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AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]

BEARING COVER COMPONENT ASSEMBLY [GF4AX-EL]

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Assembly Procedure
1. Apply ATF to the new O-ring and install it to the bearing cover.
O-ring inner diameter
85.1 mm {3.35 in}
2. Press the new bearing race into the bearing
cover.

05

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3. Press the new oil seal into the bearing cover


using the SST.

End Of Sie
control valve body

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CONTROL VALVE BODY DISASSEMBLY [GF4AX-EL]

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Caution
Denting or scratching these components will reduce the ability of the transaxle to shift properly.
When handling these components or the valve body that contains them, be careful not to drop or
hit them.
1. Disassemble in the order indicated in the table.
2. Neatly arrange the removed parts to avoid confusing the similar parts.
Warning
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.

05-17B41

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


3. Clean the removed parts with cleaning solvent, then use compressed air to dry them. Use compressed air to
clean out all holes and passages.

ymu517aa9
.

1
2
3
4
5
6
7

TFT sensor
Pressure control solenoid valve
3-2 timing solenoid valve
Shift solenoid A
TCC control solenoid valve
Front control valve body
Front/premain front gasket

05-17B42

8
9
10
11
12
13
14

Premain separator plate


Front/premain rear gasket
Rubber balls
Premain control valve body
Jet orifice and nut
Rubber ball
Oil strainer

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


15
16
17
18
19
20
21
22
23

Premain/main front gasket


Main separator plate
Premain/main rear gasket
Rubber balls
Oil strainer
Oil pipe component
Oil baffle
Shift solenoid B
Shift solenoid C

24
25
26
27
28
29
30
31
32

Rear control valve body


Main/rear rear gasket
Rear separator plate
Main/rear front gasket
Rubber balls
Oil strainers
Rubber balls
Oil strainers
Main control valve body

05

Disassembly Procedure
1. Remove the TFT sensor.
2. Remove the pressure control solenoid valve, 3-2
timing solenoid valve, shift solenoid A and TCC
control solenoid valves.
3. Remove the O-rings from the solenoid valves.

ymu517aaa

4. Remove the bolts indicated by the arrows, then


remove the front control valve body and premain
separator plate and gaskets.
5. Remove the front/premain gaskets and separator
plate from the front control valve body.
6. Remove the rubber ball from the front control
valve body.
7. Remove the rubber ball from the premain control
valve body.

w6u517adv

8. Remove the bolts, the premain control valve body


and the main separator plate and gaskets.
9. Remove the premain/main gaskets and separator
from the premain control valve body.
10. Remove the jet orifice and nut from the main
separator plate.
11. Remove the rubber balls and oil strainer from the
premain control valve body.
12. Remove the rubber balls and oil strainer from the
main control valve body.
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13. Turn the assembly over and remove the oil pipe,
baffle plate, shift solenoid B and shift solenoid C.

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05-17B43

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


14. Remove the bolts shown in the figure and remove
the rear separator plate and gaskets.
15. Remove the main/rear gaskets and separator
from the rear control valve body.
16. Remove the rubber balls and oil strainers from the
rear control valve body.
17. Remove the rubber balls and oil strainers from the
main control valve body.

End Of Sie

w6u517adz

PREMAIN CONTROL VALVE BODY DISASSEMBLY [GF4AX-EL]

ezf051721100143

Caution
Denting or scratching these precisely machined components will reduce the ability of the
transaxle to shift properly. When handling these components or the valve body that contains
them, be careful not to drop or hit them.
Using a magnet in this procedure could magnetize the valve body inner components, reducing the
ability of the transaxle to shift properly. Do not use magnets or magnetized tools when carrying
out maintenance on these components.
Note
If a valve does not slide out under its own weight, place the valve body open-side down and tap on the
valve body lightly with a plastic hammer.
1. Disassemble in the order indicated in the table.
Warning
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.

05-17B44

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


2. Clean all parts and holes using compressed air and apply ATF to them immediately before assembly.

05

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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Spring retainer
Pressure modifier accumulator spring
Pressure modifier accumulator valve
Stop pin
Stop plug
3-2 timing valve
3-2 timing spring
Stop pin
Stop plug
Cut back valve A
Cut back valve B
Cut back spring
Stop pin
Stop plug
Bypass valve
Bypass spring

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Bolts
1-2 accumulator plate
1-2 accumulator gasket
Small 1-2 accumulator spring
Large 1-2 accumulator spring
1-2 accumulator piston
Bolts
N-R accumulator plate
N-R accumulator gasket
N-D accumulator spring
N-D accumulator piston
N-R accumulator piston
Large N-R accumulator spring
Small N-R accumulator spring
Premain control valve body

End Of Sie

05-17B45

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


PREMAIN CONTROL VALVE BODY INSPECTION [GF4AX-EL]

ezf051721100144

Spring Inspection
1. Measure the spring free length.
If not within specifications, replace the spring.
Specifications
Spring
Pressure modifier accumulator spring
3-2 timing spring
Cut back spring
Bypass spring
Small 1-2 accumulator spring
Large 1-2 accumulator spring
N-D accumulator spring
Small N-R accumulator spring
Large N-R accumulator spring

Outer diameter
(mm {in})
8.2 {0.32}
8.25 {0.325}
8.2 {0.32}
6.3 {0.25}
14.8 {0.583}
20.2 {0.795}
9.8 {0.39}
7.2 {0.28}
11.2 {0.441}

Free length
(mm {in})
38.2 {1.50}
35.4 {1.394}
29.8 {1.17}
29.5 {1.16}
81.6 {3.21}
81.6 {3.21}
52.9 {2.08}
60.1 {2.37}
56.0 {2.20}

No. of coils
16.5
12.5
7.4
11.7
17.7
12.5
12.0
26.2
15.2

Wire diameter
(mm {in})
1.2 {0.047}
0.85 {0.033}
0.6 {0.02}
0.6 {0.02}
1.7 {0.067}
2.3 {0.091}
1.0 {0.039}
1.0 {0.039}
1.6 {0.063}

End Of Sie
PREMAIN CONTROL VALVE BODY ASSEMBLY [GF4AX-EL]

ezf051721100145

Assembly Procedure
1. Apply ATF to the seal rings.
2. Install the piston and N-D accumulator spring.
3. Apply ATF to the seal rings.
4. Install the N-R accumulator springs and piston.
5. Install the N-R accumulator gasket and plate.
6. Tighten the plate bolt.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}

w6u517ae1

7.
8.
9.
10.

Apply ATF to the seal rings.


Install the piston and 1-2 accumulator springs.
Install the 1-2 accumulator gasket and plate.
Tighten the plate bolt.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}

w6u517ae2

11. Install the bypass valve spring, bypass valve, stop


plug, and stop pin.
12. Install the cut back spring, cut back valve B, cut
back valve A, stop plug, and stop pin.
13. Install the 3-2 timing spring, 3-2 timing valve, stop
plug, and stop pin.
14. Install the pressure modifier accumulator valve,
pressure modifier accumulator spring, and spring
retainer.

