INTRODUCTION RE4RO1A This new Nissan transmission is a fully computerized 4 speed automatic overdrive unit. It is currently found in the 240SX and Path Finder vehicles. We have included some of the basic self diagnosing information. We thank Nissan motor company for the illustrations and infor- mation that make this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT. FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL CONSULTANT WELDON BARNETT ED KRUSE TECHNICAL CONSULTANT LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP AUSTRALIAN DISTRIBUTORS 9200 SOUTH DADELAND BLVD. 4-6 Coles Parade SUITE 720 Newport Beach 2106 MIAMI, FLORIDA 33156 AUSTRALIA (305) 661-4161s “OMATIC TRANSMISSION SERVICE GS INDEX RE4RO1A DIAGNOSIS A\T ELECTRICAL PARTS .. SELF DIAGNOSIS .... HYDRAULIC LAYOUT nn CIRCUIT DIAGRAMS ‘TEAR DOWN - ASSEMBLY CONTROL VALE BODY CLUTCH PACKS .. ‘SPECIFICATIONS - ADJUSTMENTS .. LINE PRESSURE .... SOLENOID TESTS . AUTOMATIC TRANSMISSION SERVICE GROUP 15 16 92 95. 96ATSG Technical Service Information Symptom Chart evs | fan eeonvememiees i sammenrenermmn ae La Wt Hada li AS IBREHI ie lula} ATT ak iy! HEUTE CLE EE EE EEL Le ESE EE on “fea: | ee SIC eee eee eo ae Seven ciimereneee TT a abe dle fed. [eal] |- Jo commer lol TE [ale Sone coacueemml el miele ele clea}. 0 See ph i aclot le a 7 f ee = =e eee SE Ets Sere ae ran 8, 88s U.P LBL Pal - cam manner aninatmariasmesror, TT Ty Ws lo cor aan eee tee wefe af. cf. alae}. cf. -@}- AUTOMATIC TRANSMISSION SERVICE GROUP 3Technical Service Information Symptom Chart (Cont'd) ee | Nigrekach Ford exch Creme Eran ig ro Tack mteeis rer cto lr uh ent 8 [Prone ewer men) trowOy 10 Oy : veal. [ale old. q wpermeremrommiesime Te LTT TTT | lod. [alo Yrmomeremrommrmenere Ly LL ET TTT] Vorcebrtesby percha tomo, |, Joa]ATSG Technical Service Information Symptom Chart (Cont'd) Jp or pr aten af ‘vein wren send or Comer tae Senora ner ne Fa : an na ron Oferta ane a aa chee Pe alee |e eae |e ove [ae foe |e rene enone Dane AUTOMATIC TRANSMISSION SERVICE GROUP 54 aTsG Technical Service Information A/T Electrical Parts Locat = Lo — _l aie ~\ hc | i euTechnical Service Information Self Diagnosis Inspection ‘The following procedure is used to select self diagnosis DIAGNOSIS START ‘tar engine and warm it up to normal engine operating temperature, oY = [_ Sei power shift switch in "AUTO" position. Nove selector lever to“ range cain (Barrons fener ne ne nor about 2 seconds? Yes ceeeeemeemney Nos Rafer to service manual Self Diagnosis Inspection Move selector ver to" O" rane o 6 | Mowe selector ver a [Se power sit aniteh in "POWER postion} jf ‘Check power shift indicator lamp. eer to JUDGEMENT OF SELF DIAGNOSIS CODE. Deoress lease aT] END. AUTOMATIC TRANSMISSION SERVICE GROUP 8Technical Service Information Power shift indicator lamp All judgement tickers are same. Damaged cieuit ‘Siar agra TOjcdaerent ticks ‘at judgement ticket tonger than All circuits that can be confirmed by slt.diagnoss are ox. Revolution tensor eeu is short lreuited or discon ected. a — a onl ] © Go to revolution sensor eieuit check. 2nd judgement tickers longer than | Speed sensor circuit is short circuited or disconnected, others aa soma cans 20 Shue! 1 Go to speed semor circuit check ty = 25 seconds ty = 20 seconde 3rd judgement licker is longer than ls short-circuited or disconnected At contrat ty = 10 second 7 1 Go to throttle sensor eiceuit check For circuit checks, see the Factory Service Manual. AUTOMATIC TRANSMISSION SERVICE GROUP 9ATSG Technical Service Information wees = we an Light " AIT control unit e shade ® Go to shift solenoid A circuit check. Sth judgement flicker is longer than | Shift solenoid 8 circuit is short-circuited or disconnected. Cie Shit olenois 8 ee esses a Yrowen = eo FTTt [termina 1 Go to shift solenoid B circuit check {th judgement flicker is longer than | Overrun eluteh solenoid circuit is short-circuited or dis: others. connected, ee = [rower |= TMI ae §® Go to overrun clutch solenoid circuit check. pate me coasiembiy L 1 Go to lock-up solenoid circuit check, AUTOMATIC TRANSMISSION SERVICE GROUP 10TSG Technical Service Information Power shift indieatar amp: Damaged circuit ‘th judgement Hicker i fonger than others. Ly sna Fluid temperature sensor is disconnected or A/T contro! ‘nit power source circuit is damage. ower source ciruit chee ‘th judgement Hicker i Songer than other LT TLL, = 3 TN Engine revolution signl circuit it short-circuited ods: connected {© Go to engine revolution signal eicuit check 10th judgement Hicker is longer than others I Line pesure solenoid et sort eeuited dion rected tee fre | ois {© Go 10 tine pressure solenoid circuit check. Flickers as shown below. spits afro npn TT Battery power is ow. Battery has been disconnected for slong time, Battery is connected conversly {wen reconnecting A/T control unit connectors, ~ This ‘snot a problem} t= 10 second For circuit checks, see the Factory Service Manual. AUTOMATIC TRANSMISSION SERVICE GROUP itTSG Technical Service Information TORQUE CONVERTER LOCK-UP CONTROL Revolution sensor Throttle sensor Lock-up solenoid Engine RPM signal ar x Inhibitor switch J+} contrat nit ‘Shuttle shift valve Power shift switch 7 is Oil temperature sensor [E{Lock-up ‘control V. =a relet V. (CTorque converter) Torque converter lock-up occurs in 4th gear (0.D.) only and is controlled by the automatic transmission unit after first processing signals from various input sensors in conjunction with its preprogrammed memory data. The control unit then energizes a solenoid valve, retracting its plunger, thus draining pilot pressure via the shuttle shift valve from one end of the lock-up control valve, The control valve then moves, draining torque converter pressure from the rear side of the lock-up piston. Tackp rene ‘a Sa onditions for Operation _ Conditions for Leck-Up Operation Power shift switch ‘Auto Torque converter lock-up will only Select lever range occur when all of the conditions Gear position ain listed are met. (Refer also shift Vehicle speed ore than set value Schedule) Throttle sensor Tess than set opening Oil temperature More than 40°C AUTOMATIC TRANSMISSION SERVICE GROUP 12Technical Service Information ‘SHIFT SCHEDULE CONTROL ‘The transmission gear change points are determined by the automatic trans- mission control unit after first processing information from various input sensors in conjunction with the control unit memory data on basic gear change points. The control unit then, either energizes or de-energizes shift solenoids A and/or B, thus applying or releasing pilot pressure to shift valves A and/or B. Vehicle speed 4 Revolstion sensor pYehisle speed aes =) t Throttle