Technical Service Information Place the detent spring on the manual valve body and hand tighten the two bolts first. Then, tighten them with a torque wrench Torque: 110 kg-cm (8 ft-lb, 11. N-m) NOTE: Each bolt length (mm) is indicated in the figure. Check that the manual valve lever is touching the center of the detent spring tip roller. CONNECT SOLENOID CONNECTORS INSTALL OIL TUBES Using a plastic hammer, install the tubes into the positions indicated in the figure. CAUTION: Be careful not to bend or damage the tubes. INSTALL OIL PAN WITH NEW GASKET Torque: 50 kg-cm (43 in.-Ib, 4.9 N-m) INSTALL SPEED SENSOR Install a new O-ring to the speed sensor. Install the speed sensor to the transaxle case Tighten the bolt. Connect the sensor connector. 95Technical Service Information TROUBLESHOOTING Problem Possible cause Remedy Figs smells burnt | dacolored or Fluid contaminated Torque converter faulty Transmission faulty Replace fluid Replace torque converter Disassemble and inspect ‘Vehicle does not le any forward ra ge T/M control cable out of adjustment Valve body or primary regulator faulty Transmission faulty ‘Adjust control cable Inspect valve body Disassemble and inspect Vehicle does not in any range Park lock paw! faulty Valve body or primary regulator faulty Torque converter faulty Converter drive plate broken il Pump intake strainer blocked Transmission faulty Inspect park pawi Inspect valve body Replace torque converter Replace torque converter (Clean strainer Disassemble and inspect transmission incorrect ‘Shift lever position T/M control cable out of adjustment Manual valve and lever faulty Transmission faulty ‘Adjust control cable Inspect valve body Disassemble and inspect transmission Harsh engagement Into any drive range “Throttle cable out of adjustment Valve body or primary regulator faulty ‘Accumulator pistons faulty Transmission faulty ‘Adjust throttle cable Inspect valve body Inspect accumulator pistons Disassemble and inspect 3-00 up-shitt, or shifts from OD3 3-2 then shifts ba OD 0r3 Delayed 1:2, 23 or down: or | ck to Throttle cable out of adjustment Governor faulty Valve body faulty ‘Adjust throttle cable Inspect governor Inspect valve body 3.00 upsshitt, or + shudders on tal off ‘Slips on 1-2, 23 or slips ke T/M control cable out of adjustment Throttle cable out of adjustment Valve body faulty Transmission faulty ‘Adjust control cable Adjust throttle cable Inspect valve body Disassernble and inspect upsshitt Drag, binding oF tie-up on 1:2, 23 or 30D T/M control eable out of adjustment Valve body faulty Transmission faulty ‘Adjust control cable Inspect valve body Disassemble and inspect transmission Harsh downshift Throttle cable out of adjustment Accumulator pistons faulty Valve body faulty Transmission faulty ] Adjust throttle cable Inspect accumulator pistons Inspect valve body Disassemble and inspect coasting No downshift when Governor faulty Valve body faulty Tnipect governor Inspect valve body AUTOMATIC TRANSMISSION SERVICE GROUP 5[# Non-reusable part Piston Return Spring Technical Service Information Overdrive Brake COMPONENTS Piste petsiner | sccRng 0/2 cas 0/0 Brake Psion DISASSEMBLY OF OVERDRIVE BRAKE REMOVE RING RETAINERS Using needle nose pliers, remove the three ring retainers from the oil holes of the O/D case. INSTALL RING RETAINERS Using needle nose pliers, install the three ring retainers into the oil holes of the O/D case. CHECK PISTON STROKE OF OVERDRIVE BRAKE Place the 0/ case assembly onto the rear clutch assembly, 36(7 echnical Service Information Remove the sun gear Install the sun gear. CHECK PISTON STROKE OF SECOND BRAKE Piston stroke: 1.60 ~ 1.80 mm (0.0630 ~ 0.0785 in.) If the piston stroke is less than specified, parts may have been assembled incorrectly, check and reassemble again. If the piston stroke is not as specified, select another flange. NOTE: There are four different thicknesses for flange ‘anes, ey Sa eee |e wore] S001 | 2] ORA TL ste [2 | eon ) REMOVE FLANGE, DISCS AND PLATES Using @ screwdriver, remove the snap ring Using a screwdriver, install the snap ring NOTE: Be sure the end gap of the snap ring is not aligned the cutout portion of the center support. Remove the flange, four discs and four plates, INSTALL PLATES, DISCS AND FLANGE Install the four plates and four discs in order: P = Plate D = Disc P-D-P-D-P-D-P-D Remove the return spring. INSTALL PISTON RETURN SPRING Place the return spring on the brake piston 46INTRODUCTION TOYOTA / VOLVO A-40 SERIES The A-40 series of transmissions are covered in this manual. In the teardown and assembly section we use the A-43D transmission. We refer to the different valve body configurations where applicable. Although the A.40/41 are not overdrive transmissions, the assembly is quite similar. The A-40 series transmissions are mainly found in Toyota and Volvo vehicles. The units have minor differences and use different gaskets, seals and sealing rings. The Volvo units may be referred to as _BWS55"s or AWSS's, 70, etc, which should NOT BE. CONFUSED WITH THE ASS TRANSAXLE FOUND IN THE CEL. We have illustrated the various valve body gaskets, feed pipe configurations and check ball included some electrical diagnosis for the computer shifted A43DE and the newer A46DE found in the Toyota Previa. We advise that you match your valve body gaskets and bore fit your sealing rings at time of assembly. The information and part numbers contained in this booklet have beer: carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright© ATSG 1994 We thank Toyota Motor Company for the illustrations and information that have made this manual possible. ROBERT D. CHERRNAY TECHNICAL DIRECTOR DALE ENGLAND FIELD SERVICE CONSULTANT ED KRUSE TECHNICAL CONSULTANT JIMDIAL TECHNICAL CONSULTANT JERRY GOTT TECHNICAL CONSULTANT AUTOMATIC TRe SUITE 720 MIAMI, FL 33156 (305) 670-4161 EARLY TOYOTA T locations as well as valve body disassembly. We have also i: WAYNE COLONNA. TECHNICAL SUPERVISOR PETE LUBAN TECHNICAL CONSULTANT GREGORY LIPNICK ‘TECHNICAL CONSULTANT DAVID CHALKER TECHNICAL CONSULTANT SMISSION SERVICE GROUP 9200 S. DADELAND BLVD.TROUBLE SHOOTING DISASSEMBLY COMPONENT GROUP PUMP OVERDRIVE INPUT SHAFT OVERDRIVE CASE FRONT CLUTCH REAR CLUTCH CENTER SUPPORT PLANETARY GEAR SET TRANSMISSION CASE ASSEMBLY VALVE BODY/GASKETS TECHNICAL CHANGES IDENTIFICATION .. 12 15 20 23 a7 29 35 40 . 45 56 84 93 Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami, FL 33156 (305) 661-4161Technical Service Information TROUBLESHOOTING Problem Possible cause Fluid discolored or Fluid contaminated smels burnt | Torque converter faulty Transmission faulty Vehicle does not move | Manual shift linkage out of adjustment in any drive range Valve body or primary regulator faulty Parking lock pavi faulty Torque converter faulty Converter drive plate broken Oil pump intake strainer blocked Shift ever postion | Manual shit linkage ou of aiustment Manual valve and lever faulty Transmission faulty Throttle cable out of adjustment [Harsh engagement into any drive range valve body or primary regulator faulty Accumulator pistons faulty Transmission faulty Remedy Replace fluid Replace torque converter Disassemble and inspect transmission ‘Adjust shift linkage Inspect valve body Inspect parking paw! Replace torque converter Replace torque converter Clean strainer Adjust shift linkage Inspect valve body Disassemble and inspect transmission ‘Adjust throttle cable Inspect valve body Inspect accumulator pistons Disassemble and inspect transmission Delayed 1-2, 23 0r 3:00 up-shift, or downshifts trom OD:3 for 3:2 then shifts back 10 0D or 3 Valve body faulty Throttle cable out of adjustment Throttle cable and cam faulty Governor faulty Slips on 1-2, 2-3 or 3-00 up-shitt, oF slips or shudders on take-off Manual shift linkage out of adjustment Throttle cable out of adjustment Valve body faulty Transmission faulty Drag, binding or tiewp | Manual shift linkage out of adjustment 01-2, 2301300 | Vaive Body faulty upsshift Transmission faulty Adjust throttle cable Inspect throttle cable and cam Inspect governor Inspect valve body Adjust shift linkage Adjust throttle cable Inspect valve body Disassemble and inspect transmission ‘Adjust shift linkage Inspect valve body Disassemble and inspect transmission AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information TROUBLESHOOTING (Cont'd) Problem Harsh downshift No downshift when coasting Down-shift occurs too Quick oF too late while coasting No 00:3, 3:20 2-1 kick-down No engine braking in "2" range ae Vehicle does nat hold Possible