A4AF3, A4BF2

GENERAL

SPECIFICATIONS TR -2

LUBRICANTS ............................................•. TR -4

SPECIAL TOOLS TR-4

AU~MATICTRANSAXlESYSTEM

AUTOMATIC TRANSAXLE

COMPONENTS TR -9

DISASSEMBLY TR -15

REASSEMBLY TR -23

OIL PUMP (AfT)

COMPONENTS : TR -36

DISASSEMBLY TR -36

INSPECTioN TR -37

REASSEMBLY ~ TR -37

FRONT CLUTCH

CoMPONENTS ~ TR -39

DISASSEMBLY· TR -40

INSPECTION TR -40

REASSEMBLY ~ TR-40

REAR CLUTCH

COMPONENTS TR -42

DISASSEMBLY TR-43

REASSEMBLY TR-43

END CLUTCH

COMPONENTS TR-45

DISASSEMBLy TR-46

REASSEMBLY TR-46

PLANETARY GEAR SET

COMPONENTS TR -48

DISASSEMBLY : TR -48

REASSEMBLY TR-49

ANNULUS GEAR AND OUTPUT FLANGE

COMPONENTS TR -51

DISASSEMBLY TR -51

TRANSFER SHAFT

COMPONENTS TR -52

DISASSEMBLY TR -52

REAS,SEMBLY TR -52

TRANSFER DRIVEN GEAR

COMPONENTS TR -53

DISASSEM~LY TR -53

REASSEMBLY TR -53

DIFFERENTIAL

COMPONENTS TR -54

DISASSEMBLY ; TR -54

REASSEMBLY TR-55

VALVE BODY

COMPONENTS TR -56

DISASSEMBLY TR -59

REASSEMBLY m -63

KICK DOWN SERVO

COMPONENTS TR -68

REASSEMBLY TR -68

SPEEDOMETER CABLE

COMPONENTS TR -69

REASSEMBLY TR -69

TR-2

A4AF3, A4BF2

GENERAL

SPECIFICATIONS E2EB2CA6

Items Model Endplay (mm)
Front clutch A4AF3 0.4-0.6
A4BF2 0.6-0.8
Rear clutch A4AF3 0.7-0.9
A4BF2 0.9-1.1
End clutch A4AF3 0.4-0.6
A4BF2 0.6-0.8
Low-reverse brake A4AF3 0.675-0.987
A4BF2 0.975-1.287 TIGHTENING TORQUE

Items Nm kg·em Iltoft
Oil pan bolts 10-12 100-120 7-9
Selector lever assembly mounting bolts 12-15 120-150 9-11
Starter motor mounting bolt 27-34 270-340 20-24
Oil cooler hose connector 15-22 150-220 11-16
Hose bracket 3-5 30-50 .. ' 2-4
Cover to selector knob 2.0 or more 20 or more 1.4 or more
Selector knob to lever assembly 2.0 or more 20 or more 1.4 or more
Bell housing cover to case 15-22 150-220 11-14
Transaxle mounting bOlt 43-55 430-550 31.:..40
[10 mm (0.40 iri.) diameter' bolt] -':
Transaxle mounting bolt 60-80 600-800 43-58
[12 mm (0.47 in.) diameter bolt]
Torque converter to drive plate (*) 46-53 460-530 33-38
Control cable to body 5-7 50-70 4-5
Indicator panel 1.5 or more 15 or more 1.1 or more
Lever assembly to bracket assembly 14-22 140-220 10-14
Drain plug 35-45 350-450 25-32
Pressure check plug 8-10 80-100 6-7
Pulse generator mounting bolt 10-12 100-120 7-9
Transfer shaft lock nut 200-230 2000-2300 145-166
One-way clutch outer race bolt 35-45 350-450 35-32
Differential drive gear bolt (*> 130-140 1300-1400 94-101
Differential bearing retainer 20-25 200-250 14-17
Differential bearing cap 60-80 600-800 43-58 GENERAL

TR -3

Items Nm kg·em Ib-ft
Differential cover [8 mm (0.31 in.) 20-27 200-270 14-20
diameter bolt]
Manual control lever lock nut 17-21 170-210 12-15
Manual control shaft set SCreN 8-10 80-100 6-7
Trarisaxle range switch attaching bolt 10-12 100-120 7-9
Sprag rod support bolt 20-27 200-270 15-19 .
Pump housing.to reaction shaft support bolt 10:';'12 100-120 7-9
Oil pump assembty mounting bolt 19-23 190-230 13-16
Valve body bolt 4-6 40-60 3-4
Valve body assembly mounting bolt 10-12 100-120 7-9
Oil filler tube 19-23 190-230 13-16
Speedometer sleeve locking plate bolt 3-5 30-50 2-4
End clutch cover 6-8 60-80 5-6
Kickdown lock nut 15-22 150-220 11-16
End cover (Rear cover) 19-23 190-230 14-16
Transfer drive gear bolt 180-210 1800-2100 130-150
Transfer driven gear to transfer shaft 200-230 2000-2300 140-160
Detent spring to case 10-12 100-120 7-9
Double angular ball bearing 16-22 160-220 12-15 • Indicates the tightening torque on the state of applying with ATF on the screw.

