Você está na página 1de 50

AX-1

AUTOMATIC TRANSAXLE

AX-2
AUTOMATIC TRANSAXLE

DESCRIPTION

DESCRIPTION
GENERAL DESCRIPTION
The A132L automatic transaxle described in this AX section is a 3-speed automatic transaxle
with a lock-up mechanism developed exclusively for use with transversely-mounted engines.

AX-3
AUTOMATIC TRANSAXLE

DESCRIPTION

Type of Transaxle

A132L

Type of Engine

3E-E
2.5: 1

Torque Converter Clutch Stall Torque Ratio

Equipped

Torque Converter Clutch Lock-up Mechanism


Gear Ratio

Transaxle

2nd Coast Brake (B1) Band Width

1st Gear
2nd Gear
3rd Gear
Reverse Gear
Number of Discs/Plates
Forward Clutch (C1)
Direct Clutch (C2)
2nd Brake (B2)
1st & Reverse Brake (B3)
mm (in.)

Differential
Capacity liter (US qts, Imp.qts)

3/3
2/3
2/4
5/4

25 (0.98)
ATF DEXRON II

ATF Type
Automatic Transaxle
Capacity liter (US qts, Imp.qts)

2.810
1.549
1.000
2.298

Total
Drain & Refill

5.5 (5.8, 4.8)


2.5 (2.8, 2.2)
1.4 (1.5, 1.2)

AX-4
AUTOMATIC TRANSAXLE

OPERATION

OPERATION
OPERATION

- --Operating

Shift lever
position

Gear position
Parking
Reverse
Neutral
1st
2nd
3rd
1st
2nd
1st
* 2nd
*Down-shift in L position, 2nd gear only-no up-shift.

AX-5
AUTOMATIC TRANSAXLE

OPERATION

1. FUNCTION OF COMPONENTS

Component

Function

Forward Clutch

Connects input shaft and front planetary ring gear.

Direct Clutch

Connects input shaft and front & rear planetary sun gear.

2nd Coast Brake

Prevents front & rear planetary sun gear from turning either clockwise or
counterclockwise.

2nd Brake

Prevents outer race of F1 from turning either clockwise or counterclockwise thus


preventing the front & rear planetary sun gear from turning counterclockwise.

1st & Reverse Brake

Prevents rear planetary carrier from turning either clockwise or counterclockwise.

No. 1 One-Way Clutch

When B2 is operating, this clutch prevents the front & rear planetary sun gear
from turning counterclockwise.

No. 2 One-Way Clutch

Prevents rear planetary carrier from turning counterclockwise.

Planetary Gears

These gears change the route through which driving force is transmitted in
accordance with the operation of each clutch and brake in order to increase or
reduce the input and output speed.

AX-6
AUTOMATIC TRANSAXLE

OPERATION

Power from the engine transmitted to the input shaft via the torque converter clutch is then
transmitted to the planetary gears by the operation of the clutch.
By the operation of the brake and one-way clutch, either the planetary carrier or the planetary
sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
Shift change is carried out by altering the combination of clutch and brake operation.
Each clutch and brake operates by hydraulic pressure; gear position is decided according to the
throttle opening angle and vehicle speed, and shift change occurs automatically.
The conditions of operation for each gear position are shown in the following illustrations:

AX-7
AUTOMATIC TRANSAXLE

OPERATION

2. HYDRAULIC CONTROL SYSTEM


The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves,
the accumulators, the clutches and brakes, and the governor valve as well as fluid passages
which connect all of these components.
Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs
the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance.
with the vehicle driving conditions.
The governor valve produces hydraulic pressure in response to vehicle speed. Governor pressure
increases as vehicle speed increases.
HYDRAULIC CONTROL SYSTEM

OIL PUMP

Hydr. pressure control

Fluid passage switching


Throttle Cable

Governor Valve

CLUTCHES & BRAKES

Planetary gear sets


Torque converter clutch

AX-8
AUTOMATIC TRANSAXLE

PREPARATION

PREPARATION
SST(SPECIAL SERVICE TOOLS)
09043-38100 Hexagon 10 mm Wrench

Oil pan drain plug

09201-6001 1 Valve Guide Bushing Remover &


Replacer

Speedometer driven gear oil seal

09308-00010 Oil seal Puller

Side gear shaft oil seal

09350-32014 TOYOTA Automatic Transmission


Tool Set

(09351-32010) One-way Clutch Test Tool

(09351-32020) Stator Stopper

(09351-32130) Handle

(09351-32150) Oil Seal Replacer

09921-00010 Spring Tension Tool

Speedometer driven gear oil seal

09992-00094 Automatic Transmission Oil


Pressure Gauge Set

Line pressure

AX-9
AUTOMATIC TRANSAXLE

PREPARATION

EQUIPMENT
Straight edge

Check torque converter clutch


installation.

Dial indicator or dial indicator with magnetic base

Measure inside diameter or


piston stroke.

