T T' T

T T T T T'

VALVE
BODY
85

CASE
COMP
ONENT

PITSG

94

INDEX
PAGE
TROUBLE SHOOTING
3
SERVICE ADJUSTMENT
23
COMPONENT SERVICE
27
TEARDOWN
34
ASSEMBLY

AUTO
MATI
C
TRAN
SMISS
ION
SERVI
CE
GROU
P
wo4

47
PUMP
64
CLUTCH ASSEMBLY
67
CARRIER
75

se;

;111

IV;
;IC
0'16?

7_,
Ps
1/4
4.
PI

mi.u.sig

1K
FITS 04,
E

A.

INTRODUCTION
MITSUBISHI KM-175 / 177

44TIC
TRANSMISSION
SERVICE

The KM-175 - 177 is a

computer
controlled
transaxle. This transaxle
provides
three
forward
speeds and an overdrive gear
as well as a converter
clutch. This transmission is
found in Gallants, Hyundai,
Dodge Colts and Magna
models.

We
thank
Mitsub
ishi for
the
illustra
tions
and
inform
ation
that
made
this
booklet possible.

The
information
and part numbers
contained in this
booklet have been
carefully compiled
from
industry
sources known for
their reliability, but
ATSG
does
not
guarantee
its
accuracy.

ROBERT D. CHERRNAY
ENGLAND

TECHNICAL DIRECTOR
CONSULTANT
FRANK MIETUS
COLONNA
TECHNICAL CONSULTANT
CONSULTANT

WELDON BARNETT
KRUSE
TECHNICAL CONSULTANT

DALE

FIELD SERVICE

WAYNE
TECHNICAL

ED

LAY

OUT
AUTOMATIC TRANSMISSION SERVICE GROUP
9200 SOUTH DADELAND BLVD.
SUITE 720
M
I
A
M
I
,
F
L
O
R
I
D
A
3
3

1
5
6

(
3
0
5
)
6
6
1
4
1
6
1

PITS
G

Technical Service Information

TROUBLESHOOTING

TROUBLESHO
OTING
Functional malfunctions of the ELC4A/T can lead to other problems, such
as those described below:
(1) Improper maintenance and/or
adjustments
(2) Malfunctions of the electronic control
functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of the hydraulic control
functions
(5) Malfunctions
of
engine
performance etc.
In order to properly determine
("troubleshoot") the source of these
malfunctions, it is first essential to
methodically
question
the
user
concerning the details of the problem,
such as the condition of the problem,
the situation at the time the
problem occurred, and any other relevant
information, all in
as much detail as possible. The user
should also be asked whether or not
the problem has occurred more than
once, and under what conditions.
Subsequently, certain tests should be
conducted in a certain order, as
described at the right.

Based upon use of the

troubleshooting guide, the
probable
location
of
the
problem should be estimated.

\7
Checks should be made of fluid
levels and the condition of the
ATF, as well as the condition of
the
manual
control cables;
adjustments should then be
made if found to be necessary.

\7
If a presumption has been made
that there is an abnormal
condition somewhere in the
electronic-control system, the
diagnosis tester should be used to
estimate the probable location by
checking
the
malfunctionindication pattern. If the ignition
key was already turned to OFF,
however, check by making a
road test.

When the abnormal system is

discovered during the road test,
check each element (sensors,
etc.) one by one, and makes
repairs as necessary.

When the abnormal condition is

presumed to be in the oilpressure-control system, check
by making an oil-pressure test.

When the result of the oil-pressure test does not

satisfy the specified pressure, check each system at
places related to the valve body, check the oilpressure passages for leakage, etc.

\7

If the problem is unusually

dirty ATF, abnormal noises, oil
leakage, or slippage of the
clutch or brakes, or an abnormal
condition of the transmis-sion
itself, disassemble and repair the
transmission.

AUTOMATIC TRANSMISSION SERVICE GROUP

3

ATSG Technical Service Information

Troubleshooting
Guide

Driving impossible or abnormal (before start-off)

"2
P
r
o ,
b E
l a
e ,i
m

Presumed cause
.c
e'

4.
1

-0

g e.

ut

E
:.

IA
I

.8

.g 1e

7
,.1..

Abnormal idling rpm

_o` 2 Performance malfunciton

+ 3 Improper adjustment of manual linkage

.
2.
o

e,

El-

O
a
7.

=
&

x
-2
"

E
,,

i
E
E

1,

,i;
>.'

TZg
te..;

7. a
i

la

.01 EE
if
e
-Z
-8

'LI
:2

X
X

1
,1

lc

&
i4

a
a..

we

1
a
a'

t
l
o

7,
st
ce
Ti

F6'

X
X

X
4 Malfunction of torque convertor (including damper
clutch)
5
Operation malfunction of oil pump
Malfunction of one-way clutch

E
-

.1.

IIf

1
,

0
X
X
X

8
E

_
T.
"..
Z.:
8

X
X

E
E

c4
8

a
E
T

IF.
<1
x
L.*

lot

0 1

'71

,5

.;

Dama
ged
or
worn gear
or other
rotating
part, or
improper
7
=w
adjustment of the preload
x
8 Incorrect tightening of center support
pE
9 Malfunction of parking mechanism
10 Cracked drive plate, or loose bolt
11 Worn inside diameter of front clutch retainer
12 Low fluid level
13 Line pressure too low (seal damaged, leakage,
looseness, etc.)

X
X

Li

E ..

12 14 Malfunction of valve body (sticking valve,

working cavity.

E1

adjustment. etc.)
E 15
t ...7. 16
o
17
o
18
19
r
,
""
21

22
23
24
25

X
X

XX
0 ,
0

0
0

X
0
0

X
0

X
X
0

M
a
l
f
u
n
c
t
i
o
n
o
f
f
r
o
n
t
c
l
u
t
c
h

r,.
76.
.

ear clutch or
o piston
r Malfunction of
kickdown band or
p
i piston Improper
s adjustment of
t kickdown servo
o Malfunction of lown
reverse brake or
M piston
a 0-ring of low-reverse brake
l circuit between valve body
f and case not installed
u Malfunction of end clutch or piston (check ball
n hole, other)
c Malfunction
of
t inhibitors
switch,
or
i damaged
o disconnected wiring, or
improper
adjustment
n
Malfunction of TPS. or improper adjustment
o Pulse generator (A)
or
f damaged
disconnected wiring, or
short-circuit
r
Pulse generator (B) damaged or disconnected
wiring. or short-circuit
2 Malfunction of kickdown servo switch
6 SCSV-A or B damaged or
2 disconnected wiring. or
short-circuit or sticking
7 (valve open)

2
8
1
Li/ 2
9

3
1
3
2
3
3
3
4

3
5
3
6
3
7
3
8
3
9

Malfunction of
ignition signal
system
Incorrectly
grounded
ground strap
PCSV damaged or disconnected
wiring, or short-circuit PCSV
damaged or disconnected wiring
(valve open) DCCSV damaged or
disconnected wiring (valve dosed)
DCCSV short-circuit or sticking
(valve open)

X
X
X
X

X
X

X
X

X
X

Malfunction of OD switch

Malfunction of accelerator switch, or

improper adjustment Malfunction
of water-temperature sensor
Mlafunction of
lead switch Poor
contact of ignition
switch
Malfunction of
transmission
control unit

NOTE: indicates items of high priority during inspection.

control solenoid valve

Abbreviations: TPS = Throttle position sensor

AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
4

SCSV = Shift

x
x

x
x
x

r
><

41

X
X
X
X

Si
J

Id

CI

:..

ti
7.

IS
z

SI

Id

W
J

x
x
X

7, to
I:
r.
r,
.:.
;.;

t., N -

x
x
x

d
x

I9

IS
is
It
x

x
x
x
x
x
x
x

x
x

x
x

x
x

t',9
x

>c
x

x
x

>c

0
x

x
x

x
x

x
x

x
x

X
x

x
x

x
5

X
x

x
X

X
431

x
x
x
x

x
x

x
x

x
x

>c

Exc
essi
ve
cre
epi
ng
or
idli
ng
vib
rati
on

Won't shift front 2nd to 3rd

Won't shift to 4th

OD switch doesn't function

Doesn't

shift

according to shift pattern

(shifting is possible)

ropurorz .steatcrtioff (starts off

E
x
c
e
s
s
i
v
e
v
i
b
r
a
t
i
o
n
s
h

o
c
k

vibration-

s
h
i
f
t

Excessive

shift

shock (other
described)

Abnormal
vibration in highload region in
low gear (approx.
I Hz)

vibration-

during

downshift

o
r

Sudden

3
.
4

D-2

engine

increase
during upshift

c
e

rpm

increase

during
shift,

s
s
i
v

3-2

excessive

vibration

Excessive
vibration
-shock

&

1
ii
if

n
rpm

Sudden eingine
E

B
5'

Damper clutch won't

funciton

Excessive

Abnormal noise
from convertor
housing together
with engine rpm

A'
6
3

Mechanical

noise

(clatter noise)

from

convenor housing
Abnormal
noise
inside transmission
Case
-i
3rd gear is held

>P

than already

Excessive
vibrationshock
during
upshift

shock

a
e.

vibration-

2-3 or 4-3

when
1.

shock
when

w
h
e
n

only
cold

11T5G

Technical Service Information

Manual Control Cable

Whether
manual
linkage is properly
adjusted
can
be
confirmed by checking
whether
inhibitor
switch is performing
well.
1. Apply parking brakes and service brakes securely.
2. Place selector lever to "R" range.
3. Set ignition key to "ST" position.
4. Slowly move the selector lever upward until it clicks as it
fits-in notch of
"P"
range. If
starter
motor
operates
when
lever makes a
click, "P" position
is correct.
5. Then slowly move
selector lever to
"N" range by the
same procedure
as in foregoing
paragraph. If
starter motor
operates when
selector lever fits in
"N", "N" position is
correct.
6. Also check to be
sure
the
vehicle
doesn't
begin
to
move and the lever
doesn't stop between
P-R-N-D.
7. The manualcontrol cable is
properly adjusted if,
as de-scribed above,
the starter motor
starts at both the
"P" range and the
"N" range.

Road Test

If the ignition key

has not been turned to
the OFF position, the
malfunctionindication pattern can
be checked before the
road
test
by
connecting
the
diagnosis tester.
If,
however,
the
ignition
key
was
switched to OFF, the
road test should be
made as a re-test.
Before making the
road
test,
the
"fundamental
checks" should first
be made in order to
confirm that there is
no
abnormal
condition.
Moreover, the road
test should be made,
in
the
procedural
order
described
below,
after
first
checking to be sure.
that the wiring of
sensors,
etc.
is
normal
and
is
correctly and securely
connected
to
connectors
and
ground.
1. Warm-up the engine. [Engine coolant tempearture: 50C
(120F) or higher]
2. Turn the ignition key to OFF.
3.
Connect
the
diagnosis tester to the
connector
for
diagnosis (in
the
glove compartment).
4. Set the diagnosis tester's selector to the "ELC
4-speed
automatic with overdrive" position.
5. Move the selector lever to the "P" range and switch ON
Di ag n o si s te s ter
the OD switch.
E LC 46. Conduct the test in the order
M o n i to r l i g h t
speed
described in the test order table on the
auto ma ti
next page.
c
with
Check whether or not the check
Fully automatic
overdrive:
air conditi oner
points are satisfied after each operation
che c k
* a m .
T
sw i t c h
step. If they are not, it is probable that
IolaS
pos i t i on
there is an abnormal condition of the
4
transmission control unit
(TCU) connector terminal, indicated
4-.44-0

m
in the "Presumed abnormal terminal
acaw
*4,149 2
56
of TCU" column.
3

sci

When the abnormal condition is

confirmed,
stop
the
test
immediately. Then, after checking
the malfunction-indication pattern
by using the diagnosis tester, refer
to the "Diagnosis

r
41131
.7.
0 F
F

*AC

;MODS

AUTOMATIC TRANSMISSION SERVICE GROUP

6

IAT5G1
Q

Technical Service Information

MITSUBISHI ELECTRICAL DIAGNOSIS

The KM175-177 series transaxle is fully computer controlled

and usually has four solenoids on the valve body. There are
two solenoids for shifting, one for pressure control, and one
for converter clutch engagement. Certain versions have
only three solenoids and use no converter clutch. The ELC
4 Speed Control Unit and the diagnostic connector is
located behind the glove box on 1985-1986 models, but
on later models the Transmission Controller was moved to
behind the console and the radio. The diagnostic connector
was moved next to the fuse panel in 1988. The ELC
4 Speed Control Unit can store trouble codes after a
malfunction occurs, but when the ignition is turned off the
codes are erased. To retrieve codes the ignition must remain
on after the malfunction has occurred. The codes can be
retrieved with many hand held scanner tools, analog volt
meter, or with an LED tester by jumping the pins as shown in
the figure below.

For trouble code translation refer to the following pages. The

codes and their meaning have changed year to year and it is
very important to determine the model year that you are
testing. This transmission will have 3rd gear only if
electrical failure occurs or if the Transmission control Unit
puts the transmission in fail safe.

TO
MAK
E
YOUR
OWN
L.E.D.
TEST
ER
REFE
R TO
PAGE
96.