cause Throttle cable out of adjustment ‘Throttle cable and cam faulty Accumulator pistons faulty Valve body faulty Transmission faulty Governor faulty Valve body faulty Throttle cable out of adjustment Throttle cable faulty Governor faulty Valve body faulty Transmission faulty Throttle cable out of adjsutment Governar faulty Valve body faulty Valve body faulty Transmission faulty Manual shift linkage out of adiustene Parking lock pawl cam and spring faulty | Remedy Adjust throttle cable Inspect throttle cable and cam | Inspect accumulator pistons lospect valve body Disassemble and inspect transmission Inspect governor Inspect valve body Adjust throttle cable i | | tnspect governor Inspect throttle cable Inspect vaive body Disassemble and inspect transmission Adjust throttle cable Inspect governor Inspect valve body Inspect valve body Disassemble and inspect, nt | Adjust shift linkage Inspect cam and spring AUTOMATIC TRANSMISSION SERVICE GROUP 4ATSG] Technical Service Information DISASSEMBLY OF TRANSMISSION SEPARATE BASIC SUBASSEMBLY REMOVE CLAMP FOR WIRING AND THROTTLE, CABLE REMOVE SOLENOID AND O-RINGS REMOVE SHIFT HANDLE REMOVE NEUTRAL START SWITCH REMOVE SPEEDOMETER DRIVEN GEAR ———] REMOVE SPEEO SENSOR (al Disconnect the wiring connector. “| (21 Remove ine speed sensor. REMOVE OIL PUMP (a) Remove the seven bolts, {b) Position SST on the shaft in back of the spline. SST 09610-20012 CAUTION: Do not damage the shaft bushing surface. Turn the end bolt of SST to free the pump. (cl Grasp the front pump stator shaft and pull the pump from the ease. WATCH FOR BEARING BEHIND OIL PUMPTechnical Service Information REMOVE CONVERTER HOUSING AND O-RING (a) Remove the two 12-mm bolts and four 10-mm bolts. {b) While holding the input shaft, remove the converter housing, REMOVE EXTENSION HOUSING AND GASKET REMOVE SPEEDOMETER DRIVE GEAR | emove SENSOR ROTOR, KEY AND SNAP RING FROM REMOVE GOVERNOR BODY FROM OUTPUT SHAFT {a} Loosen the staked part of the lock plate (b) Remove the governor body lock bolt. (c]_ While lifting the retaining clip with a larger screw. driver, slide off the governor body. IF NECESSARY, REMOVE GOVERNOR STRAINER (a) Remove the four screws and plate. (b) Remove the governor strainer from the case. REMOVE PAN AND GASKET (a) Remove the fourteen bolts. (b} Remove the pan with lifting the transmission case. CAUTION: Do not turn the transmission over as this will contaminate the valve body with foreign materials in the bottom of the pan.Technical Service Information EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan ‘and on the magnets to anticipate what type of wear you will find in the transmission: ‘Stee! (magnetic) = bearing, gear and clutch plate wear Brass (nonmagnetic) = bushing wear. A4oD TURN TRANSMISSION OVER AND REMOVE TUBES Pry up both tube ends with a large screwdriver and remove the tubes. REMOVE STRAINER AND GASKET Aa2D A43D REMOVE VALVE BODY (a) Remove the seventeen bolts. A43DL A44DL A45DL b) Disconnect the throttle cable from the cam and remove the valve body. A43DE A46DE REMOVE SOLENOID WIRING (a) Disconnect connector from the No. 1 and 2 solenoid and the No. 3 solenoid, {b) Remove the grommet from the transmission case (c)_ Pull the wiring out of the transmission case 7Technical Service Information COVER PISTON WITH A RAG AND, REMOVE ACCUMULATOR PISTONS AND SPRINGS WARNING: Keep your face away to avoid injury. Do not use regular high-pressure air. Position a rag to catch each piston. Using low-pressure ‘compressed air (1 kg/cm’, 14 psi or 98 kPa, max.), pop each piston into the rag. Force air into the holes shown, and remove the pistons and springs. REMOVE PARKING LOCK ROD REMOVE SPRING, PIVOT PIN AND PARKING LOCK PAWL IF NECESSARY REMOVE MANUAL LEVER AND SHAFT fa) Using a hammer and screwdriver, pry and shift the collar. (b) Using a hammer and punch, drive out the pin, (c}_ Slide the shaft out case and remove the detent plate. PLACE TRANSMISSION CASE ON CYLINDER Place the transmission on a cylindrical stand for more effi cient work. CAUTION: Place shop rags between the case and stand to avoid damaging the case. MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM SST on the case as shown in the figure. SST 09350-20013 Make 2 note of the distance for reassembly,TSG Technical Service Information REMOVE OVERDRIVE CLUTCH Grasp the shaft and pull out the overdrive clutch assembly. Watch for bearings and races on both sides of the assembly. REMOVE OVERDRIVE CASE AND BRAKE Hold both sides of the overdrive case and pull it out from the transmission case. Watch for bearings and races on both sides of the assembly. MEASURE DISTANCE BETWEEN TOP OF CASE FLANGE AND CLUTCH DRUM. Set SST in the case as shown in the figure. SST 09350-20013 Make a note of the finding for reassembly. REMOVE FRONT CLUTCH AND BEARINGS Grasp the shaft and pull out the front clutch assembly. Watch for bearings and races on both sides of the assembly, REMOVE BEARING AND RACE REMOVE REAR CLUTCH Grasp the clutch hub and pull it out from the case.Technical Service Information REMOVE CENTER SUPPORT AND SUN GEAR (a) Remove the two center support bolts. (b) Grasp the assembly and pull out the center support with the sun gear. REMOVE REACTION PLATE RETAINING RING Using a long screwdriver, compress the snap ring and then lift it above the groove with a wire hook. REMOVE REAR PARTS GROUP Grasp the intermediate shaft and pull out the rear parts group. I the brake apply tube and rear thrust bearing and races, do not come out with the assembly, remove them from the case, BASIC DISASSEMBLY IS COMPLETE The transmission is now in basic component subassemblies. Next, you will disassemble, clean, inspect, repair and as semble each of these component groups. AUTOMATIC TRANSMISSION SERVICE GROUP 10-@4aTsa Technical Service Information COMPONENT GROUP DISASSEMBLY, INSPECTION AND ASSEMBLY The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion of similar-looking parts from different subassemblies being on your workbench at the same time. ‘The component groups are inspected and repaired from the converter housing side. GENERAL CLEANING All disassembled parts should be washed clean and the fluid passages and holes blown through with compressed air to make sure that, they are not clogged. When using compressed air to dry parts, keep face away to avoid spraying solvent in your face. in proper order to allow performing the inspec ion, repairs, and reassembly with efficiency When disassembling a valve body, be sure to keep each valve together with the correspond: ing spring GENERAL ASSEMBLY Alll oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reas- sembly. All gaskets and rubber O-rings should be replaced, ‘Make sure that the ends of a snap ring are not, aligned with one of the cutouts and are in- stalled in the groove correctly, As much as possible, complete the inspection, repair, assembly before proceeding to the next com- ponent group. If a component group cannot be as sembled because parts are being ordered, be sure to keep all parts of that group in a separate con: tainer while proceeding with disassembly, inspec: tion, repair and assembly of other component groups. Cleaning solvent used should be the recom: mended ATF or kerosene. New brakes and clutches that are to be used for replacement must be soaked in transmis: sion fluid for at least two hours before as: sembly. If a worn bushing is to be replaced, the replacement must be made with the subas sembly containing that bushing. Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts in place. AUTOMATIC TRANSMISSION SERVICE GROUP ee PARTS ARRANGEMENT After cleaning, the parts should be arranged@: Non-reusabie \ Technical Service Information Pump Body | eon part — eee | Oil Pump Drive Gear Pump Cover I Oriven Gear Ot Seat Ring | DISASSEMBLY OF OIL PUMP USE TORQUE CONVERTER AS A WORK STAND REMOVE TWO OIL SEAL RINGS FROM PUMP COVER REMOVE PUMP COVER REMOVE O-RING FROM PUMP LIFT PUMP OFF CONVERTER AND REMOVE OIL PUMP DRIVE GEAR AND DRIVEN GEAR Identify the top and bottom and keep in assembly order. “12.Technical Service Information INSPECTION OF OIL PUMP CHECK BODY CLEARANCE OF DRIVEN GEAR, Push the driven gear to one side of the body. Using a feel- er gauge, measure the clearance. Standard body clearance: 0.07 ~ 0.15 mm (0.0028 — 0.0059 in.) Maximum body clearance: 0.3 mm (0.012 in.) CHECK TIP CLEARANCE OF BOTH GEARS Measure between the gear teeth and the cresent-shaped part of the pump body. Standard tip clearance: 0.11 — 0.14 mm. {0.0043 — 0.0055 in.) Maximum tip clearance: 0.3 mm (0.012 in.) CHECK SIDE CLEARANCE OF BOTH GEARSTechnical Service Information ASSEMBLY OF OIL PUMP. INSTALL DRIVEN GEAR AND DRIVE GEAR AND SET PUMP BODY ON TORQUE CONVERTER Make sure the top of the gears is facing upward LOOSELY INSTALL PUMP COVER Align the bolt holes and drop the pump cover into place. Install the six bolts with wave washers finger tight ALIGN PUMP AND PUMP COVER Install the SST around the pump and cover. Tighten SST to align the pump and cover SST 09350-20013 TIGHTEN SIX PUMP COVER BOLTS Torque: 75 kg-om (66 in.