Torque wrench
Voltmeter
Ammeter(A)
Ohmmeter

LUBRICANT
Item
Automatic transaxle fluid
w/o Differential oil
Dry fill
Drain and refill
Differential oil
w/ Automatic transaxle

Classification

Capacity

ATF DEXRON II
5.5 liter (5.8 US qts, 4.8 Imp. qts)
2.5 liter (2.6 US qts, 2.2 Imp. qts)
1.4 liter (1.1 US qts, 0.9 Imp. qts)

ATF DEXRON II

SSM(SPECIAL SERVICE MATERIALS)


08833-00070 Adhesive 1311,
THREE BOND 1311 or equivalent

Torque converter clutch mounting


bolt

AX-10
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

TROUBLESHOOTING
GENERAL INFORMATION
1. Troubles occurring with the automatic transaxle can be caused by either the engine or the
transaxle itself. These 2 areas should be distinctly before proceeding with troubleshooting.
2. Troubleshooting should begin with the simplest operation, working up in order of difficulty,
but first determine whether the trouble lies within the engine or transaxle.
3. Proceed with the inspection as follows:

PRELIMINARY CHECK (See page AX-1 1)


(a) Check the tire inflation.
(b) Check the idle speed.
(c) Check the fluid level and fluid condition.
(d) Check the throttle cable mark.
(e) Check the shift linkage.
(f) Check the park/neutral position switch.

STALL TEST (See page AX-14 )


Check the engine and torque converter clutch.

TIME LAG TEST (See page AX-15 )


Check the automatic transaxle (each clutch, brake and gear) for wear.

HYDRAULIC TEST (See page AX-16 )


Measure the line pressure and make basic check of fluid circuit.

ROAD TEST (See page AX-20 )


Confirm if trouble lies within automatic transaxle. If noisy or vibrating, the
possible cause could be with the compressor, engine, drive shaft, tires,
etc.

Matrix chart (See page AX-25 )

AX-1 1
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

PRELIMINARY CHECK
1. CHECK FLUID LEVEL
HINT: The vehicle must have been driven so that the
engine and transaxle are at normal operating temperature.
Fluid temperature: 70-80C (158-176F)
(a) Park the vehicle on a level surface, set the parking
brake.
(b) With the engine idling, shift the selector into each
gear from P position to L position and return to P
position.
(c) Pull out the transaxle dipstick and wipe it clean.
(d) Push it back fully into the tube.
(e) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side of the hot range, add fluid.
Fluid type:
ATF DEXRON II
NOTICE: Do not overfill.

2. CHECK FLUID CONDITION


If the fluid smells burnt or is black, replace it.
3. REPLACE ATF
NOTICE: Do not overfill.

(a) Using SST, remove the drain plug and drain the fluid.
SST 09043-38100
(b) Using SST, install the drain plug securely.
SST 09043-38100

(c) Add new fluid through the filler tube.


Fluid:
ATF DEXRON II
Capacity:
5.5 liters (5.7 US qts, 4.8 Imp.qts)
Drain and refill:
2.5 liter (2.6 US qts, 2.2 Imp.qts)

(d) Start the engine and shift the selector into all positions from P through L and then shift into P.
(e) With the engine idling, check the fluid level. Add fluid
up to the COOL level on the dipstick.

AX-12
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

(f) Check the fluid level with the normal fluid temperature
70-80 C (158-176F) and add as necessary.
NOTICE: Do not overfill.

4. REPLACE DIFFERENTIAL FLUID IF NECESSARY


(a) Using SST, remove the drain plug and drain the fluid.
SST 09043-38100
(b) Using SST, install the drain plug securely.
SST 09043-38100
(c) Remove the filler plug.
(d) Add new fluid until it begins to run out of the filler
hole.
Fluid type:
ATF DEXRON II

5. CHECK DIFFERENTIAL FLUID LEVEL


Remove the filler plug and check differential fluid
level.

6. INSPECT AND ADJUST THROTTLE CABLE


(a) Depress the accelerator pedal all the way and check
that the throttle valve opens fully.
HINT: If the throttle valve does not open fully, adjust
the accelerator link.
(b) Fully depress the accelerator.
(c) Loosen the adjustment nuts.
(d) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is the
standard.
Standard boot and cable stopper distance:
0-1 mm (0-0.04 in.)

(e) Tighten the adjusting nuts.


(f) Recheck the adjustments.

AX-13
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

7. ADJUST SHIFT CONTROL CABLE


(a) Loosen the swivel nut on the lever.
(b) Push the manual lever fully toward the right side of
the vehicle.
(c) Return the lever 2 notches to the NEUTRAL position.
(d) Set the shift lever in N position.
(e) While holding the lever lightly toward the R position
side, tighten the swivel nut.

8. ADJUST PARK/NEUTRAL POSITION SWITCH


If the engine will start with the shift selector in any
position other than N or P position, adjustment is
required.
(a) Loosen the park/neutral position switch bolts and set
the shift selector to the N position.
(b) Align the groove and neutral basic line.
(c) Hold is position and tighten the bolts.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)

9. INSPECT IDLE SPEED (N POSITION)


Idle speed:
800 rpm

AX-14
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

STALL TEST
The object of this test is to check the overall performance of the transaxle and engine by
measuring the maximum engine speeds in D and R positions.
NOTICE:
Perform the test at normal operating fluid temperature 50-80C (122-176F).
Do not continuously run this test longer than 5 seconds.
MEASURE STALL SPEED
(a) Chock the front and rear wheels.
(b) Mount an engine tachometer.
(c) Fully apply the parking brake.
(d) Keep your left foot pressed firmly on the brake pedal.
(e) Start the engine.
(f) Shift into the D position. Step all the way down on the accelerator pedal with your right foot.
Quickly read the highest engine RPM at this time.
Stall speed:
2,400200 rpm

(g) Perform the same test in the R position.