AUTOMATIC TRANSMISSION SERVICE GROUP

7

CIT5G

Technical Service Information

accelerator is fully closed (when
the accelerator pedal is released).

O
r
d
e
r

14

15

Operation
Connect the diagnosis
tester to the output
connector in the glove
compartment. Then set
the diagnosis tester switch
to the "ELC 4-speed
automatic with overdrive"
position.

The selector lever should

be set to "P" and the
overdrive switch to "ON".

Turn the ignition key to

"ON".

Start the engine.

With the engine speed at 1,500

rpm, move the selector lever
from "P" to "R".

With
the
engine
idling, shift from "R"
to "N".

With the engine speed at

1,500 rpm, shift from
"N" to "D".

Engine idling
(selector lever still in "D")

10

Accelerate
to
70
km/h (43 mph) with
the accelerator fully
open.

11

Drive the prescribed course at

70 km/h (43 mph).
(Continue for 20 seconds or
more.)

12
13

Switch the overdrive switch to

OFF at the same time the

Shift from "D" to "2"

after checking item 11.
Shift from "2" to "L"
after checking item 12.
Stop the vehicle (let engine idle).

Turn the ignition key to OFF.

Same as above
C
h
e Same as above
c
k
"Creeping" should be small.
i (4,500 mm (177 in.) or less in 5
t seconds)
e
m Shift from "1" to "2" at

Possible abnormal terminal

A-7, A-13
A-5, A-7, A-15
When the LED
flashes, determine
the
location of the
mal-function by
following the
indication pattern (*I).

52-62 km/h (32-38 mph).

There
should
be
no
abnormal feeling of shifting
impact.

Diagno
sis
tester
LED
illumin
ates
interm
ittently
.
LED
stops
illuminating
within
16
seconds
after
the engine is
started.
There
should
not
be
any
abnorma
l feeling
of
shifting
impact.

Shift from "2" to "3" and

then from "3" to "4"
(overdrive). There should

be no abnormal feeling of
shifting impact.
Also check damper clutch
control. After stopping, use
the diagnosis tester to check
whether there is an abnormal
condition.

A-10, B-12

A-17

A-3, A-14

Shift from 4th to 3rd to

increase
the
engine
speed.

A-4, A-7, A-14

Shift from 3rd to 2nd to

increase the engine speed.

A-7, A-8, A-14, B-10

Shift from 2nd to 1st at

42-52
km/h
(26-32
mph).

B-2,

Check to be sure that the

diagnosis tester does not
indicate a malfunction code
(LED OFF).

B-8,

B-10, A-7,
A-15

A-

14, B-1, B7, B-9

Stop the engine.

A-2, A-14, B-1, B-2, B-7, B-8

A-2, A-15

ATSG

Technical Service Information

1985 - 1988 FAULT CODES

Malfunction
indication code
Lo .0 Ln

4 sec. O -: ci
2 sec.

l`

v,
,
re

ON
OFF

r, , ,

Repeat
s

,,,
r

Diagnosis

Assumed location

Microprocessor (computer)

Low power-supply voltage

malfunction; not remedied by

resetting.

(recharging system)
Computer

First gear signal is detected

Pulse generator B

,g1 WI
41

- ci

4 sec .o -

477-'r--"
rr-

3
V

0
0

jo

at high vehicle speed.

Computer

Vehicle
speed
detected by pulse
generator B is much
lower than actual
vehicle speed.

P
u
ls
e
g
e
n
e
r
a
t
o
r
B
C
o
m
p
u
te
r

I
r
e

Operation of shiftcontrol solenoid

valve A differs
from computer
command.
Operation of
shift-control
solenoid valve B
differs from

Shift-control
solenoid valve
A Computer

r
o/,

w 0;
,

Shift-control
solenoid valve
B Computer
computer

command.
Kickdown
servo switch

signal
differ
s
from
actua

l gear
engaged.
6

Kickdown servo switch

Pressure-control solenoid
valve

WV ; i

Computer
Shifting
doesn't finish.

r
r--

Pulse generator
A Pressurecontrol solenoid
valve

0
I

Computer
Pressure-control
solenoid valve
drive differs from
computer
command.

;
o w
o r

Engine
speed
is
judged to
be
6,500
rpm
or
more.

10

11

I V

___ M_Fal f ali

Winailall

Kickdown
drum
rotation
speed
is
judged to be 6,500
rpm
or more.
Damper clutch control
solenoid

valve is directly
1
2

connected.
FAiLutkll

Pressure-control
solenoid
valve
Computer

Pu
lse
ge
ne
rat
or
B
Ig
nit
ion
coi
l
(ignition
signal
system)
Compute
r
Pulse
generat
ors A
B
Compu
ter

Damper clutch
control system
Computer

No ignition signal.
Ignition coil
Ignitio
n
signal
system
Compu
ter

AUTOMATIC TRANSMISSION SERVICE GROUP

9

A
T
S
G

Technical Service
Information
1989 FAULT
CODES

Output code

Description
Fail-safe

Co
de

N Output pattern (for

o. voltmeter)
11

5V-

Malfunction of the
code No.31 is

1
2

microprocessor

First gear command during

high speed driving

_-

Damaged or discon-nected
wiring of the pulse generator
B system

_-

Damaged or discon-nected
wiring, or
sshortho
circuit, of shift
control solenoid valve A

- -1
4

Damaged or discon-nected
wiring, or
ss hh ootr circuit, of shift control
solenoid valve B

_
lit.

17

When

-_

1
3

16

Locked in 3rd gear

fault code)

OV

1
5

N
o
t
e
(
r
e
l
a
t
i
o
n
t
o

Damaged or discon-nected
wiring, or
short circuit, of the pressure
control sole-noid valve

1jiff
-

11.

Shift steps non

g
e
n
e
r
a
t
e
d

Locked in 3rd (D) or

When code No.32 is
2nd (2, L) gear
generated 4th time.

Locked in
3rd (D) or Locked in 3rd gear
When
code
When code No.43 or
No.33 is
2nd
(2,
L)
4
t gear
h generated
4th time.
t
i
m
e
.
Locked in
3rd gear
When
code
No.41 or
42
is
generated 4th
time.

t
h
ti
m
e
.
4
4

Locked in 3rd (D) or

When code No.45
i or
46 is generated
s 2nd (2, L) gear
4th
time.
g
n
e
r
a LLockedocked in 3rd (D) or When either
t code
e
2nd (2, L) gear
No.51, 52 53 or 54
d
is
generated 4th
4
time.

AUTOMATIC TRANSMISSION SERVICE GROUP

10

ATSG

Technical Service Information

1989 FAULT CODES (CONT.)

Fa
Fault code (for
ult
voltmeter)
co
de

Cause
Abnormal increase of TPS
output

21 5V OV
----

11__
Abnormal decrease of TPS
output

22

23

Incorrect
adjustment of the
throttle-position
sensor system

_if

Remedy
Check the throttle
position
sen-sor
connector.
Check the throttle position sensor itself.
Adjust the throttle position sensor.

Check
the
accelerator
switch
(No.
28: output or
not).
Check
the
throttle position
sen-sor
output
circuit harness.

24

_Milli ____
25

26

_FIL111111111_
1111a
_

27

28

Damaged
or
disconnected wiring
of the oil temperature
sensor sys-tern

Ell
_

Damaged
or
disconnected wiring
of the kickdown servo
switch sys-tern, or
improper contact
Short circuit of the
kickdown servo switch
system

Damaged
or
disconnected wiring
of the ignition pulse
pick-up cable system
Short circuit of the
accelerator switch
system or improper
adjust-ment

Check the oil

temperature sensor
circuit
harness.
Check the oil
temperature sensor connector.
Check the oil
temperature sensor itself.
Check the
kickdown
servo switch
output circuit
harness. Check
the kickdown
servo switch
connector.
Check the
kickdown
servo
switch
itself.

Check
the
ignition
pulse
signal line.

Check
the
accele
rator
switch

o
u
t
p
u

t circuit
harness
.

_111
1:11.
1111.
_

Adjust
Malfunction of the
microprocessor

33

the

accelerator
switch.

Replace

the control unit.

31

32

Check
the
accelerator
switch
connector.
Check the accelerator switch itself.

First gear command

during
high-speed
driving

Damaged
or
disconnected wiring of
the pulse generator B
system

1111L
_

AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
11

Replace the control unit.

Check
the
pulse generator
B output circuit
harness.
Check
pulse
generator B itself.
Check the vehicle
speed reed switch
(for chattering).

ATSG

Technical Service Information

1989 FAULT CODES (CONT.)

F
Fault code (for
a
voltmeter)
ul
t
c
o
d
e

Cause

41

Short circuit of the

shift-control solenoid
valve A system

._

42

Damaged
or
disconnected wiring of
the shift control solenoid
valve A system

Remedy
Check
the
solenoid valve
con-nector.
Check
shift
control
solenoid valve
A itself.
Check the shift
control solenoid
valve
A drive
circuit harness

_
_IL_

Damaged
or
disconnected wiring of
the shift control solenoid
valve B system

43

-17.44

Short circuit of. the

shift control solenoid
valve B system

_Tin
iraL

Damaged
or
disconnected wiring of
the pressure control
solenoid valve system

45
'.
46

IT
M
I
M
I_

Short circuit of the

pressure control solenoid
valve system

First gear non-synchronous

Second gear nonsynchronous

51

Third gear non-synchronous

52
___

53
Fourth gear nonsynchronous

54

__
FUTTF
LIEJL

Check
the
solenoid
valve
con-nector.
Check
shift
control
solenoid valve
B itself.
Check the shift
control
solenoid
valve
B
drive
circuit harness.

Check
the
solenoid
valve
con-nector.
Check the pressure
control
sole-noid
valve itself.
Check the pressure
control
sole-noid
valve drive circuit
harness.

Check the pulse

generator out-put
circuit harness.
Check the pulse
generator
connector.
Check
pulse
generator A and
pulse generator B
themselves.
Kickdown brake
slippage.
Check
the
pulse generator
A output circuit
harness.
Check
the
pulse generator
A connector.
Check
pulse
generator A itself.
Kickdown breke
slippage.
Check
the
pulse generator
A output circuit
harness.
Check the pulse
generator
connector.
Check
pulse
generator A and
pulse generator B
themselves. Front
clutch slippage.
Rear clutch slippage.

Check
the
pulse
generator
A output
circuit harness.
Check
the
pulse
generator A connector.

Check
pulse
generator
A itself.

Kickdown
slippage.

brake

AUTOMATIC TRANSMISSION SERVICE GROUP

12

PTSG

Technical Service Information

FLUID LEAKAGE
TRANSAXLE
CONVERTER HOUSING AREA
1.

Check for source of leakage. Since fluid leakage at or

around converter
area may originate
from engine oil
leak, area should
be
examined
closely. Transaxle
factory fill fluid is
dyed red and,
therefore, can be
distinguished
from engine oil.
2. Prior to removing transaxle, perform following checks:
When leakage is
determined
to
originate
from
transaxle,
check
fluid level prior to
removal
of
transaxle
and
torque converter.
High oil level can
result
in
oil
leakage out of
vent located in
top of oil pump.
If fluid level is
high, adjust to
proper level and
recheck
for
leakage.
3. After completing
these steps, recheck
once more for
leakage.
DAMPER

CLUTCH

TORQUE
CONVERTER

DIAGNOSIS Test-1
Inspection of damper
clutch
torque
converter operation
with engine idling.

E
n
g
a
g
e
t
h
e
p
a
r
k
i
n
g
b
r
a
k
e
s
e
c
u
r
e
l
y

Set the selector

lever to the "P"
or "N" position
and start the
engine

Solenoid valve
is
not
completely
dosed

Replace the solenoid valve

Overhaul the valve body

With
the
engine idling,
firmly
depress
the
brake pedal

Damper clutch control valve is

stuck

Damper clutch is seized (heat

seized)

Shift
the
selector lever
to the "D" or
"R" position.
Does
the
engine stall?

the

Yes

Adjust the idle

Idle is incorrectly adjusted
1r
No

Cor
rect
ope
rati
on
(Th
e
da
mp
er
clut
ch
did
not
ope
rat
e)

Replace
torque
converter
assembly

AUTOMATIC TRANSMISSION SERVICE GROUP

13

GITSG

Technical Service Information

Test-2
Inspection procedures
and
malfunction
classification for each
element
Check for continuity in the harness,

follo
wing
the
wiri
ng
diag
ram
01K015
Is
ther
ea
brok
en
wire
in
the
harn
ess?
Are
ther
e
any
impr
oper
conn
ectio
ns?

No

(1) Wiring
(3) Throttle position
sensor
NOTE Check while set
to the MPI

(2) Coolant
temperature sensor

1710
89
Throttle position
sensor terminals

T
e

Go to (2)

T
e
r
m
i
n
a
l

Go to (3)

Check the resistance between

terminals 1 and 3.
Is the resistance 3.5-6.5
kfl at 20C (68 F)?

--1K

Yes

Is
ther
e
cont
inui
ty
bet
wee
n
ter
min
al B
and
the
case
whe
n
the
cool
ant
tem
pera
ture
exce
eds
60
C
(140
F)?

