNUT (FLANGE NUT) 2141.25 mm 78 Nem (8.0 kgm. 58 bt) SNAP RING ING WASHER 1ST CLUTCH MAINSHAFT Check spines fr excessive woar and damage. Cheek beoring surface for scoring, Setatehes and excessive weer, 1ST GEAR THRUST NEEDLE BEARING 18 GEAR COLLAR 4TH GEAR COLLAR [TRANSMISSION HOUSING BEARING. 2ND/ATH CLUTCH ‘ASSEMBLY N THRUST WASHER, 36.5 x 55 mm ‘Selective part “THRUST NEEDLE BEARING. 35 mm ‘SEALING RING, 29 mm ‘NEEDLE BEARING SET RINGBo Inspection + Clearance Measurement NOTE: Lubricate all parts with ATF during assembly. 1. Remove the meinshaft bearing from the transmis sion housing (see page 14-142) 2. Assemble the parts below on the mainshatt NOTE: Do not assemble the O-rings during inspee- tion. HOUSING BEARING THRUST WASHER 4TH GEAR COLLAR, 2ND/ATH CLUTCH ‘ASSEMBLY "THRUST WASHER 36.5 x 55 mm Selective part THRUST NEEDLE BEARING. -2ND GEAR NEEDLE BEARING ‘THRUST NEEDLE BEARING. MAINSHAFT 3 Torque the mainshaft locknut to 29 Nem (3.0 kgtm, 22 bE. 1nd threads. NOTE: Mainshaft locknut has le vocknut 129 Nem (3.0 kgfhm, 22 Itt) Hold 2nd gear against the 2nd clutch, then measure ‘the clearance between 2nd gear and 3rd gear with a feeler gauge. NOTE: Take measurements in at least three places, ‘and use the average as the actual clearance. ‘STANDARD: 0.05 ~ 0.13 mm (0.002 ~ 0.008 in} SRDGEAR —_2ND GEAR FEELER GAOGE 2h cLuTeH ‘THRUST WASHER, 36.5 x 55 mm ano Géan ] 2ND GEAR cont'd) 14-117Mainshaft Inspection (cont'd) 5. If the clearance is out of tolerance, remove the thrust washer and measure the thickness. ‘THRUST WASHER 6, Select and install a new washer, then recheck. ‘THRUST WASHER 36.5 x55 mm No. Part Number Thickness 1 | 90aa1—paP—o10 | 400 mm (0.767 in) 2 | 90442 PaP - 010 4.05 mrn (0.159 in) 3. | 90443-PaP—010 | 410mm (0.161 in) 4 | 904aa—PaP—010 | 4.18 mmi0.163im) “5 | s04a5—PaP—ot0 | 4.20mmm/(0.165 inp 6 | 90488 PaP—010 | 4.25 mm (0.167 ini 7_| 90447 - Pap -o10 4.30 mm (0.169 inh 8 | 900a8—PaP—010 | 438mm (OAT in) 8 | 90049 PaP—010 | 440mm (0173in) 10 | 90450-P4P-000 | 4.45 mm (0.175 in) 7. After replacing the thrust washer, make sure the clearance is within tolerance.4 Countershaft Disassembly/Inspection/Reassembly NoTE: ‘© Lubricate all parts with ATF before reassembly. © Before ‘© Locknut hes left-hand threads. REVERSE GEAR COLLAR, ‘COUNTERSHAFT Check spines for excessive woar ana damage. ‘Check bearing surface for scoring, soratghes and excessive wear. {ngpect the thrust needle bearings and the needle bearings for galling and rough movement. installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings. LOCKNUT (FLANGE NUT) 231.25 mm 303 Nim (10.5 kgfom, 75.9 th-A Re CONICAL SPRING. WASHER Replace PARKING GEAR REVERSE SELECTOR REVERSE SELECTOR HUB: 4TH GEAR NEEDLE BEARING BT AR COLLAR DISTANCE COLLAR. 2 Save par TRANSMISSION HOUSING BEARING 2ND GEAR unust NEEDLE \ BeAnive \ 3RO GEAR NEEDLE BEARING .3RD GEAR COLLAR, THRUST NEEDLE BEARING SPLINED WASHER ‘SRD CLUTCH ASSEMBLY 14-119Countershaft Disassembly/Reassembly 1. Using a hydraulic press, press out the countershatt while supporting 4th gear. NOTE: Place an attachment betwoon the press and the countershaft to prevent damage to the shatt. CAUTION: Do not allow the countershaft to fall and hit the ground when pressed clear. ATTACHMENT LCOUNTERSHAFT HUB. ‘Assemble the parts on the countershaft as shown below. NOTE: ‘¢ Lubricate all parts with ATF during assembly. ‘© Before installing the O-rings, wrap the shat splines ‘with tape to prevent damaging the O-rings. ATH GEAR, NEEDLE BEARING DISTANCE COLLAR, 28 mm Selective part. 2ND GEAR [THRUST NEEDLE SEARING SRD GEAR NEEDLE BEARING 3RD GEAR COLLAR, THRUST NEEDLE BEARING 3RD CLUTCH ASSEMBLY COUNTERSHAFT4 O} 3, Install the reverse selector hub on the countershaft sub-assembly, and then press the reverse selector hub using the special tool and a press as shown. DRIVER 40 mm 1D. (0746~0030700 [REVERSE SELECTOR HUB. COUNTERSHAFT SUB-ASSEMBLY Inspection + Clesrance Messurement NOTE: Lubricate all parts with ATF during assembly 1. Remove the countershatt bearing from the trans- ‘mission housing (see page 14-142) 2. Install the parts below on the countershaft using the special too! and a press as described on this page. NOTE: Do not assemble the O-rings during inspec tion, REVERSE SELECTOR HUB 4TH GEAR, NEEDLE BEARING DISTANCE COLLAR, 28 mm Selective part 2ND GEAR. ‘THRUST NEEDLE BEARING SRD GEAR NEEDLE BEARING. LARD GEAR COLLAR THRUST NEEDLE BEARING SPLINED WASHER 3RD CLUTCH ASSEMBLY ; nll 14-121 (cont)Countershaft Inspection (cont'd) \. 