-Ib, 7.4 Nem) INSTALL TWO OIL SEAL RINGS ON PUMP COVER Spread the rings apart and slide them into the groove. Hook both ends by hand Wipe off excess petroleum jelly. INSTALL NEW O-RING ON PUMP COVER Make sure 2 new O-ring is not twisted and is fully seated in the groove CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with SST and make sure that it rotates smoothly. SST 09350-20013 AUTOMATIC TRANSMISSION SERVICE GROUP 14ATSG] Technical Service Information Overdrive Input Shaft and Clutch Spring Retainer Plate Dise 00 Cluteh Hub Snap Ring | | Ftange Snap Ring Piston Return Spring 00 clutch ison | (00 ciuten Gram Outer Race Thrust Washer | Bearing Washer | Thrust Washer P48 Snap Ring One-Way Clutch Planetary Gear DISASSEMBLY OF OVERDRIVE INPUT SHAFT AND CLUTCH REMOVE THRUST BEARINGS AND RACES FROM OVERDRIVE INPUT SHAFT (a) Slide off the thrust bearing and race from the clutch side by hand. Note the position of the races. (b) Using a screwdriver, pry off the thrust washer from the planetary gear side. PULL OVERDRIVE CLUTCH ASSEMBLY FROM INPUT SHAFT CAUTION: Be careful that the thrust bearing and race do not fall out. REMOVE THRUST BEARING AND RACE Note the position of the race. 15Technical Service Information CLUTCH ASSEMBLY PLATE SNAP RING ring. SST 09350-20013 BLOW OUT PISTON REMOVE CLUTCH PISTON O-RINGS GEAR ASSEMBLY FROM PLANETARY GEAR ASSEMBLY ing them: 16. REMOVE SNAP RING AND HUB FROM OVERDRIVE REMOVE THINNER SNAP RING, FLANGE, DISC AND COMPRESS PISTON RETURN SPRINGS AND REMOVE Place SST on the spring retainer and compress the springs with a shop press. Using a screwdriver, remove the snap REMOVE SPRING RETAINER AND EIGHTEEN SPRINGS ASSEMBLE OVERDRIVE CLUTCH ON OIL PUMP AND {a} Slide the overdrive clutch onto the oil pump. (b) Apply compressed air to the oil pump to remove the piston. (If the piston does not come out completely use needle-nose pliers to remove it.) {c) Remove the overdrive clutch from the oil pump. REMOVE SNAP RING FROM OVERDRIVE PLANETARY REMOVE THRUST WASHERS AND ONE-WAY CLUTCH CAUTION: Be careful not to lose the four plugs. REMOVE FOUR PLUGS WITH MAGNETIC FINGER CAUTION: Keep the four plugs together to prevent los-Technical Service Information eee REMOVE ONE-WAY CLUTCH FROM OUTER RACE Note the direction of the one-way clutch. INSPECTION OF OVERDRIVE INPUT SHAFT AND. CLUTCH INSPECT CLUTCH PISTON (a) Chack that check ball is fre by shaking the piston. (b) Check that the valve does not leak by apply low: pressure compressed ait NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATF ASSEMBLY OF OVERDRIVE INPUT SHAFT AND CLUTCH INSTALL FOUR PLUGS INSTALL THRUST WASHER AND BEARING (a) Coat parts with petroleum jelly to hold them in place. {b) Slide bearing and then thrust washer facing lip outward, ASSEMBLE ONE-WAY CLUTCH (a) Install the one-way clutch into the outer race. (b} Install a retainer on both sides of the one-way clutch, INSTALL THRUST WASHER AND ONE-WAY CLUTCH (a) _ Install the thrust washer, facing the grooves upward (b) Install the one-way clutch in correct direction. (c) Install the thrust washer. (d} Install the snap ring. NOTE: Be sure that the spring cage side of the one-way clutch faces toward the front of the transmission. “17Technical Service Information INSTALL CLUTCH PISTON IN OVERDRIVE CLUTCH DRUM (a) Install new O-rings on the piston. Coat the O-rings with ATF (bo) Press the piston into the drum with the cup side up, being careful not to damage the O-ring, INSTALL EIGHTEEN PISTON RETURN SPRINGS AND SET RETAINER AND SNAP RING IN PLACE COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring retainer, and compress the springs on a shop press. SST 09350-20013 (b} Install the snap ring with a screwdriver. INSTALL PLATE, DISC AND FLANGE WITHOUT ASSEMBLING THINNER SNAP RING fa) Do not assemble the thinner snap ring yet. {b) Using low-pressure compressed air, blow all excess ATF from the disc. CAUTION: High-pressure air will damage the disc. Install in order: Plate-disc-flange {flat end down) CHECK PISTON STROKE OF OVERDRIVE CLUTCH (a) Install the overdrive clutch hub and outer snap ring. (b) Install the front clutch drum onto the oil pump body. With a dial indicator, measure the stroke applying and releasing the compressed air (4 — 8 kg/cm?, 57 — 114 psi or 392 — 785 kPa} as shown, Standard piston stroke: 1.47 — 2.28 mm (0.0579 — 0.0898 in.) If the stroke exceeds limit, the clutch pack is probably worn. If the stroke is less than the limit, parts may be misassem- bled or there may be excess ATF on the discs, INSTALL THINNER SNAP RING IN OVERDRIVE CLUTCH DRUM (a) Remove the overdrive clutch outer snap ring and hub to allow installation of the thinner snap ring. (b) Compress and lower the snap ring into the groove by hand. Check that the ends of the snap ring are not aligned with one of the cutouts,Technical Service Information INSTALL HUB AND OUTER SNAP RING Check that the ends of the snap ring are not aligned with ‘one of the cutouts. ASSEMBLE OVERDRIVE CLUTCH DRUM AND OVERDRIVE PLANETARY GEAR Mesh the hub with the disc, twisting and jiggling the hub as required CHECK OPERATION OF ONE-WAY CLUTCH Hold the clutch drum and turn the input shaft. The input shaft should turn freely clockwise and should lock coun- terclockwise. KEEP THRUST WASHER, THRUST BEARINGS AND RACE TOGETHER AUTOMATIC TRANSMISSION SERVICE GROUP “19Technical Service Information REMOVE RING GEAR AND THRUST WASHER, REMOVE THRUST BEARING AND RACES FROM OVERDRIVE CASE Note the position of the races. REMOVE SNAP RING, SPRING RETAINER AND RETURN SPRINGS REMOVE BRAKE PISTON Blow compressed air through the case hole indicated in the figure to pop out the brake piston. If the piston does not pop out, lift it out with needle-nose pliers. REMOVE TWO OIL SEAL RINGS FROM OVERDRIVE CASE REMOVE O-RINGS FROM PISTON INSPECTION OF OVERDRIVE CASE AND BRAKE NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATE. ASSEMBLY OF OVERDRIVE CASE AND BRAKE INSTALL TWO OIL SEAL RINGS ON OVERDRIVE CASE Spread the rings apart and slide them into the groove. Hook both ends by hand INSTALL NEW O-RING ON PISTON PotTechnical Service Information REMOVE RING GEAR AND THRUST WASHER REMOVE THRUST BEARING AND RACES FROM OVERDRIVE CASE Note the position of the races REMOVE SNAP RING, SPRING RETAINER AND RETURN ‘SPRINGS REMOVE BRAKE PISTON Blow compressed air through the case hole indicated in the figure to pop out the brake piston. If the piston does not pop out, lift it out with needle-nose pliers REMOVE TWO OIL SEAL RINGS FROM OVERDRIVE CASE REMOVE O-RINGS FROM PISTON INSPECTION OF OVERDRIVE CASE AND BRAKE NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATE. ASSEMBLY OF OVERDRIVE CASE AND BRAKE INSTALL TWO OIL SEAL RINGS ON OVERDRIVE CASE ‘Spread the rings apart and slide them into the groove. Hook both ends by hand INSTALL NEW O-RING ON PISTONTechnical Service Information INSTALL BRAKE PISTON IN OVERDRIVE CASE Install the piston with cup side up, being careful not to damage the O-rings. INSTALL TWELVE RETURN SPRINGS AND SET RETAINER AND SNAP RING IN PLACE Check that the ends of snap ring are not aligned with one of the cutouts INSTALL THRUST BEARING AND RACES TO RING GEAR AND SET RING GEAR IN OVERDRIVE CASE NOTE: Make sure that the races are installed in correct direction INSTALL CUSHION PLATE, DISCS, PLATES AND FLANGE Using low-pressure compressed alr, blow all excess ATF from the discs. CAUTION: High-pressure air will damage the discs. Install in order: Cushion plate (rounded end down)-plate- disc-plate-disc-plate-disc-flange (flat side down) INSTALL SNAP RING Check that the ends of the snap ring are not aligned with one of the cutouts.” MEASURE BRAKE CLEARANCE Measure the distance between the snap ring and flange Standard clearance: 0.40 — 1.38 mm (0.0157 — 0.0543 in.) KEEP THRUST WASHER FOR ASSEMBLY The thrust washer left over will be installed later, as the transmission is assembled 22Technical Service Information Front Clutch Front Clutch Drum Piston Piston Retuen ‘Thrust Bearing Race | Rear Clutch Hub Front