openin 1<|2 gs] t Throttle sensor 8, i]s] e]s] t angle (Ble! ele| 3 Select lever e/s| Ble] inhibitor witch 51a) 2/8 meee tors) ar | ET gL Power shift switch pSwitch position.) unit : z ' Ht & t Te it Sor ore ~ a femperature sen as Relationship of shift Solenoid to Gear Selection Shift Solenoid | 01.21.) | D2, 23,12 D; 0, (00) NP R A ON OFF OFF oN ON on 8 ‘oN on OFF OFF on oN NOTE: Gear selection is also relevant to manual valve position. Shift Solenoid Operation The shift solenoid performs 2 simple on/off function. When energized (on), its plunger protrudes blocking the drain on the pilot pressure line. When de-energized (off), the plunger retracts opening the drain on the pilot pressure line. Shift Valves A and B Operation Pilot pressure, when applied to the shift valve due to the operation of a solenoid valve, acts on the end of the shift valve, overcomes the opposing spring pressure at the other end and the valve moves. u AUTOMATIC TRANSMISSION SERVICE GROUP BATSG Technical Service Information Electrical Control Chart = Erctcl sing vance sna! > Horne preseure — h — es Cara N Overdrive off switch T Sa indicator lamp] Fa BY | cone spat Tae swtes |! [ vwnttor owen | [Shar solenoa a] [Line premre sienaig]' Farprone—] | Fluid emoeratur| | — syn solmoia 8 ----f---! a ‘Overrun elutzh GS Terotie 5955] | | Reso ‘elenoid 1 PPgpeie Co Souter 1 | _ resistor rat | Leckup soared ‘ POS 1A contrat unt Mechnical Operation Bend ene Focwars| Low | Lows smite [Reverse | ign | Forward [overrun onion | clutch | ctutch | cturen | eivten | and | ara | am |oneaiy joneway | reverse [Lockup | Remarks aooly | release | apply | “‘uteh | chute = PARK R ° © REVERSE n NEUTRAL ie ° ele o [pw Oo fyo | o e “Dor ol o [bo [2 [oe e “7 o[e =3@ | @ | 0 ° > ole ele Automate sit 2nd ofTofo e 1? 1 o [0 e o ers a 5 Sorin 2nd ° e peed ‘TGiwnn wlon rece naan eS "2. Oil oresure is applied to both 2nd “apply” side and 3rd “release side of band servo piston, However, because oil presture arta on the aus ide is grater than that on the “apply” side, brake band doesnot contract, 13. Oil premure i apptied to 4th “apply” sie in condition °2 above, and brake band contracts 4. AIT will not snl 10 4th when overdrive switch i sat t0 “OFF” postion. Operates. Operates when throttle opening it lss the Operates during “progressive” acceleration. Operates but does not stfect power transmission ‘Operates when throttle opening is lss than 1/16 but dome not affect engine brake. AUTOMATIC TRANSMISSION SERVICE GROUP 14 @80@00Technical Service Information RE4ROIA Hydraulic Layout AUTOMATIC TRANSMISSION SERVICE GROUP 1sTSG Technical Service Information Wiring Diagram COMBINATION NETER ae) ee sles a BeE ba] | eg) © E el |S t iS [pee = ere te Ee ingtrument harness) te) TONITION oetTon Biscn ON or sEARY @ 1%@ 1 ea Ib ee fn Oma Hat ot fe POWER ogg ONITION COIL] TmarTE AUTOMATIC TRANSMISSION SERVICE GROUP 16Wiring Diagram COMBINATION METER TSG Technical Service Information SRT laser wee (BT ae fel Fe Be) ee) | sg 8 iF od \ es ef of) ai] [teed [ER ERO! wee Og: @. 1@ PR | WREST | d LU oHee elec t 1 Oh or sPaar" @ aE] aye | ape : & uh be « he ey [| bE 55 uh conn ui T 1GNITION con] esisto “| ee AUTOMATIC TRANSMISSION SERVICE GROUP 16 eysane EEReEa runeTechnical Service Information Wiring Diagram (Cont'd) sag Esa] AAT contno. unit fl H Cd 2 Potdout page to" @ wns su oo AUTOMATIC TRANSMISSION SERVICE GROUP 7Technical Service Information Circuit Diagram for Quick Pin Point Check FSH Tes @ EH [5 lig 8 Beare EDs ee sf a Ei FE ON core wt TREE Si ron Lei) £8. ge a : ef Ft. cose we oe” on SENSOR . : " a SHIFT SOLENOIO 8 e+ ‘ " : Oa” SMiFT soLEnoro & KioKooms sw To 5 al 8 90 #@@ a AUTOMATIC TRANSMISSION SERVICE GROUP 18ATSG Technical Service Information MAJOR OVERHAUL Locations of Needle Bearings, Thrust Washers and Snap Rings 2001 209) 7813.07) 5312.09) 392.32) oa 150.2 (627) oor Bieck Wine AUTOMATIC TRANSMISSION SERVICE GROUP 19Technical Service Information DISASSEMBLY Disassembly 1. Remove torque converter by holding it firmly and turning while pulling straight out. revaii02100 2. Check torque converter one-way clutch. Us7055) (Rows! | a. Insert Too! into spline of one-way clutch inner race. i Hoh) b. Hook bearing support unitized with one-way clutch outer race with suitable wire. ©. Check that one-way clutch inner race rotates only clockwise with Tool while holding bearing support with wire 3. Remove inhibitor switch from transmission case. 4. Remove oil pan. Drain A.T.F. from rear extension, Raise oll pan by placing wooden blocks under converter housing and rear extension. ‘Separate the oil pan and transmission case. ‘Always place oll pan straight down so that foreign parti- cles Inside will not mov ge 5. Place transmission into Tool with the control valve facing up. AUTOMATIC TRANSMISSION SERVICE GROUP 20Technical Service Information DISASSEMBLY Disassembly (Cont'd) 6. Check oil pan and oil strainer for accumulation of foreign particles. (© If materials of clutch facing are found, clutch plates may be If metal filings are found, clutch plates, brake bands, etc. may be worn, ‘© If aluminum flings are found, bushings or aluminum cast parts may be worn. In above cases, replace torque converter and check unit for cause of particle accumulation. 7. Remove lock-up solenoid and fiuid temperature sensor connectors. © Be careful not to damage connector. Remove oil strainer. Remove oil strainer trom control valve assembly. Then remove O-ring trom oil strainer. Check oil strainer screen for damage. 9. Remove control valve assembly. Straighten terminal clips to free terminal cords then remove terminal clips. AUTOMATIC TRANSMISSION SERVICE GROUP 21Technical Service Information Disassembly (Cont'd) b. Remove bolts @ and @, and remove control valve as- sembly from transmission. Bort Lenath @ 37 mam © 50 mm ¢. Remove solenoid connector. ‘© Be careful not to damage connector. d. Remove manual valve from control valve assembly. 10, Remove terminal cord assembly from transmission case while pushing on stopper. © Be careful not to damage cord. not remove terminal cord assembly unless it is dam- ed. AUTOMATIC TRANSMISSION SERVICE GROUP 22Technical Service Information Disassembly (Cont'd) 11, Remove converter housing, ‘a. Remove converter housing from transmission case. b. Remove O-rings from converter housing c. Remove traces of sealant. ‘© Be careful not to scratch converter housing. 12, Remove O-ring from input shaft 13, Remove oil pump assembly. a. Attach Tool to oll pump assembly and extract it evenly from transmission case. b. Remove O-ring from oil pump assembly. ©. Remove traces of sealant from oil pump housing © Be careful not to scratch pump housing. AUTOMATIC TRANSMISSION SERVICE GROUP 23Technical Service Information Disassembly (Cont'd) 4. Remove needle bearing and thrust washer from oll pump assembly 14, Remove input shaft and oil pump gasket. 