2. Install he pats below on the countershattsub- | 4 Measure the clearance bemveen the 2nd gear and esembly, thon torgue the lcknut to 29 Nm (3.0 the 28 mm distance cor wih felergouse fete z2 bi NOTE: Take measurements in at least the NOTE: Countershaft locknut has left-hand threads, and use the average as the actual clearance, placos, ‘STANDARD: 0.10- 0.18 mm (0.004 - 0.007 in) Locknur Letcher threads CONICAL SPRING GS wee PARKING GEARIONE-WAY (CLUTCH/1ST GEAR ‘ASSEMBLY NEEDLE BEARING FEELER GAUGE” DISTANCE COLLAR, 26 mm 1ST GEAR COLLAR, TRANSMISSION HOUSING BEARING REVERSE GEAR coLLaR 2NO GEAR FEELER GAUGE COUNTERSHAFT 5. Ifthe clearance is out of tolerance, remove the 28 SUB-ASSEMBLY mm distance collar and measure the width, 6. Select and install a new distance collar, then recheck DISTANCE COLLAR, 28 em No, | __Part Number Width 1 | 90603-PC8~ 000 | 38.00 mm (1.535 in) 2 | 90504-PCs-000 | 39.10mmi1.539in) | [3 | 90505 PC8—000 | 39.20 mm (1.843 in) © | 90507 -Pc9- 000 | _39.30mm 1547 in) 5 | 90508-PC9-000 | 39.05 mm (1.537 in) 6 | _90508-Pca-00d | 39.18 mm (7.541 in) 7 | __90510-PC3- 000 | 38.25 mm (1.585 in) a | s05tt-Pca—o00 | 38 90mm (1.831 int 9 | 80612 Pce—c00 | 38.95 mm (1.533 in} 7. After selecting 4 new distance collar, recheck the i clearance and make sure itis within tolerance.3 4 One-way Clutch Disassembly/Inspection/Reassembly 1. Separate countershatt 1st gear from the parking ‘gear by turning the parking gear in the direction shown, PARKING GEAR ‘COUNTERSHAFT 1ST GEAR 2. Remove the one-way clutch by prying it up with the ‘end of a screwdriver ONE.WaY cLuTCH COUNTERSHAFT ISTGEAR NOTE: install inthis direction. ONEWaY CLUTCH COUNTERSHAFT 1ST GEAR 3. Inspect the parts as follows PARKING GEAR Inspect tho parking goar for west and scoring one.way curch Inspeet the one-way Cluten for damage and {uty movement. 1ST GEAR Inspect countershatt 13% gear for wear and scoring 4. After the parts are assembled, hold countershaft 1st ‘gear and turn the parking gear In the direction shown to be sure it turns freoly. Also make sure the parking gear doas not turn in the opposite direction. PARKING GEAR. ‘COUNTERSHAFT 1ST GEAR 14.123Clutch Illustrated Index (A4RA, B4RA Transmission) ano cLuTcH ciuTcH = oINGS ‘rum Replace. CLUTCH PISTON DISC SPRING RETURN SPRING SPRING RETAINER ‘SNAP RING (LUTCH PLATES Standord thickness 2ommia.a7sin ‘cuureH END PLATE Stondard thickness 136mm 0.76 i) SNAP RING 1sT CLUTCH ‘CLUTCH END PLATE cure viscs Standard thickness: 194 mm (0076 inh SNAP ANG ‘SPRING RETAINER RETURN SPRING DISC SPRING ane / pavon games i [SNAP RING cuurci pLaTes Standoed hiekness 1.8mm (0.063 in) ‘CHECK VALVEé 4 anoyrneren SNAP RING ‘CLUTCH END PLATE cuuten pisces. ‘Standard thickness 1.96 mm (0.076 nt Standord leks: 20mm a7 ny 278) yw courte eg / baum ouonad ; yccsmnne Bsr reraneh \ Ped p serum orn RETURN SPRING } View ‘SPRING RETAINER, Standard thickness 198 mm (0.076 1m) (CLUTCH END PLATE ‘SNAP RINGClutch Illustrated Index (M4RA Transmission} RD CLUTCH ‘Standard thikness: 494 mm 076m) ‘Standard thiknoss: .9¢mm (0078 nt SNAP RING cuuTeH Lares Standard thickness 118 mom (0.063 in). 14.126 ‘SPRING RETAINER SNAP RING (CLUTCH PLATES ‘Standard thickness: 20mm (0079 ni ‘cure END PLATE3 2ND/4TH- CLUTCHClutch Disassembly 1. Remove the snap ring, then remove the clutch enc plate, clutch dises and plates. ‘SCREWORIVER SNAP RING 2, Remove the disc spring, NOTE: Except 2nd clutch. Isc SPRING ‘etuTeH DRUM 14-128 3. Install the special tools as shown, CLUTCH sPAING Compressor ATTACHMENT ‘O7LAE—PX40100 (CLUTCH SPRING ‘COMPRESSOR ‘ATTACHMENT O7LAE- PX40100 cuuten Serine (OTHE ~ PL50100 ‘COMPRESSOR BOLT ASSEMBLY O7GAE - PG40200 O7GAE~ PG4az08 (CLUTCH SPRING ‘COMPRESSOR ‘ATTACHMENT ‘O7LAE~PX40100 CLUTCH SPRING ‘COMPRESSOR [ATTACHMENT O7LAE- PX40100 OTHAE = PL50100CAUTION: i either end of the special t area of the spring retainer which is uns return spring, the retainer may be damaged. ‘special tool is adjusted to have full contact with the spring retainer Do not sat here, ‘SPECIAL TOOL SPRING RETAINER 4. Compress the return spring, 5 Remove the s spring retaine ring. Then romove the special tools, i return spring. SNAP RING RETURN SPRING SPRING RETAINER Wrap 2 shop rag around the clutch drum, and apply air proscure to the ATF passage to remove the pis ton, Place a finger tip on the other end while applying air pressure. OSHA-APPROVED 30 psi NOZZLEClutch Reassembly Note: © Clean all parts thoroughly in solvent or carburetor Cleaner, and dry them with compressed ai. © Blow out ail passages. ‘© Lubricate all parts with ATF before reassembly. 