TR -4 A4AF3, A4BF2

LUBRICANTS E3B7OC02

Items Specified lubricant Quantity
Transaxle fluid lit. (U.S. qts., GENUINE DIAMOND ATF SP-III A4AF3 6.1L
fmp.qts.) A4BF2 6.7L
Drive shaft oil seal lip Automatic transaxJe fluid As required
Sliding part of bushing Chassis grease SAE J310, NLGI No.O As required
Selector lever sliding portion Multipurpose grease SAE J310, NLGI NO.2 As required SPECIAL TOOLS E221E4CE

Tool (Number and name)

09431-21200 Oil seal installer

Illustration

Y45D05C

Measurement of the oil pressure (use with 09452-21001, 09452-21002)

·09432-33800

Bearing and gear instalier

09433-21000 Removing plate

09452-21500

Oil pressure gauge

Use

Installation of differentiaf oil seal

Installation of the transfer shaft bearing and transfer driven gear

03233800

Removal of transfer shaft taper roller bearing and differential ball bearing

D3321000

EKAAOO6C

GENERAL

Tool (~umber and name)

Illustration

Use

09452~21 001·

Oil pressure gauge adapter

09452~21 002

Oil pressure gauge adapter

09452~211 00

Oil pump remover

Measurement of the oil pressure (use with 09452~21500. 09452~21002)

Measurement of the oil pressure. (use with 09452-21500 and 09452-21001)

Removal of the oil pump

09452~21200

Bearing and oil seal installer

09452~21301 Oil pump band

09452-21401 Guide pin :

Y4SOO6B

Y45OO6C

Y450060

-

Installation of oil pump oil seal.and

transfer drive gear bearing

Assembly of the oil pump

Installation of the oil pump.

TR~

A4AF3,A4BF2

Tool (Number and name)

Illustration

, 09452·2200)

I Differential bearing retainer remover

09453-21000 Spring compressor

09453·21100 Spring compressor

Y45Oll6F

Removal and installation of the· rear clutch (use with 09453·21000)

.. Use

Removal of the differential bearing retainer

Removal and installation of the snap ring and return spring of the clutch

09453-2t310· ' Center suppOrt remover and installer

Removal and installation of the center support.

Y4SOO6G

09453·21400

Dial gauge support

Measurement of the input shaft; low and reverse brake and transfer shaft end play. (Use with dial gauge)

Y45OO6H

09453·24000 Spring compressor

Installation of oil pump oil seal and transfer drive gear bearing .

Y45007A

GENERAL

TR-7

Tool (Number and name)

illustration

Use

09453-33000 Snap ring installer

Installation of end clutch snap ring

09453-33100

Dial gauge extension

Y4SQ07C

Measurement of the low and reverse brake end play (use with dial gauge) .

09455-21100 Bearing installer

a

-J

09455-32200

Bearing outer race remover

X45007A

Installation of differential ball bearing

09455-33000 Removing plate

Removal of the tranSfer driven gear

bearing outer race .

Removal of the transfer driven gear taper roller bearing

09:455-33200 Bearing installer

X45007J

Installation of transfer driven gear taper roller bearing

TR-8

A4AF3,A4BF2

Tool (Number and name)

Illustration

Use

09456-21000 Guide pin

Y45OQ8C

Assembly of the valve body

09457-22000 Removing plate

Removal of the transfer drive gear rear bearing

09457-22100

Transfer shaft bearing outer race installer

09457-22200

Transfer driven gear remover

09457-34000 Removing plate

Installation of the transfer shaft bearing outer race

Removal of the transfer diNen gear,

(use with 09526-11001) .

09526-11001

Transfer driven gear remover

Removal of the transter drive gear front bearing

Removal of the transfer dirve" gear (use with 09457-22200)

AUTOMATIC TRANSAXLE SYSTEM

AUTOMATIC TRANSAXLE SYSTEM

AUTOMATIC TRANSAXLE

COMPONENTS E6814825

KKKAOl5A

Torque (kg·m) O.D x Length (mm) Identification Mark
A 6-S [I]12x40
8 4.3-5.5 [I]1Ox70 lIJ AxB
C 2.7-3.4 !I]10x55
D 0.S-1.0 [I] 6x10
E 4.6-5.3 [I]1Qx11 EKNB01SA

TR-10

A4AF3, A4BF2

COMPONENTS (1)

A ---+-1 c --...1 B---+-I

I I I

B~iA~'

KKPC016B

AUTOMATIC.TRANSAXLE SYSTEM

TR -11

COMPONENTS (2)

IN (from the oil cooler)

60-80 (600-800, 43-58) 5 (2EA)

13

x

~

20-27(200-270,14-19) 21 (10EA)

<Section A-A>

19-23 (190-230.14-16) 108

<VIEW 'X'>

TORQUE: N·m (kg.em, Ib·ft)

121 1EA)1:3... 10-12

120 (lEA) (100-120.7-8)

119 (7EA)

<VIEW 'a'>

. ~ . .' "

EKPOOl6(

TR-12 COMPONENTS (3)

A4AF3, A4BF2

25 60-68 26

(600-680. 43-50) 9

8-10 (80-100,6-7)

<Front view>

17

58

123 5-7 (50-70

<Secr ,4-5)

Ion 8·B>

<Section C--G>

TORQUE·

. N·m (kg.em, Ib·ft)

AUTOMATICTRANSAXLESYSTEM

TR-13

COMPONENTS (4)

94 20-27 <K-K> (200-270. 14-19)

.,ijP5-22 (1 ........ 11-16) •

60-80 (600-800,43-50) 3

19-23 (190-230, 14-16) 24

17-21 (170-210.12-15) 95

96

97

98

118

l 101~102 8-10

(80-100,6-7)

p

TORQUE: N·m (kg.em, Ib·ft)

<K-K>

93

~_(ap.--- 99

\ 10.12 (100-120, 7-8)

I

<VIEW'P'>

EKPD016E

TR -14

A4AF3,A4BF2

COMPONENTS (5)

1. Torque converter
2. TransaxJe support bracket
3. Bolt washer
4. Front roll support bracket
5. Bolt washer
6. Transaxle case
7. Drain plug
8. Gasket 44. Brake plate