15, Remove brake band and band strut. ‘a. Loosen lock nut and remove band servo anchor end pin from transmission case. b. Remove brake band and band strut from transmission case c. Hold brake band in a circular shape with clip AUTOMATIC TRANSMISSION SERVICE GROUP 24Technical Service Information Disassembly (Cont'd) 16. Remove front side clutch and gear components a Remove clutch pack (reverse clutch, high clutch and front sun gear) from transmission case. b. Remove front bearing race from clutch pack ¢. Remove rear bearing race from clutch pack. d. Remove front planetary carrier from transmission case. fe. Remove front needle bearing from front planetary carrier f. Remove rear bearing from front planetary carrier g. Remove rear sun gear from transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 25rear extension. fear extension from transmission case. rear extension gasket from transmission case. ¢. Remove oll seal from rear extension. ‘© Do not remove oil seal unless it is to be replaced. d. Remove revolution sensor from rear extension @. Remove O-ring from revolution sensor. 18. Remove output shaft and parking gear. a. Remove rear snap ring from output shaft. b. Slowly push output shaft all the way forward. © Do not use excessive force. . Remove snap ring from output shaft. AUTOMATIC TRANSMISSION SERVICE GROUP 26\Iy7 J \ =] Technical Service Information Disassembly (Cont'd) d. Remove output shaft and parking gear as a unit from transmission case. 2, Remove parking gear from output shatt 1. Remove needle bearing from transmission case. 19, Remove rear side clutch and gear components. a. Remove front internal gear. b. Remove bearing race from front i ¢. Remove needle bearing from rear internal gear. AUTOMATIC TRANSMISSION SERVICE GROUP 27ATSG Technical Service Information Disassembly (Cont'd) d. Remove rear internal gear, forward clutch hub and overrun clutch hub as a set from transmission case Remove needle bearing from overrun clutch hub. Remove overrun clutch hub from rear internal gear and forward clutch hub. Remove thrust washer from overrun clutch hub. Remove forward clutch assembly from transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 28Technical Service Information Disassembly (Cont'd) 20. Remove band servo and accumulator components. ‘a. Remove band servo retainer from transmission case. b. Apply compressed air to oll hole until band servo piston comes out of transmission case. Hold piston with and gradually direct air to oil hole. Remove return springs. d. Remove springs from accumulator pistons B, C and D. fe. Apply compressed air to each oil hole until piston comes out © Hold piston with @ rag and gradually direct air to oil hole. Identification of accumulator pistons avtefle lo Identification of oil holes 2f[ele le f. Remove O-ring from each piston Front a neat poe = iB ont ae ston prston © 21, Remove manual shaft components, if necessary a. Hold width across flats of manual shaft (outside the trans- mission case) and remove lock nut from shaft. AUTOMATIC TRANSMISSION SERVICE GROUP 29ATSG Technical Service Information ll Pump Frito ng B® TI Wm hon, 8) oa ID: roo Ate feu) HED | Naty onvcium in | Ot pump housing fend EO on OED | Seve! BEI @ —_O8pu cover wembiy ving cam | tetas, nes) High eluten string ome vena cut sel rine (BNE DISASSEMBLY 1. Loosen bolts in numerical order and remove oil pump cover. 2. Remove rotor, vane rings and vanes. ‘@ inscribe a mark on back of rotor for identification of fore-aft direction when reassembling rotor. Then remove rotor. 3. While pushing on cam ring remove pivot pin. ‘© Be careful not to scratch oll pump housing. AUTOMATIC TRANSMISSION SERVICE GROUP 31Technical Service Information Disassembly (Cont'd) b. Remove retaining pin trom transmission case. Retaning pm, OF eal Soa LAL ee While pushing detent spring down, remove manual plate and parking rod from transmission case. Remove manual shaft from transmission case. 2 Remove spacer and detent spring trom transmission case. Remove oil seal from transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 30ATSG Technical Service Information ll Pump ao 2m cmpam ge ar —— ‘ewe om GD | —— pe | 16.21 (6-24, 12-18) High eaten seating ome o—— Revere cutch 4a ng (2) MEL ® DISASSEMBLY 1. Loosen bolts in numerical order and remove oil pump cover. Remove rotor, vane rings and vanes. Inserlbe @ mark on back of rotor for identification of fore-att direction when reassembling rotor. Then remove rotor. While pushing on cam ring remove pivot pin. Be careful not to scratch oll pump housing. AUTOMATIC TRANSMISSION SERVICE GROUP 31Technical Service Information Oil Pump (Cont'd) 4. While holding cam ring and spring lift out cam ring spring, © Be careful not to damage oil pump housing. @ Hold cam ring spring to prevent it from jumping. Remove cam ring and cam ring spring from oil pump housing, Remove pivot pin from control piston and remove contro! piston assembly, Remove oil seal from oll pump housing, Be careful not to scratch oll pump housing. INSPECTION il pump cover, rotor, vanes, control piston, side seals, cam ring and friction ring © Check for wear or damage AUTOMATIC TRANSMISSION SERVICE GROUP 32Dat naeator a ) —_staignt esge ‘ot pune im tng te Pousa Technical Service Information Oil Pump (Cont'd) Side clearance ‘@ Measure side clearances between end of oil pump housing land cam ring, rotor, vanes and control piston in at least four places along their circumferences. Maximum measured val- ues should be within specified ranges. © Before measuring side clearance, check that friction rings, O-ring, control piston side seals and cam ring spring are removed. ‘Standard clearance: Cam ring 0.01 - 0.024 mm (0.0004 - 0.0009 in) Rotor, vanes, control piston (0.03 - 0,044 mm (0.0012 - 0.0017 in) @ ‘if not within standard clearance, replace oil pump assembly except oil pump cover assembly, Seal © Measu’ between seal ring and ring groove ‘Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Wear limi 0.25 mm (0.0098 in) © If not within wear limit, replace oil pump cover assembly. ASSEMBLY 1. Drive oil seal into oil pump housing. © Apply A..F. to outer periphery and lip surface. 