Clutch Hub DISASSEMBLY OF FRONT CLUTCH REMOVE THRUST BEARINGS AND RACES FROM BOTH SIDES OF CLUTCH Note the position of the races USE EXTENSION HOUSING AS WORK STAND REMOVE SNAP RING FROM FRONT CLUTCH DRUM REMOVE FRONT AND REAR CLUTCH HUB Lift out the two clutch hubs together. -23-Technical Service Information REMOVE THRUST BEARING AND RACES Note the position of the races REMOVE DISC REMOVE THINNER SNAP RING REMOVE REMAINING CLUTCH PLATES AND DISCS COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING Place SST on the spring retainer and compress the springs with 3 shop press Remove the snap ring with 2 screwdriver SST 09350-20013 REMOVE SPRING RETAINER AND EIGHTEEN SPRINGS ASSEMBLE FRONT CLUTCH ON OVERDRIVE CASE AND BLOW OUT PISTON (a) Slide the front clutch onto the overdrive case. (b) Apply compressed air to the overdrive case to remove the piston. (If the piston does not come out, use pli ers to remove it.) (c)_ Remove the front clutch from the overdrive case REMOVE O-RINGS FROM PISTON INSPECTION OF FRONT CLUTCH INSPECT FRONT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that valve does not leak by applying low- pressure compressed air. NOTE: Do not allow the discs to ¢., out. Prepare new discs by soaking them at least two hours in ATE. -24-Technical Service Information ASSEMBLY OF FRONT CLUTCH (See page AT-64) INSTALL NEW O-RINGS ON PISTON INSTALL PISTON IN FRONT OF CLUTCH DRUM Press the piston into the housing with the cup side up (check ball down) Be careful not to damage the O-rings. INSTALL EIGHTEEN PISTON RETURN SPRINGS, SPRING RETAINER AND SNAP RING IN PLACE COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring retainer, and compress the springs with a shop press. SST 09350-20013 (b) Install the snap ring with a screwdriver, INSTALL DISCS AND PLATES WITHOUT ASSEMBLING ‘THINNER SNAP RING {2} Do not assemble the thinner snap ring yet. {b) Using low-pressure compressed air, blow all ex cess ATF from the discs. For measurement of the clutch pack, install all plates and discs [temporari ly without thinner snap ring) CAUTION: High-pressure air will damage the discs. Install in order: Plate-disc-plate-dise-plate-disc-plate (no snap ring)-disc CHECK PISTON STROKE OF FRONT CLUTCH (a) Install the rear clutch hub and the outer snap cing. (b) Install the front clutch drum onto the overdrive With a dial indicator, measure the stroke applying and releasing the compressed air (4 — 8 kg/cm’, 57 — 114 psi or 392 — 785 kPa) as shown Standard piston stroke: 1.40 — 2.24 mm | (0.0551 — 0.0882 in.) If not within specification, select proper plate. NOTE: There are two different thickness. Plate thickness: 1.8 mm (0.071 in.) 2.0 mm (0.079 in.) AUTOMATIC TRANSMISSION SERVICE GROUP -25-Technical Service Information INSTALL THINNER SNAP RING IN CLUTCH DRUM. (a) Remove the outer snap ring, rear clutch hub and disc to allow installation of the thinner snap ring. {b) Compress and lower the snap ring into the groove by hand. Check that the ends of the snap ring are not aligned with one of the cutouts. INSTALL DISC INSTALL INNER THRUST BEARING AND RACES IMPORTANT: Coat parts with petroleum jelly to hold them in place. Install the inner race, needle bearing and outer race. Press them into place. NOTE: Face the lip of race toward the front of the clutch body. INSTALL FRONT CLUTCH HUB Align the disc lugs with the hub teeth. Make sure the hub meshes with all discs and is fully inserted. INSTALL REAR CLUTCH HUB AND OUTER SNAP RING Check that the snap ring ends are not aligned with one of the cutouts. NOTE: Note the position of the inner thrust bearing and races, and keep them together until assembly. KEEP THRUST BEARINGS AND RACES TOGETHER AUTOMATIC TRANSMISSION SERVICE GROUP 26P4ATSG Technical Service Informatior + . Rear Clutch Snap Ring Rear Clutch Drum ‘Spring Retainer | ton Return Soring O-Ring Piston DISASSEMBLY OF REAR CLUTCH REMOVE OUTER CLUTCH PACK RETAINING SNAP RING FROM DRUM. REMOVE CLUTCH FLANGE, DISCS AND PLATES COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING Place SST on the spring retainer and compress the springs with 9 shop press. Using a screwdriver, remove the snap ring SST 09350-20013 REMOVE SPRING RETAINER, SNAP RING AND EIGHTEEN RETURN SPRINGS ASSEMBLE REAR CLUTCH ON CENTER SUPPORT AND BLOW OUT PISTON a) Slide rear clutch onto the center support. (0) Apply compressed air to center support to remove the piston. (If the piston does not come out, use pliers to remove it.) [c) Remove the front clutch from the center support. REMOVE O-RINGS FROM REAR CLUTCH PISTON -27-Technical Service Information INSPECTION OF REAR CLUTCH INSPECT REAR CLUTCH PISTON (a) Check that check ball is free by shaking each piston. (0) Check that the valve is net leaking by applying low- pressure compressed air NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATE, ASSEMBLY OF REAR CLUTCH (See page AT-68) 1. INSTALL NEW O-RINGS ON PISTON 2. INSTALL REAR CLUTCH PISTON IN DRUM. Press rear clutch piston into drum with the cup side up, being careful not to damage the O-rings. 3. INSTALL EIGHTEEN PISTON RETURN SPRINGS AND SET RETAINER WITH SNAP RING IN PLACE 4. COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE a) Place SST on the spring retainer, and compress the springs on shop press. SST 09350-20013 (b) Install the snap ring with snap ring pliers. 5. INSTALL DISCS, PLATES AND FLANGE Using low-pressure compressed air, blow all excess ATF from discs. CAUTION: High-pressure air will damage the discs. Install in order: Plate-disc-plate-disc-plate-disc-flange (flat end down} 6. INSTALL SNAP RING Check that the snap ring ends are not aligned with one of the cutouts. 7. CHECK PISTON STROKE OF REAR CLUTCH Install the rear clutch onto the center support. With a dial indicator, measure the stroke applying and releasing the compressed air (4 — 8 kgicm?, 57 — 114 psi or 392 785 kPa) as shown. Standard piston stroke: 0.90 — 1.75 mm (0.0354 — 0.0689 in.) Hf not within specification, select a proper flange. There are three different thickness. Flange thickness: 3.6 mm, 3.8 mm, 4.0 mm (0.142 in., 0.150 in., 0.15: -28-4 ATSG Technical Service Informatior Center Support AssemblyTechnical Service Information COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING Place SST on spring retainer and compress the springs with a shop press. Using a screwdriver, remove the snap ring SST 09350-20013 REMOVE SPRING RETAINER AND TWELVE SPRINGS REMOVE NO. 1 BRAKE PISTON Blow compressed air through the center support oil hole to remove the No. 1 brake piston Hf the piston does not pop out, lift it out with needle-nose pliers. REMOVE NO. 1 BRAKE PISTON O-RINGS.Technical Service Information REMOVE THREE OIL SEAL RINGS FROM CENTER SUPPORT CAUTION: Do not spread the ring ends too much. REMOVE ONE-WAY CLUTCH ASSEMBLY AND OIL SEAL RINGS FROM SUN GEAR INSPECTION OF CENTER SUPPORT ASSEMBLY CHECK OPERATION OF ONE-WAY CLUTCH Hold the No. 2 brake hub and turn the sun gear. The sun gear should turn freely counterclockwise and should lock clockwise. If the one-way clutch does not work properly, replace it. IF NECESSARY, REPLACE ONE-WAY CLUTCH (a) Bend several tabs back with a tapered punch. (b) Pry off the retainer with a screwdriver. Leave the other retainer on the hub. (c)_ Remove the one-way clutch. {d) Install the one-way clutch into the brake hub, facing the spring cage toward the front.Technical Service Information {e) Hold the brake hub in a vise with soft jaws, and flat- ten the ears with a chisel {f) Check to make sure that the retainer is centered NOTE: Do not allow the discs to dry out. Prepare new discs by soaking them at least two hours in ATF ASSEMBLY OF CENTER SUPPORT ASSEMBLY (See page AT-70) INSTALL TWO OIL SEAL RINGS AND ONE-WAY CLUTCH ASSEMBLY ON SUN GEAR INSTALL THREE OIL SEAL RINGS ON CENTER SUPPORT Spread the rings apart and slip them into the groove. Hook both ends by hand. INSTALL NEW O-RINGS ON PISTON INSTALL NO. 1 BRAKE PISTON IN CENTER SUPPORT Press the No. 1 brake piston into the center support with the cup side up, being careful not to damage the O-rings. INSTALL TWELVE PISTON RETURN SPRINGS AND SET RETAINER WITH SNAP RING IN PLACE COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring retainer, and compress the springs on a shop press. SST 09350-20013 (b) Install the snap ring using a screwdriver “32Technical Service Information INSTALL NEW O-RINGS ON PISTON AND CENTER ‘SUPPORT ‘TURN CENTER SUPPORT OVER AND INSTALL NO. 2 BRAKE PISTON Press the No. 2 brake piston into the center support with the cup side up, being careful not