45. Brake pressure plate

46. Brake reaction plate

47. Return spring

48. Wave spring

49. Thrust bearing SO. Thrust race

51. Snap ring

52. Kick down drum

53. Packing

54. Low & reverse brake piston

55. Center support

56. Kick down band

·57. Kick down servo & spring piston

58. Kick down servo switch

59. Flywheel bolt

60. Transfer driven gear set .

61. Bolt

62. Double angular

63. Taper roller bearing

64. Locking nut

65. Snap ring

66. Thrust bearing

67. Thrust race

68. Seal ring

69. Thrust bearing

70. Snap ring

71. End clutch shaft

72. Locking nut

73. Planetary carrier

74. Reverse sun gear

75. Forward sun gear

76. AnuJus gear

77. Transfer drive gear

78. Output flange

79. Snap ring

SO. Differential case

81. Differential gear

82. Differential gear spacer ·83. Washer

84. Pinion shaft

85. Lock pin

86. Ball bearing

87. Side bearing
88. Spacer
89. Spacer
90. Differential drive gear
91. Speedometer drive gear
92. Stopper plate
93. Sprag rod support
94. Flange bolt (ax25)
95. Nut
96. Spring washer
97. Manual control lever
98. O-ring
99. Bolt 100. Manual control

101. Screw

102. Seating washer

103. Pulse generator

104. Flange bolt (6x14)

105. Transaxle range switch

106. Flange bolt

107. Shift cable bracket lOS. Flange bolt

109. Clamp

110. Snap ring 111.0il pump

112. Oil pump gasket

113. Seal washer

114. O-ring

115. Seal ring 116.S~~

117. VaJvebOdy

118. Oil temperature sensor

119. Bolt (6x26)

120. Bolt (6x36)

121. Bolt (6x41)

122. Oil filter

123. Flange bolt (6x12)

124. Speedometer driven gear sleeve

125. Flange bolt (6x14)

126. Oil level gauge & filler tube

127. Flange bolt (8x16)

128. Oil level gauge

9. Oil pressur check plug

10. Oil cooler connector

11. Sealing cap

12. Oil pan

13. Magnet

14. Oil pan gasket

15. Bolt

16. Adjuster screw

17. Nut .

18. Differential bearing retainer

19. Flange boH (8x25)

20. Differatial cover

21. Bolt washer

22. Gasket

23. End cover

24. Flange bolt

25. Rear roll support bracket

26. Seal bolt

27. Bolt (10x20)

28. a-ring

29. Air bleeder cap

30. Rear clutch

31. Rear clutch hw--'

32. Thrust bearing

33. Thrust bearing

34. Thrust bearing

35. Front clutch

36. Thrust washer

37. Thrust washer

38. End clutch

39. End clutch hub

40. Thrust washer

41. Thrust bearing

42. Snap ring 43_ Brake disc

eKP0016F

AUTOMATIC TRANSAXLE SYSTEM

DISASSEMBLY E36AOEFB

TR-15

& CAUTION

Because the automatic transaxle is composed of component parts of an especially high degree of prec;s;on~ these parts should be very carefully handled during disassembly and assembly so as not to SCBTor scratch them.

A rubber mst should be placed on the workbench, and n should always be kept clean.

During disassembly, cloth gloves or rags should not be used. H such items must be used, use articles mllde of nylon, or use paper towels.

All disassembled parts must be thoroughly cleaned. Metal parts may be cleaned with ordinary detergents, but must be thoroughly air dried. Clean the clutch disc, resin thrust plate and ru~ ber parts by using ATF (automatic transsxle fluid), being very careful that dust, dirt, etc. do not ad-here.

" the transaxle main unit is damaged, also disassemble and clean the cooler system as well.

1 . Clean away any sand, mud, etc. adhered around the transaxle.

2. Place the transaxle assembly on the workbench with the oil pan down.

3. Remove the torque converter.

KKKAOISA

4. Measuring input shaft end play before disassembly wnl usually indicate when a thrust washer change is required (except when major parts are replaced). Thrust washers are located between the reaction shaft support and rear clutch retainer. and between the reaction shaft support and front clutch retainer. Mount a dial indicator to the converter housing with the dial indicator support.

Make sure that the indicator plunger is seated against the end of the input shaft.

When checking end play. pull out or push in the input shaft with pliers. Be careful not to scratch the input shaft. Record indicator reading for reference when reassembling the transaxle.

EKKA018e

5.

Remove the pulse generators "AD and "B".

Drain plug

EKPCQ18C

6. Remove manual control lever, then remove the transaxle range switch. .

Manual control lever

ASOR079O

TR -16

A4AF3,A4BF2

7. Remove the snap ring and kickdown servo switch.

1(lO(A,()' 'IT

8. Remove 6 bolts, attach the special tools (09452-21100) and remove oil pump assembly.

@JNOTE

When removing the oil pump assembly, be sure to follow to prevent the damage of onto transaxle case.

• Tum the knob of both special serviCe tools simultaneOusly and uniformly not to be inclined to -Bside.

• While turning the special service too/, tap on the -A· side of the oil pump lightly with robber or p/as-. tic hammer if necessary.

1(lO(A,()1 BE

9. Remove the fiber thrust washer.

KKKA018F

10. Pull up the input shaft, and remove the front clutch assembly and the rear clutch assembly together.

KKKAilISG

11. Remove the thrust bearing.

12. Remove the clutch hUb.

KKKAilIBH

AUTOMATIC TRANSAXLE SYSTEM TR ·17

13. Remove the thrust race and bearing. 16. Remove the snap ring.

B6It.T032F KKKAllI8J

14. Remove the kickdown drum. 17. Attach the special tool (09453-21310) on the center

support. Holding the handle of the tool, pull the center support straight upward.

1Q(l(.I0181

0945341310

15. Remove the kickdown band.

1<KKA018K

18. Remove the reverse sun gear and the forward sun gear together.

X45061D

TR -18

A4AF3, A4BF2

22. Remove the end clutch assembly.

19. Remove the planetary carrier assembly and thrust bearing.

KKKA018M

20. Remove the wave spring, return spring. reaction plate, brake disc, and brake plate ..

KKKA018N

21 . - Remove the end cover.

23. Remove the thrust plate.

24. Remove the end clutch hub and thrust bearing.

KKKA0180

AUTOMATIC TRANSAXLE SYSTEM

TR-19

25. Pull out the end clutch shaft.

KKKA01BR

26. Remove the oil pan and gasket.

27. Remove the oil filter from the valve body.

T9AT03OI

28. Remove the oil-temperature sensor installation bolt; then, after removal from the bracket, pull out from the connector.