1. Inspect the check valve; if it's loose, replace the pis- ton, ‘CHECK VALVE Piston PISTON ORING piston 14-130 4 Install the piston in the clutch drum. Apply pressure and rotate to ansure proper seating. NOTE: Lubricate the piston O-ring with ATF before installing CAUTION: Do not pinch the O-ring by installing the piston with too much force. cLUTCH ORUM a PISTON Install the return spring and spring retainer, and position the snap ring on the retainer. SNAP RING SPRING RETAINER RETURN SPRING &Install the special tools as shown. Lurch SPRING COMPRESSOR BOLT ASSEMBLY o7GAE- PG40200, O7GAE ~ PCAa20A ‘cLUTCH SPRING ‘COMPRESSOR ay tery Eg faces O7GAE = PG4n208 CLUTCH SPRING COMPRESSOR ATTACHMENT O7LAE—Px40100 ‘CLUTCH SPRING ‘COMPRESSOR [ATTACHMENT O7LAE- PxA0100 O7HAE - PL50100 CLUTCH SPRING ‘COMPRESSOR ‘ATTACHMENT ‘O7LAE~PXe0100 CLUTCH SPRING ‘COMPRESSOR ‘ATTACHMENT O7LAE - PXA0100 O7HAE ~PLS0100 CAUTION: Hf either end of the special tool is eet ‘over an area of the spring retainer which is unsup- ported by the return spring, the retainer may be damaged. Be sure the special too! is have full contact with the spring retainer. Do not st here ‘SPECIAL TOOL ‘SPRING RETAINER cont}Clutch Reassembly (cont'd) 7. Instalb the snap ting, 10. Soak the clutch discs thoroughly in ATF for @ mini- ‘mum of 30 minutes. n with flat side toward the aise, NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter. ‘CLUTCH ENO PLATE Install this direction SNAP FING 8 Remove the special tools. ‘8. Install the dise spring. NOTE: Install the dise spring in the direction shown, except 2nd clutch. ‘cLuTeH Disc CLUTCH END PLATE DISC SPRING 12, Install the snap ring, ‘SCREWDRIVER — cluTcH DRUM 14-132oo) 13, Measure the clearance between the clutch end plate ‘and top dise with a dial indicator, Zero the dial indi- ccotor with the clutch end plate lowered and lit it up to the snap ring. The distance that the clutch end. plate moves is the clearance between the clutch end. plate and top dise. NOTE: Take measurements in at least throo placos, ‘and use the average as the actual clearance. (Clutch End Piate-to-Top Dise Clearance: ‘Service Limit (0.65 ~ 0.85 mm (0.026 ~ 0.033 in) and (0.65 0.85 mm (0.026 -0.033 in) 3rd (0.40 ~ 0.60 mm (0.016 - 0.024 in) ath, (0.40 - 0.60 mm (0.016 - 0.024 in) (CLUTCH END PLATE ‘AARA, BARA Transmission: Plate No. | Part Number Thickness: 1 22551 PaR 003 | 2.1 mm (0.083 in) 22552 - PAR -003 | 2.2 mm (0.087 in} a 22553-PaR-003 | 2.3mm (0.091 in) ‘ 22554 -P4aR-003 | 2.4 mm (0.098 in) 5 22555 -PaR-003 | 2.5 mm (0.098 in) 6 22586 PaR 003 | 2.6 mm (0.102 in) 7 22587 -PaR 003 | 2.7 mm (0.106 in) a 22558-PaR-003 | 28mm (0.110 in) 9 22559-PaR-003_| 2.9mm (0.114 in) DIAL INDICATOR ‘cLUTCH END. PLATE Clearance turn pise select # new cluten end table. NOTE: Ifthe thickest clutch end piate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates. PLATE NUMBER, Thickness (CLUTCH END PLATE Plate No. | Part Number Thicknoss 4 22551-9000 | 2.4mm (0.084 in) 22882-PC3-000 | 2.5 mm (0.098 in) 3 22583-PC9-000 | 2.6 mm (0.102 in) ‘ 22558-PC3-000 | 2.7 mm (0.106 in) 5 22555-PC9-000 | 2.8mm (0.110in) 6 22556-PC9-000 | 29mm (0.114 in) 1 22557 -PC3-000 | 3.0mm (0.118in) a 22558-PC9-000 | 3.1 mm (0.122 in) 9 22553-PC3-000 | 3.2mm (0.126in) 10 22560-PC3-000 | 3.3 mm (0.130 in) n 22561 -PC9-000 | 2.1 mm (0.082 in) 2 22562 -PC3-000 | 2.2 mm (0.086 in) 3 22563-PC3-000 | 2.3 mm (0.090 in) 1“ 22574 -Pay-003 | 3.4 mm (0.138 ind 6 22561-Pav 003 | 3.5 mm (0.138 in) 6 22562 -Pav 003 | 36mm (0.142 in) 7 22563 Pav—003 | 3.7 mm (0.148 in) 18 22564-Pav-003 | 3.8 mm (0.150 in) 15. After replacing the clutch end plate, make sure that the clearance is within tolerance. 14.133Differential Illustrated Index SET RING, 80 mm BOLT, 10x 1.0 mm 101 Nem (10.3 kgfom, 74.5 ttt) Lefthond threads: \3 &@ ® nepect for faulty movement, DIFFERENTIAL CARRIER. ‘BALL BEARING Inspect for faulty movement. 14.134é Backlash Inspection 1 Place differential assembly on V-blocks and install both axles. PINION GEAR. CCheck backlash of both pinion gears. ‘Standard (New): 0.05 ~ 0.15 mm (0,002 0.008 in) 1. IF backlash is out of tolorance, replace the differen- tial carrier. Bearing Replacement NOTE: Check bearings for wear and rough rotation. if bearings are OK, removal is not necessary. 1. Remove bearings using a bearing puller BEARING PULLER (Commereisliy availabe) PRESS. DRIVER 40 mm 1.0, 07746-0030100Differential 1. Remove the final ati carrier. n gear from the differential fe left-nand NOTE: The final driven gear bolts hi theeads. 2, Pry the snap ring off differential carries, then remove the speedometer drive gear and 5 x 10 mn roller. SNAP RING, 'SPEEDOMETER DRIVE GEAR DIFFERENTIAL ‘CARRIER, 3. Install the § x 10 mm col the differential carrer. [SPEEDOMETER DRIVE GEAR stalin thie direction, cutout ROLLER. Sx 10mm 4. Install the speedometer drive gear with ite chem: {ered side facing the carrier. Align the cutout on the bore of the speedometer drive gear with the § x 10 mm roller, 14.136 5. Align the hooked end of the snap ring with the pit jon shaft as shown, then install the snap ring in the ifferontial cartier groove. ING Hooked end this direction PIMON SHAFT SPRING PIN ‘Groove 8. Install the final driven gear, thes tighten the bolts to tho specified torque. TORQUE: 101 Nem (10.3 kgfm, 74.5 tot) NOTE: The fine! driven gear bolts have left-hand threads. BOLTS 10.1.0 mm 401 Nem (10.3 kgm, 74.5 tort) Leenand threads =) FINAL DRIVEN GEAR Insta in this Giection DIFFERENTIAL CARRIER. 