2. Install cam cing in oll pump housing by the following stops a. Install side seal on control piston ‘@ Pay attention to its direction — Black surface goes toward + control piston. © Apply petroleum jelly to side seal. b. Install contro! piston on oil pump AUTOMATIC TRANSMISSION SERVICE GROUP 33Technical Service Information Oll Pump (Cont'd) ‘¢. Install O-ring and friction ring on cam ring. © Apply petroleum jelly to O-ring. d. Assemble cam ring, cam ring spring and spring seat. Install spring by pushing it against pump housing. ‘@. While pushing on cam ring install pivot pin. Install rotor, vanes and vane rings. Pay attention to direction of rotor. Install oil pump housing and oil pump cover. Wrap masking tape around splines of oll pump cover assembly to protect seal. Position oil pump cover assembly in oll pump housing assembly, then remove masking tape. Tighten bolts in a criss-cross pattern, AUTOMATIC TRANSMISSION SERVICE GROUP 34Technical Service Information ‘Oll Pump (Cont'd) 5. Install seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. @ Seal rings come in two different diameters. Check ft carefully In each groove. ‘Small dla. seal ring: No mark Large dia. seal Yellow mark ir @ Do not spread gap of it may deform ring. 1a shown by arrow ring excessively while installing. AUTOMATIC TRANSMISSION SERVICE GROUP 35TSG Technical Service Information Control Valve Assembly Loekup solenos Timm 9 137 9 o-me 6 Lower separate gasket 6% Upper separate gasket oy So alate Suppor pates —steet van AUTOMATIC TRANSMISSION SERVICE GROUP 36Technical Service Information Control Valve Assembly (Cont'd) DISASSEMBLY 1. Remove solenoids. a. Remove lock-up solenoid and side plate from lower body. b. Remove O-ring from solenoid. c. Remove line pressure solenoid trom upper body. d. Remove O-ring from solenoid e. Remove 3-unit solenoid assembly from upper body. Remove O-rings from solenoids. ‘sono 2. Disassemble upper and lower bodies. a. Place upper body facedown, and remove bolts, reamer bolts and support plates. b. Remove lower body, separator plate and separate gasket as ‘a unit from upper body. © Be careful not to drop pilot filter, orifice check valve, spring and steel balls. ¢. Place lower body facedown, and remove separate gasket and separator plate. 4. Remove pilot filter, orifice check valve and orifice check spring, AUTOMATIC TRANSMISSION SERVICE GROUP 37Technical Service Information Control Valve Assembly (Cont'd) ©. Check to see that steel balls are properly positioned in upper body and then remove them from upper body INSPECTION Lower and upper bodies © Check to see that there are pins and retainer plates in lower body. © Check to see that there are pins and retainer plates in upper body. © Be careful not to lose these parts. © Check to make sure that oil circuits are clean and free from damage. @ Check tube brackets and tube connectors for damage. Separator plates © Check to make sure that separator plate is free of damage and not deformed and oil holes are clean, AUTOMATIC TRANSMISSION SERVICE GROUP 38ATSG Technical Service Information Control Valve Assembly (Cont'd) Pilot filter @ Check to make sure that filter is not clogged or damaged, Lock-up solenoid ‘© Check that filter is not clogged or damaged. Measure resistance. — Refer to “Electrical Components Inspection’ Line pressure solenoid © Check that fer is not clogged or damaged. Measure resistance. — Refer to “Electrical Components Inspection”. S-unit solenold assembly (Overrun clutch solenoid and shift solenoids A and B) ‘© Measure resistance of each solenoid, — Refer to “Electrical Components Inspection”. Fluid temperature sensor @ Measure resistance. — Refer to “Electrical Components Inspection”. AUTOMATIC TRANSMISSION SERVICE GROUP 39Technical Service Information Control Valve Assembly (Cont'd) ASSEMBLY 1. Install upper and lower bodies a. Place oil circuit of upper body face up. Install steel balls in their proper positions. Install reamer bolts from bottom of upper body and install separate gaskets. Reamer ol (anor . Place oil circuit of lower body face up. install orifice check spring, orifice check vaive and pilot filter = d. Install lower separate gaskets and separator plates on lower body. e. Install and temporarily tighten support plates. fluid tempera- ture sensor and tube brackets. Sane sa E Bort length 37 i108) sat AUTOMATIC TRANSMISSION SERVICE GROUP 40Technical Service Information Control Valve Assembly (Cont'd) 1. Temporarily assemble lower and upper bodies, using reamer bolt as a guide. © Be careful not to dislocate or drop steel balls, orifice check spring, orifice check valve and pilot filter. g. Install and temporarily tighten bolts and tube brackets in their proper locations. Bolt length and location: Bott symbol] Item . © el) 50 33 2 Install solenoids. @. Attach O-ring and install lock-up solenoid and side plates ‘onto lower body. b. Attach O-rings and install 3-unit solenoids assembly onto upper body. ©. Attach O-ring and install ine pressufe solenoid onto upper body. 3, Tighten all bolts. AUTOMATIC TRANSMISSION SERVICE GROUP 41Technical Service Information E4aTsG Control Valve Upper Body aie sumi88 oe mou ye bo 5 Ab oan Dmowmo rye L7, iff LTE Smid suds umoy® 2NMA 19D OH re “Yq ml Dees ea ws sang, / sy /, Spas Lo o $ AUTOMATIC TRANSMISSION SERVICE GROUP 42Technical Service Information Control Valve Upper Body (Cont'd) DISASSEMBLY 1. Remove valves at parallel pins. © Do not use a magnetic hand. a. Use a wire paper clip to push out parallel pins. b. Remove parallel pins while pressing their corresponding plugs and sleeves. © Remove plug slowly to prevent internal parts trom jumping out. ¢. Place mating surface of valve facedown, and remove internal jalve is hard to remove, place valve body facedown ightly tap It with a soft ham ‘careful not to drop or dam . Remove valves at retainer plates. Pry out retainer plate with wire paper clip. Y \ AUTOMATIC TRANSMISSION SERVICE GROUP 43Technical Service Information Control Valve Upper Body (Cont'd) b. Remove retainer plates while holding spring cc. Place mating surface of valve facedown, and remove internal parts, © Ia valve Is hard to remove, lightly tap valve body with a soft hammer. © Be careful not to drop or damage valves, sleeves © 42 sequence valve and relay valve are located tar back in Paral on upper body. If they are hard to remove, carefully push them out using stif wire. © Be careful not to scratch sliding surface of valve with wire. INSPECTION Valve springs © Measure free length and outer diameter of each valve spring Also check for damage or deformation, @ Numbers of each valve spring listed in table below o spas 34 = ay apanne | nsaen | saan ® [casa | aa, To | Beer amsin_]snoe | eowe Dames somes] min | ea © er Tare © an eo <7 soe [Lte0z0 © Paneer | aes | Toere @ ee oe | ateene rn syaana | some] Seman @ [rca Spasina | arene] orem OT ome: [area [asern| pense AUTOMATIC TRANSMISSION SERVICE GROUP 44Technical Service Information VALVE BODY LAYCUT Shute sit ‘s ive B conver overrun eaten feaucing valve AUTOMATIC TRANSMISSION SERVICE GROUP 45Technical Service Information Control Valve Upper Body (Cont'd) ‘ASSEMBLY 1. Lubricate the control valve body and all vaives with ATF. Install control valves by sliding them carefully into thei bores. © Be careful not to scratch or damage valve body. ‘© Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position. Pressure regulator valve © If pressure regulator plug is not centered properly, sleeve cannot be inserted into bore in upper body. If this happens, use vinyl tape wrapped screwdriver to center sleeve unti it can be inserted. © Turn sleeve slightly while installing, Accumulator control plug ‘© Align protrusion of accumulator control sleeve with notch in lug, © Align parallel pin groove in plug with parallel pin, and install accumulator control valve. 