Yes

Gene
rally
disen
gage
s in
all
rang
es

Repair or correct the wiring

Disengages in all ranges

Resistance
Resistance too high
No
Replace the coolant temperature sensor

Broken
wire

Disengages in all range

Resistance less than 8%
No
Replace the throttle position sensor
more then 8%

/Check
the
resistance
between
terminals 2
and 1 while
idling
Is
the
resistan
ce just
8% of
resistan
ce
between
termina
ls 1 and
3?

No

Engine stalls during sudden braking

with wheels locked

Adjust
the
resistance value
by
using
the
adjusting screw

Yes
Disengages at 20 km/h (13 mph) in 2nd

Adjust

the

resistance value
by
using
the
adjusting screw

R
e
s
i
s
t
a
n
c
Check
the e
resistance
between
)
terminals 2
and 1 at full t
open
o
Is
the
o
resistance
just 96%
h
of
i
resistance
g
between
h
terminals
1 and 3?

No
Disengages in all
range

AUTOMATIC TRANSMISSION SERVICE GROUP

14

MIITSG

Technical Service Information

Becomes W

midway

through stroke
Does the resistance value between

Disengages at a throttle opening when

terminals 2 and 3 change continuously
engine speed exceeds approx. 2,500

between idling and full open?

rpm

C
h
a
n
g
e
s
c
o
n
t
i
n
u
o
u
s
l
y
G
o
t
o
(
4
)
:
b
r
o
k
e
n
w
i
r
e
O
r

0 : short
Check the resistance between terminals 1
Operation is OK
and 2.
in 2nd. but when
Is the resistance approx.
subsequently
driven in 3rd for
52051 at 20C?
Yes
longer
than 5 seconds, disengages in all ranges

(4) Pulse generators A B

...(

A: Kickdown side lead

wire with
short transparent tube
B:
Transfer
driven
gear
side lead wire
with
long
black tube

Replace the pulse generator

:
b
r
o
k
e
n

Check the resistance between

terminals 3

w
i
r
e

o
r
0 : short
Aand
= 1 and 2

Puls
e
gene
rato
rs A
- B
ter
min
als

(Use
an
oscil
losc
ope
to
chec
k.)

4.

No

171090
Disengages in all ranges Is the resistance approx. 52011 at
20C?
Yes
(5) Pulse generators A B
Go to (5)
Replace the pulse
generator

Connect the wiring harness and the pulse

generator, and check with a
chassis dynamometer, or with
the front wheels raised
Insufficient voltage
With the engine running at
800 rpm in low ("L"), use
the oscilloscope to
check the voltage waveform
between terminals 1 and 2.
Is the voltage approx. 650
mV P-P or more?

) No

Operation is OK in 2nd, but when

subsequently driven
in 3rd for longer
than 5 seconds,
disengages in all
ranges

Yes
No
ise

Adjust
the
gap
between
pulse
generator A and the
kickdown
drum
because
it is excessive,
or replace the
pulse
generator

AA

Noise in the waveform

isengages in 3rd only

01K
015

Poor grounding of
shielded wire of pulse
generator circuit

Operation is OK in 2nd

AUTOMATIC TRANSMISSION SERVICE GROUP

15

ATSG

Technical Service Information

No

the voltage waveform between terminals

3 and 4.
Is the voltage approx. 180 mV P-P or more?
Yes

With the engine running at 1,000 rpm in

voltage
low ("1.."), use the oscilloscope to check
gap between pulse
Disen
generator A and the
gages
kickdown
drum
in all
because
range
it is excessive,
s or replace the
pulse generator

Insufficient

Noise
Noise in the wave form

A
d
j
u
s
t

9.
0.

Disengages in all
ranges, or vibration
occurs

t
h
e

Go to (6)
01K015

Poor
grounding
of
shielded wire of pulse

generator circuit

:
b
r
o
k
e
n
w
i
r
e
o
r

(6) Solenoid

NOTES
(1) If resistance is
()
side
lead
wire
may

minus

Chec
k the
resist
ance
betw
een
the
solen
oid
termi
nals
and
the
trans
axle
case.
Is the
resist
ance
appro
x.
3r1 at
20C
(68F
)?
n
o
t

0 : short

No

Disengaes in all ranges

be
connected
(2) If there is a
short in the
solenoid,
the control
unit

Refer to notes (1) and (2)

may be damaged
Yes

Replace the solenoid

V
Is there any foreign matter
on the valve seat?

) Yes _

Engine stalls when shifted from "N" or

"P" to a driving gear

trans
missi
on
fluid

Replace the solenoid

V
Go to (7)

(7)
Brand
s of
auto
matic

Excessive vibration
Run the engine at 2,500
rpm or more and check
the steering wheel for
vibration

_.
<

Check the
brand of the
automatic
transmission
fluid

AUTOMATIC TRANSMISSION SERVICE GROUP

16

ATS
G
(8) Computer

Technical Service Information

Discon
nect
the
body
harness
from
the
comput
er.
After
connect
ing the
extensi
on
harness
to the
body
harness
,
connect
anothe
r
comput
er

(Same abnormal cond.tion

computer

Replace the

Yes

Normal

(
d
a
m
a
g
e
o
r
d
i
s
c
o
n
n
e
c
t
i
o

n
)
o
r
0
(
s
h
o
r
t
c
i
r
c
u
i
t
)
Check the resistance between solenoid
valve
terminal
1
and
the

(9)
Pressu
re
contro
l (PC)

transmission

Replace the PC solenoid valve case (ground)

2.6-3.211 at 20C (68F)

solenoi
d
valve

V
Check
whethe
r there
is dirt
in the
valve
seat

Solenoid
valve
connector

1: PC
solenoid
valve 2:
Damper
clutch
solenoid
v
alve
3:
SC
solen
oid
valve
A
4: SC solenoid
valve B

171095
(
dirty valve seat) Solenoid valve
sound can be heard when

12V is connected between

terminal
1 and the transmission case

1Yes

Normal

)
No

Replace the PC solenoid valve

AUTOMATIC TRANSMISSION SERVICE GROUP

17

ATSG Technical Service Information

(damage or disconnection) or
0 (short-circuit)
(10) Shift control
(SC) solenoid
valve A B

Check the resistance between solenoid

valve
terminal
3
or
4
and

the

Replace the SC solenoid valve transmission case

(ground).

I.(

20.8-23.811 at 20C (68F)

C
h
e
c
k
w
h
e
t
h
e
r
t
h
e
r
e
i
s

d
i
r
t
i
n
t
h
e
v
a
l
v
e
s
e
a
t
.
(dirty valve seat)

Solenoid valve sound can be heard when

12V is connected between terminal
3 or 4 and the transmission case.
Yes

No

Replace the SC solenoid valve

Normal
17109
6

(11) Accelerator
switch

,; Problem not solved

Replace the accelerator switch

Adjust the accelerator switch instalktion

With the accelerator pedal released,

check the resistance between 1 and 2

on

Check the resistance between 1 and

2 with the accelerator pedal slightly
(about 5%) depressed

on

Problem not solved

Adj
ust
the
acce
Replace the accelerator switch
lera
tor
swit
ch
inst
allat
ion

AUTOMATIC TRANSMISSION SERVICE GROUP

18

ATS
G

(12) Inhibitor
switch

Technical Service Information

ln the "P" range,

check
continuity
between 3 and 4 and
between B and 9.

na<

Continuity

(In the "R" range, check continuity between 4 and 7.

)

Continuity

In the "N" range,

check
continuity
between 2 and 4 and

between 8 and 9.

No continuity

Continuit
y

Replac
e
the
inhibit
or
switch

In the "D" range,

check continuity
between 4 and 6.

Continuit
y

In the "2" range,

check continuity
between 1 and 4.
Continuit
y
V

In the "L" range,

check continuity
between 4 and 5.

Continuit
y

V
Nor
mal

No
continuity

(13) Kickdown (KID) servo switch

Check continuity between the kickdown servo switch terminal and the
transmission case (ground).

w(

Continuity
Start the engine and, with the engine idling and the transmission in the "D" range (be sure the brake is applied
securely), check for continuity between the kickdown servo switch terminal and the transmission case.

No continuity
V
Normal
Replace the kickdown servo switch

Continuity

Replace the kickdown servo switch

AUTOMATIC TRANSMISSION SERVICE

GROUP
19

AT5Gi

Technical Service Information

OIL PRESSURE TESTS

1.
1.

Completely warm up the transaxle.

Raise the vehicle by using a jack so that the front wheels
can be rotated.
3. Connect an engine
tachometer and place
it in a position where
it's easy to see.
4. Attach the special oil-pressure gauge
30 kg/cm2
6
(MD998330) and the adaptor
Torque(MD998332-01) to each oil-pressure
converto
r
outlet port.
When the reverse pressure is to be
pressure
tested, the 30 kg/cm' type of gauge
should be used.

,!
`Reducing
pressure

F
ro
nt
cl
ut
c
h
pr
es
su
re

Kickd
own
brake
pressu
re

5. Measure the oil pressure under

various conditions, and check to be
sure that the measured results are within
the

175103

standard value range shown in the

"Standard oil pressure table" below.
If the oil pressure is not within
the specified range, check and repair
as
described
in
the
section
"Remedial steps if oil pressure is not
normal" on the next page.

5
Lowrevers
e

(4:\
End
clut
ch

Standard Oil Pressure Table

Conditions

brake
pressu
re

pre
ssu
re

175102

Standard oil pressure

kg/cm2
3
N
o
1
2

4
5
6

7 Select
lever
8

positio
n
N

N
D
D
(SW-ON)
D
(SW -OFF)

L
R

35 (0)

(Referen
ce)
vehicle
speed
km/h 0
0
0
110

Engine
speed
rpm
Idling
A pprox.
2500
Idling
Approx.
2500
Approx

75

25 00

50

Approx.
2500

ADD
r"'
1000

Shift

Neutral

2nd gear
1.0 -2.1

2.5 - 3.9

Front clutch
pressure

End clutch
pressure

Low-reverse
brake
pressure

Torqueconvertor
pressure

2.5 -3.9

2.0 -2.4

Redu
cing
4th gear
Kick 6.2 --6.8
dow
n
positio 3rd gear
n
6.2
pressur
e
brake
2nd gear
pressure
6.2 - 6.8
Neutr
al
2.5
-3.9
-

2.5 - 3.9
^-6.8

2.5 - 3.9

1st gear
-

2.5 - 3.9

Reverse
-

2.5 - 3.9

Approx.

2500

6.2 - 6.8

6.2 - 6.8

6.2 - 6.8

3.0 - 4.2

11.6 - 17.6

11.6 -17.6

NOTE
- must he 0. I kg/cm or less.
SW-ON : Switch ON the OD switch.
SW-OFF : Switch OFF the OD switch.

AUTOMATIC TRANSMISSION SERVICE GROUP

20

E1,3 PTSG

Technical Service Information

Remedial Steps If Oil Pressure Is Not Normal

r
a
Trouble
Probable cause
k
symptom
e
a.
Clogging of oil filter
1. Line
p
b.
Improper adjustment of oil pressure
pressures
r
are
(line pressure) of regulator valve
e
all
s
low (or
s
c.
Sticking of regulator valve
high).
u
r
NOTE
e
d.
Looseness of valve body tightening part

"Line
pressures"
e. Improper oil pump dischange pressure
refers to oil
pressures

Cl, ,

T. ) and 31
in the
"Standar
d
oil
pressure
table" on
the
previous
page.

Imprope
r front
clut
ch
pres
sure

2.
Improper
reducing
pressur
e

5.
Imprope
r end
clut
ch
pres
sure

3.
Improper
kickd
o
w
n
b

a.

Improper line pressure

b.

Clogging of the filter (L-shaped type) of

the reducing-pressure circuit
Improper adjustment of the reducing
pressure

4.

c.
d.

Sticking of the reducing valve

e.

Looseness of valve body tightening

part

a.

Malfunction of the D-ring or seal

ring of the sleeve or
kickdown servo piston.

b.

Looseness of valve body tightening part

c.

Functional malfunction of the valve

body assembly

a.

Malfunction of the D-ring or seal

ring of the sleeve or kickdown
servo piston.

b.

Looseness of valve body tightening

part
Functional malfunction of the valve
body assembly
Wear of the front clutch piston or
retainer, or malfunction of the 10
D-ring and 2 seal ring.
(Refer to the figure on the next page.)

c.
d.

a.