EVALUATION
(a) If the engine speed is the same for both positions but lower than specified value:
Engine output may be insufficient
Stator one-way clutch is not operating properly
(b) If the stall speed at the D position is higher than specified:
Line pressure too low
Forward clutch slipping
One-way clutch No.2 not operating properly
(c) If the stall speed at the R position is higher than specified:
line pressure too low
Direct clutch slipping
First and reverse brake slipping
(d) If the stall speed in the R and D positions is higher than specified:
Line pressure too low
Improper fluid level

AX-15
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

TIME LAG TEST


When the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag
before the shock can be felt. This is used for checking the condition of the forward clutch, direct
clutch and first and reverse brake.
NOTICE:
Perform the test at normal operating fluid temperature 50-80C (122-176F).
Be sure to allow 1 minute interval tests.
Make 3 measurements and take the average value.
MEASURE TIME LAG
(a) Fully apply the parking brake.
(b) Start the engine and check the idle speed. (Cooling fan and A/C OFF)
Idling speed:
N position 800 rpm

(c) Shift the shift lever from N to D position. Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag:
Less than 1.2 seconds

(d) In same manner, measure the time lag for NR.


Time lag:
Less than 1.5 seconds

EVALUATION
(a) If ND time lag is longer than specified.
Line pressure too low
Forward clutch worn
Line pressure too low
Direct clutch worn
First and reverse brake worn

AX-16
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

HYDRAULIC TEST
1. MEASURE LINE PRESSURE
(a) Warm up the transaxle fluid.
(b) Remove the transaxle case test plug and mount the oil pressure gauge (SST).
SST 09922-00094
NOTICE: Perform the test at normal operating fluid temperature 50-80C (122-176F).

(c) Fully apply the parking brake and chock the 4 wheels.
(d) Start the engine and check the idle speed.
(e) Shift into the D position, step down strongly on the brake pedal with your left foot and while
manipulating the accelerator pedal with the right foot, measure the line pressure at the engine
speeds specified in the table.
(f) In the same manner, perform the test in the R position.
Line pressure
Idling
Stall

D position

kPa (kgf/cm2, psi)

363-422 (3.7-4.3, 53-61)


902-1,049 (9.2-10.7,131 -152)

R position

kPa (kgf/cm2, psi)

530-706 (5.4-7.2, 77-102)


1,412 -1,648 (14.4 -16.8, 205 - 239)

(g) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
(See page AX-12 ) and retest.

AX-17
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

EVALUATION
(a) If the measured values at all positions are higher than specified:
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
(b) If the measured values at all positions are lower than specified:
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
(c) If pressure is low in the D position only:
D position circuit fluid leakage
Forward clutch defective
(d) If pressure is low in the R position only:
R position circuit fluid leakage
First and reverse brake defective
Direct clutch defective

AX-18
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

2. MEASURE GOVERNOR PRESSURE


(a) Warm up the transaxle fluid.
(b) Remove the transaxle case test plug and mount the oil pressure gauge (SST).
SST 09992-00094
NOTICE: Perform the test at normal operating fluid temperature 50-80C (122-176F).

(c) Check the parking brake to see that it is not applied.


(d) Start the engine.
(e) Shift into the D position and measure the governor pressures at the speeds specified in the table.
EVALUATION
If governor pressure is defective:
Line pressure defective
Fluid leakage in governor pressure circuit
Governor valve operation defective
Except Puerto Rico
Count drive gear

Vehicle speed (Reference)

Governor pressure

1.000 rpm

30 km/h
(19 mph)

49-127 kPa
(0.5-1.3 kgf/cm2, 7-19 psi)

1,800 rpm

54 km/h
(34 mph)

147-226 kPa
(1.5 - 2.3 kgf/cm2, 21 -33 psi)

3,500 rpm

105 km/h
(65 mph)

412-490 kPa
(4.2 - 5.0 kgf/cm2, 60 - 71 psi)

Puerto Rico
Count drive gear

Vehicle speed (Reference)

1,000 rpm

27 km/h
(17 mph)

Governor pressure
49-127 kPa
(0.5-1.3 kgf/cm2, 7-19 psi)

1,800 rpm

49 km/h
(31 mph)

147-226 kPa
(1.5-2.3 kgf/cm2, 21 -33 psi)

3,500 rpm

96 km/h
(60 mph)

412-490 kPa
(4.2 - 5.0 kgf/cm2, 60 - 71 psi)

AX-19
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

AX-20
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

ROAD TEST
NOTICE: Perform this test at normal fluid temperature,
50-80 C (122-176F).