2. Install paralle! pins and retainer plates. AUTOMATIC TRANSMISSION SERVICE GROUP 46Technical Service Information Control Valve Upper Body (Cont'd) © While pushing plug, Install parallel pin. 4-2 sequence valve and relay valve ‘© Push 4-2 sequence valve and relay valve with wire wrapped in vinyl tape to prevent scratching valve body. Install paralle! pins. @ Insert retainer plate while pushing spring AUTOMATIC TRANSMISSION SERVICE GROUP 47Technical Service Information 4 ATSG Body Control Valve Lower AUTOMATIC TRANSMISSION SERVICE GROUP 48Technical Service Information Control Valve Lower Body (Cont'd) DISASSEMBLY 1. Remove valves at parallel pins. 2. Remove valves at retainer plates. For removal procedures, reter 10 "DISASSEMBLY" of Con: trol Valve Upper Body. INSPECTION z Valve springs i © Check each valve spring for damage or deformation. Also : measure free length and outer diameter. 3 @ Numbers of each valve spring listed in table below © Free tengin Inspection standard: een Trem oa — Part No, ‘ o @D | Moditier accumulator piston spring si7azatxis | 30511201) | 9.8 (0.386) @ | tstreducing valve spring 31756-41x05 | 25.4 (1.000) | 6.75 (0.2657) ® | 32 timing vaive spring 31742-41x08 | 20.55 (0.8091) | 6.75 (0.2667) @ | Servo charger valve spring airaz-arxos | 230(0.908) | 67 (0.264) © Replace valve springs if deformed or fatigued Control valves @ Check sliding surfaces of control valves, sleeves and plugs for damage. ASSEMBLY © Install contro! valves. For installation procedures, refer to "ASSEMBLY" of Control Valve Upper Body. AUTOMATIC TRANSMISSION SERVICE GROUP 49TSG Technical Service Information Reverse Clutch For the numberof clutch sheet (di driven put, rer tothe below ED doy are 1 Select mah proper thekness, ‘Return spring: Dish plate ose QED pata pe oa iver oe DISASSEMBLY 1. Remove reverse clutch assembly from clutch pack. 2. Check operation of reverse clutch. a. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. Check to see that retaining plate moves to snap ring, It retaining plate does not move to snap ring, D-ring or oil seal may be damaged or fluid may be leaking at piston check ball AUTOMATIC TRANSMISSION SERVICE GROUP 50Technical Service Information Vai 102000 (434788 ane AUTOMATIC Reverse Clutch (Cont'd) 3. Remove drive plates, driven plates, retaining plate, dish plate and snap ring, 4, Remove snap ring from clutch drum while compressing clutch springs. Do not expand snap ring excessively. Remove spring retainer and return spring 6. Install seal ring onto oil pump cover and install reverse clutch drum. While holding piston, gradually apply com- Pressed air to oil hole until piston is removed, © Do not apply compressed air abruptly. 7. Remove D-ring and oil seal from piston. INSPECTION Reverse clutch snap ring and spring retainer © Check for deformation, fatigue or damage. Reverse clutch return springs © Check for deformation or damage. Also measure free length and outside diameter. Inspection standard: Unit: mm (ia) Pars Part No. ° ee Reverse clutch drive plates © Check facing for burns, cracks or damage @ Measure thickness of facing, Thickness of drive plate: Standard value: 2.0 mm (0.079 in) Wear limit: 1.8 mm (0.071 in) © If not within wear limit, replace. Reverse clutch dish plate © Check for deformation or damage. TRANSMISSION SERVICE GROUP 51Technical Service Information To a wala ‘Crack ball Reverse Clutch (Cont'd) Reverse clutch piston ‘© Shake piston to assure that balls are not seized, © Apply compressed air to check ball oll hole opposite the return spring to assure that there is no air leakage. © Also apply compressed air to oil hole on return spring side to assure that air leaks past ball ASSEMBLY 1. Install D-ring and oil seal on piston. © Apply A..F. to both parts. 2. Install piston assembly by turning it slowly and evenly. © Apply ATF. to Inner surface of drum. 3. Install return springs and spring retainer. 4. Install snap ring while compressing clutch springs. AUTOMATIC TRANSMISSION SERVICE GROUP 52Technical Service Information Reverse Clutch (Cont'd) ‘@ Do not align snap ring gap with spring retainer stopper. [samp *d:~ Install drive plates, driven plates, retaining plate and dish | plate ewe plate ren plate Dien plate 6. Install snap ring. 7. Measure clearance between retaining plate and snap ring. If ot within allowable limit, select proper retaining plate. Specified clearance: Standard 0.5 - 0 Allowable 1.2 mm (0.047 in) Retaining plate: Refer to S.D.S. mm (0.020 - 0.031 in) it 8. Check operation of reverse clutch. Refer to "DISASSEMBLY" of Reverse Clutch. AUTOMATIC TRANSMISSION SERVICE GROUP 53ATSG Technical Service Information High Clutch aie ae To Soca seamen ean eee Bere a FE (ont ED re : po! eS vee pie ED : poo aT. | Select with proper thickness. Service procedures for high clutch are essentially the same as those for reverse clutch, with the following exception: © Check of high clutch operation AUTOMATIC TRANSMISSION SERVICE GROUP 34Technical Service Information High Clutch (Cont'd) @ Removal and instalation of return spring vev3n102600 (334268 ane suaesar) ‘@ Inspection of high clutch return springs Unit: mm fi) Inspection standard: Part No. e D 31505-21X03, 22.06 (0.8685) 11.6 (0.457) © Inspection of high clutch drive plate ‘Thickness of drive plate: Standard 1.4 mm (0.055 in) core pate © Measurement of clearance between retaining plat ring ‘Specified clearance: Standard 4.8 - 22 mm (0.071 - 0.087 in) Allowable limit 3.0 mm (0.118 in) Retaining plate: Refer to S.0.S. AUTOMATIC TRANSMISSION SERVICE GROUP 354ATSG Technical Service Information Forward and Overrun Clutches EBD: avo are. = Sect with prope chess AUTOMATIC TRANSMISSION SERVICE GROUP 56Technical Service Information Forward and Overrun Clutches (Cont'd) Service procedures for forward and overrun clutches