End Of Sie
w6u517ae3

05-17B46

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


MAIN CONTROL VALVE BODY DISASSEMBLY [GF4AX-EL]

ezf051721100146

Caution
Denting or scratching these precisely machined components will reduce the ability or the
transaxle to shift properly. When handling these components or the valve body that contains
them, be careful not to drop or hit them.
Using a magnet in this procedure could magnetize the valve body inner components, reducing the
ability of the transaxle to shift properly. Do not use magnets or magnetized tools when carrying
out maintenance on these components.
Note
If a valve does not slide out under its weight, place the valve body open-side and tap on the valve body
lightly with a plastic hammer.
1. Disassemble in the order indicated in the table.
Warning
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
2. Clean all parts and holes using compressed air and apply ATF to them immediately before assembly.

w6u517ae4
.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Spring retainer
Converter relief spring
Converter relief valve
Stop pin
Stop plug
Solenoid reducing spring
Solenoid reducing valve
Spring retainer
Low reducing spring
Low reducing valve
Stop pin
Stop plug
1-2 shift valve
1-2 shift spring

15
16
17
18
19
20
21
22
23
24
25
26
27
28

Stop pin
Stop plug
2-3 shift valve
2-3 shift spring
Stop pin
Stop plug
Coast timing spring
Coast timing valve
Stop pin
Stop plug
TCC shift valve
TCC shift spring
Stop pin
Stop plug

05-17B47

05

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


29
30
31
32

3-4 shift valve


3-4 shift spring
Stop pin
Stop plug

33
34
35

Pressure modifier spring


Pressure modifier valve
Main control valve body

End Of Sie
MAIN CONTROL VALVE BODY INSPECTION [GF4AX-EL]

ezf051721100147

Spring Inspection
1. Measure the spring free length.
If not within the specifications, replace the spring.
Specifications
Spring
Converter relief spring
Solenoid reducing spring
Low reducing spring
1-2 shift spring
2-3 shift spring
Coast timing spring
TCC shift spring
3-4 shift spring
Pressure modifier spring

Outer diameter
(mm {in})
7.4 {0.29}
8.0 {0.31}
8.7 {0.34}
7.4 {0.29}
7.4 {0.29}
6.2 {0.24}
6.0 {0.24}
7.4 {0.29}
5.0 {0.2}

Free length (mm


{in})
32.3 {1.27}
39.7 {1.56}
38.3 {1.51}
36.6 {1.44}
36.6 {1.44}
28.0 {1.10}
40.0 {1.57}
36.6 {1.44}
19.0 {0.75}

No. of coils
13.5
12.0
12.5
12.0
12.0
16.0
13.8
12.0
12.7

Wire diameter
(mm {in})
1.1 {0.043}
0.9 {0.03}
0.9 {0.03}
0.8 {0.031}
0.8 {0.031}
0.6 {0.02}
0.5 {0.02}
0.8 {0.031}
0.6 {0.024}

End Of Sie
MAIN CONTROL VALVE BODY ASSEMBLY [GF4AX-EL]

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Assembly Procedure
1. Install the 3-4 shift spring, 3-4 shift valve, stop
plug, and stop pin.
2. Install the TCC shift spring, TCC shift valve, stop
plug, and stop pin.

w6u517ae5

3. Install the coast timing valve, coast timing spring,


stop plug, and stop pin.

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05-17B48

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


4. Install the 1-2 shift spring, 1-2 shift valve, stop
plug, and stop pin.
5. Install the 2-3 shift spring, 2-3 shift valve, stop
plug, and stop pin.

05
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6. Install the low reducing valve, low reducing


spring, and spring retainer.
7. Install the solenoid reducing valve, spring, stop
plug, and stop pin.
8. Install the converter relief valve, converter relief
spring, and spring retainer.

End Of Sie

w6u517ae8

REAR CONTROL VALVE BODY DISASSEMBLY [GF4AX-EL]

ezf051721100149

Caution
Denting or scratching these precisely machined components will reduce the ability or the
transaxle to shift properly. When handling these components or the valve body that contains
them, be careful not to drop or hit them.
Using a magnet in this procedure could magnetize the valve body inner components, reducing the
ability of the transaxle to shift properly. Do not use magnets or magnetized tools when carrying
out maintenance on these components.
Note
If a valve does not slide out under its own weight, place the valve body open-side down and tap on the
valve body lightly with a plastic hammer.
1. Disassemble in the order indicated in the table.
Warning
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.

05-17B49

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


2. Clean all parts and holes using compressed air and apply ATF to them immediately before assembly.

w6u517ae9

1
2
3
4
5
6

Manual valve
Stop pin
Pressure regulator plug sleeve
Pressure regulator plug
Pressure regulator spring seat
Pressure regulator spring

7
8
9
10
11
12

Pressure regulator valve


Stop pin
2-3 timing plug
2-3 timing spring
2-3 timing valve
Rear control valve body

End Of Sie
REAR CONTROL VALVE BODY INSPECTION [GF4AX-EL]

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Spring Inspection
1. Measure the spring free length.
If not within the specifications, replace the spring.
Specifications
Spring
Pressure regulator spring
2-3 timing spring

End Of Sie

05-17B50

Outer diameter
(mm {in})
12.0 {0.472}
4.7 {0.19}

Free length
(mm {in})
33.9 {1.34}
22.3 {0.878}

No. of coils
7.0
14.0

Wire diameter
(mm {in})
1.1 {0.043}
0.65 {0.026}

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


REAR CONTROL VALVE BODY ASSEMBLY [GF4AX-EL]

ezf051721100151

Assembly Procedure
1. Install the 2-3 timing valve, 2-3 timing spring, 2-3
timing plug, and stop pin.

05

w6u517aea

2. Install the pressure regulator valve, pressure


regulator spring, pressure regulator spring seat,
pressure regulator plug, pressure regulator plug
sleeve, and stop pin.

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3. Install the manual valve.

End Of Sie

w6u517aec

05-17B51

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


CONTROL VALVE BODY ASSEMBLY [GF4AX-EL]

ezf051721100152

ymu517aab
.

1
2
3

Main control valve body


Oil strainers
Rubber balls

05-17B52

4
5
6

Oil strainers
Rubber balls
Main/rear front gasket

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


7
8
9
10
11
12
13
14
15
16
17
18
19

Rear separator plate


Main/rear rear gasket
Rear control valve body
Shift solenoid C
Shift solenoid B
Oil baffle
Oil pipe component
Oil strainer
Rubber ball
Premain/main rear gasket
Main separator plate
Premain/main front gasket
Oil strainer

20
21
22
23
24
25
26
27
28
29
30
31
32

Rubber ball
Jet orifice and nut
Premain control valve body
Rubber ball
Front/premain rear gasket
Premain separator plate
Front/premain front gasket
Front control valve body
TCC control solenoid valve
Shift solenoid A
3-2 timing solenoid valve
Pressure control solenoid valve
TFT sensor

05

Assembly Procedure
1. Install the oil strainer and rubber balls into the
main control valve body.

w6u517aee

2. Install the oil strainer and rubber ball into the rear
control valve body.

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3. Set the new main/rear front gasket, rear separator


plate, and new main/rear rear gasket on the rear
control valve body. Refer to the figure to
distinguish the two gaskets.
4. Set the rear control valve body onto the main
control valve body.

w6u517aeg

05-17B53

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


5. Install and hand-tighten the bolts shown in the
figure. Each type of bolt has a different letter on
its head. Match the bolt letter with the letter
stamped next to its installation hole on the valve
body.

w6u517aeh

6. Install the oil strainers and rubber balls into the


main control valve body.

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7. Install the oil strainer and rubber balls into the


premain control valve body.

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8. Install the jet orifice and nuts to the main


separator plate.
Tightening torque
1.72.2 Nm {1723 kgfcm, 1519 inlbf}

w6u517ael

9. Set a new premain/main rear gasket, main


separator plate, and new premain/main front
gasket on the premain control valve body. Refer to
the figure to distinguish the two gaskets.
10. Set the premain control valve body onto the main
control valve body.

w6u517aem

05-17B54

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


11. Install and hand-tighten the bolts indicated by the
arrows. Each type of bolt has a different letter on
its head. Match the bolt letter with the letter
stamped next to its installation hole on the valve
body.

05
w6u517aen

12. Install the rubber ball into the premain control


valve body.

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13. Install the rubber ball into the front control valve
body.