7. Install a now ball bearing (see page 14-195), Xu1 2, a il Seal Removal Remove the differenti sssembly. Romove the oil seal from the transmission housing. ‘TRANSMISSION HOUSING on seat Replace. Remove the oil seal from the torque converter housing, Olt SEAL Replace. ‘TOROUE CONVERTER HOUSING Oil Seal Installation/Side Clearance 1. Install 9 2.60 mm (0.098 in) set ring, 80 mm in trans: mmission housing. NOTE: Do not install the oll seal yet. TRANSMISSION HOUSING 2, Install the differential assembly into the torque con- verter housing using the special tool as shown. DRIVER 40 mm 1. 077460030100 S|? Coaieten HOUSING 3, Install the transmission housing and tighten the bolts (see page 14-146 and 14-147), cont’) 14-137Differential Oil Seal Installation/Side Clearance (cont'd) ‘Tap on the transmission housing side of the differ. tential assembly with the special tool to seat the dif- ferential assembly in the torque converter housing, 5. DRIVER 40 mm 10. (07745-03010 mamouen HousiNG ¥ TORQUE CONVERTER HOUSING & Measure the clearance between the 60 mm set ring and outer race of the ball bearing in the transmis sion housing, STANDARD: 0 - 0.15 mm (0 - 0.006 in} SET RING, 80 mm, FEELER GAUGE If the clearance 's more than the standard, select & ew set ring from the table, and instal ‘SET RING, 80 mm Part Number Thickness ‘90814 689-000 1250 rr (0.098 In) ‘90415 - 889 - 000 2.60:mm (0.102 in) | ‘90416 ~ 689 - 000 2.70 mm (0.106 in) 90417 - 689-000 2.80 mm (0.119 in) 80418 - 689-000 280.mm (0.114 in) [soar PHE 000 | 3.00 mm (0.118 in) NOTE: If the clearance measured in step § is stan. dard, itis not necessary to perform steps 7 and 8 Remove the transmission housing. Replace the 2.50 mm {0,098 in] 80 mm set ring with the one of the correct thickness selected in sep 6.é 9, Install the new oil seal flush with the transmission. housing using the special tools as shown. river Pot, DRIVER ATTACHMENT, 68 mm 26x30 mm (07867 ~6110501, ‘o7saD -PH80200 Install the new oi seal flush with the torque con verter housing using the special tools as shown, river | 197749 - 0010000 oniven Puor, ‘ATTACHMENT 307mm ATTACHMENT anda Ponz00Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement 1. Remove the mainshatt bearing and oil seal using the special tools as shown, 578°.16 SUDE HAMMER {Commeorciaiy availabe) ADJUSTABLE BEARING PULLER, 25 ~ 40 mm (07736. A0T0008 14-140 & 2. Drive in the now mainshaft bearing unti it bottoms inthe housing using the special tools as shawn, Driver (07749 - 0010000 2. salt ne now ot se! sh wih tre housing ving Ae the special tools as shown.J Countershaft Bearing Replacement 1. Remove the countershaft bearing using the special toole as shown, 3/6°-16 SLIDE HAMMER {Commercially availabe) 2, Install the ATF guide plate 3, Drive the new bearing into the housing using the special tools as shown. DRIVER 97749 - 0010000 ATTACHMENT, 62x 68 mm (0 0.001 in) 3d ATE GUIDE PLATE” 14.141Transmission Housing Bearings Mi shaft/Countershaft Bea 1. To remove the mainshatt and countershatt bearings from the transmission housing, expand each snap ‘ing with snap ring pliers, then push the bearing out Using the special tools and a press as shown, NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing, PRESS DRIVER 07248 - c010900 ATTACHMENT, 52x 68 mm 0745 - 0010590 (MAINSHAFT BEARING Driver ‘07749 - 0010000 ATTACHMENT HOUSING ATTACHMENT ‘© Mainshaft Bearing Installation use: ATTACHMENT, 72 x 75 mm (07748 - 0010600 (07748 ~ 0010500 14-142 gs Replacement 2. Expand each snap ring with snap ring pliers, insert the new bearing part-way into the housing using the special tools and # press as shown. install the bearing with the groove facing outside the housing, NOTE: Coat all parts with ATE 3. Release the pliers, then push the bearing down into ‘the housing until the ring snaps in place around it DRIVER 107749 - 0010000 ATTACHMENT ATTACHMENT ‘© Mainshaft Bearing Removal use: ATTACHMENT, 72 x 75 mm (07746 - 0010600 ‘© Countershaft Bearing Removal ute: ATTACHMENT, 62 x 68 mm 07746 - 0010500 4. After installing the be Ing verity the following: ‘© The snap ring is seated in the bearing and hous: ing grooves. 1# The ring end gap is correct. END GAP: 0-7 mm (0-028ia) &é é é Reverse Idler Gear Installation 1. Install the reverse idler gear 2. Install the reverse idler gear shaft holder and needle bearing into the transmission housing, then tighten the bolts. REVERSE IDLER GEAR SHAFT ‘ASSEMBLY REVERSE IDLER GEAR 6x10 mm A2Nem (1.2 kgtem, 8.7 lott Parking Brake Stop Inspection/Adjustment 1. Set the parking brake fever inthe [F position 2, Measure the distance between the parking brake pawl shaft and the parking brake lever roller pin as shown, STANDARD: 72.9 ~ 73.9 mm (2.87 ~2.91 in} ROLLER PIN PARKING ‘BRAKE Lever PARKING BRAKE ParKiNG broe GEAR PARKING BRAKE PAWL SHAFT 3, If the measurement is out of tolerance, select and install the appropriate parking brake stop from the table below. PARKING BRAKE stop b ou PARKING BRAKE STOP (Mack) Part Number u L 1 | 28637 PAS —003| 11.00mm | 17.00 mm (0.433 in)_| (0.433 in) 2 | 24598 -PAG—003| 10.80mm | 10.65 mm | (0.426 in}_| (0.419 in) 3 [24688 - Pas 008 | 10.60 mm | 10.90 mm Tosti | (oaosin 4, After replacing the parking brake stop, make sure the distance is within tolerance. 