Malfunction of a seal ring or D.

ring 1) of the end clutch or 0-ring '01
of the pipe (Refer to the following
figure.)

b. Looseness of valve body

tightening part
c. Functional malfunction of the
valve
body assembly

Remedy
a.
Visually inspect the oil
filter; replace the oil
filter if it is clogged..
b. Measure line pressure CI)
(kickdown brake
pressure); if the
pressure is not
the standard
value, readjust
the line pressure,
or, if necessary,
replace the valve
body assembly.
c.
Check the operation of the
regulator valve;
repair
if
necessary, or
replace
the
valve
body
assembly.
d.
Tighten the valve body
tightening bolt and installation bolt.
e. Check the side clearance of
the oil pump gear;
replace the oil pump
assembly if necessary.
a.
Check the kickdown
brake pressure (line
pressure); if the
line pressure is
not the standard
value, check as
described in item
I above.
b.
Disassemble the valve body
assembly and check
the filter; replace the filter
if it is clogged.
c.
Measure the (D reducing
pressure; if it is not
the
standard
value, readjust,
or replace the
valve
body
assembly.
d.
Check the operation of the
reducing valve;
if
necessary,
repair
it,
or

replace the valve body

assembly.
e. Tighten the valve body tightening bolt
and installation bolt.
a.
Disassemble the kickdown servo and
check
whether the seal ring or Dring is damaged. If it is cut or
has scratches, replace the seal
ring or D-ring.
b.
Tighten the valve body tightening bolt
and installation bolt.
c. Replace the valve body assembly.
a.
Disassemble the kickdown servo and
check
whether the seal ring or
D-ring is damaged. If it
is cut or has scratches,
replace the seal ring or
D-ring.
b.
Tighten the valve body tightening bolt
and
installation bolt.
c.
Replace the valve body assembly.
d. Disassemble the transaxle itself and
check
whether or not there is wear
of the front clutch piston and
retainer inner circumference,
or
damage of the D-ring or
seal ring. If there is any
wear or damage, replace
the piston, re-tainer. Dring and/or seal ring.
a.
Disassemble the end clutch and check
the seal
ring, D-ring of the
piston, seal ring of the
retainer, 0-ring of the
pipe, etc.; replace if
there are cuts, scars,
scratches or damage.
b. Tighten the valve body tightening bolt
and
installation bolt.
c. Replace the valve body assembly.

AUTOMATIC TRANSMISSION SERVICE

GROUP
21

ATSG

Technical
Service Information
End clutch
Seal ring
D-ring

1'D-ring

Rear clutch
Front clutch

j 0-ring
3
S
e
a
l
r
i
n
g
1

I
1
4
=
b
2

D-ring

Seal ring

JL
19'Seal r ing

Trouble symptom

Probable cause

6. Improper lowa.
valve body and transreverse
brake

0-ring between

mission damaged or missing

pressure
b. Looseness or
improper tightening
of
center support
tightening bolt

c.
Loosene
ss of
valve
body
tightenin
g part
d.
Functio
nal
malfunc
tion of
the
valve

body assembly
e. Malfunction of
the D-ring of the
low-

e 0-ring
175143

Remedy
a.

b.

c.
d.
e.
reverse brake
piston or the
0-ring of
the
retainer
(Refer to the
figure above.)
7. Improper torque
a.
damper clutch control
a.
convertor pressure
(DCCSV) or the damper

Sticking of the

Remove the valve body assembly and check to

be sure that the 0-ring at the
upper surface of the upper
valve body is not missing or
damaged; install or replace
the 0-ring if necessary.
After removing the valve body assembly, check
the tightened condition of
the bolt; re-tighten it if
necessary.
Tighten the valve body tightening bolt and
installation bolt.
Replace the valve body assembly.
Disassemble the transaxle itself and check
the D-ring and 0-ring for
damage; replace if there
are cuts, scars, scratches
or damage.
Check the operation of the
damper clutch system and
the DCCSV.

Repair
or
replace,
as
necessary, the cooler and/or
clutch control valve. piping.
b. Clogging or leaking Disassemble the transode
itself and check for damage
of the oil cooler
of the seal ring; replace the
b.
seal ring if there is damage.
and/or piping
Replace the torque convertor.
c. Damaged seal ring
@ of the input
c.
shaft (Refer to the
figure above.)
solenoid valve

d. Malfunction of the
torque convertor
d.

AUTOMATIC TRANSMISSION SERVICE GROUP

22

USG

Technical Service Information

SERVICE
ADJUSTM
ENT
PROCEDU
RESMAINTEN
ANCE AND
ADJUSTM
ENT

LUBRICATION
Checking Fluid Level

and Replenishing Fluid

Check and replenish

interval:
Every 24,000 km (15,000 miles)
Inspect fluid level on dipstick with
engine idling, transaxle in neutral
position and vehicle on level ground.
A
proper fluid level should be
between upper and lower lines of
dipstick when fluid temperature is
50-80C (120-180 F).

Changing Fluid
Recommended fluid
DEXRON II
NOTES
When factory fill fluid is changed as
recommended above. If transaxle is
disassembled for any reason, fluid
and filter should be changed.
Flu
id
Ch
an
gin
g
Pr
oce
du
re

i
o
n
Wh
en
the
unit
is
dam
age
d
and
the
ATF
is
cha
nge
d,
be
sure
to
also
clea
n
the
cool
er
syst
em.
1.
Raise
vehicl
e on

hoi
st.
Pla
ce
dra
in
con
tai
ner
wit
h
lar
ge
openin
g,
under
drain
plug.
2.
Re
mo
ve
dra
in
plu
g
to
let
flui
d
dra
in.
3.
Pla
ce
a
dra
in
co
nta
ine
r

with large opening under the

transaxle oil pan.
4. Loosen the oil pan bolt. (Do not
remove it.) Then gently
tap the corner of the oil pan to
remove it and drain the ATF. Then
remove the oil pan, taking care
not to spill the ATF still remaining
in it.
5. Check for clogging or damage of
the oil filter; replace if necessary.
6. Clean gasket surfaces of transaxle case
and oil pan.
7. Install oil pan with new gasket and
tighten oil pan bolts
to 10 to 1 I Nm (7.5 to 8.5 ft.lbs.).
8. Clean drain plug and tighten drain
plug with gasket to
30 to 34 Nm (22 to 25 ft.lbs.).
9. Pour 4 liters (4.2 U.S.qts., 3.5
Imp.qts.) of recommended ATF
into
case through dipstick hole. [Total
quantity of
ATF required is approx. 5.8 liters
(6.1
U.S.qts.,
5.1
Imp.qts.).
Actually, however, approx. 4.5
liters (4.8 U.S.qts., 4.0 Imp.qts.) of
fluid can be replaced because rest
of
fluid
remains
in
torque
converter.]
10. Start engine and allow to idle for
at least two minutes. Then,
with
parking brake on, move selector lever
momentarily to each position, ending in "N"
Neutral position.
11. Add sufficient ATF to bring fluid
lever to lower mark.
Recheck fluid level after transaxle
is at normal operating temperature.
Fluid level should be between
upper and lower marks of "HOT"
range. Insert dipstick fully to
prevent dirt from
entering transaxle.

V-------

LL I

---

Fluid
level
must
be
within
this
range.

--;
o_

_
_
_.
..175124

AUTOMATIC TRANSMISSION SERVICE GROUP

23

ATSG

Technical Service Information

INHIBITOR SWITCH ADJUSTMENT

1 Place manual control lever in "N" Neutral position.
2. Turn inhibitor switch body until
12 mm (.472 in.)- wide
end
"A"
of
manual
control
lever
overlaps
switch body fl
ange.
3. Tighten two attaching bolts to torque between
10 and
11.5 Nm (7.5
and
8.5
ft.lbs.)
while
paying attention
to prevention of
switch
body
dislocation.

ADJUSTMENT OF THE KICKDOWN SERVO

1.
Completely
remove all dirt and
other
materials
adhered around the
kickdown servo cover.
2. Remove the kickdown servo switch.
3. Remove the snap ring and cover.
4. Loosen the lock nut.

5. While holding
with special tool
MD998902 so that
the kickdown servo
piston won't turn,
use special tool
MD998901 to
"tighten", at 9.8 Nm
(7.2 ft.lbs.), and
"return" the
adjustment screw two
times each, and then

tighten at a
torque of 4.9 Nm
(3.6 ft.lbs.). Then
return the adjustment
screw 2 to 2-1/4
turns.
6. While holding
with special tool
MD998902 so that
the kickdown servo
piston won't turn,
tighten the lock nut to
the specified
torque.
Lock nut

25-31 Nm (18-23 ft.lbs.)

7. After fitting
a
new D-ring in the
groove around the
cover, install the
cover to the case so
that the D-ring
won't
be twisted,
and
then
install
the
snap ring. 8.
Install
the

kickdown
servo
switch
to
the cover.
Kickdown servo switch screw
1.0-1.4 Nm (0.7-1.0 ft.lbs.)

AUTOMATIC TRANSMISSION SERVICE GROUP

24

AT5G

Technical Service Information

ADJUSTMENT OF THE LINE PRESSURE

1. Drain out the ATF.
2. Remove the oil pan.
3. Remove the oil filter.
4. Remove the valve body assembly. The manual valve can
come out, so be careful not to drop it.
5. Turn the
adjustment screw of
the regulator valve
and adjust so that the
line pressure
(kickdown brake
pressure) becomes
the standard value.
Standard value

647 9.8 kPa (94 1.4 psi)

Oil pressure change for each

turn of adjustment screw
6.

Check to be sure that the

upper surface of
the valve body at
the place shown
in the figure.

28 kPa (4 psi)
0-ring is installed on the

7. Replace the 0-ring

of the solenoid valve
connector with a new
one.
8. Install the valve
body assembly to
the case and then
insert the
solenoid valve
connector into the
case. Be sure, at this
time, that the
notched part of the
connector faces as
shown in the figure.
Also be careful that the lead wiring isn't caught.

9.

Tighten valve body assembly mounting bolts (10 pieces)

to 10-11.5 Nm (7.5-8.5 ft.lbs.).
A bolt
B bolt
C bolt

20 mm (.787 in.) long

28 mm (1.102 in.) long
45 mm (1.772 in.) long

10. Install the oil filter.

11. Install a new oil pan gasket and oil pan, and tighten the
12 bolts.
12. Pour in the specified amount of ATF.
13. Make the oil pressure test. Readjust if necessary.

AUTOMATIC TRANSMISSION SERVICE GROUP

25

ATSG

Technical Service Information

ADJUSTMENT OF THE REDUCING PRESSURE

1.

Remove parts up to the oil filter in the same way as for

adjustment of the
line pressure. The
valve body need
not be removed.
2.
Turn
the
adjustment screw of
the lower valve body
and adjust so that the
reducing pressure is
the standard value.
Standard value

314 9.8 kPa (46 1.4

Oil pressure change for each

turn of adjustment screw
3.
4.

16 kPa (2.3 psi)

Install the oil filter and oil pan in the same way as for
adjustment of the line pressure.
Make the oil pressure test. Readjust if necessary.

ADJUSTMENT OF
THE THROTTLEPOSITION
SENSOR (TPS)
1. Measure
and
make a note of the
resistance between
terminals 1 and 3.
2. Measure and
make a note of the
resistance between
terminals 2 and
3. Measure the
resistance after the
engine has
warmed up, in the

throttle idle open

condi-tion.
3. If the measured
resistance is not the
standard value, turn
the body of the TPS
to adjust to get the
standard value.
Standard value
Resistance between terminals 2 and 3: 8% of
resistance between terminals 1 and 3.

AUTOMATIC TRANSMISSION SERVICE GROUP

26

AT5G

Technical Service Information

COMPONENT SERVICE-AUTOMATIC TRANSAXLE CONTROL

Adjusting
nut
Clip
Adjuster

rt
Bushing

4
Pushbutton
knob

Selector

f
i
t
l
b
s
.

Slee
ve

Set screw

2.0 Nm
1.4 ft.lbs.
Bracket

Cover

REMOVAL
1.5
N
m
1.1
ft.t
bs.
Position
indicator
light

1
4
2
0
N
m
1
0
1

1. Remove the console box.

(Refer to GROUP 23.)
2. Disconnect the overdrive
switch connector.

Selector lever

Slider

Indicator panel
Cable end

Control cable
09R
006
5

Indicator

3.
Remove
the
terminal from the
overdrive
switch
connector case.
(09R0054)

AUTOMATIC TRANSMISSION SERVICE

GROUP
27

ATSG

Technical Service Information

4. Push the cover downward.

5. Remove the
selector knob
from
the
selector lever.
(09R0039)

6.
7.

Remove the indicator panel. (09R0036)

Disconnect the connector of the position indicator light.

8.

Disconnect the control cable from the lever.

9.

Remove the bracket from floor panel.

AUTOMATIC TRANSMISSION SERVICE GROUP

28

m
ATSG

Technical Service Information

10. Raise the vehicle,

remove the cable end
installation nut from
the floor panel, and
pull the control cable
toward the lower
part of the chassis.
11.
Remove
the
control
cable
installation bolt and
holding band at the
floor panel. (09R0021)

12.
Remove
the
control cable from
the transaxle and
the transaxle mount
bracket.

INSPECTION
Check detent place for wear.
Check pin at the end of selector lever for wear.
Check contact surface of the push button and the sleeve
for wear.
4. Check control cable for function and for damage.
5. Check busing for wear or damage.
6. Check overdrive switch for continuity. (09R0056)
1.

2.
3.

Terminal
Switch position
Overdrive activation (OFF)

1
(0.3-RW)

2
(0.3-BW)

3
(0.3-YW)

Overdrive non-activation (ON)

INSTALLATION
1.

2.

Apply chassis grease to each sliding part.