KKl<K141 A

29. Remove the clip of the solenoid valve harness grommet and pull it.

KKl<K144A

I(J(KK145A

TR-20

A4AF3, A4BF2

32. Remove the locking nut.

30. Remove the 9 valve body bolts. Remove the valve body.

KIO<K14GA

31. Unstake the transafer shaft lock nut stopper.

Transfer driven gear

Transfer driw gear

BMTIl22.I

33. Using the special tool, remove the transfer driven gear.

1<XNIIQ11C

34. Remove the taper roller bearing outer race.

35. Remove the snap ring.

- ~;t,~

.,' ,,-

AUTOMA~CTRANSAXLESYSTEM

36. Remove the transfer shaft and taper roller bearing.

TR~21

37. Remove the transfer drive gear lock nut and the tranfer drive gear.

38. Remove the speedometer sleeve.

KKKA018U

39. Remove the differential cover and the gasket.

40. Before removal of the differential gear, measure the end play of the differential gear with a dial gauge.

Standard value: 0-0.15 mm (0-0.006 in.)

KKK.IoIl18V

41. Remove the 5 differential bearing retainer mounting bolts.

KKKA018W

~ • .;!'-

42. Using the special tool, remove the differential bearing retainer.

KKPD018A

TR -22

A4AF3, A4BF2

43. Loosen the mounting bolts and remove the bearing cap.

44. Remove the differential assembly.

KKKAOl8Z

45. Remove two bolts of the sprag rod support and the bolt of the detent spring assembly.

T8AT03OE

46. Remove the set screw, the manual control shaft assembly, the sprag rod and the detent spring assembly.

c---c~=t==+---- O-ring I..:::::::FZI:u--- Set screw

S6AT819A

47. Remove the kickdown servo snap ring.

KI<KAOl2A

48. Remove the kickdown piston assembly.

KKKAOl2B

AUTOMATIC TRANSAXLE SYSTEM

REASSEMBLY E9CFAE09

TR-23

& CAUTION

Do not reuse gaske~ oil seals and rubber parts. Replace them with new ones at every reassembly. The O-ring of the oil level dipstick need not be

replaced.· .

Do not use grease other than petrolatum or indu. b1a1 vaseline.

Apply automatic transaxle fluid to friction elements,rotating parts, and sliding parts before installation. New clutch discs should be immersed in automatic transsxle fluid for a minimum of two hours before installation.

Do nor apply sealer or adhesive to gaskets.

Do nor use shop towels during disaSsembly and reassemblyDperIItJon.

The oil in the cooler should also be replaced.

1. After installing the detent spring assembly and the sprag rod assembly on manual control shaft, insert manual control shaft into transaxle case and push it fully toward manual control lever. At this time, do not install the O-ring (large one of two O-rings) on manual control shaft.

2. After installing the new O-ring on manual control shaft. draw shaft back into case, then install set screw and gasket.

c~:r-+--O-ring ~~~----~t~mw

S6ATC2ON

3. Install the sprag rod support and tighten two bolts.

Install the washer and tighten the bolt of the detent spring assembly.

Sprag rod support bolts:

2(}...27Nm (200-270 kg'cm, 15-19IMt) Detent sprag assembly bolt:

10-12 Nm (100-120kg·cm, 7.5-8.4Ib·ft)

TSAT030E

4. Before assembly of the transaxie, measure the end play of the low-reverse brake, and select a pressure plate to be used so that the end play will be the standard value.

1) Install the brake reaction plate. brake plate and brake disc to the transaxle case.

& CAUTION

If new brake discs are used, be sure to immerse them in ATF for a minimum of two hours.

KKKA01SN

TR-24

A4AF3, A4BF2

5) Install the snap ring.

2) Install the appropriate pressure plate and then install the return spring.

it CAUTlON

Be sure that the return spring Is installed so that it faces in the correct direction.

Case

A5DRl340

3) Apply a coating of petroleum jelly to the wave spring and attach it to the center support.

4} Install the special tool (09453-21310) to the oenter support.

09453-21310

KKKA018K

Snap ring

EKKA019B

6) Install the special tools (09454-21400, 09453- 33100) and a dial gauge at the rear side of the transaxJe case.

in CAUTION

InstlllI the dial9lluge so that it contscts the brake relICtion plate at II right angle ftom the transfer Idler shlllt hole.

A.5ORl390

AU~MA~CTRANSAXLESYSTEM

TR-25

7. Insert the spacer on the transfer shaft.

7) Using a manual pump, pump air (5 kg/crJl2) in from the position shown in the illustration. Read the dial indicator gauge. and select the pressure plate that will provide the standard value.

8) After selecting pressure plate, remove center support. brake plate, brake disc, brake reaction plate and pressure plate

KKKA019D

5. Install the transfer shaft, and press-fit the bearing outer race to the transaxte case.

~B011D

6. Install the transfer shaft snap ring.

KKKA019F

KKKAOI9G

8. Install the bearing cage on the case.

9. Press-fit the transfer driven gear to the transfer shaft

KKKAOI91

TR-26

10. Tighten the lock nut to the specified torque.

A4AF3, A4BF2

Transfer lock nut:

200-230Nm (2000-2300kg·cm, 146-166lb·ft)

t00<A0l9K

11. After installing the dial gauge, measure the end play of the transfer shaft: then select the spacer(s) needed to obtain the standard value, and refit.