14.143Transmission Reasembly Nore: © Coat all parts with ATF. ‘© Replace the following parts: O-rings = Lock washer — Gaskets — Mainshaft and countershaft locknuts and conical spring washers — Sealing washers TORQUE: 12 Nem (1.2 kgf, 8.7 Ibttt) 6x1.0mm 7 Bolg [ATF FEED PIPE: A 6x1.0 mm 2Bote Lock-uP VaLvE BooY ATF STRAINER, LOCK-UP SEPARATOR: PLATE REGULATOR VALVE SERVO DETENT BODY BASE powarms2— 5x10mm cooten nELEr vatve———————"_ f° 7 Boks e SERVO BODY TORQUE CONVERTER CHECK VALVE SERVO SEPARATOR ‘STATOR SHAFT. PLATE. o-nING ‘SECONDARY VALVE STOP SHAFT BODY [ATE FEED PIPE: H- 6x10 mm. DOWEL PINS, 2 5 ots ‘Main VALVE BODY [ATF PUMP DRIVEN: SECONDARY (GEAR SHAFT ‘SEPARATOR PLATE PUMP DRIVEN. tan contnot ‘SHAFT MAIN SEPARATOR: (98 model PLATE DOWEL Pins, 2 HOUSING 14.144eo | od 1. Install the ATF magnet and suction pipe collar in the torque converter housing, if necessary 2. Install the main seperator plate and the two dowel pins on the torque converter housing, 3, Insta the ATF pump drive gear, ATF pump driven ‘gear and ATF pump driven gear shaft on the torque ‘converter housing. NOTE: Install the ATF pump driven gear with its ‘grooved and chamfered side facing down. [ATE PUMP ORIVEN. (GEAR SHAFT Grooved and chamfered sce faces eparstor MAIN SEPARATOR Plate PLATE Loosely install the main valve body with five bots. ‘Make sure the ATF pump drive gear rotates smoothiy in the normal operating direction and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions. 5, Install the secondary valve body, separator plate ‘and two dowel pins on the main valve body. NOTE: Do not install the bolts. 6, Install the control shaft in the housing with the con- {rol shaft and manual valve together. 7. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm. ‘SERVO SEPARATOR PLATE ~— DETENT ARMA ai | ‘contRot saat NS Shar i ee MANUAL VALVE i @ 10, ” 8, Ts 1% 16. Install the servo body and separator plate on the secondary valve body (sever bolt) Install the servo detent base and the ATF strainer {two bolts). Tighten the five bolts on the main vaive body to 12 Nem (1.2 kgm, 8.7 IDF. ‘Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly. IW the ATF pump drive gear and ATF pump driven ‘gear shaft do not move freely, loosen the five bolts ‘on the main valve body, and disassemble the valve bodies. Realign the ATF pump driven gear shaft and reassom: bie the valve bodies, then retighten the bolts to the specified torque. CAUTION: Failure to align the ATF pump driven gear shat correctly will result in seized ATF pump drive gear or ATF pump driven gear shaft. wate are’PuMP DRIVE GEAR DRIVEN GEAR DRIVEN GEAR SHAFT Install the stator shatt and stop shaft. Install the bolts and the shaft stop on the secondary valve bady, then tighten the bolts (three bolts) Install the torque converter check valve, cooler reliot valve and valve springs in the regulator valve body, then install the regulator valve body on the main valve body (one bolt. Install the lock-up valve body on the regulator valve body (seven bolts Install the ATF feed pipes in the main valve body, the three ATF feed pipes in the secondary valve and the four ATF feed pipes in the servo body. cont'd) 14-145-_—— Transmission Reassembly (cont'd) a | rane rouse | TRANSMISSION ‘MOUNTING BOLTS ! Mancen ox125 mm 44M (45 kat, 35 be TRANSMISSION HOUSING , REVERSE GEAR | ‘COLLAR REVERSE GEAR t oma NEEDLE BEARING & REVERSE SELECTOR [MAINSHAFT SPEED’ SENSOR WASHER (01677 engine) COUNTERSHAFT SUB-ASSEMBLY DIFFERENTIA ASSEMBLY TRANSMISSION HOUSING GASKET 14.146eo ) of 17. Install the reverse idler gear and the gear shaft holder (see page 14-143). 18, Install the differential assembly in the torque con: verter housing. 18. Assemble the mainshatt sub-assembly and the countershaft sub-assembly, then install them together in the torque converter housing, MaINsHAFT SUB-ASSEMBLY COUNTERSHAFT ‘SUB-ASSEMBLY 1 20, Turn the shift fork so the large chamfered hole is facing the fork bolt hole, then install the shift fork With the reverse selector, and torque the lock bolt. Blond the lock tab against the bolt head. SHIFT FORK, LOCK WASHER Replace. 6x10 mm 4a.Nem (1.8 kghem, 10 tort) Large chamfered hole 21. Install the needle bearing, countershaft reverse gear and reverse gear collar on the countershatt. 