Apply a coating of multi-purpose grease to the sliding
part of the selector lever bushing. (19R0040)
Recommended multi-purpose grease
SAE J310a, NLGI grade #3

0,11.11111, IN

AUTOMATIC TRANSMISSION SERVICE GROUP

29

ATSG

Technical Service

Information
3.

Place the selector lever in the "N" position, and then

turn the sleeve so that the
clearance
between
the
sleeve and the selector lever
end is within the specified
range. (09 R0070 )

7.
Adjust
the
adjusti
ng nut
on the
transax
le side
so that
t
h
e
r
e

Clearance between sleeve and selector lever end

15.2-15.9 mm (.598-.625 in.)
NOTE
Be sure to face B of the
adjusting
cam
to
the
pushbutton
(driver's
side)
(09R0070)
4.
After installing the
indicator panel, move the
selector lever
to
each
position and check to be sure
that the
indicator panel indication agrees with the
transmission position.

i
s
n
o

Inhibitor switch
Neutral position
aligning hole

5.

Move the selector lever and the inhibitor switch to the

"N" position, and install the control cable. (09R0553)

Caution
When connecting the control
cable to the transaxle mount
bracket, install the clip until it
contacts the control cable, in
the position shown in the figure.
(09R0058)

6.

Apply a coating of the specified multi-purpose grease to

the interior of the bushing, and fill it.
Recommended multipurpose grease
SAE J310a, NLGI grade
#3

l
o
o
s
e
n
e
s
s
i
n
t
h
e
c
o
n
t
r
o
l
c
a

ble. (09R0059) 8. Confirm that

selector lever operation is
smooth, that the
correct gear is selected at
each position of the lever,
and that the corresponding
position mark is indicated
at each position.
9. Confirm that the ignition switch will operate the starter
motor when the selector
lever is moved to the "N"
and "P" positions, and that
it will not in the other
.ositions.
10. With the vehicle moving, operate the overdrive switch and
check to be sure that overdrive operates and is released

Sleeve

Selector
lever

09R0070

AUTOMATIC TRANSMISSION
SERVICE GROUP
30

Tranza
xle
mount
bracke
t
09R0058

ATS
G

15-2'

35.42

TRANSAXLE
Removal

COMPONENTS

1.

Nm
A
43-55
B
43-55
C
22-32
D
30-35
E
10-12

Remove the hood.

Technical Service
Information

09 K069

ft. lbs.

O.D. x Length mm (in.)

Bolt identification

31-40

10 x 40 (1.6)
Ax B

31-40

10 x 65 (2.6)

16-23

10 x 55 (2.2)

72-25

10 x 60 (2.4)

7-9

8 x 14 (0.6)
Y09512

11-16
8 x 20 (0.8) 25-30

2. Remove the air cleaner case.

3. Disconnect the control cable from the transaxle.
(09R0059)

AUTOMATIC TRANSMISSION SERVICE GROUP

31

ATSG

Technical Service Information

4.

Disconnect the inhibitor switch connector, pulse generator

connector,
oil cooler
hoses,
speedomet
er
cable.
(09R0044,
09R0015)
5. For models
equipped with the
Electronic
Controlled
Suspension
system, remove the
compressor assembly
and the reserve tank
assembly. (Refer to
GROUP 2.)
Caution
Be careful that the
fluid does not drain
out of the cooler
hoses after the hoses
have
been
disconnected,
and
install plugs on the
hoses
and
the
transaxle
so
that
foreign matter does
not enter.

6. Disconnect the starter motor harness.

7.
Remove the
upper
five
bolts
connecting
the

transaxle to
the
engine. (09K033)
8. Remove the starter motor.

9. Lift the vehicle and remove the wheels.

10. Remove the undercover panel.
11. Drain transmission fluid. (09R0017)
12. Remove the right
and left drive shafts
from the transaxle as
follows.
(1) Using the
special tool,
(MB990778-01)
disconnect the
knuckle
from the lower
arm ball joint.
(Refer to GROUP
2.)
(2)
Using
the
special
tool,
(MB990635-0 I )
disconnect the tie
rod
from
the
knuckle. (Refer to
GROUP 19.)
(3) Remove the
drive shaft from
the
transaxle.
(Refer
to
GROUP 2.)
13. Attach the wire
to the engine hook,
suspend the engine
by a block &
tackle to the extent
that there is no
loose- ness in the
wire, and then
remove the center
member.

AUTOMATIC TRANSMISSION SERVICE GROUP

32

AT5G

Technical Service Information

14. Remove the bell housing cover.

15. Remove the three
special bolts (three
pieces) connecting
the converter with
the
drive
plate.
(09K023)
NOTE
Remove the converter
while rotating the
flywheel by turning
the crank pulley.
In order not to leave
the torque converter
in the engine, push
the torque converter
into the transaxle
after removal of the
special bolts.

16. While supporting

the lower part of the
transaxle with a
transmission jack,
remove the remaining
engine connect- ing
bolts.
Caution
Support a wide area
of the transaxle so
that the oil pan is not
distorted
when
supported.
17. Remove the transaxle mount insulator bolts. (09R0043)
18.
Slide
the
transaxle
assembly
toward the right then
lower it to remove.

Installation
1.

Be sure to install the torque converter first to the transaxle and then to the engine.

Caution

If the torque converter is installed first to the engine, oil seals

on the transaxle side may be damaged.
2. Refill the transaxle with fluid to the
specified level.
(72R0012)

HOT1

Recommended fluid
72R001
2

ATF DEXRON II type

Quantity
3.0 lit. (3.2 U.S.qts., 2.6
Imp.qts.)
NOTE
With the vehicle on a level
surface, check by shifting the
selector lever from "P" through
"L" positions with the engine
idling.
3. Adjust the throttle control cable.
4. Adjust the control cable. (Refer to P.21-43.)
5. Be sure the inhibitor switch harness does not
contact the
transaxle insulator bracket.
6. Be sure the engine does not start when the
selector lever
is placed at other than the "N" and "P"
positions.
7. Install the parts and torque to specifications.

AUTOMATIC TRANSMISSION SERVICE

GROUP
33

It2111T5
G

SECTIONAL
VIEW

Technical Service Information

COMPONENT SERVICE-AUTOMATIC TRANSAXLE

ASSEMBLY
2

3 45

10 11 12 13
14

49
48

15
16
17

47,
48-

e
l
.
I
f

it_
L
23
24
25

3
2

3
1

3
0

2
9
2
8

1 . Converter housing
Forward sun gear

20.

2.

21.

Oil pump housing

Reverse sun gear

3. Oil pump drive gear

way clutch
4. Oil pump driven gear
Parking sprag

22. One-

5. Reaction shaft support

Transfer shaft
6. Adapter

24.

7. Front clutch
Transfer driven gear
8. Rear clutch
generator 8
9. Pulse generator A
Center support

26.

10. Low.reverse brake

Clutch hub

23.

25. Cover

27. Pulse
28.
29.

18
11. Planet gear set
30. Kickdown drum
12. Internal gear
31. Kickdown band
13. Output flange
32. Transaxle case
14.
33.
15.
34.

Transfer idle gear

Drain plug
Lock plate

Differential drive gear

(Ring gear)
16. Transfer idle shaft
35.
Pinion shaft
17.
36.

End clutch
Differential case

18.
37.

Transfer drive gear

Pinion gear (21

19.
38.

Bearing retainer
Side gear (2)

19
20

175001

-21

39. Drive shaft oil seal (2)

40. Speedometer drive gear
41.
Pinion shaft lock pin
42.

Impeller

43. Turbine
44. Stator
45.
Pump oil seal
46.
Input shaft
47.

One-way clutch

48.

Clutch plate

49. Starter ring gear

AUTOMATIC TRANSMISSION SERVICE GROUP

34

AT5G
D
I
S
A
S
S
E
M
B
L
Y
C
a
u
t
i
o
n
Because
the
automatic transaxle is
composed
of
component parts of
an especially high
degree of precision,
these parts should be
very
carefully
handled
during
disassembly
and
assembly so as not to
scar or scratch them.
A
rubber
mat
should be placed on
the workbench, and
it should always be
kept clean.
During disassembly,
cloth gloves or rags
should not be used. If
such items must be
used,
use
articles
made of nylon, or use
paper towels.
All
disassembled
parts
must
be
thoroughly cleaned.
Metal parts may be

Technical Service Information

cleaned
with
ordinary detergents,
but
must
be
thoroughly air dried.
Clean the clutch disc,
resin thrust plate and
rubber parts by using
ATF
(automatic
transmission
fluid),
being very careful
that dust, dirt, etc. do
not adhere.
If the transaxle main
unit is damaged, also
disassemble and clean
the cooler system.
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.

4.

Measuring input shaft end play before disassembly will

usually
indicate
when a thrust
washer change is
required (except
when major parts
are
replaced).
Thrust
washers
are
located
between reaction
shaft
support
and rear clutch
retainer,
and
between reaction
shaft support and
front
clutch
retainer.
Mount a dial
indicator
MIT209038 to
ing
converter hous
with the Dial
Indicator
Support. Make
sure that the
indicator plunger
is seated against
end of 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
transaxle.
5. Remove the cover retainer and then remove the co

ver.

AUTOMATIC TRANSMISSION SERVICE

GROUP
35

In ATSG

Technical Service Information

6.

Measuring transfer shaft end play before disassembly will

usually
indicate
when a spacer
change is required.
Spacer is located
between the front
transfer
shaft
bearing
outer
race
and
the
converter housing.
Attach a dial
indicator
to
transaxle
case
using
Special
Tool,
Dial
Indicator
MIT209038 with
its plunger seated
against
end of
transfer shaft.
After removing
the idler shaft
lock plate, install
the special tool
into the lock plate
bolt hole. When
checking end play,
pull out or push in
on transfer shaft
with pliers. Be
careful not to
scratch the shaft.
Record indicator
reading
for
reference
when
reassembling
transaxle.

7.

Remove the pulse generator "A" and "B".

8.

Remove manual control lever, then remove inhibitor

switch.

9.

Remove the end clutch cover.

AUTOMATIC TRANSMISSION SERVICE GROUP

36

ATSG

Technical Service Information

10. Remove the end clutch assembly.

11. Remove the thrust washer.

12. Remove the end clutch hub.

13.
Remove
the
thrust washer, and
pull out the end
clutch shaft.

AUTOMATIC TRANSMISSION SERVICE

GROUP
37

Q ATSG

Technical Service Information

14. Place transaxle with engine mounting surface up.

15. Remove
13 bolts and
remove
converter
housing.
(175149)

16. Remove six oil

pump mounting
bolts. Screw Special
Tools MD998333,
into two oil pump
removing holes in oil
pump housing. Turn
both removers
simultaneously and
uniformly to remove
oil pump assembly.
Oil pump may
sometimes tilt to A
side, because straight
line connecting oil
pump removing holes
does not pass center
of pump. If this is the
case, tap oil pump
lightly on B side or
tilt removers to B side
as pump is removed.
17. Remove the oil pump gasket.

18. Remove the oil pump adapter and gasket.

19. Remove the differential assembly.

AUTOMATIC TRANSMISSION SERVICE GROUP

38

r
ATS
G
Te
ch
nic
al
Ser
vic
e
Inf
or
ma
tio
n

. Remove the fiber thrust

washer, the metal thrust
race, and
the
thrust
bearing.

23. Remove the rear clutch assembly.

20.
Remove
the fiber
thrust
washer.

AUTOMATIC TRANSMISSION SERVICE GROUP

39

21. Remove

the front
clutch
assembly.

"NA AL_
v,ise
Law
(4
c
1112
2

ATSG

Technical Service Information

24. Remove the thrust bearing.

25. Remove the clutch hub.

26. Remove the thrust race and bearing.

Thrust race

Thrust
bearing

175157

27. Remove the kickdown drum.

AUTOMATIC TRANSMISSION SERVICE GROUP

40

ATSG

Technical Service Information

28. Remove the kickdown band.

29.
Remove
the
kickdow
n servo
cover
snap
ring.
Then
remove
the
kickdow
n servo
switch.

30. Remove the kickdown servo cover.

31. Using the valve

spring compressor
and special tool MD998341-01, push
in the kickdown
servo and remove the
snap ring.

AUTOMATIC TRANSMISSION SERVICE

GROUP
41

am

ATSG

Technical Service Information

32. Remove the anchor rod.

33.
Remove
the
kickdown
servo
piston and
spring.
Caution
Do not place (turn)
transaxle
upside down as planetary gearset
thrust washers could fall out of place.
35. Turn
the
transaxle
over
so
that the
oil pan is
facing
34. Hold reverse sun gear with
Special Tool MD998345, so that
when transaxle is placed upside
down, forward sun
gear front and rear thrust
bearings will stay in position.
When no center support or further
disassembly is made, it is especially
important to hold reverse sun gear.

upward.
Be careful
not
to
scratch or
scar
the
end of the
manual control
shaft.
36. Remove the oil
pan and gasket.
37. Remove the oil
filter from the valve
body.

Spring

Kickdown servo piston

1751
59

AUTOMATIC TRANSMISSION SERVICE GROUP

42

IITSG

Technical Service Information

38. Disconnect the

throttle control cable
from the throttle
cam
which
is
attached to valve body.

39. Push catches and

remove
the
ELC
connector from the
tflutsaxle case.