1. D POSITION TEST
Shift into D position and while driving with the accelerator pedal held constant at the throttle valve full
open, check on the following points:
(a) Check to see that the 1 -2 and 2-3 up-shifts take
place and also that the shift points conform to those
shown in the automatic shift schedule.
(See page AX-24 )
EVALUATION
If there is no 1-2 up-shift:
Governor valve is defective
1-2 shift valve stuck
If there is no 2-3 up-shift:
2-3 shift valve stuck
If the shift point is defective:
Throttle cable out-of adjustment
Throttle valve. 1-2 shift valve, 2-3 shift valve,
etc. defective

(b) In the same manner, check the shock and the slip at 1
-2 and 2-3 up-shifts.
EVALUATION
If the shock is severe:
Line pressure is too high
Accumulator is defective
Check ball is defective

(c) Run in the 3rd gear of D position, check the abnormal


noise and vibration.
HINT: Check for cause of abnormal noise and vibration must be made with extreme care as they could
also be due to imbalance in the drive shaft, differential, tires, torque converter clutch etc.

AX-21
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

(d) While running in the 3rd gear of D position, check to


see that the possible kick-down vehicle speed limits
for the 3-1 and 3-2 kick-down conform to those
indicated in the automatic shift schedule.
(See page AX-24 )
EVALUATION
If the possible kick-down vehicle speed limit is defective:
Throttle cable out-of adjustment
Throttle valve, 1- 2 shift valve, 2-3 shift valve,
etc. defective
(e) Check the abnormal shock and slip at kick-down.

(f) While running about 60 km/h (37 mph) in the 3rd gear
of D position, release your foot from the accelerator
pedal and shift into L position. Then check to see if
the 2 - 1 down - shift point conform to those indicated in the automatic shift schedule.
(See page AX-24 )

2. INSPECT LOCK-UP MECHANISM


(a) Drive in D position at a steady speed (Lock-up ON) of
about 80 km/h (50 mph).
(b) Lightly depress the accelerator pedal and check that
the engine speed does not change abruptly.
If there is a big jump in engine RPM, there is no lock up.

3. 2 POSITION TEST
(a) While running in 2 position, 2nd gear, release the
accelerator pedal and check the engine braking effect.
EVALUATION
If there is no engine braking effect:
Second coast brake is defective

AX-22
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

(b) Check the abnormal noise during acceleration and


deceleration.
(c) Check the shock at up-shift and down-shift.

4. L POSITION TEST
(a) While running in L position, check to see that there is
no up-shift to 2nd gear.

(b) While running in L position, release the accelerator


pedal and check the engine braking effect.
EVALUATION
If there is no engine brake effect:
First and reverse brake is defective

(c) Check the abnormal noise during acceleration and


deceleration.

5. R POSITION TEST
Shift into R position and, while running at full throttle,
check the slipping.

AX-23
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

6. P POSITION TEST
Stop the vehicle on a gradient (more than 9%) and,
after shifting into P position, release the parking
brake. Then check to see that the parking lock pawl
prevents the vehicle from moving.

AX-24
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

AUTOMATIC SHIFT SCHEDULE


SHIFT POINT
Except Puerto Rico
Shift position

Vehicle speed km/h (mph)

Shifting point
Throttle valve fully opened

D position

Throttle valve fully closed

L position

Throttle valve fully opened

12
23
32
21
Lock -up ON
Lock-up OFF

21

51-64 (32-40)
98-1 11 (61- 69)
92-107 (57-66)
37-45 (23-28)
77-84 (48-52)
72-79 (45-49)

40-48 (25-30)

Puerto Rico
Shift position

Vehicle speed km/h (mph)

Shifting point
Throttle valve fully opened

D position

Throttle valve fully closed

L position

Throttle valve fully opened

12
23
32
21
Lock-up ON
Lock-up OFF

21

47-59 (29-37)
90-100 (56-62)
84-99 (52-62)
34-41 (21 -25)
70-77 (43-48)
66-72 (41 -45)

36-44 (22-27)

AX-25
AUTOMATIC TRANSAXLE

TROUBLESHOOTING

TROUBLESHOOTING MATRIX CHART

Does not move in any forward position


Does not move in reverse position
Does not move in any forward position
or reverse position
1st 2nd
No-up shift
2nd 3rd
3rd 2nd
No-down shift
2nd 1st
Shift point too high or too low
N R
N D
N L

Harsh
engagement

1st 2nd
(D position)
1st 2nd
(2 position)

1st 2nd 3rd


2nd 3rd
3rd 2nd

Primary regulator valve

Throttle modulator valve

Throttle valve

B2 accumulator

2nd coast modulator valve

Low coast modulator valve

No. 1 one-way clutch (F1)

C1 accumulator

2nd coast brake (B1)

1st and reverse brake (B3)

Second brake (B2)

Rear planetary gear

No.2 one-way clutch (F2)

Front planetary gear

Forward clutch (C1)

Direct clutch (C2)

2-3 Shift valve

1-2 Shift valve

Governer valve

AX-41
Parking lock pawl

Symptom

Manual valve

Suspect Area

Torque converter clutch

See page

AX-34

Use the table below to help you find the cause of the problem.
The numbers indicate the priority of the likely cause of the problem. Check each part in order. If
necessary, replace these parts.

AX-26

Slip

No engine braking

AX-41

Forward clutch (C1)


No. 2 one-way clutch (F2)
1st and reverse brake (B3)
Second brake (B2)
No. 1 one-way clutch (F1)
Pressure relief valve
Oil strainer
Second coast brake (B1)
1-2 Shift valve
2-3 Shift valve
Lock-up relay
Lock-up signal valve

AX-27

TROUBLESHOOTING

Direct clutch (C2)

AUTOMATIC TRANSAXLE

See page

Symptom

Forward & Reverse

R position

1st

2nd

3rd

1st (L position)

2nd (2 position)

Suspect Area

No kick-down

Poor acceleration

No lock-up

: Refer to 94 A131L, A132L Automatic Transaxle Repair Manual.