to damage the O-rings. INSTALL TWENTY PISTON RETURN SPRINGS AND SET RETAINER WITH SNAP RING IN PLACE COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE la) Place SST on the spring retainer, and compress the springs on a shop press. SST 09350-20013 (b) Install the snap ring with a screwdriver. TURN CENTER SUPPORT OVER AND INSTALL NO. 1 BRAKE PISTON PLATE, DISC AND FLANGE Using the low-pressure compressed air, blow all excess ATF from the disc. CAUTION: High-pressure air will damage the disc. Install in order: Plate-disc-plate-plate-disc-flange (rounded edge down) INSTALL SNAP RING IN CENTER SUPPORT Check that snap ring ends are not aligned with one of the cutouts, CHECK PISTON STROKE OF NO. 1 BRAKE With a dial indicator, measure the stroke applying and releasing the compressed air (4 — 8 kgicm?, 57 — 114 psi or 392 — 785 kPa) as shown, Standard piston stroke: 0.80 — 1.73 mm (0.0315 — 0.0681 in.) Il the stroke exceeds the limit, the clutch pack is probably wor). If the stroke 1s less than the limit, parts may bo mis: assomblad oF there may be excoss ATF on tho discs. TURN CENTER SUPPORT OVER AND INSTALL NO. 2 BRAKE PLATES, DISCS AND FLANGE Using the low-pressure compressed air, blow all excess ATF from the discs. CAUTION: High-pressure air will damage the disc. Install in order: Plate-dise-plate-disc-plate-disc-flange (flat side down) INSTALL SNAP RING IN CENTER SUPPORT Check that the snap ring ends are not aligned with one of the cutouts. “33Technical Service Information CHECK PISTON STROKE OF NO. 2 BRAKE With a dial indicator, measure the stroke applying and releasing the compressed air (4 — 8 kgicm?, 57 — 114 psi or 392 — 785 kPa) as shown. Standard piston stroke: 1.01 — 2.25 mm (0.0398 — 0.0886 in.) If the stroke exceeds the limit, the clutch pack is probably worn. If the stroke is less than the limit, parts may be mis: assembled or there may be excess ATF on the discs. ASSEMBLE CENTER SUPPORT AND SUN GEAR SHAFT (a) Align the brake No. 2 disc flukes. {b) Mesh the brake hub with the discs, twisting and jig gling the hub as required. INSTALL SNAP RING ON END OF SUN GEAR SHAFT AUTOMATIC TRANSMISSION SERVICE GROUP “34@4ATSG Technical Service Informatior Planetary Gear Output Shaft Race Set Ring Ring Gear Steel Washer | | Rear Pianetary Gear snap ins Pressure Pate Reveton Pe ‘appt Tobe Die Seap Ring | | Puce | | One-Way Clutch eh} 0) By) Front Planetary Gear Nylon Washer Theust Bearing | | out seat Ring | | Race oleput shane THU Bearing Thrust Bearing Imace set ing Ring Gear Race DISASSEMBLY OF PLANETARY GEAR OUTPUT SHAFT REMOVE NO. 3 BRAKE DISC/PLATE PACK AND FRONT PLANETARY PINION GEARS Grasp the components and pull off the front end of the out put shaft, Be careful to avoid dropping the bearing on the output shaft REMOVE THRUST WASHER FROM PLANETARY GEARS NOTE: The thrust washer may have stuck to the inside of the planetary gear case. REMOVE BRAKE DISCS AND PLATES FROM PLANETARY GEARS REMOVE REACTION PLATE FROM PLANETARY GEARS “35Technical Service Information REMOVE SNAP RING AND ONE-WAY CLUTCH FROM PLANETARY GEARS REMOVE NYLON THRUST WASHER FROM PLANETARY GEARS REMOVE APPLY TUBE AND CLUTCH PRESSURE PLATE COMPRESS SHAFT SNAP RING AND REMOVE FRONT PLANETARY RING GEAR ‘While pulling up the ring gear, compress the snap ring with snap ring pliers and pull out the ring gear by hand REMOVE INTERMEDIATE SHAFT, RING GEAR AND PLANETARY GEAR FROM OUTPUT SHAFT ASSEMBLY REMOVE THRUST BEARING AND RACES FROM OUTPUT SHAFT ASSEMBLY Note the position of the races REMOVE THREE OIL SEAL RINGS FROM OUTPUT SHAFT REMOVE STEEL THRUST WASHER AND REAR PINION GEARS FROM INTERMEDIATE SHAFT ASSEMBLY REMOVE RACE AND THRUST BEARING FROM INTERMEDIATE SHAFT Note the position of the raceTechnical Service Information INVERT INTERMEDIATE SHAFT AND REMOVE SET RING REMOVE REAR PLANETARY RING GEAR AND BEARING RAGE FROM INTERMEDIATE SHAFT Note the position of the race. INSPECTION OF PLANETARY GEAR OUTPUT SHAFT ATF. ASSEMBLY OF PLANETARY GEAR OUTPUT SHAFT INSTALL THRUST BEARING RACE AND REAR PLANETARY RING GEAR ON INTERMEDIATE SHAFT Slip the thrust bearing race and ring gear onto the shaft with the exterior splines up, as shown. INSTALL SET RING ON INTERMEDIATE SHAFT Push down and wind the set ring into place. Check to make sure it is secure. TURN OVER INTERMEDIATE SHAFT AND INSTALL THRUST BEARING AND RACE Make sure the flat side of the race is against the bearing INSTALL PINION GEAR ASSEMBLY AND STEEL THRUST WASHER ON REAR PLANETARY CARRIER Install the washer with the lugs down, fitting into the rear planetary gear carrier. CAUTION: Make sure the different lug shapes match the ‘openings on the plate. -37- | | \ NOTE: Do not allow the discs to dry out Prepare new discs by soaking them at least two hours in |Technical Service Information INSTALL THREE OIL SEAL RINGS ON OUTPUT SHAFT ‘Spread the rings apart and slide them into the groove. Hook both ends by hand INSTALL THRUST BEARING AND RACE ON OUTPUT SHAFT Hold the cup of the race toward the bearing, USE EXTENSION HOUSING AS ASSEMBLY STAND INSTALL INTERMEDIATE SHAFT ASSEMBLY IN OUTPUT SHAFT INSTALL REAR PLANETARY CARRIER IN OUTPUT SHAFT Slide the carrier into place, and make sure that the lugs interlock. SET IN PLACE FRONT PLANETARY RING GEAR Slide the snap ring downward, and align the lugs with the notches, ‘Align the ends of the snap ring with the wide gap between the teeth: INSTALL FRONT PLANETARY RING GEAR WITH SNAP RING While pushing down the ring gear, squeeze the snap ring end with snap ring pliers and install it into the groove, NOTE: When the snap ring is fully seated, the gap is the width of one lug. INSTALL NYLON THRUST WASHER IN FRONT PLANETARY PINION GEAR Face the lugs downward and match them with the slots in back of the planetary gear. INSTALL ONE-WAY CLUTCH Install the one-way clutch into the outer race, facing the spring cage toward the front. -38-Technical Service Information TEMPORARILY INSTALL REACTION PLATE ON PLANETARY Insert the plate into place for testing of the one-way clutch. TEST ONE-WAY CLUTCH The planetary gear must rotate freely counterclockwise and lock clockwise. If the clutch does not work correctly, it must be replaced. REMOVE REACTION PLATE INSTALL NYLON THRUST WASHER ON FRONT PLANETARY CARRIER Apply petroleum jelly to the washer to hold it in place dur- ing later assembly. Match the lugs with the planetary carrier INSTALL FRONT PLANETARY GEAR ASSEMBLY TO oe INTERMEDIATE SHAFT INSTALL PRESSURE PLATE Install the pressure plate, facing the flat surface toward the intermediate shaft. INSTALL NO. 3 BRAKE CLUTCH PACK Using low-pressure compressed air, blow all excess ATF from discs. CAUTION: High-pressure air will damage the discs. Install_in order: Disc-plate-disc-plate-disc-plate-disc- plate-disc KEEP INNER RACE, APPLY TUBE, THRUST BEARING AND RACE TOGETHER AUTOMATIC TRANSMISSION SERVICE GROUP -38-ATSGI Technical Service Information Transmission Case and Rear Brake Pistons ssi | | Outer Piston | 2 | | 4 Non eusable part _ a DISASSEMBLY OF TRANSMISSION CASE AND REAR BRAKE PISTONS. COMPRESS RETURN SPRINGS AND REMOVE SPRING RETAINER SNAP RING la) Install the SST. Gradually and evenly tighten the bolt to compress the springs, being careful not to damage the transmission case with SST. SST 09350-20013 (b) Using a screwdriver and hook, remove the snap ring, REMOVE SPRING RETAINER AND SIXTEEN SPRINGS -40-Technical Service Information REMOVE OUTER PISTON AND REACTION SLEEVE WITH COMPRESSED AIR (a) Remove the adapter. (b) Place several clean shop rags on the piston to catch the piston and sleeve. To pop them out, apply com- pressed air to the outer and inner piston oil holes. If the piston and sleeve do not pop out with the compressed air (c)_ Using needle-nose pliers, lift out the piston from the (d)__ Insert two long hooks behind the reaction sleeve and gradually lift it out of the case. (e) Using hooks, lift the inner piston out of the case in the same manner. REMOVE O-RINGS FROM OUTER AND INNER PISTONS AND REACTION SLEEVE INSPECTION OF CASE COMPONENT GROUP REPLACEMENT OF MANUAL SHAFT OIL SEALS (a) Remove the manual shaft oil seals with a screwdriver (b) Drive in new left and right oil seals with SST. SST 09350-20013Technical Service Information ASSEMBLY OF TRANSMISSION CASE AND REAR BRAKE PISTONS (See page AT-81) INSTALL NEW O-RINGS ON REACTION SLEEVE AND PISTONS CAUTION: The thinner O-ring goes on the outside of the reaction sleeve. INSTALL INNER AND OUTER PISTONS IN REACTION SLEEVE (a) Push the inner piston into the cupped side of the reac- tion sleeve, (b) Push the outer