40. Remove 10 valve body assembly bolts. (175058)

41. Remove valve body from transaxle case.

42. Remove two center support bolts.

AUTOMATIC TRANSMISSION SERVICE

GROUP
43

ATSG

Technical Service Information

43. Place case with oil pump side up.

44. Remove Special Tool MD998345 from the case.

45. Remove Special
Tool
MD998340-01
and MB990211-01, to
center support.
Holding
tool,
pull
center
support straight
upward. (170064)

46. Remove reverse sun gear and forward sun gear together.

47. Remove planet carrier assembly.

48. Remove the thrust bearing and thrust races.

\ Thrust race

'/
A

/ ,
i

Thrust bearing

r) (')

AUTOMATIC
TRANSMISSION SERVICE
GROUP
44

IITSG
49.

Remove

bearing

Technical Service Information

the

retainer,

then remove the oil

pipe. Caution
The flat-head bolt
with hexagonal hole
may be difficult to
remove because of
attached adhesive. If
so, remove it after
first tapping its head
with a hammer.

50. Remove idler shaft lock plate.

51. Loosen transfer idler shaft with Special Tool MB99834401.

52. Pull out transfer

idler shaft. Remove
transfer idle gear
bearing inner
races (2 pieces) 'and
spacer from inside of
case.

AUTOMATIC TRANSMISSION SERVICE GROUP

45

ATSG

Technical Service Information

53. Remove snap ring from bearing.

54. Remove internal

gear, output flange,
transfer drive gear
and bearing as
assembly from case.

55. Remove transfer shaft rear end snap ring.

56. Using steel drift

on rear end of
transfer shaft, drive
transfer shaft
toward engine
mounting surface.

Transfer driven gear

comes off.

AUTOMATIC TRANSMISSION SERVICE GROUP

46

PTSG

Technical Service

Information
COMPONENT SERVICE-AUTOMATIC
TRANSAXLE ASSEMBLY
57. Remove snap ring
from transaxle case,
then remove taper
roller
bearing
inner and outer races.

REASSEMBLY
Caution
Do not reuse gaskets,
oil seals and rubber
parts. Replace them
with new ones at every
reassembly. 0-ring of
oil level dipstick need
not be replaced.
Do not use grease
other
than
petrolatum
or
industrial vase-line.
Apply automatic
transmission fluid
to friction element,
rotating parts, and
sliding parts before
installation. Use
"DEXRON II" type
automatic
transmission fluid.
New clutch disc
should be immersed
in automatic
transmission fluid for
more than two hours
before installation. Do
not apply sealer or
adhesive to gaskets.

When bushing must

be replaced, replace
assembly
which
includes it.
Do not use shop
towels
during
disassembly
and
reassembly operation.
The oil in the cooler should also be replaced.
1. Place transaxle case on bench with oil pan mounting
surface up.
2. Insert in position internal gear and output flange assembly (with two ball bearings and transfer drive gear attached) from inside of transaxle case. (170082)

3. Install snap ring on output flange rear bearing.

AUTOMATIC TRANSMISSION SERVICE

GROUP
47

8
.

AT5G

Technical
Service Information

I
n
s
e
r
t

4. Install two taper roller bearings and spacer to

transfer
idler gear.
Using petrolatum or vaseline
for industrial use, affix spacer
to inner race of bearing
installed on non-grooved side
of transfer idler gear. (170140)
5. Install new 0-ring in the groove of transfer idler
gear
shaft. (170140)

S
p
e
c
i
a
l

Spacer

6. Place the transfer idler gear

(assembled in the preceding
section) into the case, and
then insert the idler shaft
from the outer side of the case and screw it in.

T
o
o
l
M
D
9
9
8
3
6
3
0
1
i
n
t
o

7. Tighten the idler shaft by using special

tool
MD998344-01. Replace the 0ring of the idler shaft with a
new one.
Caution
Be sure to install transfer idler
gear in proper direction as shown
in illustration. (170140)

o
u
t
p
u
t
f
l
a
n
g
e
a
n

d measure preload using a low

reading torque wrench.
Adjust preload by tightening
or loosening transfer idler
shaft.
Preload

1.5 Nm (1 ft. lbs.)

brit

Torque converter side

Torque
wrench

MD998363.01

Groove for
id
e
nt
if
ic
at
io
n
o
f
in
st
al
li
n
g
di
re
ct
io
n

Inner races
Outer races
Transfer idler gear
170140

A040,)
forkSo

175169

AUTOMATIC TRANSMISSION SERVICE GROUP

48

ATSG
9.

Technical Service Information

After completing preload adjustment, install idler shaft

lock plate. Tighten lock plate bolt.
Lock plate bolt

20-26 Nm (15-19 ft. lbs.)

Caution
The
clearance
between the idler
shaft and the lock
plate
should
be
closed
in
the
direction that will
prevent idler shaft
looseness, and then the
lock plate should be
tightened.
Lock
plate
175170

10. Install two new

0-rings on the oil
pipe, and install the
oil pipe to case,
being sure to install
it in the proper
direction.
(175067)

11. Fit a new 0-ring

into
the
groove
(output flange part)
in the rear of the
transaxle case.
12. Install bearing
retainer, and tighten
screws to speci- fied
torque, apply a 5
mm (.2 in.) width of

sealant
(THREEBOND
#1303) the top of
screws. Sealant
should not stick out
of screw head.
Install new 0-ring
for re- tainer edge.
Screw

17-21 Nm (13-15 ft. lbs.)

13. Insert transfer shaft (with taper bearing inner race) into
Case.

14. Install Special

Tool MD998319-01,
to converter housing
mating surface of
transaxle
case.
(172012)

AUTOMATIC TRANSMISSION SERVICE

GROUP
49

AT5G
15. Using Special
Tool MD998350-01,
drive bearing inner
race onto transfer
shaft. (175198)
16.
Install
taper
roller bearing outer
race, then install
snap ring.

17. Using Special Tool

MD998350-01, install
transfer driven gear
onto transfer shaft.
(175199)
Be sure to install
transfer
driven
gear in proper
direction as shown
in
illustration.
(175199)

18. Install snap ring

to end of transfer
shaft. Turn transaxle
so that engine side
is up.

Technical Service Information

19. Apply petrolatum

(or vaseline for
industrial use) to
thrust races #13
(175100) and thrust
bearing #12 (175100)
and position it on
output flange.

AUTOMATIC TRANSMISSION SERVICE GROUP

50

ATSG

Technical
Service Information

2
#1

#2

#12

#3

#7

#11

(selection)

(selection)
175100
Unit: mm

Identification of thrust bearings, thrust races and thrust washers

Part no.
1

Shape

t_

D
Shape

.11

.A

70
55.7
1.8
70
55.7
2.2

D
55.7

70
2.6
70

55.7
3.0 _t___

d
D

t
d

Part no.
MD707901
(incL
0 *11
55.7
MD7079
1.8
170232
02
(incL
48.1
"2)
34.4
#1
-

Code

MD707903 (incl. 3)
MD707904
(incL 4)
MD707290

#2

MD707271

#4

Code

V
t

48.9
37
1.2
2

HH

48.9
37
0.8

48.9

37

L6

48.9

37

2.0

40

19
#5

2.4

MD704980

1.6

MD704936

26
#10

1.2

MD955671

38.7
#13

0.B

MD704935

26
#9

MD704933

#3 54

D
42.6

26

38.0

22.2
#11

MD704930

#6

52

I
I

36.4

-.

MD707270
54
170229

d
D

41

38.7
#7

MD720010

#8
#1
2

41
d
D

17
02
47

170228

AUTOMATIC TRANSMISSION SERVICE GROUP

51

AT5G

Technical Service Information

20. Assemble the planet carrier assembly.

Check
whether
or
not
thrust
bearing #11 is
assembled within
the carrier.

21. After attaching

thrust race #10 and
thrust bearing #9 to
the forward sun
gear by using
petrolatum, assemble
the reverse sun gear
and then assemble both
sun gears together
within the planet
carrier assembly.

22. Install the 0-ring

into the pressure plug
port of the center
support assembly.

23. Attach Special Tool

MD998340-01
and
MB990211-01
to
center support.
24. Apply automatic transmission fluid to overrunning clutch
Center support

inner race fitting

area of center
support.
Insert
center
support
(with low-reverse
brake) assembly
into
case
by
holding handle of
tool.

1 , n ^ C A

AUTOMATIC TRANSMISSION SERVICE GROUP

52

1:1T5G

Technical Service Information

25. Install two center

support locking bolts.
While
pressing
center
support
firmly with about 98
N (22 lbs.) pressure
and

i
i

tighten

bolts

to

specified
torque.
Center

_,
0
ioo0c
Lente
r supP
/41,--lockin
g
bolts
O.ND"

support lock
bolts
20-26 Nm
(15-19 ft.
lbs.)
NOTE
For proper alignment of the reverse
and low apply port, be sure to tighten
bolt A first.

If
installed
before
inserting
shaft, the 0ring
will
interface with
shaft
set
screw hole.

26. Attach Special Tool MD998345,

to retain reverse sun gear firmly.

27. Insert manual control shaft into

transaxle case and push it
fully
toward manual control lever.
At this time, do not install 0-ring
(larger one of two 0-rings) on
manual control shaft.
NOTE

28.
After
installing new
0-ring
on
manual
control shaft,
draw shaft
back
into
case,
then
install
set
screw
and
gasket.
Also
install
detent
steel ball
and
spring at
the same
time.
(170150)

29. Place case with oil pan mounting surface

up.

.1 "if'

L:.,`i7\B :.1.

?.. 3 )Z1--.
,,
'-.. --.-.
., \ ....,) .

.;.)-)

17
01
48

8-9.5 Nm
(6-7 ft. lbs.)
Detent plate
Detent ball
shaft

Manual control

17
01
50

AUTOMATIC TRANSMISSION SERVICE

GROUP
53

AT5G

Technical Service Information

30. The oil pan installation surface should face upward.

31. Install parking
sprag rod to detent
plate (manual control
shaft).
32. Install sprag rod support and tighten two bolts.
Sprag rod support bolts . .

20-26 Nm (15-19 ft. lbs.)

33. Install 0-ring at center of top of valve body assembly

(brake oil pressure passage). (175087)
34. Install valve body
assembly to case,
fitting detent plate
(manual
control
shaft) pin in slot of
manual valve.

35. Replace the 0-ring

of the solenoid valve
connector with a new
one.
36. Insert the solenoid
valve connector into
the case. Be sure that
the notched part of
the connector faces as
shown in the figure.

37. Tighten valve body assembly mounting bolts (10 pieces)

to 10-11.5 Nm (7.5-8.5 ft.lbs.).
A bolt
B bolt
C bolt

20 mm (.787 in.) long

28 mm (1.102 in.) long
45 mm (1.772 in.) long

AUTOMATIC TRANSMISSION SERVICE

GROUP
54

oh

ATSG

Technical Service Information

38. Install oil filter.

Tighten four oil filter
mounting bolts to 56.5 Nm (4-5 ft. lbs.).

39. Install new oil pan gasket and oil pan by tightening
bolts to 10-11.5 Nm (7.5-8.5 ft. lbs.). (170066)

40. Place transaxle

case with oil pump
mounting surface
facing upward.
41. Remove Special Tool (MD998345).

42. Install the anchor rod for the kickdown band.

12

AUTOMATIC TRANSMISSION SERVICE GROUP

55

PTSG

Technical Service Information

43. Assemble a new seal ring

(small diameter)
to the kickdown
servo piston, and
install a new 0ring
in
the
groove
around
the sleeve; then
assemble
the
kickdown servo
spring, piston and
sleeve
in
the
transaxle case.

(large diameter) and D-ring

44. Press the

kickdown servo and
sleeve in by using the
valve spring
compressor and
special tool
MD998341-01, and
then install the
snap ring.

45.
Install
the
kickdown servo cover,
and then install the
kick- down
servo
switch.
46. Install the kickdown servo cover snap ring.

47. Install kickdown

band; attach the ends
of band to the ends
of anchor rod and
servo piston rod.

AUTOMATIC TRANSMISSION SERVICE GROUP

56

ATSG

Technical Service Information

48. Install kickdown

drum with its
splines in mesh with
sun gear. Place
kickdown band on
kickdown drum and
tighten
kickdown servo
adjusting screw to
keep band in
position.

49. Apply petrolatum

to thrust bearing #8
(refer to P.21-62) and
thrust race (#7) and
position these parts
on kick- down drum.

50. Install clutch hub to sun gear splines.

51. Attach thrust bearing #6 onto the hub with petrolatum.

Thrust
bearing

AUTOMATIC TRANSMISSION SERVICE GROUP

57

1:1T5G

Technical Service Information

52. Install the rear clutch assembly.

53. Attach thrust washer

the rear clutch
retainer
by
using
petrolatum. Then
attach
thrust
bearing #4 to the
rear
clutch
retainer by using
petrolatum.

#2 (resin) (refer to P.21-62.) to

54. Install thrust race #3. If the end play of the input shaft
(measured
and
noted
at
the
time
of
disassembly)
is
the
standard
value, make the
selection of thrust
race #3 so that the
end play will be
within
the
standard value.
If thrust race #3 was changed for one of a different
thickness, thrust washer #1 (between the oil pump and
the front clutch) must be replaced with one which will
correspond to the thickness of the thrust race.