Transfer shaft end play: O.01-0,06mm

KKJ<AOl9L

12. Using a punch. lock the lock nut to prevent rotation.

KKKAOl9M

13. Install the transfer drive gear assembly and tighten the lock nut.

Transfer driven gear

Transfer driw gear

T9AT03OF

14. Apply specified sealant to the rear cover.

Specified sealant: THREE BOND 1281 B

KKKAOl9N

AUTOMATIC TRANSAXLE SYSTEM

. TR ·27

IDENTIFICATION OF THRUST BEARINGS. THRUST RACES AND THRUST WASHERS

Outer Inner diameter Thickness Code OUler Inner diameter Thickness Code
diameter No. diameter No.
70 (2.756) 55.7 (2.193) 1.4 (0.055) 48.1 (1 .906) 34.4 (1.354) 2.8 (0.110) #4
70 (2.756) 55.7 (2.193) . 1.8 (0.071) 40 (1.575) 21 (0.827) 2.4 (0.094) #5
#1
70 (2.756) 55.7 (2.193) 2.2 (0.087) 42 .. 6. (1 .6n) 28 (1.102) 2.5 (0.098) #6
70 (2.756) . 55.7 (2.193) 2.6 (0.·102) 54 (2.126) 38.7 (1.524) 1.6 (0.063) #7
70 (2.756) Q~, 7 (2.193) 1.8 (0.071) #2. 52 (2.047) 36.4(1~ 2.8 (0.110) #8
48.9 (1.925) 37 (1.457) 1.0(0.039) 41 (1.614) 28 (1.102) 2.0 (0.078) #9
48.9 (1 .925) 37 (1.457) 1.2 (0.047) 39 (1.535) 28 (1.102) 1.2 (0:047) #10
48.9 (1.925) 37 (1.457) 1.4 (0.055) 38 (1.496) 22.2 (0.874) 6.0 (0.236) #11
48.9 (1.925) 37 (1.457) 1.6 (0.063) 52 (2.047) 36.4 (1.433) 2.8 (0.110) #12
#3
48.9 (1.925) 37 (1.457) 1.8 (0.071) 58 (2.283) 44 (1.732) 5.0 (0.196) #13
48.9 (1.925) 37 (1.457) 2.0(0.079)
48.9 (1.925) 37 (1.457) 2.2 (0.087)
48.9 (1.925) 37 (1.457) 2.4 (0.094) TR~28

A4AF3, A4BF2

15. Apply a coating of petroleum jelly to thrust bearing #12 and attach to the planetary carrier.

EKPD019Z

16. Install the planetary carrier to the case.

17. Assemble· the reverse sun gear and the forward sun gear in the following order:

1) Attach the seaLfing and the snap ring tothe rewrse . sun gea,.. When attaching, squeeze the seal ring as shown in the figure.

2) Attach thrust race #10 to the forward sun gear.

3) Attach thrust bearing #9 to the forward sun gear.

4) Assemble the reverse sun gear, and then the forward sun gear.

X45078D

, 8. Install both of the previously assembled sun gears into the planetary carrier.

KKKAOI9P

19; Install the brake disc and brake plate.

X45079A

AUTOMATIC TRANSAXLE SYSTEM

TR-29

20. Install the setected brake pressure plate.

23. Install the two new O-rings to the center support.

ASOR1640

lCA5079E

21. Install the return spring. (Spring type)

24. After applying a coating of ATF to the O-rings, install the special tool (09453-21310) to the center support, and install into the case.

& CAUTION

Be sure that the wave spring ;s not out of position.

22. Apply a coating of petroleum jelly to the wave spring and attach it to the center support.

ASORl680

25. Install the snap ring.

A50R0890

TR-30

A4AF3, A4BF2

29. Install the end clutch hub to end clutch.

26. Assemble a new seal ring (large diameter) and D-ring (smau diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.

KKKAOl28

27. Press the kickdown servo and sleeve, and install the snap ring.

KKKAOl9T

28. Install the end clu1ch shaft. Be sure to install the longer spline toward the front as shown.

A5ZR09ZO

X4&lB1B

30. Attach, using petroleum, thrust bearing #13 to the end clutch hub.

A5ZR203O

31. Instail the end clutch assembly.

KKKKOBSA

32. Attach a new O-ring and D-ring to the end clutch cover.

ill CAUTION

Install so that the D-ring is not twisted.

Apply a sufficient amount of automatic transaxle fluid to the bearing.

AUTOMATIC TRANSAXLE SYSTEM

TR-31

33. Attach the end cover and fasten it with bolts.

& CAunON

When installing the end cover, be sure the screw hole is coirectIy aligned. If the end cover is tumed (after it;s installed) in order to align with the screw hole, the ()..ring and/or the O-ring may be twisted as result.

34. Instan kickdown drum with its splines in mesh with the sun gear.

Place the kickdown band on the kickdown drum and tighten the kickdown servo adjusting screw to keep the band in position.

KKKA019V

35. Apply a coating of petroleum jelly to thrust bearing #8, and then attach to the kickdown drum.

X45082C

36. Apply a coating of petroleum jelly to thrust race #7, and then attach to the rear clutch hub.

EKKA019W

37. Install the clutch hub to the sun gear splines.

KKKA019X

38. Attach thrust bearing #6 onto the hub using petroleum jelly.

Thrust bearing #6

TR-32

A4AF3, A4BF2

39. Apply a coating of petroleum jelly to thrust washer #2 and thrust bearing #4. Attach to the rear clutch assembly.

Thrust washer 112

Thrust washer #4

A5DR1840

40. Combine the rear clutch and the front clutch assernblies.

AS01'I18S0

41. Install the end clutch assembly.

ASDR0B30

42. If end play which was measured and recorded at disassembly is not within standard value, adjust to specification by selecting thrust race #3.

Standard value: 0.3-1.0 mm (0.012-0.040 in.)

When the thrust race is replaced with that of a differ· ent thickness, also replace thrust washer #1 located between the oil pump and front clutch. Use a washer

of proper corresponding thickness corresponding to thrust race.

Find correct pair of thrust races (metal) and thrust washers (fiber) from following table.

Thrust washer #1 (fiber) ThrUstrace 13 (metal)
Thickness mm (tn.) Thickness.mm (in.)
1.4 (0.055) 1.0 (0.039)
1.4 (0.055) 1.2 (0.047)
1.8 (0.071) 1.4 (0.055)
1.8 (0.071) 1.6 (0.063)
2.2 (0.087) 1.S (0.071)
2.2 (O.OSn 2.0 (0.079)
2.6(0.102) 2.2 (0.087)
2.6 (0.102) 2.4 (0.095) EXAMPLE:

When a different thickness thick thrust race is sa. lected. a corresponding thrust washer must be paired with it.