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14. Set a new front/premain rear gasket, premain


separator plate, and new front/premain front
gasket on the front control valve body. Refer to
the figure to distinguish the two gaskets.
15. Set the front control valve body onto the premain
control valve body.

w6u517aer

16. Install and hand-tighten the bolts indicated by the


arrows. Each type of bolt has a different letter on
its head. Match the bolt letter with the letter
stamped next to its installation hole on the valve
body.

w6u517aes

05-17B55

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


17. Install four control valve body bolts as shown for
alignment.
18. Tighten the mounting bolts.
(1) Tighten the front control valve body.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}
(2) Tighten the rear control valve body.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}

w6u517aet

19. Apply ATF to new O-rings and install them onto


the solenoid valve.
20. Install the solenoid valve.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}
21. Apply ATF to new O-ring and install them onto the oil pipe component.
22. Install the oil pipe component.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}
23. Install the baffle plate.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}
24. Install the TFT sensor.
Tightening torque
6.57.8 Nm {6680 kgfcm, 5869 inlbf}

End Of Sie
FRONT DIFFERENTIAL PREINSPECTION [GF4AX-EL]
differential

ezf051727100102

Backlash Inspection
1. Measure the backlash of the side gear.
If not as specified, replace parts as
necessary.
Backlash
Standard: 0.0250.10 mm {0.00100.0039
in}
Maximum: 0.10 mm {0.0039 in}

End Of Sie
ymu517aac

05-17B56

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


FRONT DIFFERENTIAL DISASSEMBLY [GF4AX-EL]

ezf051727100103

1. Disassemble in the older indicated in the table.


6 SST
16
10
9 R

05

11
15

13

12

8
7

14
12

13

SST

10
9 R

1
bue517zaa002
.

1
2
3
4
5
6
7

Bolts
Ring gear
Sun gear
(See 05-17B-57 Sun Gear Disassembly Note.)
Screw
Differential cover
Bearing
(See 05-17B-58 Bearing Disassembly Note)
Thrust washer

8
9
10
11
12
13
14
15
16

Side gear
Roll pin
Pinion shaft
Pinion carrier
Pinion gear
Thrust washer
Side gear
Thrust washer
Gear case

Sun Gear Disassembly Note


1. Install the SST to the front differential as shown.
2. Remove the sun gear using the press.

buj0517a297

05-17B57

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


Bearing Disassembly Note
1. Remove the bearing (sun gear side) from the gear
case using the SSTs.

ymu517aae

2. Remove the bearing (ring gear side) from the


gear case using the SST.

End Of Sie

xme5614a033

FRONT DIFFERENTIAL ASSEMBLY [GF4AX-EL]

ezf051727100104

Assembly Procedure
1. Apply ATF to each part immediately before assembly.
2. Set the sun gear onto the gear case.
3. Install the bearing using the SST.
4. Install the thrust washer to the gear case.
5. Install the side gear.

buj0517a401

05-17B58

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


6. Install the pinion gears and thrust washers into
the gear case.

05
ymu517aah

7. Install the pinion carrier.

ymu517aaj

8. Install the pinion shafts.


Caution
Assemble the roll pin so that the roll pin
opening is perpendicular to the pinion
shaft.

ymu517aak

9. Install the roll pin, and crimp it to prevent it from


coming out of the gear case.
10. Install the side gear and thrust washer.

ymu517aal

11. Install the differential cover.


Tightening torque
7.910.7 Nm {80110 kgfcm, 7095
inlbf}

ymu517aam

05-17B59

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


12. Measure the backlash of the side gear as follows:
(1) Install the left and right drive shafts in the
differential.
(2) Support the drive shaft on V-blocks.
(3) Measure the backlash of both side gears.
If the backlash is not within the
specification, adjust the thrust washer.
Backlash
Standard: 0.0250.10 mm {0.00100.0039
in}
Maximum: 0.10 mm {0.0039 in}

ymu517aap

13. Select the thrust washer so that the backlash is


as specified.
Thickness of thrust washer
mm {in}
2.00 {0.078}
2.15 {0.085}

2.05 {0.080}
2.20 {0.087}

2.10 {0.083}

14. Install the SST to locate gear case and sun gear.
15. Install the sun gear using the press.
16. Install the ring gear.
Tightening torque
152176.5 Nm {15.517.9 kgfm, 112130
ftlbf}

End Of Sie
output gear

buj0517a408

OUTPUT GEAR BEARING PRELOAD [GF4AX-EL]

ezf051719204103

1. Align the bearing cover with guide bolts as shown.


2. Press the bearing cover in using the SST.
3. Remove the guide bolts and install the bearing
cover installation bolts.
Tightening torque
10.813.7 Nm {110140 kgfcm, 96121
inlbf}
4. Mount the converter housing onto the SST
(transaxle hanger).
5. Remove the bearing race and adjustment shims
from the bearing housing using a pin punch and a
hammer.

w6u517af2

6. Set the output gear into the converter housing.


7. Install the bearing race removed in Step 5 to the
selector, and install the selector and bearing race
to the output gear.

w6u517af3

05-17B60

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


8. Turn the selector to eliminate the gap between its
two halves.

05
ymu517aaq

9. Set the SST (collars) in the position shown.

w6u517af5

10. Set the bearing housing on the SST (selector)


and install the SST (bolts). Tighten the bolts to the
specified torque.
Tightening torque
27.434.3 Nm {2.793.5 kgfm, 20.225.3
ftlbf}

w6u517af6

11. Turn the SST (selector) to increase the clearance


(arrow) with the SST (bars) until it no longer turns.
12. Turn the selector in the opposite direction until the
preload is eliminated (gap is reduced).

w6u517af7

05-17B61

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


13. Mount the SSTs and a pull scale or a torque
wrench on the output gear.
14. Adjust the clearance of the SST (selector) to
obtain the specified preload/pull scale reading.
Preload
0.91.6 Nm {917 kgfcm, 7.914.7 inlbf}
Reading on pull scale
916 Nm {0.91.7 kgf, 2.03.7 lbf}
Note
Measure the clearance around the entire
circumference, and select shims equivalent
to the maximum clearance.
The maximum allowable number of
adjustment shims is seven.

w6u517af8

15. Measure the gap between A and B around the


circumference of the SST (selector) using a feeler
gauge.
16. Take the maximum reading and determine the
shims to be used. Use no more than one shim.
Thickness of shim
mm {in}
0.375 {0.015}
0.525 {0.021}
0.625 {0.025}
0.725 {0.029}
0.825 {0.032}
0.925 {0.036}
1.025 {0.040}
1.125 {0.044}
1.225 {0.048}
1.325 {0.052}

0.425 {0.017}
0.55 {0.022}
0.65 {0.026}
0.75 {0.030}
0.85 {0.033}
0.95 {0.037}
1.05 {0.041}
1.15 {0.045}
1.25 {0.049}
1.35 {0.053}

0.475 {0.019}
0.575 {0.023}
0.675 {0.027}
0.775 {0.031}
0.875 {0.034}
0.975 {0.038}
1.075 {0.042}
1.175 {0.046}
1.275 {0.050}
1.375 {0.054}

0.50 {0.020}
0.60 {0.024}
0.70 {0.028}
0.80 {0.031}
0.90 {0.035}
1.00 {0.039}
1.10 {0.043}
1.20 {0.047}
1.30 {0.051}
1.40 {0.055}

17. Remove the bearing housing and the SST.

ymu517aar

18. Install the required shims and press the bearing


race into the bearing housing using the SST.
19. Install the output gear and idler gear.
20. Install the bearing housing.
Tightening torque
27.434.3 Nm {2.793.5 kgfm, 20.225.3
ftlbf}

w6u517afa

05-17B62

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


21. Verify that the preload/pull scale reading is within
the specification.
If not, return to Step 5.
Preload
0.92.0 Nm {921 kgfcm, 7.918.2 inlbf}
Reading on pull scale
920 Nm {0.92.1 kgf, 2.04.6 lbf}

05

22. Remove the bearing housing and output gear


component.