22. Align the spring pin on the control shaft with the transmission housing groove by turning the control shat ‘SPRING PIN, ‘CONTROL SHAFT 23. Install the two dowel pins and 9 new gasket on the torque converter housing, 24, Place the transmission housing on the torque eon: verter housing, CAUTION: Make sure that the mainshaft speed ‘sensor is not installed on the transmission housing before installing the transmission housing on the torque converter housing. 25. Install the transmission housing mounting bolts along with the transmission hanger, then tighten the bolts in two or more steps in the sequence as shown. TORQUE: 44 Nem (45 kgtm, 33 Ibt#t) TRANSMISSION MANGERTransmission Reassembly (cont'd) 26. ‘Slip the special too! onto the mainshaft as shown, MAINSHAFT HOLDER _S7GAB = PrsOIO: 27. Install the parking brake lever on the control shaft. 28. Assemble the one-way clutch and the parking gear ‘with the countershaft 1st gaar (see page 14-123) 28, Install the countershaft 1st gear collar, needle bear ing, and the countershaft 1st gear/parking gear ‘assembly on the countershaft TSTCLUTCH PARKING ‘ASSEMBLY GEAR, PAWL ‘SPRING mamstart COUNTERSHAFT 30. Install the parking broke pawi shaft, spring, pawl, and pawl stop on the transmission housing, then engage the parking brake paw! with the parking gear. 31. Install the mainshaft 1st gear collar on the mi shaft. 32. Wrap the shaft splines with tape to prevent the O- rings, then install new O-rings on the mainshstt 38, Assemble the thrust washer, thrust needle bearing, ‘needle bearing, and mainshaft 1st gear in the 1st clutch assembly, then install tham on the mainshaft 34. Install new conical spring washers and lacknuts on each shaft, CAUTION: Install the conical spring washers in the MAINSHAFT LockNuT Let-nand theeads ‘CONICAL SPRING WASHERS Install in tis direction 35. Tighten the locknuts to the specified torque. Nore: * Do not use an impact wrench. Always use @ torque wrench to tighten the locknut, ‘© Mainshatt and countershett locknuts have left- hhand threads, Torque: MAINSHAFT —_ 78.Nm (8.0 kgfim, 58 Ibl4t) COUNTERSHAFT 103 Nim (10.5 kgfm, 75.9 Ib¢t)é 36. Remove the special tool from mainshatt, then stake ‘each locknut using a 3.6 mm punch as shown, 39 COUNTERSHAFT. ~ un toomnt — wr SF Pointto be oy: ih / 0.7-12mm \ We 3 e / 37. Sot the parking brake levar in the [F] position, then verify that the parking brake pew! engages the park- ing gear. VF Bs. trrepowt oes not engoe ty chock he paring Drake pew atop cleranco ie ago 1414) 39. Tighten the lock bolt and bend the lock tab. 6x 1.0 mm 14. Nem (1-4 kgm, 10 Itt) PARKING GEAR PARKING BRAKE PAWL 40, Inctall the anew ga ht side cover with two dowel pins and (thirteen bots) TORQUE: 12 Nem (1.2 kgf, 8.7 bt) {a RIGHT SIDE COVER 41. Install the ATF cooler tines with new sealing wash- ‘TORQUE: 28 Nm (2.9 kaf-m, 21 IbF ft) 42, Install the ATF dipstick. 14.149Torque Converter/Drive Plate Bx 10mm V2 Norm (1.2 kate, 8.7 Ite) 1241.0 mm 74 Nem (7.8 kgfom, 64 Iottth Torque in & ensscrose pattern, pol i 14-150housing, then install the two 14 mm dowel pins in the torque converter housing, 4 Place the transmission on a jack, and raise it to the engine assembly level. 5. Attach the transmission to the engine, then install two transmission housing mounting bolts and two ‘9ar engine mounting bolts Transmission @ instaltation 1. Flush the ATF cooler as described on page 14-185 and 14-156, 2, Install the torque convert assembly securely with 2 now O-ring an the mainshatt 458m 45 kgf, STARTER MOTOR S31) 14 mm DOWEL PIN iB roraue ong —Y4mmDowel PW CONVERTER Repise dé 3. Install the starter motor on the torque converter [REAR ENGINE ‘MOUNTING BOLTS 14x15 mm ‘TRANSMISSION HOUSING 83 Nem (65 kgm, 61 It) (MOUNTING BOLTS Replace, 124125 mm 64 Ne (65 kgm. 47 A washer REAR ENGINE MOUNTING ‘BRACKET TRANSMISSION ack 6 1 8 Install the transmission mount bracket, 12125 mm (64m (65 Kg, 47H ‘TRANSMISSION oxat " MOUNT BRACKET 1241.25 mm TRANSMISSION MOUNT TaN 7.5 kgm, sabe {nota the remaining transmission housing mount- ing bolts end remaining rear engine mounting bolt. wasten REAR ENGINE os MOUNTING BOLT 34x15 mm 83 em (85 kof, erie feptce, WASHER ‘TRANSMISSION HOUSING MOUNTING BOLTS x125 mm 4 Nem (65 kof, 47 ttt) Remove the transmission jack. {cont'd} 14.151Transmission Installation (cont'd) 9. Attach the torque converter to the drive plate with eight drive plate bolts and tocque as follows: Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a orisserose pattern, After tightening the last bolt, check that the crank- shaft rotates freely. TORQUE: 12 Nem (1.2 kgf, 8.7 IDFR) 101.25 mm 44 Non (45 gm, 33 WE ENGINE STIFFENER a7 ibth) 8x125mm 24Nm 2.4 kot, Tre ‘TOnauE conveRTER coven 10. Install the torque converter caver and the engine stiffener. 11. Tighten the crankshaft pulley bolt, If necessary section 6). 