43. Attach the reused thrust washer #1, or the one selected in step 42 to the front clutch by using petroleum jelly.

44. Install the special tool (09452·21401 ) to ttte· case.

09452·21401

45. Attach the reused thrust race #3 or the one selected in step 44 to the oil pump by using petroleum jelly.

Thrust washer #1

A50R1880

AUTOMATIC TRANSAXLE SYSTEM

TR-33

46. Install a new oil pump gasket and the oil pump assembly.

ASDR1890

47. Install a new O-ring in the groove of the oil pump housing and lightly apply automatic transaxle fluid to the outside surface of the O-ring.

48. Install the oil pump assembly by tightening the six bolts evenly. When installing this oil pump assembly, be careful that the thrust washer remains in place.

Kl(](AQl2G

49. Check the input shaft end play. Readjust if necessary (see step 44)

Standard value: 0.3-1.0 mm (0.012-0.040 in.)

KKKAOl2H

50. Install the O-ring at the center of the top of the valve body assembly (brake oil pressure passage) and install the valve body assembly to the case, fitting the detent plate (manual control shaft) pin in the slot of the manual valve.

TSAT030H

51. Replace the O-ring of the solenoid valve connector with a new one.

52. Tighten the valve body assembly mounting bolts to 10-12Nm (100-120kg·cm, 7-9Ib·ft)

53. Install the oil filter. Tighten the four oil filter mounting bolts to 5-7Nm (5O-7Okg·cm, 4-5Ib·ft)

T9ATOJOI

54. Install five magnets into the five depression provided in the oil pan.

KKKA012

TR -34

A4AF3, A4BF2

58. Install the pulse generator A and B.

55. Install a new oil pan gasket and oil pan. Tightening 12 bolts to 10-12Nm (l00-l20kg·cm. 7-9Ib·ft)

EKKA012J

56. Install a new D-ring to the kickdown servo switch.

Press into the case and secure using the proper snap ring.

57. Install the transaxle range switch and manual lever and adjust thetra~e range switch.

EKKAll12K

Drain plug

EKPCOlac

59. Install the differential assembly.

60. Place two pieces of solder, roughly 10mm (0.4 in.) long and 3mm(O.12 in.) in diameter. at the position shown on the differential bearing retainer outer race.

Solder

EKKAOI2N

AUTOMATIC TRANSAXLE SYSTEM

TR~35

61. Install the differential bearing retainer and tighten the bolt to specified torque.

Standard value: 43-55Nm (430-550kg'cm, 31-40 Ib·ft)

Retainer

62. Remove the differential bearing retainer.

63. Remove the crushed solder from the outer race of the differential bearing.

64. Using a micrometer, measure the thickness of the crushed solder.

65. Select and install a spacer so that the preload of the differential bearing wiil be the standard value.

Standard: 0-0.15mm (O-O.OO6in.)

t<KKAIl12P

66. Apply the ATF to the new installed O-ring and install the differential bearing retainer.

67. Install the differential ~aring cap.

Tighteniilgtorque

Standard value: SO-BONm (600-BOOkg·cm. 43-58lb·ft)

<;

68. Install the differential cover and the rear roll bracket with new gasket.

Tightening torque

Differential cover: 1 0-12Nm (100-120kg'crn, 7 -9Ib·ft) Rear roll bracket: 43-55Nm(430-550kg·cm, 31-40lb·ft)

T8AT03QO

69. Install the speedmeter sleeve.

KKXA0120

70. After applying automatic transaxle fluid to the outside surface of the oil pump-side cylindrical portion of the torque converter. install the torque converter carefully so as not to damage the seal lip. Make certain that the torque converter is in mesh with oil pump drive gear.

71. Measure the distance between the ring gear end and the converter housing end. The torque converter has been properly installed when measurement is approximately 12mm (O.47in.).

TR -36

A4AF3, A4BF2

OIL PUMP (A / T)

COMPONENTS ESCE57S5

Drive gear

Drive gear

Housing

Oil seal

DISASSEMBLY E962DDB6

1. Place the oil pump body on the torque converter.

2. Remove the two searrings and O-ring.

X45089B.

3. Remove five botts and remove the reaction shaft support from housing.

4. Remove the oit pump body from the torque converter.

Seal ring

Steel ball

Seal ring

Reaction shaft support

5. Ma~ the reassembly alignment marks on the drive and driven gear.

6. Remove the oil pump drive and driven gears from pump housing.

7. Remove the steet ball from housing.

AUTOMATIC TRANSAXLE SYSTEM TR -37

X450890

8. Remove the snap ring and the oil seal from the oil pump drive gear.

INSPECTION E99C135A

1. Measure the side clearance of the oil pump gear. If the clearance e)f~ the standard value, or if an in· spection of the surface area (of the oil pump housing) that contacts the oil pump gear reveals indications of interference. replace the entire oil pump assembly.

Standard value: O.02-0.048mm (0.0008-0.oo19in.)

2. Check the surface of the reaction shaft support that contacts the oil pump gear. If there are indications of interference, replace the entire oil pump assembly.

VSAT039A

3. Check oil pump drive gear rotation.

X45090C

REASSEMBLY E1E70EAS

1. lnstall the oil seal to the oil pump drive gear.

2. Install the snap ring. -~~.:7-

X45O!iOe

3. After immersing the drive and driven gears in automatic transaxle fluid, install them into pump housing. When reusing gears, install with mating marks properly aligned.

4. Fit a new O-ring into the groove at the inner circumference of the drive gear.

TR-38

A4AF3, A4BF2

5. Install the steel ball in the hole as shown in the iIIus6 tration.

6. Install the two seal rings, coated with automatic transaxie fluid, to the reaction shaft support.

ASAT022C

7. Make .sure that oil e_u!!lP gear tumsfreely.

8. Install a new O·ring in the groove provided in the circumference of the pump housing and apply petroleum jelly to the circumference of the O-ring.