End Of Sie
differential

FRONT DIFFERENTIAL BEARING PRELOAD [GF4AX-EL]

w6u517afb
ezf051727100105

1. Remove the bearing race and adjustment shims from the transaxle case.
2. Install the bearing race into the converter housing
using a suitable pipe.
3. Remove the ring gear.
4. Remove the sun gear.
5. Remove the differential cover.
6. Remove the roll pin.
7. Remove the short pinion shaft.
8. Install the differential cover.
Tightening torque
7.910.7 Nm {80110 kgfcm, 69.595.4
inlbf}

w6u517afc

9. Set the differential into the converter housing.


10. Turn the selector to eliminate the gap between its two halves.
11. Install the bearing race removed in Step 1 into the
SST. Set the SST and bearing race onto the
differential.

w6u517afd

05-17B63

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


12. Set the six SST (collars) on the converter housing
in the positions shown.
13. Set the transaxle case on the converter housing.

w6u517afe

14. Tighten the SST (bolts) to the specified torque.


Tightening torque
3851 Nm {3.85.3 kgfm, 2838 ftlbf}
Note
Bend the bar as shown to turn the SST.

w6u517aff

15. Turn the SST (selector) to increase the clearance


(arrow) using the SST (bars), until it no longer
turns. This is to seat the bearing race.
16. Turn the selector in the opposite direction until the
preload is eliminated (gap is reduced).
17. Install the SST through the transaxle case and
attach it to the pinion shaft.

w6u517afg

05-17B64

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


18. Install the SST and a pull scale or torque wrench.
Note
Read the preload when the differential starts
to turn.
Measure several times and calculate the
average value.

05

19. Adjust the clearance of the SST (selector) to


obtain the specified preload/pull scale reading.
Preload
0.5 Nm {5 kgfcm, 4.3 inlbf}
Reading on pull scale
5 N {0.5 kgf, 1.1 lbf}
Note
Measure the clearance around the entire
circumference, and select shims based on
the maximum clearance.
The maximum allowable number of
adjustment shims is three.
w6u517afh

20. Measure the clearance as shown.


21. Add 0.3 mm {0.0118 in} to the measured
clearance, and select the shims closest in value
to that measurement.
Thickness of shim
mm {in}
0.1 {0.0039}
0.16 {0.0062}
0.50 {0.0197}

0.12 {0.0047}
0.18 {0.0071}
0.70 {0.0276}

0.14 {0.0055}
0.20 {0.0079}
1.0 {0.0394}

22. Remove the transaxle case and SST (selector).


w6u517afj

23. Install the required adjustment shims and tap the


bearing race into the transaxle case.
24. Install the transaxle case.
Tightening torque
3851 Nm {3.85.3 kgfm, 2838 ftlbf}
25. Install the SST to the pinion shaft through the
transaxle case.
Note
Measure several times and calculate the
average value.

w6u517afk

26. Verify that the preload is within the specification.


If not, return to Step 1.
Preload
3.03.9 Nm {3040 kgfcm, 2734 inlbf}
Reading on pull scale
3039 N {3.04.0 kgf, 6.68.8 lbf}
27. Remove the differential cover.
28. Install the short pinion gear.
29. Install the new roll pin.

05-17B65

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


30. Install the differential cover.
Tightening torque.
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
31. Install the sun gear.
32. Install the ring gear.
Tightening torque.
152176.5 Nm {15.517.9 kgfm, 112130 ftlbf}

End Of Sie
AUTOMATIC TRANSAXLE AND TRANSFER ASSEMBLY [GF4AX-EL]
automatic transaxle

ezf051700000109

Precaution
General notes
1. Select the adjustment shims, referring to Bearing Preload.
2. If the drive plates or 2-4 brake band are replaced with new ones, soak the new part in ATF for at least two hours
before installation.
3. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
4. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
5. Use petroleum jelly, not grease, when assembling again.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assemble the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after
assembly before filling the transaxle with ATF.
Warning
Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold
the rotating handle firmly when turning the transaxle.

05-17B66

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


Assembly
Bearing and race locations

05

w6u517afl

Note
The bearing and race at locations 2, 3, 4, 6, and 7 are one-piece units.
Outer diameter of bearing and race
Bearing (mm {in})
Race (mm {in})

1
86.1 {3.39}
88.0 {3.46}

2
56.1 {2.21}

3
62.15 {2.447}

4
62.15 {2.45}

5
72.0 {2.83}
72.0 {2.83}

6
56.1 {2.21}
57.0 {2.24}

7
71.0 {2.80}
72.0 {2.83}

05-17B67

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


Components
10.813.7
{110140, 96121}

4 R
4 R

1
2

4.05.8
{4060, 3552}

7
SST

16
3
R

6
SST

6
9

SST 6

5
4
R

8
11

13

15

14
R

6
7.910.7
{80110, 7095}

SST

10

12 R

27.434.3 Nm
{2.793.5 kgfm,
20.225.3 ftlbf}
Nm {kgfcm, inlbf}

bue517zaa001
.

1
2
3
4
5
6
7
8

Converter housing
Baffle plate
O-rings
Oil seals
Adjustment shim
Bearing races
Bearing cover component
Output gear

05-17B68

9
10
11
12
13
14
15
16

Idler gear
Bearing housing
Baffle plate
Roll pin
Orifice check valve
Orifice check spring
2-3 accumulator
Front differential

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]

05

bue517zab062
.

1
2
3
4
5

Baffle plate
Parking pawl
Parking assist lever
Actuator support
Manual shaft and manual plate

6
7
8
9

Detent spring
Low and reverse brake
Output shell
Transaxle case

05-17B69

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]

bue517zab063
.

1
2
3
4
5
6
7
8

Turbine shaft
3-4 clutch
Internal gear
Low and reverse brake
Retaining plate
Snap ring
Friction plate
One-way clutch 2 and carrier hub component

05-17B70

9
10
11
12
13
14
15

Band servo
Anchor strut and shaft
2-4 brake band
Small sun gear and one-way clutch 1
Clutch component
Snap ring
Piston stem

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]

05

bue517zab064
.

1
2
3
4
5
6
7

Oil pump
Control valve body
Coupler component
Control valve body cover
Oil strainer
Oil pan
Oil pipe

8
9
10
11
12
13

TR switch
Input/turbine speed sensor
Transfer
Oil dipstick and oil filler tube
Oil pump shaft
Torque converter

05-17B71

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


Assembly procedure
1. Align the bearing cover with guide bolts as shown
and press it in. Install and tighten the mounting
bolts.
Tightening torque
10.813.7 Nm {110140 kgfcm, 96121
inlbf}
2. Press the bearing race into the converter housing.

w6u517afr

3. Assemble the SST.


4. Install the idler gear and output gear by tapping in
with a plastic hammer.

w6u517afs

5. Install the selected shims and bearing race into


the bearing housing using the SST.
6. Install the bearing housing.
(1) Install the bearing housing on the converter
housing, and tighten the bolts evenly and
gradually.
Tightening torque
27.434.3 Nm {2.793.5 kgfm, 20.225.3
ftlbf}
(2) Align the slot of the idler shaft with the mark
on the bearing housing.
(3) Tap a new roll pin in using a pin punch and a
hammer.
7. Install the 2-3 accumulator piston.
(1) Install the orifice check valve spring and orifice check valve.
(2) Apply ATF to new O-rings and install them into the 2-3 accumulator.
(3) Install the 2-3 accumulator piston.
Tightening torque
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
8. Install the bearing race into the converter housing.
9. Install the baffle plate.
Tightening torque
4.05.8 Nm {4060 kgfcm, 3552 inlbf}
10. Install the front differential.
11. Install the selected shims and bearing race into the transaxle case.