Thrust race #3 (metal)

washer #1 (fiber)
Thickness mm (in.)
Thickness mm (in.)

Thrust

Example

0.8 (.031)

1.8 (.071)

1.2 (.047)

2.2 (.087)

1.6 (.063)

2.6 (.102)

2.0 (.079)

3.0 (.118)

MD707901
MD707902
Parts No. of
thrust washer set

M0707903
MD707904

When 1.6 mm (.063 in.)thick thrust race #3 is

selected, 2.8 mm (.102 in.)
thrust washer #1 is one to be
paired with it.

55. Install the front clutch assembly.

AUTOMATIC TRANSMISSION SERVICE GROUP

ATSG

Technical Service Information

56. Attach the reused thrust washer

#1,
or
the
one
selected in step 54, to
the front clutch by
using petrolatum.

57. Install the differential assembly.

58. Install special tool MD998336-01 to the case.

59. Install new oil pump gasket and the adapter.

AUTOMATIC TRANSMISSION SERVICE GROUP

59

ATSG

Technical Service Information

60. Install new oil pump gasket and the oil pump assembly.

61. Install new 0-ring in groove of oil pump housing and

apply automatic
transmission
fluid lightly to
outside surface of
0-ring.
62. Install oil pump
assembly by
tightening six bolts
evenly to 15-21 Nm
(11-15 ft. lbs.). When
installing this oil
pump assembly,
be careful that thrust
washer will not drop.

63. Prior to
installation of
converter housing,
make certain that
transfer shaft end
play measured and
recorded at
disassembly is
same. If measurement
is out of specification, pull off
taper roller bearing
outer race from converter housing and
replace spacer with

spacer of suitable
thickness.
Standard
end
play is between
0.025

mm

(.0010 in.) (tight)

and 0.025 mm
(.0010
in.)
( loose).
Use Special Tools
MD998346 and
MD998347-01
and MB99093801
to
remove
taper
roller
bearing outer race
from and install
it to converter
housing. (170127
and 170128)

170127

AUTOMATIC TRANSMISSION SERVICE GROUP

60

ve'ATSG

Technical Service Information

64. Place spacer on differential bearing out race.

65.
Apply
silicon
grease
to shaded
area of transaxle case

flange.
66. Install new case gasket to transaxle case.

67. Install converter

housing by tightening
13 bolts to torque
between 19-22 Nm
(14-16 ft. lbs.). (175149)

68. Using Dial

Indicator Special
Tool MIT209038,
check input shaft end
play, transfer shaft
end play and differential case end play.
Readjust if necessary.
(170046)
Input
shaft
end play .
0.5-1.4
mm
(.020-.055 in.)
Transfer shaft
end play

0
.
0
2
5
(
t
i
g
h
t
)
0
.
0
2
5
m
m
(
l
o
o
s
e
)
[
.
0
0
1
0
(
t
i
g
h
t
)
.
0
0
1
0
i
n
.
(
l

o
o
s
e
)
]
Differential end play

0-0.15 mm (0-.006 in.)

69. Install transfer shaft cover, then cover holder.

70. Using
Special
Tool
MD998325-01
and MB990938-01,
drive two drive
shaft oil seals into
transaxle case and
converter housing. (170155)
71. Install inhibitor
switch and manual
lever. Adjust inhibitor
switch. (See
ADJUSTMENT.)

Y*"iOrg
MIIPP11."-"1111

144'410

11re
M B990938-0

MD998325-01

X.-----c-170155

AUTOMATIC TRANSMISSION
SERVICE GROUP
61

ell

PTSG

Technical Service Information

72. Insert the end

clutch shaft. Be sure
to install the longest
spline toward the
front as shown.

73. Install the thrust washer with the grooved side outward.

74. Install the end clutch hub.

75. Fit the thrust

washer
to
the
return spring at the
end clutch side.

AUTOMATIC TRANSMISSION SERVICE

GROUP
62

CITSG

Technical Service Information

76. Install the end clutch assembly.

77. Install the end

clutch cover. Install
and torque the two
bolts and nut to
6.0-8.0 Nm (4.0-6.0
ft.lbs.).

78. Install the pulse generator A and B.

79. After applying

automatic
transmission fluid to
outside surface of oil
pump-side

cylindrical portion of
torque converter,
install torque
converter carefully so
as not to damage the
oil seal lip. Make
certain that torque
con- verter is in mesh
with oil pump drive
gear.
Measure distance
between ring gear
end and converter
housing
end.
Torque converter
has been properly
in-stalled
when
measurement
is
about 12 mm (.47
in.).

AUTOMATIC TRANSMISSION SERVICE GROUP

63

1:1T5G

Technical Service Information

COMPONENT SERVICE-OIL PUMP ASSEMBLY
Bolt (5)
R
e
a
c
t
i
o
n

s
h
a
f
t

s
u
p
p
o
r
t

D
r
i
v
e
n

g
e
a
r
S
t
e
e
l
b
a

l
l
D
r
i
v
e
g
e
a
r

H
o
u
s
i
n
g

O
i
l

s
e
a
l

S
e
a
l
r
i
n
g
S
e
a
l
r
i
n
g

0-ring

170173

DISASSEMBLY
1. Removp 0-ring from oil pump housing.
2. Remove
five
bolts and remove
reaction
shaft
support from housing.
3. Remove oil pump
drive and
driven
gears from pump
housing.
4. Make reassethbly alignment marks on drive and driven
gears.
5. Remove steel ball from housing.

6.

Remove two seal rings from reaction shaft support.

AUTOMATIC TRANSMISSION SERVICE GROUP

64

PITSG

Technical Service Information

INSPECTION
1. Measure the side clearance of the oil pump gear; if the
measurement
exceeds
the
standard
value,
replace the gear or
the
oil
pump
assembly.
2. Replace if the gear contact part of the reaction shaft
support shows step-like wear.
Drive and driven gear side clearance
0.025 to 0.05 mm (.001 to .002 in.)

REASSEMBLY
1. After immersing
drive and driven
gears in automatic
transmission
fluid, install them to
pump housing. When
reusing gears,
install with mating
marks properly
aligned.
2. Fit a new 0-ring
into the groove at the
inner circumfer- ence
of the drive gear.
3. Install steel ball
in hole as shown in
the
illustration.
(170302)

4.

Install two seal rings coated with automatic transmission

fluid to reaction shaft support.

5. Make sure that oil pump gear turns freely.

6. Install new 0-ring in groove provided in circumference of
pump housing and
apply petrolatum
or
industrial
vaseline
to
circumference of
0-ring.
7. Loosely install
reaction
shaft
support on pump
housing. Tighten five
bolts fingertight.
8. With reaction shaft support properly positioned on pump
housing using Special Tools MD998336-01
and
MD998335-01
tighten five bolts
to
10-11.5 Nm (7.58.5 ft. lbs.).

AUTOMATIC TRANSMISSION SERVICE GROUP

65

ATSG

Technical Service Information

OIL SEAL REPLACEMENT

1.

Pry off pump housing oil seal using a screwdriver.

2. Use Special Tool

MD998334-01 and
MIT208977 install
oil seal to pump
housing. Apply thin
coat of automatic
transmission fluid
to oil seal lip before
installation.

FRONT CLUTCH ASSEMBLY

COMPONENTS

S
na
p
ri
ng

se
le
ct
C
l
u
t
c

h
r
e
a
c
t
i
o
n
p
l
a
t
e
(
4
)

t
h
i
c
k
n
e
s
s
3
.
8
m
m
(
.
1
5
0
i
n
.
)
Snap ring.
S
p
r
i
n
g

r
e
t
a
i
n
e

R
e
t
u
r
n

s
p
r
i
n
g

D
r
i
n
g
F
r
o
n
t
c
l
u
t
c
h
p
i
s
t
o
n

D
r
i
n
g
Front clutch retainer

Clutch disc (3)

AUTOMATIC TRANSMISSION SERVICE GROUP

66

EITSG

Technical Service Information

COMPONENT SERVICE-FRONT

CLUTCH ASSEMBLY
DISASSEMBLY
1. Remove snap ring from clutch retainer.
2. Take out four clutch reaction plates and three 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 return spring
compressed with
Special Tool, Spring
Compressor
(MD998337-01),
remove snap ring,
then spring retainer
and return spring.
(170094) 4. Remove
piston from retainer.
5. Remove the Dsection rings from the
inner and outer circumferences of the
piston.
REASSEMBLY
1. Install D-section ring in groove in outside
surface of
piston with its round side out. Install another
D-section ring to front clutch retainer. (170096)
D-section ring

2. Apply automatic transmission

fluid to outside surface of Dsection rings, then push piston
into front clutch
retainer by hand.

3. Install return spring and spring retainer.

4.
Compres
s return
spring
with
Special
Tool
MD9983
37-01
and
instal
l
snap
ring.

Piston

Front clutch

5. Install four clutch reaction

plates and three clutch discs.
Prior to installation, apply
automatic transmission fluid
to them.
Caution
When new clutch discs are used, they should be
immersed in automatic transmission fluid for
more than two hours before installation.

0-section ring

Snap ring

retainer

1700
96

Shear drop

AUTOMATIC
TRANSMISSION
SERVICE GROUP

6
7
C
l
u
tc
h
p
la
te

(
4
)
C
l
u
tc
h
d
is
c
s

1720
18

fiT5G

Technical Service Information

6. After installing
snap ring, check to
see if there is a 0.60.8 mm (.024-.031
in.) clearance
between snap ring
and clutch reaction
plate.
To
check
clearance,
hold
entire
circumference of
clutch
reaction
plate down with
50 N (11 lbs.)
force. If clearance is out of
specification,
select snap ring
for
correct

clearance.
Kinds of snap ring
Thickness mm (in.)

Ident. color
Parts No.

1.6 (.063)

None

MD955630
1.8 (.071)

Blue

MD955631
2.0 (.079)

Brown

REAR CLUTCH
ASSEMBLY
COMPONENTS

MD955632
2.2 (.087)

None

MD955633
2.4 (.094)

Blue
Wave pring D-ring

MD955634
2.6 (.102)

Brown

MD955635
2.8 (.110)

None

MD955636
3.0 (.118)

MD955637

Blue

Rear clutch
piston
Rear
clutc
h
retain
er

Thrust race
Clutch disc (3)

Snap ring

Clutc
h
reacti
on
plate

thick
ness
3.8
mm
(.150

in.)

Snap ing Select

Clutc
h
plate
(2)
thick
ness
1.8
mm
(.071
in.)

C
l
u
t
c
h

p
r
e
s
s
u
r
e

p
l
a
t
e

R
e

t
u
r
n

s
p
r
i
n
g
Dring

Seal ring (3)

175135

AUTOMATIC TRANSMISSION SERVICE

GROUP
68

voKAT56

Technical Service Information

DISASSEMBLY
1. Remove snap ring and then remove thrust race. (175060)
2. Remove the input shaft from the rear clutch retainer.
3. Remove snap ring from clutch retainer.
4. Remove the clutch reaction plate, two clutch plates,
three clutch discs and clutch pressure plate from retainer.

5. Compress the return

spring by using the
spring compressor.
(170101)
6. Using a screwdriver, remove wave spring.
7. Remove return spring and piston.
8. Remove the two D-section rings from the piston.

REASSEMBLY
1.

Install D-section rings in grooves in outside and inside

surfaces of piston. (170102)
2. After applying automatic transmission fluid to outside
surface of D-section rings, push piston into rear clutch
retainer by hand.
3. Install return spring on piston.
4. Compress return spring with snap ring, by pushing down
with a screwdriver and setting snap ring in its groove.

5. Install clutch pressure plate, three clutch discs, two

clutch plates
and clutch
reaction plate to rear clutch
retainer.
When reaction plate, clutch plate
and clutch discs are removed,
reinstall them by reversing

order of
disassembly.
Prior
to
installing,
apply

Clutch reaction plate

automatic trans-mission fluid to

plates and discs.

Snap ring

Caution
When new dutch discs are used,
immerse
them
in
automatic
transmission fluid for more than two
hours before installa-tion.

Clutch plate (2)

Clutch disc (3)

Shear drop
Snap ring
R
e
a
c
t
i
o
n

p
l
a
t
e

R
e
t
u
r
n

s
p
r
i
n
g
1
7
5
1
7
5

AUTOMATIC TRANSMISSION SERVICE GROUP

69

fiT5G

Technical Service

Information
6.

Install snap ring. Check to see that clearance between

snap ring and
clutch
reaction
plate is 0.4-0.6
mm (.016-.024 in.)
To
check
clearance,
hold
entire
circumference of
clutch
reaction
plate down with
50 N (11 lbs.)
force.
If
clearance is out
of specification,
adjust clearance
by selecting a
proper snap ring.
Snap rings are
common to those
for front clutch.
7. Insert the input shaft into the clutch retainer.