piston onto the other side of the reac. tion sleeve. INSTALL PISTONS AND SLEEVE IN CASE CAUTION: Be careful not to damage the O-rings. Hold the assembly with the outer piston upward (spring seats visible), and push the assembly into its bore in the INSTALL SST BASE UNDER CASE SST 09350-20013 INSTALL SIXTEEN PISTON RETURN SPRINGS AND SET RETAINER WITH SNAP RING IN PLACE NOTE: The springs are visible through the cutout in the case, which helps position them more easily. COMPRESS PISTON RETURN SPRINGS TO ALLOW INSTALLATION OF SNAP RING CAUTION: Do not overtighten the bolt and bend the spring retainer, (a) Carefully position the spring compressor on the spring retainer (b) Gradually and evenly tighten the bolt to compress the springs, being careful not to damage the transmission case with SST SST 09350-20013 INSTALL SNAP RING (a) Push the ring into place with your fingers. Visually check to make sure it is fully seated and centered by the three lugs on the spring retainer. (b) Remove the SST. SST 09350-20013 KEEP MANUAL VALVE LEVER. PARKING LOCK PAWL AND ACCUMULATOR 42(install SS toe SST 19.7 — 20.9 mm (0.778 ~ 0.799 in.) oa Sst Technical Service Information Extension Housing INSPECTION OF SPEEDOMETER GEAR AND EXTENSION HOUSING IF NECESSARY, REPLACE SPEEDOMETER GEAR OIL SEAL (a) Using SST, remove the oil seal SST 09921-00010 {b) Using SST, install the new oil seal, SST 09201-60011 IF NECESSARY, REPLACE OIL SEAL AND DUST SEAL (a) Using SST, remove the oil seal. SST 09308-10010 (b) Using SST, drive in a new oil seal and dust seal SST 09325-20010 Torque Converter CLEAN TORQUE CONVERTER If the transmission is contaminated, the torque converter and transmission cooler should be thoroughly flushed, us. ing Toyota Transmission Cleaner. INSPECTION OF TORQUE CONVERTER INSERT SST IN END OF TORQUE CONVERTER {a} Insert a turning tool in the inner race of the one-way clutch. (b) Install the stopper so that it fits in the notch of the converter hub and other race of the one-way clutch. SST 09350-20013 43Technical Service Information ‘TEST ONE-WAY CLUTCH The clutch should lock when turned counterclockwise, and should rotate freely and smoothly clockwise. Less than 25 kg-em (22 in.-Ib, 2.5 N-m) of torque should be required to rotate the clutch clockwise. If necessary, clean the con- verter and retest the clutch. Replace the converter if the clutch still fails the test Electrical Parts INSPECT SOLENOID Check the resistance between the terminal and body. Standard resistance: 11 — 15 9 INSPECT NEUTRAL START SWITCH Using an ohmmeter, check the continuity of the terminals for each switch position shown in the table below If continuity between the terminals is not as specified, replace the switch [Srerminal Range 9 INSPECT SPEED SENSOR Connect on ohmmeter to the speed sensor and check that the meter deflects when the sensor is repeatedly brought close to the rotor sensor magnet and removed from it. eaeATSG] technical Service Information ASSEMBLY OF TRANSMISSION Disassembly. inspection and assembly of each com- ponent group have been indicated in the preced- ing chapter. This chapter deals with assembly of ‘AA3DE transmission. GENERAL ASSEMBLY NOTE: The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance, Before assembling new clutch discs, soak them in automatic transmission fluid for at least two hours. Apply automatic transmission fluid on sliding or rotating surtaces of the parts before as sembly. Use petroleum jelly to keep the small parts in their places. Before assembly. make sure again that all compo: nent groups are assembled correctly. If something wrong is found in a certain component group dur- ing assembly, inspect and repair this group im. mediately. Do not use adhesive cements on gaskets and similar parts. When assembling the transmission, be sure to use new gaskets and O-rings. Dry ail parts by blowing with compressed ai. Never use shop rags. Be sure to install the thrust bearings and races, in the correct direction and position. Front ON w= J ° Spring Sane CIT Te Downshift Plug Cover check Ba INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils Measure the spring free height and replace if less than that shown below = Free height mm tin) ‘Secondary regulator | 3 12.9461 — | 2) Bown-shvtt plug 39.71 (1.5634) | Lo HACC (3). Throttle valve 19.24 (0.0787) = rin AUTOMATIC TRANSMISSION SERVICE GROUP “58.Technical Service Information (Upper Rear Valve Body) _ | Plug B- | Detent Regulator Valve e eee 2 ee | | coro OI | 2 Plug ——— Retamne Governor Modulator Valve j INSPECT VALVE SPRINGS Check for damage. squareness, rust and collapsed coil Measure the spring free height and replace if less than th shown below. Free height mm (in) } Wnt rn) Lowscoast madison meena Rear cluich sequence Free Governor modulator valve 36.07 (1.4201) ai 6) a T_ : (5) Detent regulator valve 32.08 (1.2630) ay Itermecate modulator 25 50 40078) AUTOMATIC TRANSMISSION SERVICE GROUP “50Technical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP -60-Technical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP -61-@4ATSG Technical Service Information A40D Valve Body Rear Upper Valve Body | 7 Fem Uee CO nm Valve Body el Ns a iff Lower Valve Body AUTOMATIC TRANSMISSION SERVICE GROUP -62-Technical Service Information ower Plug = INSPECT VALVE SPRINGS Check for damage, squareness, rust and distorted coils. Measure the spring free length and replace if less than that shown below, lise. | Valve Body) 1-2 Shift Valve aya cotatem vie D-2 Down Timing Valve wi OF a] 9 PY Primary Reguator Vale Plunger Manu Va Cj—sex nie ee, Seat ‘assess (} Sear 1) 0th Pug T a Seat Primary Regulator Valve Sleeve Free length mm (in. Primary regulator ; oy eae 60.13 (2.3673) (2) 1-2 site valve 3462 (1.3630) (3134 shit van 35.18 (1.3850) Check valve (4) forall eecter) 3332 (1.3118) Pressure relat valve ©) po 32.14 11.2654) (8). Damping bal 20.00 (0.7874) (2) Oveuteve eluteh exhaust 31.09 (1.2240 (8) Cooter return 13.70 (0.5394) AUTOMATIC TRANSMISSION SERVICE GROUP -63-Technical Service Information (Upper Front Valve Body) Retainer Throttle Cam Curback Valve marae | | | | | 7 | a | Retainer i my | ] H— Sleeve my Secondar > = Down shift Plug Cover Check Ball Check Valve INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils, Measure the spring free length and replace if less than that shown below, pS — | Freeman mm tiny] Secondary regulator | | [un Seco | 71.27 (2.9050) pee ose | 21 Down-shitt plug | 39.71 (1.5634) | —}|—______ (3) Throtte valve 21.94 (0.8638) a (21 cy eee AUTOMATIC TRANSMISSION SERVICE GROUP -64- om, ayTechnical Service Information (Upper Rear Valve Body) 2-3 Shift Lower Valve 2.3 Shutt Vawe Intermediate Shitt Valve 3-2 Kick-down Orifice Control Valve Detent Regulator Valve 2.3 Shift Timing Valve LZ WN OO =) | °] = Rear Clutch Sequence Valve ANON, O | ox O-0> Governor Modulator Valve | Low-coast Modulator Valve INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils. Measure the spring free length and replace if less than that shown below. Free length mm (in.) Low-coast modulator = 4 | 42.35 (1.6873) «ay REBr ute sequence eee ee (3) Governor modulator valve 36.07 (1.4201) (4) 23 shift valve 34.09 (1.3421) 18) Detent regulator valve 30.43 (1.1980) 29.82 (1.1740) ick-down orifice 32 kick 25.17 (0.9908) [2 contotvewe aTechnical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP -66-Technical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP -67-ATSG] Technical Service Information A42D A43D Valve Body Upper Rear Valve Body For easy comprehension and saving space, A43D transmission 1s represented in this overview illustration Upper Front Valve Body Valve Body Plate Valve Body Gasket No. 2 Lower Valve Body ‘Small Cover (A420, A430} AUTOMATIC TRANSMISSION SERVICE GROUP -68-Technical Service Information (Lower Valve Body) Ct 12 snitt vane Loweoen Sit Vaee _ vw of}—sex sO is © oN oO Seat § ma arr OP eon itv cl ¢-——__seat 02 Down Timing Vate eS Co tim O Manual Valve INSPECT VALVE SPRINGS Check for damage, squareness, rust and distorted coils [ Primary Regulator Valve Plunger Primary Regulator Valve Sleeve Free heh ind Messure the apring fee height sndrepiuce ices thant | = Messi te its [rato | a8 «Panay eguntr | 7332 | [610 valve (2.8866)| (2.4094) A42D, A43D I | 34.62 far ean [seat — | — 3308 | Sere | oa85 4 = a S) 34 shit valve |q 3240)|(1.38500](1.3240 i Sheskvave 5032 | | i, fforoteoote) —|iiatia) ~~ oe ow» — [o Pesue iat | 3218 | valve ball (1.2654) 7 : 19.50 | 20,00 1) Comping vor 8380, | 20007 -69- INSPECTION OF LOWER VALVE BODY ,Technical Service