05-17B72

w6u517aft

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


12. Install the manual shaft and manual plate.
(1) Install the manual plate, spacer, washer, and nut.
(2) Tighten the nut to the specified torque.
Tightening torque
4254 Nm {4.25.6 kgfm, 3140 ftlbf}
(3) Install the detent spring.

05

Tightening torque
1521 Nm {1.52.2 kgfm, 1115 ftlbf}
(4) Move the manual shaft and verify that the parking pawl operates correctly.
13. Install the output shell to the output gear, and install the thrust bearing onto the output shell.
Thrust bearing outer diameter
71.0 mm {2.80 in}
14. Apply a light coat of silicone sealant to the contact
surfaces of the converter housing and the
transaxle case.
15. Install new O-rings into the converter housing.

w6u517afu

16. Install the transaxle case on the converter


housing, and tighten the bolts evenly and
gradually.
Tightening torque
3851 Nm {3.85.3 kgfcm, 2838 inlbf}

buj0517a332

17. Install the SST into the differential side gears.


18. Install the turbine shaft and 3-4 clutch component.
(1) Assemble the turbine shaft and 3-4 clutch
component.
(2) Verify that the thrust bearing and race are
properly installed.
(3) Install the turbine shaft and 3-4 clutch
component into the transaxle case.

w6u517afv

05-17B73

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


19. Adjust the SST position so that it contacts and
holds the turbine shaft.
20. Install the internal gear.
(1) Install the internal gear to the output shell.
(2) Install the snap ring.
21. Install the carrier hub component.
(1) Verify that the thrust bearing and bearing race
are installed in the correct position.
(2) Hold the turbine shaft with one hand to
prevent it from rotating.
(3) Install the carrier hub component into the 3-4
clutch drum by rotating it.
22. Install the friction plate.
23. Install the one-way clutch 2.
(1) Hold the one-way clutch 2 horizontally.
(2) Install it by turning the carrier hub component counterclockwise.
(3) Install the snap ring.
24. Install the band servo to the transaxle case.
(1) Install the servo return spring and band servo.
(2) Compress the servo using the SSTs.
(3) Install the snap ring.
(4) Remove the SSTs.
25. Install the piston stem.
26. Loosely tighten the piston stem by hand.
27. Install the anchor strut.

w6u517afw

w6u517afx

28. Install the 2-4 brake band in the transaxle case,


and interlock it to the anchor as shown.
29. Install the small sun gear and one-way clutch 1.
(1) Verify that the thrust bearing and bearing race
are installed in the correct position.
(2) Install the small sun gear and one-way clutch
1 component by rotating it.
30. Install the clutch component.
(1) Verify that the thrust bearing is installed in the
correct position.
(2) Install the clutch component by rotating it.
w6u517afy

31. Measure the height difference between the


reverse and forward drum and the transaxle case.
If the height is not within specification, assemble
again beginning with Step 21.
Height difference
0.71.9 mm {0.0280.075 in}
32. Install the new snap ring into the bottom ring
groove of the turbine shaft.
w6u517afz

05-17B74

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


33. Use the following procedure to adjust the total end play and select a suitable bearing race.
(1) Set the thrust bearing onto the clutch component.
(2) Remove the bearing race and the oil pump gasket.
(3) Set the thickest bearing race (2.2 mm {0.084 in}) onto the oil pump.
(4) Set the oil pump onto the clutch component.
(5) Measure clearance A between the transaxle
case and the oil pump. Take several
measurements and calculate the average
value.
(6) Select a suitable bearing race from the chart
below.
Clearance A (mm {in})
0.911.10 {0.036-0.043}
0.710.90 {0.028-0.035}
0.510.70 {0.020-0.027}
0.310.50 {0.012-0.019}
0.110.30 {0.004-0.011}
00.10 {0-0.003}

Select this bearing race


(mm {in})
1.2 {0.047}
1.4 {0.055}
1.6 {0.063}
1.8 {0.071}
2.0 {0.078}
2.2 {0.087}

05

w6u517ag0

(7) Remove the oil pump.


(8) Place the selected bearing race and a new gasket onto the oil pump.
(9) Install the oil pump onto the clutch component, and tighten the bolts evenly and gradually.
Tightening torque
1925 Nm {1.92.6 kgfm, 1418 ftlbf}
(10)Install the oil pipe.
34. Adjust the 2-4 brake band.
(1) Loosen the locknut and tighten the piston stem to the specified torque.
Tightening torque
11.814.7 Nm {120150 kgfcm, 105130 inlbf}
(2) Install a dial indicator and magnetic base to
the oil pump. Set the dial indicator against the
piston stem.
Warning
Using compressed air can cause dirt and
other particles to fly out, causing injury
to the eyes. Wear protective eye wear
whenever using compressed air.

w6u517ag1

(3) While keeping compressed air applied to the


2-4 brake band engagement passage, set the
dial indicator to zero.
Air pressure
390400 kPa {3.94.1 kgf/cm2, 5658 psi}
(4) Stop applying compressed air, and verify the
piston stroke by inspecting the dial gauge.
Adjust the piston stem and apply compressed
air repeatedly until the stroke is within
specification.

w6u517ag2

Stroke
0.81.2 mm {0.03940.0472 in}

05-17B75

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


(5) Hold the piston stem and tighten the locknut to the specified torque.
Tightening torque
2539 Nm {2.54.0 kgfm, 1928 ftlbf}
35. Install a new O-ring and oil strainer to the transaxle.
Tightening torque
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
36. Install the magnets inside the oil pan in the positions shown in the figure.
37. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the oil pan.
38. Install the oil pan to the transaxle case.
Tightening torque
8.410.7 Nm {85110 kgfcm, 73.895.4
inlbf}

w6u517ag3

39. Align the manual valve with the pin on the manual
plate.
40. Install the control valve body into the transaxle
case, and tighten the bolts evenly and gradually.
Tightening torque
10.814.7 Nm {110150 kgfcm, 96130
inlbf}
41. Install a new O-ring to the coupler component.
42. Install the coupler component.
43. Match the harness coupler, and connect the
solenoid connectors and TFT sensor connector.
44. Apply a light coat of silicone sealant to the contact
surfaces of the transaxle case and control valve body cover.
45. Install a control valve body cover, and tighten the bolts evenly and gradually.
Tightening torque
8.410.7 Nm {85110 kgfcm, 73.895.4 inlbf}
46. Install the steel ball, spring, packing, and oil pipe.
47. Install the bolt.
Tightening torque
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
48. Install the input/turbine speed sensor.
Tightening torque
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
49. Install the TR switch.