9. Loosely install the reaction shaft support on the pump

housing. .

Tighten the five bolts.

10. With the reaction shaft support properly positioned on the pump housing. using special tools (09452-21401, 09452-21301), tighten the five bolts to 10-12Nm (1 00-120kg·cm. 7 -9Ib·ft).

X45091C

OIL SEAL REPLACEMENT

1 . Pry off the pump housing oil seal using a screwdriver.

X45091B

2. Using the special tool (09452-21200). instal.1 the oil seal to the pump housing. Apply a thin coat of automatic transaxle fluid to the lip of the oil seal before installation.

Pump housing

X45(l91E

AUTOMATIC TRANSAXLE SYSTEM

TR-39

FRONT CLUTCH

COMPONENTS E30EB122

Clutch reaction plate (a: 3EA) (B: 4EA)

Snap ring

Front clutch retainer

Clutch reaction plate

Retum spring

Front clutch piston

Front clutch retainer

~~ "_ ..

Snap ring

EKPOO24J

DISASSEMBLY EC3A9FF7

TR -40 A4AF3, A4BF2

1. Remove the snap ring from the clutch retainer.

2. Take out the three clutch reaction plates and two clutch discs.

If the clutch reaction plates and the clutch discs are to be reused, be sure not to change the installation order or direction.

3. With the return spring compressed with the special tool (09453-24000), Spring Compressor, remove the

snap ring. then the spring retainer and the return

spring.

4. Remove the piston from the retainer.

5. Remove the O-section rings from the inner and outer circumfer-ences of the piston.

09453-24000

INSPECTION EDGG2ee"

~

1. Check to see if the sliding surface of the disc, plate are worn or burnt, if necessary, replace them.

~NOTE

If the lining of the disc is peeling off, replace all discs.

T450402

2. Check that the check ball is free by shaking the piston.

REASSEMBLY EB101'99f'

1. Install the D-section ring in the groove on the outside surface of the piston with its round side out. Install another O-section ring to the front clutch retainer.

2. Apply automatic transaxle fluid to the outside surface of the O-section rings. Then push the piston into front clutch retainer by hand.

Frcntdutch retainer

3. Install the return spring and spring retainer.

4. Compress the return spring with the special tool (09453-24000) and install the snap ring.

AUTOMATIC TRANSAXLE SYSTEM

TR-41

5. Install the three clutch reaction plates and two clutch discs.

Prior to installation, apply automatic transaxle fluid to them.

ill CAUTION

1. When new clutch discs are used, they should be immersed In automatic transaxle fluid a minimum of two hours prior to installation.

2. As you know. the color of current clutch disc turns to blaclc when burnt When tire new clutch disc Is immersed In ATF for two hours. its color also tums to bla~ which makes It dJfficult to identify it the clutch disc is normal orbss been bUrnt Therefore, care should be taken not to confuse Or misuse the burnt clutch d"1SC of current· type and new type clutch discs Immersed in ATF.

3. The burnt clutch disc of new type should be identified by looking at the height difference of protruded section and base section.

Shear drop

6. After installing the snap ring, check to see if there is a O.4-0.6mm (O.01S7-0.0236in.) clearance between the snap ring and the clutch reaction plate.

To check clearance, hold the entire circumference of the clutch reaction plate down with SON (11Ib.) force. If clearance is out of specification, adjust the clearance by selecting the proper snap ring.

TR -42

REAR CLUTCH

A4AF3, A4BF2

COMPONENTS

E13470E1

Snap ring

Thrust race

Clutch disc (4)

Wave spring

O-ring

Rear clutch piston

Rear clutch retainer

Snap ring

Seal ring (3)

Clutch reaction plate

Clutch plate (5) Clutch pressure Plate

O-ring

Seal ring

Rear clutch piston

Rear clutch retainer

ring

Coil spring

Disc (4EA)

EKPOOVA

AUTOMATIC TRANSAXLE SYSTEM

TR-43

DISASSEMBLY eAEB3300

REASSEMBLY EAABE2E2

1. Remove the snap ring and thrust race .:

2. Remove the input shaft from the rear clutch retainer.

3. Remove the snap ring from the clutch retainer.

4. Remove the clutch reaction plate, three clutch plates, two clutch discs and clutch pressure plate from the retainer.

5. Compress the return spring by using the spring com-

pressor.

6. Using a screwdriver, remove the wave spring.

7. Remove the return spring and piston.

S. Remove the two D-section rings from the piston.

09453-21100

1. Install the ·D-section rings in the grooves in the outside and inside surfaces of the piston.

2. After applying automatic transaxle fluid to the outside surface of the D-section rings, push the piston into the rear clutch retainer by hand. .

3. Install the return spring on the piston.

4. Compress the return spring with the snap ring, by pushing dOvvn with a screwdriver and setting the snap ring. in its groove.

D-section ring

X4S096C

5. Install clutch pressure plate, two clutch discs, clutch plate and clutch reaction plate into the rear clutch retainer.

When the reaenon plate, clutch plate and clutch disc are removed, reinstall them by reversing the order of disassembly.

Prior to installing, apply automatic transaxle fluid to the plates and discs...._~.?

Shear drop

TR -44

. A4AF3, A4BF2

ill CAUTION

• When new clutch discs are used. Immerse them in automatic InInssxle fluid for a minimum of two hours prior to installation.

• The four splines of diSc are deleted to discriminate the rear clutch disc from front clutch disc.

• "the lining of the disc is peeling off, replace all discs.

• As you know, the color of current clutch disc tums to black when bumt When the new clutch disc is immfH'Sed In ATF for two hours. its eotor also turns to disc is normal or has been bumt Therefore, care should be taken not to confuse or misuse the bumt clutch disc of current type and new type clutch discs immersed in ATF.

• The burnt clutch disc of new type should be ldentirlfHl by looking at the height difference of protruded section lind base section.