12. Connect the ATF cooler hoses to the ATF cooler lines (soe page 14-160 10% 1.25 mm 44m (65 kote, samen) RIGHT FRONT 1241.25 mm ’ MOUNT/BRACKET 641mm (6.5 kot, { ar tates 113, Install the right front mountibracket 14.152 TaN (12 gh, 14. Install the control lever with @ new lock washer to the control shaft, then install the shift cable cove CAUTION: Take care not to bend the shift cable. SHIFT CABLE 2x1Zmm 22m (2zkgtm, 16 wer] SHIFT CABLE COVER 61.0 mm 14am (14 gt, roe) 15. Install the exhaust pipe A, NOTE: D16V8 engine is shown: D16Y7 engine is sim iter. chsker Replace SELF-LOCKING NUT Replace, casket 10x125 mm Repisce, 54 Nem (8 kgm, some SELF-LOCKING NUT SELF-LOCKING NUT Replace. Replace. 8x 125mm 82125 mm 22Nem (22 kot, ib) 1G Na (1. kgm, rat)3} 16. Install a new sat ring on the ond of each criveshatt 17. Install the right and let driveshafts (see section 16). CAUTION: While installing the driveshafts in the differential, be sure not to allow dust and other for- ign particles to enter into the transmission. NOTE: © Clean the areas where the driveshafts contact the transmission (differential) thoroughly with sol- vent or carburetor cleaner, and dry with com- pressed air. ‘© Turn the right and loft steering knuckle fully out- ward, and slide each driveshaft into the ditferen- tial until you feel its set ring clip engage the side 9 18. Install the damper fork, then install the right and loft ball joints to the each lower arm with the castle nuts and new cotter pins. DAMPER PINCH BOLT 1041.25 mm Nm (6s kgten, 22 ibe Ax hoe fern SELFAOCKING NUT castienur — GOTTER 4241.25 mm 1241.25 mm SEN 65 kgf, 47 bth) 49-59 Nhe Replace. (60-60 Kgtm, 36-43 mn Ne cur’ 42Nm (12 kote, 8.7 IH) 20. Connect the mainshaft speed sensor, the li ‘noid and tho shitt control solenoid connectors. ‘SHIFT CONTROL SOLENOID CONNECTOR LINEAR SOLENOID ‘CONNECTOR 6x10 mm 12mm (12 kgm, a7 met) MAINSHAFT SPEED SENSOR ‘CONNECTOR CONNECTOR BRACKET 21. Connect the countershaft speed sensor and the vehi cle speed sensor (VSS) connectors. VEHICLE SPEED ‘SENSOR CONNECTOR vgs COUNTERSHAFT ‘COUNTERSHAFT SPEED SENSOR SPEED SENS( ‘SPEED SENSOR {conr') 14-153Transmission Installation (cont‘d) 22. Connect the lock-up control solenoid connector, and install the transmission grouns eable. 5x1.0mm FAN (1.2 kgm, 8.7 wer) ‘TRANSMISSION (GROUND CABLE Lock.UP conTAOL ‘SOLENOID CONNECTOR 23. Connect the starter cables on the starter motor, and Install the cable holder. NOTE: When installing the starter cable termin make sure that the crimped side of the ring terminal Js facing out (see section 23) came 8x1.0mm HOLDER 12. (3 2ugFm, 8.7 10th) Nm (03 Wate, TER STARTER CABLE TERMINAL ‘STARTER CABLE 14-154 24, Install the intake air duct. D16¥7 engint Install the intake air duct and the D16Y8 engine: Install the intake air duct and the air cleaner hous- ing assembly. 25, Refil the transmission with ATF (see page 1486), 26, Connect the positive (+) cal tive (-) cable to the battery. first, then the nega: 21. Check the ignition timing (see section 23) 28. Start the engine, Set the parking brake, and shift the transmission through all gears, three times. Check the shift cable adjustment (see page 14-158), 29, Chack the front wheel alignment (see saction 18) 30. Let the engine reach operating temperature (the ‘cooling fan comes on} with the transmission in IW cor [B position, then turn it off and check the fluid level 31, Road test as described on pages 14-82 thru 14-84Bo Cooler Flushing To provent jury to foes and eye, aways Wear ately gasses or a face shield when using te ansmission fsher NOTE: This procedure should be performed before rein- stalling the transmission. 1. Check tool and hoses for wear and cracks before using. If wear or eracks are found, replace the hoses ‘eefore using. 2. Using the measuring cup, fil the tank with 21 ounces [approximately 23 full) of biodegradable flushing fluid (J35844 - 20). D9 not substitute with any other fluld, Follow the handling procedure on the fluid container. 3. Secure the flusher filer cap, and pressurize the tank with compressad air to botwoon 850 ~ 829 kpa (6.6 — 8.45 katie, 80 - 120ps NOTE: The airline should be equipped with a water trap to ensure a dry air system. 4. Hang the tool under the vehicle. 5. Attach the tank’s discharge hose to the return line of the transmission cooler using 8 clamp, 6. Connect the drain hose to the inlet line on the trans- mission cooler using a clamp. IMPORTANT: Securely clamp the opposite end ofthe drain hose to 8 bucket or floor drain. ‘TRANSMISSION TRANSMISSION COOLER FLUSHER (Commercial available) Bucket Kent Moore £28405-8 or equivalent 7. With the water and air valves of, attach the water and. air supplies tothe flsher. (Hot water if available.) or 8 Turn on the flusher water valve so water will flow through the cooler for 10 seconds. NOTE: if water does not flow through the cooler, it 's completely plugged, cannot be flushed, and must be replaced, 8. Depress the trigger to mix the flushing fluid into the ‘water flow. Uso the wire clip to hold the rigger down, 410. While flushing with the water and flushing Muid for ‘two minutes, turn the air valve on for five seconds ‘every 15-20 seconds to create e surging action. [AIR PRESSURE: MAX B45 kpa (8.45 kgffer?, 120 psi) 11. Turn the water valve off. Release the trigger, then reverse the hosas to the cooler 80 you can flush in the opposite direction. Repeat steps 8 through 10. 