05-17B76

w6u517ag4

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


50. Adjust the TR switch.
(1) Connect an ohmmeter between the terminals
A and H.
(2) Rotate the manual shaft fully
counterclockwise, then return it two notches
to the N position.
(3) Adjust the switch to the point where there is
continuity between the terminals.
(4) Tighten the switch.
Tightening torque
7.910.7 Nm {80110 kgfcm, 7095
inlbf}

05
w6u517ag5

Note
When it is necessary to install the manual shaft lever to the manual shaft, use an adjustable wrench to
hold the manual shaft lever, then use a wrench other than an impact wrench to tighten the manual shaft
nut to the specified torque
Caution
Do not use an impact wrench or tighten the manual shaft nut without holding the manual shaft
lever, as the transaxle may become damaged.
51. Tighten the manual shaft nut.
Tightening torque
3246 Nm {3.24.7 kgfm, 2433 ftlbf}
52. Remove the transaxle from the SST (transaxle hanger).
53. Install a new O-ring to the transfer.
54. Install the transfer to the converter housing.
Tightening torque
36.553.9 Nm {3.735.49 kgfm, 27.039.7
ftlbf}
55. Install the oil dipstick and oil filler tube along with
a new O-ring to the transaxle case.
Tightening torque
6.99.8 Nm {80110 kgfcm, 69.595.4
inlbf}

buj0517a344

56. Install the oil pump shaft.


57. Install a new O-ring onto the turbine shaft.
58. If the torque converter has been drained and washed, hold the torque converter in an upright position and fill it
with new ATF.
ATF type
M-III or equivalent (e.g.DexronII)
59. Carefully install the converter to the torque converter housing. Rotate the torque converter to align the splines.
60. To ensure that the torque converter is installed
accurately, measure distance A between the end
of the torque converter and the face of the
DISTANCE (A)
converter housing.
Distance A
16.20 mm {0.6378 in}

End Of Sie
transfer

bue517zab008

05-17B77

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


TRANSFER CLEANING [GF4AX-EL]

ezf051727500103

Cleaning Precautions
1. Clean the surface of the transfer using steam and cleaning fluids when disassembly.
Warning
Always wear safety glasses when using compressed air since the foreign material could be blown
by the compression air and damage your eyes.
2. Clean removed components with cleaning fluids and use compressed air to blow off the oil. Clean the oil holes
and passages with compressed air.

End Of Sie
TRANSFER DISASSEMBLY [GF4AX-EL]

ezf051727500104

Before Service Precautions


To prevent the foreign material from entering the transfer, perform disassembly and servicing in a clean, dustfree environment.
Inspect the each part while disassembling.
Disassemble with bare hand or using vinyl gloves. To prevent foreign material from entering the transfer, do not
use cotton work gloves or rag.
When disassembling areas of the transfer that are made of light alloy, tap lightly with a plastic hammer. Do not
use a flathead screwdriver.
Warning
The engine stand is equipped with a self-lock mechanism. However, if the transfer is tilted, the
self-lock mechanism could become inoperative. This could cause the transfer to rotate
accidentally, resulting in injury. Therefore, make sure that the transfer is not tilted when it is on the
engine stand. When turning the transfer, grasp the rotation handle firmly.
Disassembly

buj0517a346
.

1
2
3
4

Side cover
Rear cover
Locknut (idle gear)
Locknut (companion flange)

05-17B78

5
6
7
8

Washer
Companion flange
Oil seal
Idle gear

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


9
10
11
12
13
14
15
16
17
18
19

Spacer
Bearing cap
Spacer
Adjustment shim
Ring gear component
Bearing outer race (side)
Drive pinion gear
Bearing inner race (rear)
Collapsible spacer
Bearing inner race (front)
Spacer

20
21
22
23
24
25
26
27
28
29

Clip
Bearing
Oil seal
Spacer
Bearing outer race (rear)
Bearing outer race (front)
Bearing inner race (side)
Ring gear
Ring gear shaft
Transfer carrier

05

Disassembling Procedure
1. Remove the rear cover and drain the transfer oil.
2. Assemble the SST.
3. Install the transfer to the SST.
4. Remove the side cover.
5. Remove the O-ring from the side cover.

buj0517a347

6. Using the SST, secure the companion flange, and


remove the idle gear locknut.

buj0517a348

7. Using the SST, secure the companion flange, and


remove the locknut and washer.

buj0517a349

05-17B79

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


8. Using the SST, remove the companion flange.
9. Using a flathead screwdriver, remove the oil seal.
10. Using a copper hammer and pin punch, tap the
idle gear locknut lightly to remove the idle gear.
11. Remove the spacer (locknut side).

buj0517a350

12. Make alignment marks on the bearing cap and


carrier.
13. Remove the bearing cap.

buj0517a351

14. Using the SSTs, remove the ring gear


component.
15. Remove the spacer (idle gear side).
16. Install an appropriate nut to the drive pinion to
prevent the thread from being damaged.

buj0517a352

17. Lightly tap the drive pinion using a copper


hammer and remove the drive pinion.
18. Remove the bearing inner race (rear) and
distance piece.

buj0517a353

19. Using the SST, remove the bearing inner race


(front).
20. Remove the spacer.
21. Detach the clip.

buj0517a354

05-17B80

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


22. Using the SST, remove the bearing.
23. Using a flathead screwdriver, remove the oil seal.

05
buj0517a355

24. Attach the brass stick to the notch, tap the race
end lightly and evenly, then remove the outer
race.

buj0517a356

25. Using the SSTs, remove the bearing inner race


(side) (locknut side).

49 0839 425C
(ATTACHMENT
39.5 mm {1.56 in})

49 H027 002
bue517zab001

26. Using the SSTs, remove the bearing inner race


(side), then remove the ring gear.

End Of Sie

49 0839 425C
(ATTACHMENT
39.5 mm {1.56 in})

49 H027 002

bue517zab002

05-17B81

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


TRANSFER ASSEMBLY [GF4AX-EL]

ezf051727500105

Before Service Precautions


Assemble with bare hand or using vinyl gloves. To prevent the foreign material from entering the transfer, do not
use cotton work gloves or rag.
Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it
since it may cause oil leakage.
When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing
area with the cleaning fluids.
After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this
time.
Warning
The engine stand is equipped with a self-lock mechanism. However, if the transfer is tilted, the
self-lock mechanism could become inoperative. This could cause the transfer to rotate
accidentally, resulting in injury. Therefore, make sure that the transfer is not tilted when it is on the
engine stand. When turning the transfer, grasp the rotation handle firmly.
Assembly

buj0517a359
.

1
2
3
4
5
6
7
8
9
10
11

Transfer carrier
Ring gear shaft
Ring gear
Bearing inner race (side)
Bearing outer race (front)
Bearing outer race (rear)
Spacer
Oil seal
Bearing
Clip
Spacer

05-17B82

12
13
14
15
16
17
18
19
20
21
22

Bearing inner race (front)


Distance piece
Bearing inner race (rear)
Drive pinion gear
Bearing outer race (side)
Ring gear component
Adjustment shim
Spacer
Bearing cap
Spacer
Idle gear

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


23
24
25
26

Oil seal
Companion flange
Washer
Locknut (companion flange)

27
28
29

Locknut (idle gear)


Rear cover
Side cover

Assembly Procedure
1. Assemble the SST.
2. Install the transfer to the SST.

05

buj0517a360

3. Using a press, assemble the locknut side bearing


inner race (side) to the ring gear shaft.
4. Using a press assemble the ring gear to the ring
gear shaft.

buj0517a361

5. Using a press, assemble the ring gear side


bearing inner race (side).

buj0517a362

6. Using the SSTs, assemble the bearing outer


race.

buj0517a363

05-17B83

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


7. Using the SSTs, adjust the drive pinion height as
follows:
(1) Install the SSTs to the removed spacer and
bearing.
(2) Assemble the spacer, bearing and SSTs.
Using an O-ring, secure the SST.
(3) Assemble the bearing, SSTs, companion
flange, washer, and nut.
(4) Tighten the nut to the companion flange to
where it can still be rotated by hand.
buj0517a364

(5) Place the SSTs on the plate surface and set


the dial gauge to 0.

buj0517a365

(6) Position the SST (49 0727 570) on the driver


pinion model.
(7) Attach the dial gauge head to where the
carrier bearing outer race (side) is installed
and measure lowest position. Also, measure
the value of where the side bearing outer race
(side) is installed on the opposite side.

buj0517a366

(8) Add the values for the both sides measured in


Step 7 and divide by 2. From this value,
subtract the value listed on the drive pinion
end (if not written, it is 0) divided by 100, and
then add 1.47. This is the pinion height
adjustment value.