Torque converter clutch

AX-27
AUTOMATIC TRANSAXLE

VALVE BODY

VALVE BODY
VALVE BODY REMOVAL
1. CLEAN TRANSAXLE EXTERIOR
To help prevent contamination, clean the exterior of
the transaxle.
2. DRAIN TRANSAXLE FLUID
Using a heagon wrench, remove the drain plug and
drain the fluid into suitable container.
3. REMOVE OIL PAN AND GASKET
NOTICE: Some fluid will remain In the oil pan. Remove all
pan bolts, and carefully remove the oil pan assembly.
Discard the gasket.

4. REMOVE OIL STRAINER


Remove the 3 bolts, and the oil strainer.
NOTICE: Be careful as some oil will come out with the
strainer.

5. REMOVE OIL TUBES


(a) Remove the 2 bolts and apply tube bracket.

(b) Pry up the both tube ends with a large screwdriver


and remove the 4 tubes.

AX-28
AUTOMATIC TRANSAXLE

VALVE BODY

6. REMOVE MANUAL DETENT SPRING

7. REMOVE MANUAL VALVE AND VALVE BODY

8. REMOVE VALVE BODY


(a) Remove the 14 bolts.

(b) Disconnect the throttle cable.


(c) Remove the valve body.

9. REMOVE SECOND BRAKE APPLY GASKET AND


GOVERNOR OIL STRAINER

AX-29
AUTOMATIC TRANSAXLE

VALVE BODY

VALVE BODY INSTALLATION


1. INSTALL GOVERNOR OIL STRAINER AND SECOND
BRAKE APPLY GASKET

2. INSTALL VALVE BODY


(a) While holding the cam down with your hand, slip the
cable end into the slot.
(b) Bring valve body into place.
NOTICE: Be careful not to entangle the kick - down
switch and solenoid wire.

(c) Finger tighten all the bolts first. Then tighten them
with a torque wrench.
Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

3. PLACE MANUAL VALVE AND BODY ON TRANSAXLE


(a) Align the manual valve with the pin on the manual
valve lever.
(b) Install the valve body into place.
(c) Finger tighten the 4 bolts first. Then tighten them with
a torque wrench.
Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

4. INSTALL DETENT SPRING


(a) Finger tighten the 2 bolts first. Then tighten them with
a torque wrench.
Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

(b) Check that the manual valve lever is in contact with


the center of the roller at the tip of the detent spring.

AX-30
AUTOMATIC TRANSAXLE

VALVE BODY

5. INSTALL OIL TUBES


(a) Tap the tubes with a plastic hammer to install them
into the positions indicated in the illustration.
NOTICE: Be careful not to bend or damage the tubes.

(b) Install the apply tube bracket.

6. INSTALL OIL STRAINER

7. INSTALL MAGNETS IN PAN

8. INSTALL OIL PAN WITH GASKET


NOTICE: Make sure that the magnet does not interfere
with the oil tubes.
Torque: 4.9 N-m (50 kgf-cm, 43in.-Ibf)

AX-31
AUTOMATIC TRANSAXLE

VALVE BODY

9. INSTALL DRAIN PLUG WITH NEW GASKET


Using SST, install the drain plug with a new gasket
and tighten it.
Torque: 49 N-m (500 kgf-cm, 36 ft-lbf)

SST 09043 - 38100

10. FILL TRANSAXLE WITH ATF


Add only about 2 liters of ATF.
NOTICE: Do not overfill.
Fluid type:
ATF DEXRON II

11. CHECK FLUID LEVEL


(See page AX-1 1)

AX-32
AUTOMATIC TRANSAXLE

THROTTLE CABLE

THROTTLE CABLE
THROTTLE CABLE REMOVAL
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.

2. REMOVE PARK/NEUTRAL POSITION SWITCH


(a) Disconnect the transaxle control cable from the transaxle control shaft lever.
(b) Remove the transaxle control shaft lever.
(c) Remove the park/neutral position switch.
3. REMOVE VALVE BODY
(See page AX-27 )

4. REMOVE THROTTLE CABLE


(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.

THROTTLE CABLE INSTALLATION


1. INSTALL CABLE INTO TRANSAXLE CASE
(a) Be sure to push it in all the way.
(b) Install the retaining plate and bolt.
2. INSTALL VALVE BODY
(See page AX-29 )

3. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON


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

AX-33
AUTOMATIC TRANSAXLE

THROTTLE CABLE

4. CONNECT THROTTLE CABLE TO ENGINE


5. ADJUST THROTTLE CABLE
(See page AX-12 )

6. INSTALL PARK/NEUTRAL POSITION SWITCH


(a) Install the park/neutral position switch.
(b) Adjust the park/neutral position switch.
(See page AX-13 )
(c) Install the transaxle control shaft lever.
(d) Connect the transaxle control cable.
7. TEST DRIVE VEHICLE

AX-34
AUTOMATIC TRANSAXLE

GOVERNOR VALVE

GOVERNOR VALVE
GOVERNOR VALVE REMOVAL
1. REMOVE TRANSAXLE DUST COVER
2. DISCONNECT LH DRIVE SHAFT
(See page SA-22 )