are es- sentially the same as those for reverse clutch, with the following exception © Check of forward clutch operation Check of overrun clutch operation Removal of forward clutch drum Remove forward clutch drum from transmission case by holding snap ring. Removal of forward clutch and overrun clutch pistons While holding overrun clutch piston, gradually apply com- pressed air t0 oil hole Remove overrun clutch from forward clutch. AUTOMATIC TRANSMISSION SERVICE GROUP 37Technical Service Information Forward and Overrun Clutches (Cont'd) © Removal and installation of return springs SO \ seyatseat00 SSenasone ea © Inspection of forward clutch and overrun clutch return ! _ springs ami Ay i i\ Inspection standard: Unt 8 i rane i 3 ° ° (31505-41X01 (38.77 (1.4083) 9.7 (0.382) Fee mein tt Tess ‘© Inspection of forward clutch drive plates ‘Thickness of drive plate: Standard Facing 2.0 mm (0.079 in) Wear limit 1.8 mm (0.071 in) cave ‘© Inspection of overrun clutch drive plates ‘Thickness of drive plate: ‘Standard Facing 2.0 mm (0.079 in) Wear limit 1.8 mm (0.071 in) © Installation of forward clutch piston and overrun clutch piston 1. Install forward clutch piston by turning it slowly and evenly. © Apply A.T.F. to inner surface of clutch drum. AUTOMATIC TRANSMISSION SERVICE GROUP 58Technical Service Information Forward and Overrun Clutches (Cont'd) '@ Align notch In forward clutch piston with groove in forward clutch drum. 2. Install overrun clutch by turning it slowly and evenly. © Apply A..F. to inner surface of forward clutch piston. © Measurement of clearance between retaining plate and snap ring of overrun clutch 1.0 - 1.4 mm (0.039 - 0.055 in) Allowable limit 2.0 mm (0.079 in) Retaining plate: Refer to S.D.S. © Measurement of clearance between retaining plate and snap ring of forward clutch ‘Specified clearance: ‘Standard 0.45 - 0.85 mm (0.0177 - 0.0335 in) Allowable limit 1.85 mm (0.0728 in) Retaining plate: Refer to S.0.S. AUTOMATIC TRANSMISSION SERVICE GROUP 59Technical Service Information Low & Reverse Brake BD: poo are KEBO: Aovly petroleum ity Select with prope thickness. ‘For the rumber of clutch sheet (rive plate ond ‘even plate refer tothe below crow sation ee mara EERE to nese riven plate iF seeing 4 26Nen Drive plate TE) ae 18-20) Driven piace Direction of oi see DISASSEMBLY 4. Check operation of low and reverse brake. a. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. b. Check to see that retaining plate moves to snap ring. ©. If retaining plate does not move to snap ring, D-ring or oil seal may be damaged or fiuid may be leaking at piston check ball 2. Remove snap ring, low and reverse brake drive plates, riven plates and dish plate. AUTOMATIC TRANSMISSION SERVICE GROUP 60Outer ame ° uu e Technical Service Information Low & Reverse Brake (Cont'd) 3. Remove low one-way clutch inner race, spring retainer and return spring from transmission case. 4, Remove seal rings from low one-way clutch inner race. 5, Remove needle bearing from low one-way clutch inner race. 6. Remove low and reverse brake piston using compressed air. 7. Remove oil seal and D-ring from piston INSPECTION Low and reverse brake snap ring and spring retainer '@ Check for deformation, or damage. Low and reverse brake return springs © Check for deformation or damage. Also measure free length and outside diameter. Inspection standard: Unit:_mm find Part No, @ D 31521-2100 237 (0.933) 11.6 (0.457) Low and reverse brake drive plates © Check facing for burns, cracks or damage. © Measure thickness of facing Thickness of drive plate: ‘Standard value 2.0 mm (0.079 in) limit 1.8 mm (0.071 in) © If not within wear limit, replace Wes AUTOMATIC TRANSMISSION SERVICE GROUP 61Technical Service Information Low & Reverse Brake (Cont'd) Low one-way clutch Inner race © Check frictional surtace of inner race for wear or damage. Install a new seal rings onto low one-way clutch inner race. earance ° qpore © Bo careful not to expend seal ring gap excessively. @ Measure seal ring-to-groove clearance. QYSGA Inspection standard Standard value: 0.10 - 0.25 mm (0.0039 - 0.0088 in) Allowable limit: 0.25 mm (0.0098 in) trot within allowable limit, replace low one-way clutch inner race ASSEMBLY Cee 4. Install bearing onto one-way clutch inner race © Pay attention to He dlvection — Black surlace goes to rear side, © Apply petroleum jelly to needle bearing. Install oil seal and D-ring onto piston Apply A.T.F. to oil seal and D-ring. Install piston by rotating it slowly and evenly. Apply A.T.F. to Inner surtace of transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 62Technical Service Information Low & Reverse Brake (Cont'd) 4. Install return springs, spring retainer and low one-way clutch inner race onto transmission case. 5. Install dish plate, low and reverse brake drive plates, driven plates and retaining plate 6. Install snap ring on transmission case. 7. Check operation of low and reverse brake clutch piston, Refer to “DISASSEMBLY”. 8. Measure clearance between retaining plate and snap ring, If not within allowable limit, select proper retaining plate. Specitied clearance: ‘Standard 11 = 1.5 mm (0.043 - 0.059 in) Allowable limit 2.5 mm (0.098 in) Retaining plate: Refer to S.D.S. 9. Install low one-way clutch inner race seal ring © Apply petroleum jelly to seal ring. © Make sure seal rings are pressed firmly into place and held by petroleum jelly. AUTOMATIC TRANSMISSION SERVICE GROUP 63Technical Service Information Forward Clutch Drum Assembly Sap on Fate cuten acum sesembly : Low one-way citer Sie plate ‘soap nog DISASSEMBLY 1, Remove snap ring from forward clutch drum, 2. Remove side plate from forward clutch drum. 3. Remove low one-way clutch from forward clute:. drum AUTOMATIC TRANSMISSION SERVICE GROUP 4Technical Service Information Forward Clutch Drum Assembly (Cont'd) 4, Remove snap ring from forward clutch drum 5. Remove needle bearing from forward clutch drum. INSPECTION Forward clutch drum ‘@ Check spline portion for wear or damage. © Check frictional surfaces of low one-way clutch and needle bearing for wear or damage Needle bearing and low one-way clutch ‘© Check frictional surface for wear or damage ASSEMBLY >) 1. Install needle bearing in forward clutch drum. AUTOMATIC TRANSMISSION SERVICE GROUP 65Technical Service Information Forward Clutch Drum Assembly (Cont'd) 2. Install snap ring onto forward clutch drum. 3. Install low one-way clutch onto forward clutch drum by pushing the roller in evenly. ‘© Install low one-way clutch with flange facing rearward. 