T450401

6. Install the snap riRtr.-Cheek to see that the clearance between the snap ring and clutch reaction plate is O.3-0.5mm (O.0118-0.0197in.). To check clearance, hold the entire circumference of the clutch reaction plate down with SON (-11Ibs.) force. If clearance is out of specification, adjust by selecting the proper snap ring. Snap rings are the same as those used for the front clutch.

Y45093e

7. Insert the input shaft into the clutch retainer.

8. Install the thrust race, and snap ring.

9. Install the three seal rings to the grooves in the input shaft.

J

AUTOMATIC TRANSAXLE SYSTEM

TRe45

END CLUTCH

COMPONENTS EC1BCC12

End clutch retainer

Oil seal

Oil seal

Piston

Clutch reaction plate

Clutch disc

Clutch plate

Clutch plate

Snap ring

Seal ring

Washer

Return spring

O-ring

Snap ring

Clutch . plate

Clutch disc

fi~~~----R~onp~te ~~7

Clutch plate

EKPD030A

TR -46

A4AF3, A4BF2

DISASSEMBLY El16F9OG

REASSEMBLY EB340406

1. Remove the snap ring, clutch reaction plate, clutch disc, and the clutch plate. If the disc and plate are reused, note the instaflation order and direction when they are disassembled.

KKNB031"

2. Remove the snap ring with snap-ring pliers, and then remove the washer and return spring.

KKNB0318

--

3. Remove the piston. If it is difficult to remove, face the

piston side downward and with the retainer on a base, blow air in through the oil passage on the rear surface.

4. Remove the seal ring from the retainer.

5. Remove the two D·section rings and oil seal from the piston.

Y45100c

1 . Install the D-section rings and oil seal in the piston inner and outer grooves.

2. After applying a coating of automatic transaxle fluid to the D·section rings outer circumference, manually press the piston into the end clutch retainer.

3. Install the return spring and washer.

4. After fitting a nE!'N snap ring into the guide of the special tool (09453-33000), install the retainer. Push the snap ring as far down on the guide as possible. Attach the instaJler and press until the snap ring enters the groove. Do not press more than necessary. The places indi-cated by arrows in the illustration (center projections) are not to be supported.

5. Install the clutch plate, clutch disc and reaction plate to the end clutch retainer.

If the reaction plate, clutch plate and clutch disc are reused, install them in ·the same order they were disassembled. ApplY a coating of automatic transaxle fluid.

& CAUTION

When • new clutch disc is used, soak it In automatic tnlnsaxle fluid for 2 hours before using It.

Reaction plate

Clutch disc

AUTOMATIC TRANSAXLE SYSTEM

TR-47

6. Install the snap ring. Check that the clearance between the snap ring and the clutch reaction plate is O.4-0.65mm (O.016-0.026in.).

To check the clearance, hold the circumference of the clutch reaction plate down with SON (11Ib.) force.

If clearance is out ot specifications, adjust the clearance by selecting the proper snap ring.

. -: . .l?

TR-48

PLANETARY GEAR SET

A4AF3, A4BF2

COMPONENTS SOAC796C

Thrust washer front

Front washer C

Overrunning clutch

Front washer B

Front washer A

Roller

Part A

Stopper plate ---II

B

Lock plate

DISASSEMBLY 'E20C0456

1 . Remove three bolts.

V5AT052A

2. Remove the overrunning clutch outer race assembly.

V4S102C

3. Remove the shaft of only one short pinion.

4. Remove the spacer bushing and two front thrust washers.

5. Remove the pinion. Do not drop the 17 roller bearings in the pinion.

AUTOMATIC TRANSAXLE SYSTEM

TR-49

REASSEMBLY E042-46AE

6. Remove the thrust bearing (#11).

Y45103A

X4511l2A

7. Push the overrunning clutch out of the outer race by hand.

Y45103C

1. Install the thrust bearing in the carrier. Be sure that it fits correctly in the carrier.

X451Q2C

2. Apply a generous amount of petroleum jelly to the lnside of the short pinion to hold the 17 rollers bearings in place.

X.4S1Q2D

3. Line up the holes in the rear thrust washer and front thrust washer with the shaft of the carrier.

4. Install the short pinion, spacer bushing and two front thrust washers and align the holes. Use care not to allow the rollers to move out of position.

Rear thrust washer

X45102E

TR -50

A4AF3, A4BF2

5. Insert the pinion shaft. Be sure that the flattened end of the pinion shaft fits properly into the hole in the rear thrust plate when the pinion shaft is inserted.

X45103A

6. Install the end plate in the outer race.

A451038

7. Press the overrunning clutch into the outer race. Be sure that the arrow on the outside circumference of the cage is pointi~ard as shown in the illustration when the OVerrunning clutch is.installed.

X4S100c

8. Apply petroleum jelly to the overrunning clutch end plate to retain it inside the overrunning clutch. Install the end plate in the clutch.

Y4S\04E

AUTOMATIC TRANSAXLE SYSTEM

ANNULUS GEAR AND OUTPUT FLANGE

COMPONENTS EOBl66F2

Output flange

Annulus gear

Snap ring

X45104A

DISASSEMBLY E56010FS

1. Remove the snap ring from the rear of the output flange.

J(4$loaB

TR-52

A4AF3, A4BF2

TRANSFER SHAFT

COMPONENTS E9EB89M

----f.---- Transfer shaft

EKPC041'"

DISASSEMBLY EB68i'372

REASSEMBLY E4413ABB

1. Using speciaI100f(09433-21000), remove the bearing from the transfer shaft.

"":;:./"

1. Press the bearing inner race on to the transfer shaft.

Y45074B

X451 066

REASSEMBLY EC21~

AUTOMATIC TRANSAXLE SYSTEM

TRANSFER DRIVEN GEAR

COMPONENTS E0A416FO

DISASSEMBLY .~.BCD51F6

1. Using special tool (09455-33000). pull off tapered 1 . Using special tool (094

roller bearing from the transfer driven gear. bearing onto the trans

X45105B