3. REMOVE GOVERNOR BRACKET

4. REMOVE GOVERNOR COVER WITH O-RING


5. REMOVE GOVERNOR BODY WITH THRUST
WASHER
6. REMOVE PLATE WASHER
7. REMOVE GOVERNOR BODY ADAPTOR

GOVERNOR VALVE INSTALLATION


1. INSTALL GOVERNOR BODY ADAPTOR
2. INSTALL PLATE WASHER
3. INSTALL GOVERNOR BODY WITH THRUST
WASHER
4. INSTALL GOVERNOR COVER WITH O-RING

5. INSTALL GOVERNOR BRACKET


6. CONNECT LH DRIVE SHAFT
(See page SA-26 )
7. INSTALL TRANSAXLE DUST COVER
8. ADD FLUID TO DIFFERENTIAL IF NECESSARY
(See page AX-1 1)

Fluid type:
ATF DEXRON II

AX-35
AUTOMATIC TRANSAXLE

DIFFERENTIAL OIL SEAL

DIFFERENTIAL OIL SEAL


DIFFERENTIAL OIL SEALS REMOVAL
1. DRAIN TRANSAXLE FLUID
Remove the drain plug and drain the fluid into a
suitable container.
2. REMOVE ENGINE UNDER COVER
3. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-22 )
4. REMOVE LH AND RH SIDE OIL SEALS
Using SST, drive out the both side oil seals.
SST 09308-00010

DIFFERENTIAL OIL SEALS INSTALLATION


1. INSTALL LH SIDE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09350-32014 (09351-32150, 09351-32130)
Oil seal drive in depth:
0 mm (0 in.)

(b) Coat the oil seal lip with MP grease.

2. INSTALL RH SIDE OIL SEAL


(a) Using SST and a hammer, drive in a new oil seal until
its surface is flush with the case surface.
SST 09350-32014 (09351-32150, 09351-32130)
Oil seal drive in depth:
00.5 mm

(b) Coat the oil seal lip with MP grease.


3. INSTALL LH AND RH DRIVE SHAFT
(See page SA-26 )
4. INSTALL ENGINE UNDER COVER
5. FILL TRANSAXLE WITH ATF
(See page AX-1 1)
NOTICE: Do not overfill.
Fluid type:
ATF DEXRON ll

6. CHECK FLUID LEVEL

AX-36
AUTOMATIC TRANSAXLE

SPEEDOMETER DRIVEN GEAR OIL SEAL

SPEEDOMETER DRIVEN GEAR OIL


SEAL
SPEEDOMETER DRIVEN GEAR OIL
SEAL REMOVAL
1. REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, pull out the oil seal.
SST 09921-00010

SPEEDOMETER DRIVEN GEAR OIL


SEAL INSTALLATION
2. INSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL
SST 09201 -60011
Drive in depth:
19 mm (0.75 in.)

AX-37
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

ASSEMBLY REMOVAL AND


INSTALLATION
Remove and install the parts, as shown below.

AX-38
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

TRANSAXLE REMOVAL
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the LOCK position
and the negative (-) terminal cable is disconnected from
the battery.

1. REMOVE BATTERY
2. REMOVE AIR DUCT
3. REMOVE THROTTLE CABLE FROM ENGINE
4. DISCONNECT SPEEDOMETER CABLE
5. REMOVE UPPER SIDE MOUNTING BOLTS
6. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the 2 bolts.
7. RAISE VEHICLE
NOTICE: Be sure the vehicle is securely supported.

8. REMOVE UNDER COVERS


9. DRAIN TRANSAXLE AND DIFFERENTIAL OIL
10. DISCONNECT LEFT DRIVE SHAFT
(See page SA-22 )
HINT: Suspend the drive shaft with cord.

11. DISCONNECT RIGHT DRIVE SHAFT


(See page SA-22 )
HINT: Suspend the drive shaft with cord.

12. DISCONNECT CONTROL CABLE


(a) Remove the clip from the control cable.

AX-39
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

(b) Disconnect the control cable from the lever.

13. DISCONNECT OIL COOLER HOSE FROM PIPE

14. REMOVE FRONT EXHAUST PIPE


(a) Remove the 3 bolts from engine.
(b) Disconnect the oxygen sensor connector.

(c) Remove the 2 bolts from rear exhaust pipe.

15. DISCONNECT PARK/NEUTRAL POSITION SWITCH


CONNECTOR

AX-40
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

16. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS


(a) Turn the crankshaft to gain access to each bolt.
(b) Hold the crankshaft pulley nut with a wrench and
remove the 6 bolts.

17. DISCONNECT BOND CABLE FROM LH ENGINE


MOUNTING BRACKET

18. DISCONNECT LH ENGINE MOUNTING


Remove the 2 mounting bolts.

19. REMOVE ENGINE REAR MOUNTING BRACKET


(a) Hold the engine and transaxle with 2 jacks, or a chain
block and jack.

(b) Remove the 3 bolts and disconnect the rear mounting


bracket from the body.

AX-41
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

20. REMOVE TRANSAXLE MOUNTING BOLTS


21. REMOVE TORQUE CONVERTER CLUTCH FROM
TRANSAXLE

TORQUE CONVERTER CLUTCH CLEANING


If the transaxle is contaminated, the torque converter
clutch and transaxle cooler should be thoroughly flushed with ATF.