4, Install side plate onto forward clutch drum. 5. Install snap ring onto forward clutch drum. AUTOMATIC TRANSMISSION SERVICE GROUP 66Technical Service Information Rear Internal Gear and Forward Clutch Hub Rear internal gear (wth forward onecnay eltch inne race) Treust washer HEAD | Forward ehuleh hub (wth forward one-way clutch outer race) Forward onesway clutch 9090 DISASSEMBLY 1. Remove rear internal gear by pushing forward clutch hub forward. 2. Remove thrust washer from rear internal gear. 3. Remove snap ring from forward clutch hub. ALTOMATIC TRANSMISSION SERVICE GROUP 67Technical Service Information Rear Internal Gear and Forward Clutch Hub (Cont'd) 4. Remove end bearing. 5. Remove forward one-way clutch and end bearing as a unit from forward clutch hub. 6. Remove snap ring from forward clutch hub. INSPECTION Rear internal gear and forward clutch hub ‘@ Check gear for excessive wear, chips or cracks. © Check frictional surfaces of forward one-way clutch and thrust washer for wear or damage. © Check spline for wear or damage. ‘Snap ring and end bearing ‘@ Check for deformation or damage AUTOMATIC TRANSMISSION SERVICE GROUP 68&) Technical Service Information Rear Internal Gear and Forward Clutch Hub (Cont'd) ASSEMBLY 1. Install snap ring onto forward clutch hub 2. Install end bearing. Install forward one-way clutch onto clutch hub. Install forward one-way clutch with flange { Install end bearing Install snap ring onto forward clutch hub rearward, 3 ° 4 5. Install thrust washer onto rear internal gear. Apply petroleum jelly to thrust washer. Securely insert pawls of thrust washer into holes in rear internal gear. 7. Position forward clutch hub in rear internal gear. 8. After installing, check to assure that forward clutch hub rotates clockwise. AUTOMATIC TRANSMISSION SERVICE GROUP 6Seno cushion spring retainer Technical Service Information Band Servo Piston Assembly — Return spring A D-rng €I GID Ho sere pte png rane itn se ome GD eae ons ED oma OD 00. seme ome ED os QD roo are Te Return song © Band sero pston| ‘Servo piston retaner DISASSEMBLY 1. Block one oil hole in ©.D. servo piston retainer and the center hole in O.D. band servo piston. 2. Apply compressed air to the other oil hole in piston retainer to remove O.D. band servo piston from retainer. 3. Remove D-ring from 0.0. band servo piston. 4, Remove band servo piston assembly from servo piston retainer by pushing it forward. Place piston stem end on a wooden block. While pushing ‘servo piston spring retainer down, remove E-ring. eng AUTOMATIC TRANSMISSION SERVICE GROUP 70— e a i—_ } Seno cushion sang rtarer Technical Service Information Band Servo Piston Assembly (Cont'd) 6. Remove servo piston spring retainer, return spring C and piston stem from band servo piston. 7. Remove E-ring from band servo piston 8 Remove servo cushion spring retainer from band servo piston, 9, Remove D-rings from band servo piston. 40. Flemove O-rings from servo piston retainer. INSPECTION Pistons, retainers and piston stem ‘@ Check frictional surfaces for abnormal wear or damat Return springs © Check for deformation or damage. Measure free length and outer diameter. Inspection standard: Units_mm tnd Parte Free length Outer diameter ‘Spring A 45.6 (1.795) 34.3 (1.350) Sorina B 538 2.118) 40.3 1587) Sering © 29,0 (1.142) 27.8 (1.087) AUTOMATIC TRANSMISSION SERVICE GROUP nTechnical Service Information Band Servo Piston Assembly (Cont'd) ASSEMBLY 1. Install O-rings onto servo piston retainer. © Apply A.TF. to O-rings. © Pay attention to position of each O-ring. Large 0 aD 2. Install seryo cushion spring retainer onto band servo piston. 3. Install E-ring onto servo cushion spring retainer. 4, Install D-rings onto band servo piston. © Apply A.T.F. to D-rings. 5. Install servo piston spring retainer, return spring C and piston stem onto band servo piston. AUTOMATIC TRANSMISSION SERVICE GROUP 2Technical Service Information Band Servo Piston Assembly (Cont'd) 6. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, install E-ring, 7. Install band servo piston assembly onto servo piston re- tainer by pushing it inward. Install O-ring on 0.0. band servo piston. Apply ATF. to D-ring. Install 0.0. band servo piston onto servo piston retainer by pushing it inward. AUTOMATIC TRANSMISSION SERVICE GROUP BTSG Technical Service Information Parking Paw! Components in \ if rm 2-28 4m a (24 - 3.0 kg-m, 17 - 22 Mb) Paving acta muon ra = Parking gear Output shat DISASSEMBLY 1. Slide return spring to the front of rear extension flange. 2. Remove return spring, pawl spacer and parking pawl from rear extension. 3. Remove parking pawl shaft from rear extension. 4. Remove parking actuator support and rod guide from rear extension. AUTOMATIC TRANSMISSION SERVICE GROUP 74TSG Technical Service Information @ Parking Paw! Components (Cont'd) INSPECTION Parking paw! and parking actuator support ‘@ Check contact surface of parking rod for wear. ASSEMBLY 1. Install rod guide and parking actuator support onto rear extension. 2. Insert parking pawl shaft into rear extension. 3. Install return spring, pawl spacer and parking paw! onto parking paw! shaft 4, Bend return spring upward and install it onto rear extension AUTOMATIC TRANSMISSION SERVICE GROUP 15Technical Service Information Assembly 1. Install manual shaft components. Install oil seal onto manual shatt © Apply A.T.F. to oll seal. © Wrap threads of manual shaft with masking tape. . Insert manual shaft and olf seal as a unit into transmission case ©. Remove masking tape. . Push oil seal evenly and install it onto transmission case. e. Align groove in shaft with drive pin hole, then drive pin into position as shown in figure at left {. Install detent spring and spacer. g. While pushing detent spring down, install manual plate onto manual shatt. AUTOMATIC TRANSMISSION SERVICE GROUP 76TSG Technical Service Assembly (Cont'd) h. Install lock nuts onto manual shatt peso baton A ston © 2. Install accumulator piston. a © Apply A..F. to O-rings. Accumulator piston O-rings: Install O-rings onto accumulator piston Information Unit: mm (in) ‘Accumulator a 8 c D ‘Smal diameter end | 2917.14) | 92 (1.26) | 48 (1.77) | 290.14) Large diameter end | 45 (1.77) | 50(1.97) | $07.97) | 45 (1.77) ‘Accumulator PSIEN © pcoumulatr b, Free length of return spring: ‘Accumulator Free length Apply A..F. to transmission case. Install band servo piston. Install return springs onto servo piston AUTOMATIC TRANSMISSION SERVICE GROUP. 