12, Release the trigger, and rinse the cooler with water only for one minute. 18, Turn the water valve off, and tur off the water supply 114, Turn the air valve on to dry the system out with air for two full minutes or until no moisture is visible leaving the drain hose. CAUTION: Residual moisture in the cooler oF pipes ‘can damage the transmission. 15, Remove the flusher from the cooler line, Attach the drain hose to a container 16. Install the transmission, and leave the drain hose attached to the cooler line. (cont'd) 14.155Transmission Cooler Flushing (cont’d) 11. Make sure the transmission isin the Pl position. Fill the transmission with ATF, and cun the engine for 30 seconds oF until approximately 0.95 f (1.0 US Gt, 0.8 Imp gt is discharged. 18, Remove the drain hose, and reconnect the cooler return hose to the transmission (see page 14-160), 19. Rofl the transmission with ATF to the proper level (see page 14-86) TOOL MAINTENANCE 1. Empty and rinse after each use. Fill the ean with water and pressurize the can. Flush the discharge line to ensure thatthe unit is clean, 2. Ifdischarge liquid does not foam, the orifice may be blocked. 3. To clean, disconnect the plumbing from the tank at the large coupling nut FILLER CAP O-RING 4. Remove the imine fiter from the discharge side and clean if necessary 5. The fluid orifice is located behind the fier. Clean it with the pick stored in the bottom of the tank handlo, or blow it clean with air. Securely reassemble ll parts3 Shift Cable Removal/Installation REREEIEIED aie sure tts are placed propery (see section 1. Remove the front console [see section 20} 2. Shift to [Hl] position, then remove the lock pin from the adjuster Locknut Tim (0.7 ktm. 5 to 3. Remove the shift cable bracket ‘SHIFT CABLE BRACKET 88m (10 kgm, 7240 Remove the shift cable holder. Remove the shift cable cover Remove the control lever from the control shat, then remove the shift cable, Toke care not to bend ble when removingfinstalling it. 81.25 mm 22Nm SHIFT CABLE HOLDER. 2 kgtm, 6x 1.0mm 12Nm (12gtm, a7 bent conmmocieven Sz48mm Ih etgr tote 7. Install the shit cable in the reverse order of removal 8 Check the cable adjustment on reassembly (see page 14-158). 14-157Shift Cable 1 j 2 Adjustment RENTED eke sure ts section fe placed properly {see Romove the front console {see section 20). Shift to IN] position, then remove the lock pin from the adjuster. apuUsTER Locknut 7m (0.7 gt, Stott) 14.158 3, Check that the hole in the adjuster is perfectly aligned with the hole in the shift eable. There ere two holes in the adjuster. They ate positioned 90° apart to allow cable adjustment in 1/4 turn incre ments, ADJUSTER SHIFT CABLE | ——__— poet se 3 | L 4 - _ cable Cable Exect Too Short Too Long Alignment 4, the hole is not perfectly aligned, loosen the lock hut on the adjuster and adjust as required. 5. Tighten the locknut to 7 Nem (0.7 kot, 8 IDF 6. Install the lock pin on the adjuster. If you foe! the lock pin binding as you reinstall it, the cable ut of adjustment and must be readjusted 7. Make sure the lock pin is seeted in the adjui securely. 8. Move the shift lever to each gear, and verify that the shift position indicator follows the automatic trans: axle gear pasitian switch, 9. Start the engine, and check the shift lever in all gears. If any geat does not work properly, refer to troubleshooting (see page 14-78 thru 14-81) 10. Insert the ignition key into the key cylinder on the AIT gear position indicator panel, and verify that the shift lock lever is released,Shift Lever ox)| O fb PUSH KNOB SPRING PUSH BUTTON: 4 SHIFT LEVER KNOB. \ screw C 3 Nem (03 kg, 2 ttt > ‘Apply non hardening theead lock slant. sonew OM non ‘SIICONE GREASE ae ‘SHIFT LOCK, SOLENOID ‘AIT GEAR POSITION SWITCH ‘screw Nm 03 gt, 2ubH ‘SHIFT LEVER BRACKET BASE ‘SHIFT LEVER BRACKET” BASE COLLAR. 8x20mm 98 N6m (1.0 kgm, 7.2 ht) 14-159Shift Indicator Panel ATF Cooler Hoses Adjustment 1. Check that the index mark on the indicator aligns with the [i] mark on the shift indicator panel whan the transmission is in NEUTRAL, INDEX MARK, MOUNTING SCREW 3.Nem (0.3 kgm, 2 tee) SHIFT INDICATOR PANEL 2. If not aligned, remove the front console {see section 20) 3. Remove the shift indicator panel mounting screws and adjust by moving the panel. NOTE: Whenever the shift indicator panel is moved, ‘install the panel as described above, 14-160 Connection 1. Connect the ATF cooler hoses to the ATF cooler lines and ATF cooler, and secure them with the clips as shown, TRANSMISSION CLIP. ATF COOLER HOSES RADIATOR cur &