buj0517a367

05-17B84

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


Note
If the value measured in Step 7 and 8 is -1.47 mm {-0.0579 in} and 1.45 mm {0.0571 in}, and the drive
pinion end value is 2, the formula would be (-1.47)+ (-1.45)/2-2/100+1.47=-0.01. Therefore, a spacer 0.01
mm {0.0004 in} thinner than the old one would be used. Since spacer thickness varies by 0.015 mm
{0.0020 in}, select the spacer nearest the required size and assemble.
Identification mark
08
11
14
17
20
23
26
29
32
35
38
41
44
47

Thickness (mm {in})


3.08 {0.1213}
3.11 {0.1224}
3.14 {0.1236}
3.17 {0.1248}
3.20 {0.1260}
3.23 {0.1272}
3.26 {0.1283}
3.29 {0.1295}
3.32 {0.1307}
3.35 {0.1319}
3.38 {0.1331}
3.41 {0.1343}
3.44 {0.1354}
3.47 {0.1366}

Identification mark
09
12
15
18
21
24
27
30
33
36
39
42
45

Thickness (mm {in})


3.095 {0.1219}
3.125 {0.1230}
3.155 {0.1242}
3.185 {0.1254}
3.215 {0.1266}
3.245 {0.1278}
3.275 {0.1289}
3.305 {0.1301}
3.335 {0.1313}
3.365 {0.1325}
3.395 {0.1335}
3.425 {0.1348}
3.455 {0.1360}

8. Assemble the spacer selected for pinion height adjustment with the round off side facing the gears.
9. Using the SST, assemble the bearing inner race
7 INCH SIDE/8 INCH SIDE
(front) to the drive pinion gear.
10. Assemble a new distance piece to the drive pinion
SPACER
49 F401 331
gear.
11. Assemble the drive pinion to the transfer carrier.
12. Install the bearing inner race (rear), companion
flange, washer, and new locknut to the drive
pinion and temporarily tighten.
13. Rotate the companion flange by hand and to seat
49 F401 337A
the bearing.
14. Using the SST, tighten the locknut from the lower
limit of the specified tightening torque and set to
bue517zab003
the preload value. Note the tightening torque
when the specified preload value is obtained.
Tightening torque
127284 Nm {13.029.0 kgfm, 95209 ftlbf}
Drive pinion preload value
0.881.37 Nm {9.014.0 kgfcm, 7.912.1 inlbf}
15.
16.
17.
18.

Remove the locknut, washer, and companion flange.


Apply oil to the lip area of a new oil seal.
Using the SST, assemble the oil seal.
Apply the grease to the bearing contact surface of
the companion flange.
19. Assemble the companion flange.

buj0517a370

05-17B85

05

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


20. Using the SST, tighten the new locknut to the
tightening torque noted when preload was
adjusted.
21. Reverify the preload.
Preload value
0.881.37 Nm {9.014.0 kgfcm, 7.912.1
inlbf}
22. Install the spacer to the bearing outer race (side)
locknut side installation area.
buj0517a371

23. Place the side bearing race and on top of ring


gear on the surface plate as shown in the figure,
and measure the height using a vernier caliper
and straight edge. This is dimension A.

buj0517a372

24. Measure the width of the transfer carrier ring gear


installation area with the spacer installed. This is
dimension B.
25. Total thickness C of the adjustment shims on both
sides can be expressed by the following formula:

B
SPACER

C1=B-A+0.096
C2=B-A+0.28
26. If the total thickness of the installed adjustment
shims is between C1C2, use the shims as they
are.
bue517zab004
27. If the total thickness of the installed adjustment
shims is not between C1C2, select two appropriate adjustment shims from the table below and use them.
Identification mark
350
360
370
380
390
400
410
420
430
440
450
460

Thickness (mm {in})


3.50 {0.1378}
3.60 {0.1417}
3.70 {0.1457}
3.80 {0.1496}
3.90 {0.1535}
4.00 {0.1574}
4.10 {0.1614}
4.20 {0.1654}
4.30 {0.1693}
4.40 {0.1732}
4.50 {0.1772}
4.60 {0.1811}

Identification mark
355
365
375
385
395
405
415
425
435
445
455

Thickness (mm {in})


3.55 {0.1398}
3.65 {0.1437}
3.75 {0.1476}
3.85 {0.1516}
3.95 {0.1555}
4.05 {0.1594}
4.15 {0.1634}
4.25 {0.1673}
4.35 {0.1713}
4.45 {0.1752}
4.55 {0.1791}

Note
When reusing adjustment shims, do not mix up the right one and left.
Do not mix up the right and left side bearing race and spacer.
28. Install the adjustment shim chose for the transfer carrier ring gear side and spacer on opposite side.
29. Assemble the ring gear and bearing race to the transfer carrier.

05-17B86

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


30. Using the SST, assemble the selected adjustment
shim in between the spacer and bearing race as
shown in the figure.
31. Align the alignment mark of the bearing cap,
assemble the bearing cap, and tighten the bolt
temporarily.
32. Set the dial gauge with the measuring probe
attached perpendicularly to the end of one of the
ring gear teeth.

05
buj0517a374

33. Secure the drive pinion and measure the


backlash from when the ring gear is moved.
Standard
Backlash: 0.090.11 mm {0.00350.0043
in}
Caution
Perform the backlash measurement on
the ring gear circumference at four
points.
34. If the backlash is not within the specified range
above, adjust it by sliding the ring gear in the shaft
direction.

buj0517a375

Note
Slide the ring gear in the shaft direction by replacing the adjustment shim. If the right side adjustment shim
is replaced with one that is 0.05 mm {0.002 in} thicker, the left side shim must be replaced with one that is
0.05 mm {0.002 in} thinner.
35. Align the bearing cap alignment mark and
assemble the bearing cap.
Tightening torque
17.626.5 Nm {1.802.70 kgfm, 13.119.5
ftlbf}

buj0517a369

36. Perform the drive pinion and ring gear tooth


contact inspection.
(1) Apply tooth marking compound evenly to both
surfaces of the ring gear.
(2) Rotate the ring gear back and forth several
times.
(3) Inspect for gear tooth contact at four points on
the ring gear circumference and verify that the
gear tooth contact indicated by tooth marking
compound is as indicated in the figure.
If the tooth contact points are normal,
wipe off the marking compound.
If the tooth contact points are not normal,
adjust the pinion height, then adjust the
backlash.

buj0517a376

05-17B87

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


(4) If toe and flank contact is indicated as shown
in the figure, replace the drive pinion spacer
with a thinner one to maintain the drive pinion
further away.

TOE CONTACT

FLANK CONTACT

bue517zab005

(5) If heal and face contact is indicated as shown


in the figure, replace the drive pinion spacer
with a thicker one to bring the drive pinion
closer.