7 Install return spring for accumutator A onto transmission Uni: mm (in) A 43 (1.69) Install accumulator pistons A, B, C and D.Technical Service Information Assembly (Cont'd) b. Install band servo piston onto transmission case. © Apply A.T.F. to O-ring of band servo piston and transmis. sion case. Install gasket for band servo onto transmission case. e Install band servo retainer onto transmission case, FS Install rear side clutch and gear components, Place transmission case in vertical position. (caress) Slightly lift forward clutch drum assembly and slowly rotate it clockwise until its hub passes fully over the clutch inner race inside transmission case. Check to be sure that rotation direction of forward clutch assembly is correct. AUTOMATIC TRANSMISSION SERVICE GROUP 8Technical Service Information Assembly (Cont'd) 4. Install thrust washer onto front of overrun clutch hub, © Apply petroleum jelly to the thrust washer. @ Insert pawls of thrust washer securely into holes In overrun clutch hub. Install overrun clutch hub onto rear internal gear assembly, Install needle bearing onto rear of overrun clutch hub. Apply petroleum jelly to needle bearing. 9. Check that overrun clutch hub rotates as shown while holding forward clutch hub. fh. Place transmission case into horizontal position, AUTOMATIC TRANSMISSION SERVICE GROUP 9ATSG Technical Service Information Assembly (Cont'd) i. Install rear internal gear, forward clutch hub and overrun clutch hub as a unit onto transmission case. j. Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing. Install bearing race onto rear of front internal gear. Apply petroleum jelly‘to bearing race. Securely engage pawls of bearing race with holes In front Interns eer Install front internal gear on transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 80Technical Service Information Adjustment When any parts listed in the following table are replaced, total fend play of reverse clutch end play must be adjusted bosnne rem | routensouy | Rerancien Tenino ee Lo. ° Srerun teh > > Fearne ear . . Fer sn ger ° ° From planetary erie . . Front singe . . Hh clutch ab eo ° ih uch gram ° ° dipmeow ide Reve cach dam = 7 1. Install front side clutch and gear components Install rear sun gear on transmission case. © Pay attention to its direction. Install needle bearing on front of front planetary carrier. Apply petroleum jelly to needle bearing. Install needle bearing on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction — Black side goes to front. AUTOMATIC TRANSMISSION SERVICE GROUP 81Technical Service Information Adjustment (Cont'd) 4. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum. Check that portion A of front planetary carrier protrudes Frnt ey caer approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly. a Portion Ay Forward euteh dram Install bearing races on rear of clutch pack. Apply petroleum Jelly to bearing races. jawis of bearing race with hole In clutch Place transmission case in vertical position. Install clutch pack into transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 82Technical Service Information Adjustment (Cont'd) 2. Adjust total end play Total end play “T.”: 0.25 - 0.55 mm (0.0098 - 0.0217 in) With needie’ bearing installed, place 94291-1 (bridge). Lock 1J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil ap sez91 2) pump. The long ends of legs should be placed firmly on machined surface of oil pump assembly and gauging cylin- der should rest on top of the needle bearing. Lock gauging \ ceveansn cylinder in place with set screw. b. Install 134291-23 (gauging plunger) into gauging cylinder. c. With original bearing race installed inside reverse clutch drum, place shim selecting gauge with its legs on machined surface of transmission case (no gasket) and allow gauging plunger to rest on bearing race. Lock gauging plunger in place with set screw. d. Remove Tool and use feeler gauge to measure gap between ‘gauging cylinder and gauging plunger. This measurement should give exact total end play. Total end play “T.” 0.25 - 0.85 mm (0.0098 - 0.0217 in) © I end play is out of specification, decrease or increase thickness of oll pump cover bearing race as necessary. ‘Available oil pump cover bearing race: Refer to S.DS. AUTOMATIC TRANSMISSION SERVICE GROUP 83me ten pack uusa2ei.t) (342912) eaar.sh Technical Service Information Adjustment (Cont'd) 3 Adjust reverse clutch drum end play. Reverse clutch drum end play ‘'T: 0.55 - 0.90 mm (0.0217 - 0.0354 in) Place J34291-1 (bridge), J34291-2 legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket) and allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw. Install J34291-23 (gauging plunger) into gauging cylinder. With original thrust washer installed on oil pump, place shim setting gauge legs onto machined surface of oil pump assembly and allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch crum and play. Reverse clutch drum end play 0.55 - 0.90 mm (0.0217 - 0.0354 in) It end play is cut of specification, decrease or increase thickness of oil pump thrust washer as necessary. Available oil pump thrust washer: Refer to S.D.S. AUTOMATIC TRANSMISSION SERVICE GROUP 84Technical Service Information Assembly Install output shaft and parking gear. Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case. Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft Check to be sure output shaft cannot be removed in rear direction, s Install needle bearing on transmission case. Pay attention to its direction — Black side goes to front. Apply petroleum jelly to needle bearing. Install parking gear on transmission case. Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direciton. AUTOMATIC TRANSMISSION SERVICE GROUP 85Technical Service Information Assembly (Cont'd) 2. Install rear extension 4. Install cll seal on rear extension ‘© Apply ATF. to oll seal. . Install O-ring on revolution sensor. © Apply A.TF. to O-ring. Install revolution sensor on rear extension, Install rear extension gasket on transmission case. Install parking rod on transmission case. {Install rear extension on transmission case. AUTOMATIC TRANSMISSION SERVICE GROUP 86Technical Service Information Assembly (Cont'd) a. Install rear sun gear on transmission case. © Pay attention to its direction. carrier © Apply petroleum jelly to needle bearing. carrier © Apply petroleum jelly to bearing. planetary carrier on forward clutch drum ronten Af y= Font peta carer fa clutch assembly. ward een dram ack. Apply petrol Securely enga clutch pack. to bearing races. AUTOMATIC TRANSMISSION SERVICE GROUP 87 3. Install front side clutch and gear components. b. Make sure needle bearing is on front of front planetary c. Make sure needle bearing is on rear of front planetary © Pay attention to its direction — Black side goes to front. d. While rotating forward clutch drum clockwise, install front © Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward fe. Make sure bearing races are on front and rear of clutch paws of bearing races with holes In