Information (Upper Rear Valve Body) Detent Regulator Valve Intermediate Modulator Valve Rear Clutch oly fp — ale ( ‘SC woman i) ise g Governor Modulator Valve ni I Intermediate [i ees evans Low-coast Modulator Valve INSPECT VALVE SPRINGS Check for damage, equareness, rust and collapsed cols. Measure the spring free height and replace if less than that shown below want mm tn Tae A | sop | A420 aaa | pases area) ser] | | 3) Govemor mocuster vave | 2527 [3409 P3510 | a) 238 usazn)ivaera) = ik sora 3043 | 2603 | 2993 st 15) Betenteguator wave | yggoi|.o24a)| (1.1789) : Nef 2582 6) 2-9 ant uming v win ite modawior | 7} 2560 | 2726 7 rearai| 10732), AUTOMATIC TRANSMISSION SERVICE GROUP -70-i Technical Service Information (Upper Front Valve Body) Adjusting Ring mh Retainer Cutback Valve Plug to Cover Secondary Regulator Valve ‘Throttle Cam J— Sleeve Throttle Valve Downshift Plug INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils. Measure the spring free length and replace if less than that shown below. Secondary regulator (1) valve ° aon | agzo | A430 71.27 (28059) | - (2) Down-shift plug 43.00 | 4024 | 3971 (3) Throttle valve (1.6929) | (1.5842) | (1.5634) 2194 | 1924 (8638) | (0.7575) | +L _} AUTOMATIC TRANSMISSION SERVICE GROUP atTechnical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP “72.Technical Service Informatio! A43DL A44DL Valve Body Upper Rear Valve Body Upper Front Valve Body Manual Valve | Manusl Detent Spring SS ==, @ Non-reusable part AUTOMATIC TRANSMISSION SERVICE GROUP “13Technical Service Information (Lower Valve Body) Low-coast Reverse Brake Plug Shift Valve eS =D AF CH ole i oO Srd-coast 3-4 Coast Valve Shift Valve, . Pressure Rell Va Witue, j a 2 @ @ 6) 7 1-2 Shift Upper Valve me's Sava: ooo 10-2 Down Timing Valve Cre maw Lock-up Signat Valve! Sleeve i er | Primary Regulator Valve rma on QO Fonte vtg H a Et Sleeve Lock-up Relay Valve Manual Valve INSPECT VALVE SPRINGS Check for damage, squareness, rust and distorted coils. Measure the spring free height and replace it if less than that shown below. Free length mm (in)| Color 67.20 2.4094) | White 34.62 (1.3630) | None 36.26 (1.4283) [Red 33.32 (1.3118) _| Yellow 32.14 (1.2664) | None 20.00 10.7874) _| None 18.50 (0.7283) _| White 38.60 (1.5197) _|Light Blue 9.70 (0.3835) [None | 73.70 105394) [None (1) Primary regulator valve (a4 (3)3-4 shift valve ft valve (4) Oil cooler by-pass valve ) Pressure relief valve ) Damping check ball (7) Lock-up relay valve (8) Lock-up signal valve Converter charge ball Coller return ball AUTOMATIC TRANSMISSION SERVICE GROUP “14Technical Service Information (Upper Front Valve Body) Retainer Cut-back Valve i Plug Throttle Cam Cam Pin Retzine_—_——] 6} spring i = | = | Throttle Valve Down-shift Spring ‘Secondary Regulator Valve cover INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils. = Measure the spring free height and replace if less than that € = shown below = — = —= [ree engin am ind Color [ar Secondary reguator vabe| 71.27 8059) _| Green o 2 2 (2) Down-shift plug 39.76 (1.5654) | Purple (3) Throttle valve 21,94 (0.8638) | None AUTOMATIC TRANSMISSION SERVICE GROUP -75-Technical Service Information (Upper Rear Valve Body) Detent Regulator Valve etme 0 Intermediate Modulator Valve 23 Shitt Valve Rear Clutch Sequence Valve 7 ©] xB o}emp aE ar Governor Modulator Vale c \, Greek Ba ' Shift Valve — ooOFa eee INSPECTION OF UPPER REAR VALVE BODY INSPECT VALVE SPRINGS. . Check for damage, squareness, rust and collapsed coils i Meosure the spring te height and replace it less thon thet shown below a @ 6 | Free length _mm (in) | Color (itow-cossi modulator vawe | 62.38 176673) | None [timer ouch sean vave [7.58 WaTeSi | Rea | (312-3 shift valve 35.10 (1.3819) White (é) Daten regulator vave | 32.08 1126307 | None (Glinermedinte modultarvavel 27.26 11.0732) | Green AUTOMATIC TRANSMISSION SERVICE GROUP “76Technical Service Information GROUP AUTOMATIC TRANSMISSION SER TTTechnical Service Information TorOTA MADL/AA3DL AUTOMATIC TRANSMISSION SERVICE GROUP “78ATSGI technical Service Information A43DE Valve Body | —— AUTOMATIC TRANSMISSION SERVICE GROUP “79Technical Service Information (Lower Valve Body) Cooler By-pass Valve Damping Check Ball Prem Reet vake i Low Coast Modulator Valve MGasker | | on Valve Bot Cover | Lockup Alay Contol Valve ———1) Lock-up Relay Valve ——} Slewve | & i Sleeve 4 @ | Nonveusable part INSPECTION OF LOWER VALVE BODY INSPECT VALVE SPRINGS | 3332 113118] Yelow Bate 1680] Ne AUTOMATIC TRANSMISSION SERVICE GROUP -80-Technical Service Information (Upper Front Valve Body) CurBack Valve Plug Throttle Cam us nN Adiating Ring - 7 D J [os AAR Cover Down-shitt Plug Secondary Regulator Valve INSPECTION OF UPPER FRONT VALVE BODY INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils. Measure the spring free height and replace if less than that shown below. Spring Free height. mm tin.)| Color ‘Secondary regulator a 71.27 (2.8059) | Green valve (2)Down-shift plug 39.65 (1.5571) | Green (@) Throttle vaive 19.24 (0.7575) | None (4) Cur-back valve 23.00 (0.9055) | Green AUTOMATIC TRANSMISSION SERVICE GROUP “81Technical Service Information (Upper Rear Valve Body) fe oo Foot fr | | NAH} ? cover ooo 1-2 Shift Valve ax} Gasket | 34 Shift Valve es u jetainer fer Clutch Sequnes Vale HH f Ore 8 ©: Nonseusable part INSPECTION OF UPPER REAR VALVE BODY INSPECT VALVE SPRINGS Check for damage, squareness, rust and collapsed coils. Measure the spring free height and replace if less than that, shown below. | Sping 7) Feoheime ommpleas | Spring Free height_ mm (in.) | Color (1)_3-4 Shitt valve 29.15 (1.1476) | Blue (2) 2-3 Shut valve 29.15 (1.1476) | Blue (3) 1-2 Shift valve 29.15 (1.1476) | Blue 4) Rear starch Seavence] 37.85 (1.4783) | None AUTOMATIC TRANSMISSION SERVICE GROUP -82-Technical Service Information A43DE A46DE Technical Service Information 83-ATSG] Technical Service Information 1982 AUTOMATIC TRANSMISSION CHANGES: A40, A40D, A¥3D, A93DL To improve performance of the automatic transmission, have been carried out. These modifications affect all 1 automatic transmission, except Tercel following modifications models equipped with AUTOMATIC TRANSMISSION TYPE AND MODEL APPLICATION AsO Te ASOD: TE, RA, RT AS30: MX, RN Ad3DL: MA Refer to sectioi @) this Toyota for details AUTOMATIC TRANSMISSION SERVICE GROUP 84-Technical Service Information TITLE 1952 AUTOMATIC TRANSMISSION CHANGES A40, A40D, A43D, A43DL 1. Clutch Piston Outer “O” Ring Tran E fec smission Type: A40, A40D, A430 and A¥OL tive Date: August, 1981 Description: To improve durability of the “O” ring for the overdrive clutch a > (CO), front clutch (Ci), and rear clutch (C2), the “O" ring cross-sectional diameter has been increased Consequently, the “O” ring groove of each clutch piston has been changed in width and diameter Clutch Piston "0" ring Previous _ New Piston groove width 30mm “3.Smm Piston Sroove diameter 122:95mm 122!25mm 0” ring cross-sectional diameter <62mm "3. 10mm Remarks: The front clutch (C1) for A43D and A43DL has previously been modified (March, 1951) Clutch Piston Return Spring Effect Deser ission Type: ASO ive Date: August, 1981 iption: To improverreturn action of the clutch piston, the return spring for front clutch (C1) and rear clutch (C2) has been changed from a single spring type to a multiple spring typeTechnical Service Information 1982 AUTOMATIC TRANSMISSION CHANGES A40, A40D, A430, A430L TITLE Tl) 3. Clutch Cylinder Oil Seal Ring Portion Transmission Type: A40, A40D, AS3D and AY3DL Effective Date: August, 1981 Description: To improve performance of the oil seal ring of clutch cylinder for the overdrive clutch (CO), front clutch (C1) and rear clutch ( the cylinder bore, oil seal ring and ring groove diameters have been increased (1) Overdrive clutch (CO) oil pump cover Transmission Type: A40D, AY3D and A43DL Clutch Drum Dit Pump Cover Dez ASOD A43D & AG3DL AOD, A430 £ AS3DL Ag0D, AY3O & A43DL ASOD, A43D ¢ A43DL aoeTechnical Service Information Piston Piston sorina fff \\ ry Retainer Retainer Previous New Clutch Cylinder Oil Seal Ring Portion Transmission Type: AO, A40D, A43D and AY3DL Effective Date: August, 1981 Description: To improve performance of the oil seal ring of clutch cylinder for the overdrive clutch (CO), front clutch (C1) and rear clutch (C2), the cylinder bore, oil seal cing and ring groove diameters have been increased (1) Overdrive ch (CO) oil pump cover Transmission Type: ASOD, AS3D and AS3DL Clutch Drum Oi1 Pump Cover Seal Ring 1 a ee a d Previous New 45.77mm 45.92mm 45.50mm 45, 92mm 51.10mm 51.52mm 31.56mm 51.38mm 51.56mm 51.98mm AUTOMATIC TRANSMISSION SERVICE GROUP -87-Technical Service Information Tite 1982 AUTOMATIC TRANSMISSION CHANGES A40, A40D, A430, A43DL Front Clutch (C1) Overdrive Case (3) Transmission Type: A40D, A43D and A43DL Clutch rum as Overdrive Case Seal Ring ll 98mm 98mm ear clutch (C2) center support Transmission Type: AsO, ASOD, AS3D and AS3DL New SY.5Smm 51, 98mm 51.88mm 46.14mm angeLE} Technical Service Information 4. Rear Clutch Hub Transmission Type: A40 Effective Date: August, 1981 Description To improve durability of the splines on the rear clutch hub, the number of splines has been increased from 8 to 24 8-splines 24-splines ep Remarks vy A has been made on the A43D and ic transmissions since production AABDL aut start This modification will not be made on the ASOD automatic trans. 