TOE CONTACT

FLANK CONTACT

bue517zab006

37. Assemble the idle gear side spacer.


38. Using the SSTs, assemble the oil seal.

buj0517a379

39. Using the SSTs, assemble the bearing.


40. Assemble the clip.
41. Align the idle gear and ring gear shaft serrations
and tap the idle gear lightly to assemble.
42. Assemble the locknut side spacer.
43. Assemble a new locknut.

buj0517a380

05-17B88

AUTOMATIC TRANSAXLE (SERVICE) [GF4AX-EL]


44. Using the SST, secure the companion flange and
tighten the locknut to the specified tightening
torque.
Tightening torque
127206 Nm {13.021.0 kgfm, 95151
ftlbf}

05
buj0517a381

45. Crimp the locknut using a chisel and hammer.


LOCKNUT

Crimp size
2.7 mm {0.11 in} or more

2.7 mm {0.11 in}


OR MORE

46. Remove the transfer from the SST.


47. Apply oil to a new O-ring and assemble the side
cover.
48. Assemble the side cover to the transfer.
Tightening torque
6.99.8 Nm {70100 kgfcm, 6186 inlbf}

bue517zab007

Note
Before applying silicone sealant, completely clean off any old silicone sealant and remove any oil or
grease.
After applying silicone sealant, install the rear cover within 10 min.
After connecting the sealing area, leave it for 30 min or more, then add transfer oil.
49. Clean the alignment surface of the rear cover and transfer, and lightly apply silicone sealant.
50. Assemble the rear cover.
Tightening torque
6.99.8 Nm {70100 kgfcm, 6186 inlbf}
51. Remove the oil level plug and washer.
52. Position the transfer on level ground.
53. Add the specified oil through the oil level plug hole
until it reaches the oil level plug hole filling port.
Specified oil
API Service GL-5 (SAE 80W-90)
Oil capacity (approx. quantity)
0.35 L {0.37 US qt, 0.31 lmp qt}

End Of Sie
buj0517a383

05-17B89

AUTOMATIC TRANSAXLE (SERVICE) [LA4AX-EL (CD4E)]


99. Install the transaxle filler tube component.
(1) Install the tube.
(2) Install the transaxle filler tube bolt.
Install the fluid level indicator.

8 Nm {0.8 kgfm, 5.9 ftlbf}

05
bue0517a038

100.Install the turbine shaft speed (TSS) sensor.


(1) Use petroleum jelly on the O-ring seal and
position the TSS sensor.
Install a new O-ring seal.
(2) Install the TSS sensor bolt.
13 Nm {1.3 kgfm, 9.6 ftlbf}

bue0517a039

101.Using the SST, install the LH differential seal.


49 B001 795

buj0517w039

102.Using the SST, install the RH differential seal.


307-428
(49 UN30 7428)

buj0517w038

103.Using the SST, install the torque converter fluid


seal.
Note
Make sure the torque converter seal garter
spring does not become dislodged during
fitting. If the garter spring does become
dislodged, install a new torque converter
seal.
Coat the torque converter seal garter spring
with petroleum jelly.
v9610116

05-17D103

AUTOMATIC TRANSAXLE (SERVICE) [LA4AX-EL (CD4E)]


104.Install the drain plug.

27 Nm {2.8 kgfm, 20 ftlbf}

bue0517a040

105.Install the output shaft speed (OSS) sensor.

v9910123

106.Install the pump drive shaft.


Note
Inspect correct rotation of the pump drive
shaft.

gd1439a

107.Remove the transaxle from the SSTs.

End Of Sie

yuj30701w02

05-17D104

TECHNICAL DATA

05-50

TECHNICAL DATA

TRANSMISSION/TRANSAXLE
TECHNICAL DATA [GF4AX-EL] . . . . . . 05-501

TRANSMISSION/TRANSAXLE
TECHNICAL DATA
[LA4AX-EL (CD4E)] . . . . . . . . . . . . . . . . 05-503

End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA [GF4AX-EL]
automatic transaxle

ezf055000000101

Automatic Transaxle
Item
Transaxle type
Torque converter

Bushing inner diameter


(mm {in})
Outer and inner rotor
clearance (mm {in})

Oil pump

Forward clutch

Spool outer diameter


(mm {in})

Standard
Maximum
Standard
Maximum
Standard
Maximum
Standard

Clearance between the oil


pump base and the inner
Maximum
rotor (mm {in})
Number of drive/driven plates
Drive plate thickness
Standard
(mm {in})
Minimum
Forward clutch clearance (mm {in})
Snap ring size (mm {in})

Sun gear drum


Small sun gear
Carrier hub

Coasting clutch

Bushing inner diameter


Maximum
(mm {in})
Bushing inner diameter
Maximum
(mm {in})
Clearance between pinion
washer and planet carrier Maximum
(mm {in})
Number of drive/driven plates
Standard
Drive plate thickness
(mm {in})
Maximum
Coasting clutch clearance (mm {in})
Snap ring size (mm {in})

Reverse clutch

3-4 clutch

Number of drive/driven plates


Drive plate thickness
Standard
(mm {in})
Minimum
Reverse clutch clearance (mm {in})
Snap ring size (mm {in})
Number of drive/driven plates
Drive plate thickness
Standard
(mm {in})
Minimum
3-4 clutch clearance (mm {in})
Snap ring size (mm {in})

Low and reverse


brake

2-4 brake band

Number of drive/driven plates


Standard
Drive plate thickness
(mm {in})
Minimum
Low and reverse brake clearance
(mm {in})
Snap ring size (mm {in})
Piston stem stroke (mm {in})

Specification
GF4AX-EL
53.030 {2.088}
53.076 {2.090}
0.020.04 {0.00080.0015}
0.05 {0.0019}
13.97013.980 {0.55000.5503}
13.970 {0.5500}
0.0400.115 {0.001570.00453}
0.125 {0.00492}
3/3
1.6 {0.063}
1.5 {0.059}
0.971.20 {0.0380.047}
2.00 {0.079}, 2.15 {0.085}, 2.30 {0.091}, 2.45 {0.096},
2.60 {0.102}, 2.75 {0.108}
33.4 {1.31}
24.0 {0.945}
0.20.7 {0.0080.028}
2/3
1.6 {0.063}
1.5 {0.059}
1.01.2 {0.0390.047}
1.50 {0.059}, 1.65 {0.065}, 1.80 {0.071}, 1.95 {0.077},
2.10 {0.083}, 2.25 {0.089}
2/2
1.6 {0.063}
1.5 {0.059}
1.51.8 {0.0590.070}
2.0 {0.079}, 2.2 {0.087}, 2.4 {0.094}, 2.6 {0.102}, 2.8 {0.110}
4/4
1.6 {0.063}
1.5 {0.059}
1.31.5 {0.0510.059}
3.80 {0.150}, 3.91 {0.154}, 4.04 {0.159}, 4.17 {0.164},
4.30 {0.169}, 4.43 {0.174}, 4.56 {0.179}, 4.69 {0.185},
4.80 {0.189}
4/4
1.6 {0.063}
1.5 {0.059}
1.51.8 {0.0600.070}
6.8 {0.268}, 7.0 {0.276}, 7.2 {0.283}, 7.4{0.291}, 7.6 {0.299}
0.81.2 {0.03940.0472}

05-501

05

SERVICE TOOLS

05-60

SERVICE TOOLS

TRANSMISSION/TRANSAXLE SST
[GF4AX-EL] . . . . . . . . . . . . . . . . . . . . . . 05-601

TRANSMISSION/TRANSAXLE SST
[LA4AX-EL (CD4E)] . . . . . . . . . . . . . . . . 05-603

End of Toc
TRANSMISSION/TRANSAXLE SST [GF4AX-EL]
automatic transaxle

ezf056000000101

49 0107 680A

49 0180 510B

49 0727 570

Engine stand

Preload
measuring
attachment

Pinion height
gauge body

49 0839 425C

49 8531 565

49 B017 209

Bearing puller
set

Drive pinion
model

Attachment J

49 F017 1A0

49 F027 003

49 F027 005

Universal
wrench

Handle

Attachment 62

49 F207 007

49 F401 331

49 F401 337A

Attachment 72

Body

Attachment C

49 F401 366A

49 FT01 361

49 FT01 439

Plate

Bearing
remover

Idler gear
shaft holder

49 G019 011

49 G019 012

49 G019 013

Bearing installer

Leak checker

Bearing
remover

49 G019 017

49 G019 022

49 G019 0A0

Oil seal installer

Attachment K

Transaxle
hanger set

05-601

05