TORQUE CONVERTER CLUTCH AND DRIVE


PLATE INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter
hob and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held up right, the
clutch should lock when turned counterclockwise,
and should rotate freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.

2. MEASURE DRIVE PLATE RUNOUT AND INSPECT


RING GEAR
Set up a dial indicator and measure the drive plate
runout.
If runout exceeds 0.20 mm (0.0079 in.) or if the ring
gear is damaged, replace the drive plate. If installing a
new drive plate, note the orientation of the spacers
and tighten the bolts.
Torque: 88 N-m (900 kgf-cm, 65 ft-lbf)

AX-42
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE


RUNOUT
(a) Temporarily mount the torque converter clutch to the
drive plate. Set up a dial indicator.
Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

If runout exceeds 0.30 mm (0.0118 in.) try to correct


it by reorienting the installation of the converter. If
excessive runout cannot by corrected, replace the
torque converter clutch.
HINT: Mark the position of the converter to ensure
correct installation.
(b) Remove the torque converter clutch from the drive
plate.

TRANSAXLE INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH IN TRANSAXLE
If the torque converter clutch has been drained and
washed, refill with new ATF.
Fluid type:
ATF DEXRON II

2. CHECK TORQUE CONVERTER CLUTCH INSTALLATION


Using calipers and a straight edge, measure from the
installed surface to the front surface of the transaxle
housing.
Correct distance:
More than 13.4 mm (0.528 in.)

3. ALIGN TRANSAXLE AT INSTALLATION POSITION


(a) Align the 2 knock pins on the block with the converter
housing.
(b) Temporarily install 1 bolt.
4. INSTALL TRANSAXLE HOUSING MOUNTING
BOLTS
Install the transaxle housing mounting bolts.
Torque: 12 mm 64 N-m (650 kgf-cm, 47 ft-lbf)

AX-43
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

5. CONNECT LH MOUNTING BRACKET


(a) Install the LH engine mounting bracket with 2 bolts.
Torque the 2 bolts.
Torque: 43 N-m (440 kgf-cm, 32 ft-lbf)

(b) Connect the bond cable with the bolt.

6. CONNECT REAR MOUNTING BRACKET


Install the rear mounting bracket with 3 bolts.
Torque the bolts.
Torque: 73 N-m (740 kgf-cm, 54 ft-lbf)

7. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS


(a) First, install the gray bolt and then the 5 black bolts.
(b) Tighten the bolts evenly.
Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

8. INSTALL ENGINE REAR END PLATE


9. INSTALL FRONT EXHAUST PIPE
(a) Install the bolts.
Torque: 62 N-m (630 kgf-cm, 46 ft-lbf)

(b) Install the bolts.


Torque: 62 N-m (630 kgf-cm, 46 ft-lbf)

(c) Connect the oxygen sensor connector.


10. CONNECT PARK/ NEUTRAL POSITION SWITCH
CONNECTOR

AX-44
AUTOMATIC TRANSAXLE

ASSEMBLY REMOVAL AND INSTALLATION

11. CONNECT OIL COOLER HOSE TO PIPE

12. CONNECT CONTROL CABLE


(a) Connect the control cable to the lever.
(b) Install the clip to the control cable.
13. CONNECT PARK / NEUTRAL POSITION SWITCH
CONNECTOR

14. INSTALL DRIVE SHAFT


(See page SA-26 )
15. INSTALL ENGINE UNDER COVER

16. FILL DIFFERENTIAL


Fluid Type:
ATF DEXRON ll
Differential Fluid Capacity:
1.4 liters (1.5 US qts, 1.2 Imp.qts)
17. CHECK DIFFERENTIAL FLUID LEVEL
(See page AX-12 )

18. INSTALL STARTER


(a) Install the starter with 2 bolts.
(b) Connect the 2 connector.
19. INSTALL UPPER SIDE MOUNTING BOLTS
20. CONNECT SPEEDOMETER CABLE

AX-45
AUTOMATIC TRANSAXLE

21.
22.
23.
24.

ASSEMBLY REMOVAL AND INSTALLATION

INSTALL AND ADJUST THROTTLE CABLE


INSTALL AIR DUCT
INSTALL BATTERY AND CONNECT
NEGATIVE BATTERY TERMINAL

25. FILL TRANSAXLE


Fluid type:
ATF DEXRON ll
Automatic Transaxle Fluid Capacity:
5.5 liters (5.8 US qts, 4.8 Imp.qts)

26. CHECK FLUID LEVEL


(See page AX-1 1)

AX-46
AUTOMATIC TRANSAXLE

SHIFT LOCK SYSTEM


COMPONENT

WIRING DIAGRAM

SHIFT LOCK SYSTEM

AX-47
AUTOMATIC TRANSAXLE

SHIFT LOCK SYSTEM

SHIFT LOCK SOLENOID INSPECTION


INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between
terminals.
Standard resistance:
30-35 

(c) Apply battery positive voltage between terminals.


Check that an operation noise can be heard from the
solenoid.

SHIFT CONTROL ECU INSPECTION


INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminals.
HINT: Do not disconnect the ECU connector.