3. Thrus' Bearing for Pump Cover and Clutch (C: Transmission Type: AS3D and A43DL Effective Date: October (A430), August, 1931 (A¥30L) Description: To increase capacity of the overdrive clutch (CO) thrust bearing, the first thrust bearing has been modified as +L ——_— Front ——_—— Front -89-Technical Service Information Toyota ECT TILE — ELECTRONIC CONTROLLED TRANSMISSION ELECTRICAL DIAGNOSIS The purpose of this bulletin is to aid in the electrical diagnosis and repair of the ECT transmission. CONDITION/CONDITIONS - Transmission slips or shudders during acceleration - Engine hesitation when transmission 1s engaged - Fluctuating shifting characteristics POSSIBLE ELECTRICAL CAUSE/CAUSES: - Poor continuity between the ECT computer and main wiring harness - Poor continuity between wire harness from ECT computer to solenoids + Shift solenoids - ECT computer - Throttle position sensor ‘ansmission speed sensors CORRECTION The following flow chart will assist in the proper diagnosis and repair of these conditions Road Test Verify the stated condition/customer complaint Preliminary Checks) 1. Transmission fluid level and condition 2. Throttle cable adjustment 3. Shift linkage 4. Neutral start switch 5. Idle speed * If the fluid is contaminated with evidence of burnt clutches, etc., it may be necessary to proceed to internal checks diagnosis. Correct as necessary and road test, proceed to harness connector checks 1 if necessary AUTOMATIC TRANSMISSION SERVICE GROUP -90-Technical Service Information TITLE ~~ ELECTRONIC CONTROLLED TRANSMISSION ELECTRICAL DIAGNOSIS (Harness Connector Checks) 1. Check connector continuity from wire harness to ECT computer. Check for loose cannections, loose connectors, loose or bent pins, or loose wires. . Check connector continuity from ECT computer to solenoids. Check for loose connections, loose connectors, loose or bent pins, or loose. wires Perform solenoid operation verification as per the appropriate manual. 3. Check throttle position sensor connections. 4. Check speed sensor connections in transmission and speedometer. Correct as necessary and road test, proceed to DG terminal checks if necessary (0G Terminal Checks Perform DG terminal checks as per the appropriate repair manual. Confirm voltage readings with appropriate repair manual specifications. If voltage readings are not within specification, and if good connections/continuity| are certain, replace transmission electrical components as necessary. Correct as necessary and road test, proceed to manual mode road test if necessary (Manual Mode Road Test) Unplug the ECT computer from the transmission and verify the following Shift lever position Po RON D 2 4 Gear mode N RN OD 3 1 The manual mode test will check the operation of internal “mechanical” components of the transmission. If discrepancies are found during the manual mode test, internal mechanical components maybe suspected. The transmission should be removed, disassembled and carefully inspected according to the appropriate repair manual. Road test to confirm correction, AUTOMATIC TRANSMISSION SERVICE GROUP “91Technical Service Information DIAGNOSING ELECTRONIC PROBLEMS TOYOTA TRANSMISSIONS A43DE OR A140E A voltage test must be made at the 0.G. (DIAGNOSTIC TERMINAL) located either under the hood, in the left kick panel or the left door arm rest depending on car and model. An Analog Volt Meter must be used. The following voltages must be obtained: (5) (6) VOLTAGE AT D.G. TERMINAL GEAR POSITION Ist gear 2nd gear 2nd lockup 3rd 3rd lockup ovo 0/0 lockup If voltage rises from 0 to 7 in above sequence the control system is 0.k. If there is a constant 8 volt indication, the solenoid is defective. If there is a constant 4 volt indication, the speed sensor is faulty. Stop the vehicle, but do not stop the engine, stopping the engine will cancel all codes’ from the ECU memory CHECK THE FOLLOWING VOLTAGES O VOLTS Volt system normal or defective brake signal 4 VOLTS Faulty speed sensor #2 8 VOLTS Faulty Solenoid Inspect throttle position sensor. Turn off the engine, and while slowly depressing the gas pedal, check that the terminal 0.G. Voltage rises in sequence. Inspect the brake signal: (a) depress the gas pedal to where 8 volts is indicated for the 0.G. Terminal (>) depress the brake pedal and check the voltage reading for the 0.G. Terminal Brake pedal depressed 0 volts Brake pedal released 8 volts,” AUTOMATIC TRANSMISSION SERVICE GROUP -92-Technical Service Information ELECTRONICS DIAGNOSIS OF THE A46DE TRANSMISSION Diagnosis System DESCRIPTION 1. A self-diagnosis function is built into the electrical con: trol system. Warning is indicated by the overdrive OFF indicator light. HINT: Warning and diagnostic codes can be read only when the overdrive switch is ON. If OFF, the overdrive OFF light is lit continuously and will not blink (s) If @ malfunction occurs within the speed sensors (No.1 oF 2) oF solenoid (No.1 or 2), the overdrive (OFF light will blink to warn the driver. However, there will be no warning of a malfunc- tion with lock-up solenoid. (©) The diagnostic code can be read by the number of blinks of the overdrive OFF indicator light when terminal 7E; and E, are connected. (c)_ The throttle position sensor or brake signal are not Indicated, but inspection can be made by checking the voltage at terminal T of the check connector. (4) The signals to each gear can be checked by m suring the voltage at terminal T of the check connector while driving. 2. The diagnostic code (trouble code) is retained in mem- ory by the ECU (of Engine and ECT ECU) and due to back-up voltage, is not canceled out when the engine is turned off. Consequently, after repair, itis necessary to turn the ignition switch off and remove the fuse EFI (15 A) or disconnect the Engine and ECT ECU connector to cancel out the diagnostic (trouble) coe. HINT: + Low battery voltage will cause faulty operation of the diagnosis system. Therefore, always check the battery first + Use a voltmeter and ohmmeter that have an impedance of at least 10 kQWV. (CHECK “0/D OFF” INDICATOR LIGHT 1. Turn the ignition switch ON. 2. The *O/D OFF" tight will come on when the O/D switch is placed at OFF. 3. When the O/D switch is set to ON, the “O/D OFF* light should go out. If the 70/0 OFF" light flashes when the O/D switch is ‘sot to ON, the electronic contro! system is faulty Technical Service Information 93-Technical Service Information DIAGNOSTIC CODES Diagnosis System a “TNO. Datecive No. 2 peed seneortn ATH) = | | Severe ohare or hon cre a ANON | Severed No. 1 solenoid or short circuit — severed wire harness or short circuit i” | Severed lockup solenoid or shor eieuit — | SUA severed wire narness or shor circuit HINT: If codes 62, 63 or 64 appear, there is an electri- cal malfunction in the solenoid. Causes due to mechanical failure, such as a stuck valve, will not appear. CANCEL OUT DIAGNOSTIC CODE 1. After repair of the trouble area, the diagnostic code retained in memory by the Engine and ECT ECU must be canceled by removing the fuse EFI (15 A) for 10 seconds or more, depending on ambient temperature (the lower the temperature, the longer the fuse must be left out) with the ignition switch OFF. HINT: * Cancellation can be also done by removing the jattery negative (-) terminal, but in this case other memory systems will be also canceled out. ‘+ The diagnostic code can be also canceled out by dis- connecting the Engine and ECT ECU connector. * If the diagnostic code is not canceled out, it will be retained by the Engine and ECT ECU and appear along with @ new code in event of future trouble. 2. After cancellation, perform a road test to confirm that 2 “normal code" is now read on the O/D OFF light. Technical Service Information 94