Connector

Terminal
ACC -E
IG - E
STP-E

Measuring condition

Voltage (V)

Ignition switch ACC position

10- 14

ignition switch ON position

10- 14

Depress brake pedal

10- 14

(1) Ignition switch ACC position and P position


KLS - E

(2) Ignition switch ACC position and except P position


(Approx-after one second)

8 - 14
6-9

(1) Ignition switch ON position and P position


SLS (+) - SLS (-)

(2) Depress brake pedal

8.5- 13.5
(Approx-after 20 seconds)

5.5 - 9.5

(4) Except P position


P1 - P
P2-P 1

(1) Ignition switch ON, P position and depress brake pedal


(2) Except P position

9 - 13.5

(3) Ignition switch ACC position and P position

9 - 13.5

(4) Except P position

AX-48
AUTOMATIC TRANSAXLE

SHIFT LOCK SYSTEM

KEY INTER LOCK SOLENOID INSPECTION


1. INSPECT KEY INTER LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between
terminals.
Standard resistance:
12.5-16.5 

(c) Apply battery positive voltage between terminals.


Check that an operation noise can be heard from the
solenoid.

2. INSPECT SHIFT LOCK CONTROL SWITCH


Check whether there is continuity between each terminal.
Tester condition to
terminal number

Specified value

P position (Release
button is not pushed)

P-P 1

Continuity

R position (Release
button is pushed)

P-P 1
P-P 2

Continuity

R, N, D, 2, L position

P-P 2

Continuity

Shift position

AX-49
AUTOMATIC TRANSAXLE

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
SERVICE DATA
Governor Pressure
Counter drive gear
1,000 rpm
1,800 rpm
3,500 rpm
Counter drive gear
1,000 rpm
1,800 rpm
3,500 rpm

(Vehicle speed reference)


Except Puerto Rico
30 km/h (19 mph)
54 km/h (34 mph)
105 km/h (65 mph)
Puerto Rico
27 km/h (17 mph)
49 km/h (31 mph)
96 km/h (60 mph)

Line pressure (wheel locked)

Engine idling
D position
R position

0.5-1.3 kgf/cm2
1.5-2.3 kgf/cm2
4.2-5.0 kgf/cm2

7-19 psi
21-33 psi
60-71 psi

49-127 kPa
147-226 kPa
412 -490kPa

0.5-1.3 kgf/cm2
1.5 - 2.3 kgf/cm2
4.2 - 5.0 kgf/cm2

7-19 psi
21 -33 psi
60-71 psi

363-422 kPa
530-706 kPa

3.7 -4.3 kgf/cm2


5.4-7.2 kgf/cm2

53-61 psi
77-102 psi

9.2-10.7 kgf/cm2
14.4-16.8 kgf/cm2

131-152 psi
205 - 239 psi

49-127 kPa
147-226 kPa
412-490 kPa

AT stall (Throttle valve fully opened)


D position
R position

902 -1,049 kPa


1,412-1,648 kPa

2,400200 rpm

Engine stall revolution


N position D position
N position R position

Time lag

Less than 1.2 seconds


Less than 1.5 seconds

Engine idle speed (Cooling fan and A/C OFF)


N position
Throttle cable adjustment (Throttle valve fully opened)
Torque converter clutch sleeve runout
Drive plate runout

800 rpm
Between boot and face and inner cable stopper
0-1 mm
0-0.04 in.
0.30 mm
0.20 mm

Limit
Limit

0.0118 in.
0.0079 in.

SHIFT POINT
Except Puerto Rico
Shift position

Shifting point
Throttle valve fully opened

D position
Throttle valve fully closed

L position

Throttle valve fully opened

Vehicle speed km/h (mph)


12
23
32
21
Lock-up ON
Lock -up OFF
21

51 -64 (32-40)
98-1 11 (61- 69)
92-107 (57-66)
37-45 (23-28)
77-84 (48-52)
72-79 (45-49)
40-48 (25-30)

Puerto Rico
Shift position

Shifting point
Throttle valve fully opened

D position
Throttle valve fully closed

L position

Throttle valve fully opened

Vehicle speed km/h (mph)


12
23
32
21
Lock -up ON
Lock -up OFF
21

47-59 (29-37)
90-100 (56-62)
84-99 (52-62)
34-41 (21 -25)
70-77 (43-48)
66-72 (41 -45)
36-44 (22-27)

AX-50
AUTOMATIC TRANSAXLE

SERVICE SPECIFICATIONS

TORQUE SPECIFICATIONS
N-m

Part tightened

kgf-cm

Engine rear mounting bracket x Engine

590

Engine rear mounting bracket x Body

740

LH engine mounting

440

Transaxle x Engine

12 mm bolt
10 mm bolt

64
34

650
350

Torque converter clutch x Drive plate

185

Valve body x Transaxle case

100

Oil strainer

100

ft-lbf

47
25

43 in.-lbf

Oil pan
500

Oil pan drain plug

275

Cooler pipe union nut


Testing plug

7.4

65 in.-lbf

Parking lock pawl bracket

7.4

65 in.-lbf
250

Transaxle rear cover x Transaxle case


Park/Neutral position switch x Transaxle case (bolt)
Park/Neutral position switch (nut)

5.4

48 in.-lbf

6.9

61 in.-lbf