8. Install thrust race, then snap ring.

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

END CLUTCH
COMPONENTS
Seal ring
E
n

c
l
u
t
c
h

r
e
t
a
i
n
e
r

D
r
i
n
g
R
e
t
u
r
n

s
p
r
i
n
g

S
n

a
p

r
i
n
g
C
l
u
t
c
h

d
i
s
c

C
l
u
t
c
h

d
i
s
c

C
l
u
t
c
h

d
i

s
c
Snap ring

D-ring
Piston
Washer
C
l
u
t
c
h

p
l
a
t
e

C
l
u
t
c
h

p
l
a
t
e

C
l
u
t
c
h

l
a
t
e
Clutch reaction plate

175061

AUTOMATIC TRANSMISSION SERVICE

GROUP
70

CITSG

Technical Service Information

DISASSEMBLY
1. Remove the snap
ring by using snapring pliers, and then
remove the washer
and return spring.
2. Remove the snap ring, and then remove the clutch
reaction plate, the
clutch disc, and
the clutch plate. If
the
disc
and
plate are reused,
be sure not to
change
the
installation order
and
direction
when they are
disassembl-ed.

175062

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.

REASSEMBLY
1. Install the Dsection rings and oil
seal in the piston

inner and
outer
grooves.
2. After applying a coating of automatic transmission 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 new snap ring into the guide of the special
tool snap-ring
installer
(MD998367),
install the
retainer. Fit the
snap ring as far
down on the guide
as possible. Attach
the installer and
press until the
snap ring enters
the groove. Do not
press more than
necessary. The
places indicated
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
transmission
fluid.
Caution
When a new clutch
disc is used, soak it
in automatic transmission fluid for 2
hours before using it.

AUTOMATIC TRANSMISSION SERVICE GROUP

71

I.

1:1T5G

Technical Service

Information
6.

After installing the snap ring, check to be sure that the

clearance
between the snap
ring
and
the
clutch
reaction
plate is from 0.4
to 0.65
mm.
When measuring
the
clearance,
apply
a
firm
pressure (5 kg)
all around the
circumference of
the clutch reaction
plate.
If the clearance is
not within the
specified range,
use a snap ring of
a thickness which
will adjust to the
specified range.

Types of snap rings

Snap ring thickness mm (in.)

Ident. color
Part no.

1.05 (.04)

White
MD715800

L30 (.05)

Yellow
MD715801

1.55 (.06)

None
MD715802

1.80 (.07)

Green
MD715803

2.05 (.08)

Brake disc (6)

Brake pressure plate

Return spring
D-r ng
Pist
on

Pink
MD720849
Center
support

Brake plate (5)

Snap
ring Wave spring

LOW-REVERSE BRAKE ASSEMBLY

COMPONENTS

0-ring

Snap ring Select

17202
1

Brake reaction plate

AUTOMATIC TRANSMISSION SERVICE GROUP

72

ATSG

Technical Service Information

DISASSEMBLY
1. Remove snap ring from center support.
2. Take out reaction plate, brake discs, brake plates and
brake pressure plate.
If the discs and
plates are to be
re-used, be sure
not to change the
installation order
or direction.
3.
Compress
the
return spring by using
the spring compressor,
and then remove
the snap ring.

4. Remove return spring and wave spring.

5. Remove the
piston. If it is
difficult to remove,
face the piston side
downward, place
the center support
on a working
surface, and then
blow air through
the oil passages to
remove.
6. Remove the D-section ring from the piston.

REASSEMBLY
1. Install new D-section rings to piston. (170108)
2. Apply automatic transmission fluid to circumference of
D-section rings,
and push piston
into
center
support by hand.

3.

Install wave spring and return spring.

AUTOMATIC TRANSMISSION SERVICE GROUP

73

ATSG

Technical Service Information

4.

Compress return spring with snap ring by pushing down

with a screwdriver and setting snap ring in its groove.

5.

Install pressure plate, three plates, four discs and reaction

B

rake reaction plate

plate to center support.

Caution

2.
6
(.
1
0
2)

Snap ring

When
a new disc is used,
immerse it in automatic transmission fluid for more than two
hours before installation.

Pressure
Snap ring
Return spring

6.

Install snap ring, then check to see if clearance

between

snap ring and brake reaction

plate is 1.2-1.4 mm (.047- .
055 in.). To check clearance,
hold entire circumference of
clutch reaction plate down
with 50 N (11 lbs.) force. If
clearance
is
out
of
specification,
adjust
by
selecting proper snap ring.
Kinds of snap ring
Thickness mm (in.)

Ident. color

Parts No.

1.8 (.071)

Blue

MD707413

2.0 (.079)

Brown

MD707406

2.2 (.087)

None

MD707407

2.4 (.094)

Blue

MD707408

B
r
o
w
n
M
D
7
0
7
4
0
9

2.8 (.110)

None

MD707410

3.0 (.118)

Blue

MD707411

3.2 (.126)

Brown

MD707412

Bra
ke
plat
e (5)
Bra
ke
disc
(51

AUTOMATIC
TRANSMISSION
SERVICE GROUP

175176

7
4

1:1T5G

Technical Service Information

COMPONENTS

COMPONENT SERVICE-PLANET CARRIER

ASSEMBLY
Long pinion (3)
Roller (120)
A Planet carrier assembly

Front washer C (3)

Pinion shaft (6)
Front

washer

Spacer ring (3)

(3)

Thrust washer tear

Outer race Front washer A (3) \`'

Thrust bearing

Overrun
ning
clutch

Part A
(6)

Thrust washer front

Short pinion (3)

B
(3)

2. Remove
overrunning clutch
outer race assembly.
Remove
overrunning clutch
end plate.
DISASSEMBLY
1. Unbend three lock plates and then remove
three bolts.

Roller (60)

175066

illininoulin II Lop
1702
54

AUTOMATIC TRANSMISSION SERVICE GROUP

75

ATSG

Technical Service Information

3.

Remove pinion shaft. (any one place of the short pinion).

Remove spacer bushing and two front thrust washers.
5. Remove only one
short pinion. Use care
not to drop and lose
20 rollers in short
pinion.

4,

6. Remove thrust bearing.

7.

Push overrunning clutch out of outer race with fingers.

REASSEMBLY
1.
Install
thrust
bearing to carrier.
Be sure that it fits
cor-rectly in carrier.

AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
76

IITSG
2.

Technical Service Information

Apply a generous amount of vaseline to inside diameter

of short pinion to hold the 20 rollers.

3. Line up holes in
rear thrust washer
and front thrust
washer with shaft
hole of carrier.
4. Install short
pinion, spacer
bushing and two
front thrust washers
and align holes. Use
care not to allow
rollers to get out of
position.

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

6.

Install end plate to outer race.

AUTOMATIC TRANSMISSION SERVICE GROUP

77

ATSG

Technical Service Information

7.

Push overrunning clutch into outer race. Be sure that

arrow
on
outside
circumference of
cage is directed
upward
as
shown
in the
illustration
(170263)
when
overrunning clutch
is installed.

8.

Apply vaseline to overrunning clutch end plate to retain

it
to
overrunning
clutch.
Install
the end plate to
the clutch.

9.

Install overrunning clutch assembly to carrier and align

bolt holes.
10. Install three lock
plates and three bolts
and tighten three
bolts to 12 to 13.5
Nm (9 to 10 ft. lbs.).

Caution
Lock plates must not be reused.

11. Bend lock plates exactly along bolt heads.

AUTOMATIC TRANSMISSION SERVICE

GROUP
78

AT5G

Technical Service Information

Snap ring

Bearing

Interial gear

Bearing
Transfer drive gear

Output flange

170178

DISASSEMBLY
1. Remove snap ring from rear end of output flange.

2. Using Special Tool MD998348, pull off ball bearings

(2 pieces) and transfer drive gear from output flange.
(170113, 170114 and 170115)

1
70113
1.70114

AUTOMATIC TRANSMISSION SERVICE GROUP

79

PTSG
3.

Technical Service Information

Remove snap ring, and separate internal gear from output

flange.

REASSEMBLY
1.

Using Special Tool MD998349-01 press ball bearing and

transfer drive gear onto output flange.

MD998349-01

Caution
Replace output flange and transfer drive gear as a set.

Groove

2. Install transfer
drive gear in proper
direction with attention paid to groove
provided
in
side
surface.

Install in
this
direction
170118

3.

Install the ball bearing.

MD99834901

170119

4.

Select snap ring, which should be the thickest one that

can be installed in groove.

170120

AUTOMATIC TRANSMISSION SERVICE GROUP

80

ATSG

Technical Service Information

COMPONENTS

Transfer shaft

170179

DISASSEMBLY
If
tapered
roller
bearing is damaged,
remove
it
using
Special
Tool
MD990339-01
(MIT45287
and
MTT304325).
Caution
Replace taper roller bearing inner and outer races as a set.

REASSEMBLY
Install taper roller
bearing inner race
assembly
using

Special
MD998318-01.

Tool

AUTOMATIC TRANSMISSION SERVICE

GROUP
81

ATSG

Technical Service Information

COMPONENTS

Taper
roller
bearing

Washer

Differential drive gear

Pinion gear

Lock pin
Pinion shaft
Bolt
(8)

Side gear
Pinion gear
Spacer
(

;)--

Washer

Differential case

Taper roller bearing

166012

DISASSEMBLY
1 Remove the drive gear retaining bolts and remove the
2.

3.

drive gear from differential case.

Remove the taper roller bearing inner race by using gear
puller . (166013)

Drive out lock pin with a punch inserted in hole "A"

(160017)

Lock pin

4.
5.

Remove the pinion shaft, the pinion gears and washers.

Remove the side gears and spacers.
Pinion shaft

Distinguish
between
the
removed
gears
and spacers for
the left and right
sides.

AUTOMATIC TRANSMISSION SERVICE GROUP

82

ATSGJ

Technical Service Information

REASSEMBLY
1. With spacers
installed to back of
differential side
gears, install gears in
differential case. If
reusing removed
parts, install them in
original positions
noted during
disassem- bly. If using
new differential side
gears, install spacers
of
medium thickness 1.0

_0 .07 mm (.039

_00 ,03 in.).

2. Install washers to back of pinion gears, install gears in

differential case, and then insert pinion shaft.

3.

Measure backlash between side gear and pinion gear.

Backlash should
be 0-0.076 mm
(0-.0030 in.) and
right
and
left
hand gear pairs
should
have
equal backlash. If
backlash is out
of specification.
Disassemble and
re-assemble
them by
using
spacers selected
for
correct
backlash. (160124)
1.0 +0.094'16(0394 +4063)+.0035
Backlash
1.0 4+0.10/81(.0394 ++:00000341)
Kinds of

1.0 _0.0.7(0394 .0028)0

spacer
ID
Thickness mm
(in.)

_0.08(Q394_.003

167) _002.180.394 _7..001(f':9781)

MA180876
0-0.076 mm (0-.0030 in.)

MA180875
MA180860

Parts No.

MA180861
1.0

MA180862

4.
Install pinion
shaft lock pin in
direction
specified
in illustration.
After
installation,
check
to
ensure
that
projection is less than 3 mm (.118 in.).
(160029)

Caution
Lock pin must not be reused. Lock
pin not requiring more than 1,960 N
(44 lbs.) installation load must not be
used.

Lock
pin
Differential case
Pinion shaft

Projection of
3 mm
(.118
in.)
max.
I
n
s
t
a
l
l
i
n
g
d
i
r
e
c
t
i
o
n

160029

AUTOMATIC TRANSMISSION SERVICE GROUP

83

ATSG
5.

Technical Service Information

Press taper roller bearing inner races onto both ends of

differential case. Apply load to inner race when pressing
in bearings. Do not apply load to outer race.

Press
Taper

roller

6.

Install the differential drive gear onto the case.

bearing

1
60125

7. Apply ATF to bolts and tighten bolts to specified to

Numerals (1) through

(8) indicate

torque in sequence shown in illustration.

sequence.

Tightening torque

128-127 Nm (94-101 ft.lbs.)

the bolt tightening

AUTOMATIC TRANSMISSION SERVICE GROUP

84

1:1T5G

Technical Service Information

COMPONENT SERVICE-VALVE BODY

(AUTOMATIC TRANSAXLE)

Torque converter control valve

Pressure control valve

Regulator valve
Shift control plug,*

Upper valve
body
2-3 shift valve
R
e
a
r

c
l
u
t
c
h

e
x
h
a
u
s
t

a
l
v
e

R
e
a
r

c
l
u
t
c
h

e
x
h
a
u
s
t

v
a
l
v
e

F
r

o
n
t

e
n
d

c
o
v
e
r

175078

DISASSEMBLY
1. Remove the 4 solenoid valves.

2.

Remove the manual valve.

AUTOMATIC TRANSMISSION SERVICE GROUP

85

USG

Technical Service Information

3.

Remove the valve stopper and clamp.

4.

Remove the N-D control sleeve and valve.

N-D control valve

-----

5. Remove the bolts

(13),
and
then
remove the lower
valve body assembly
and the separation
plate.
6. Remove the relief spring and steel balls (two) from the
intermediate plate.

7.
8.

Remove the bolts (8), and then remove the intermediate

plate and upper separation plate.
Remove the four steel balls from the upper valve body.

17C471,1

AUTOMATIC TRANSMISSION SERVICE GROUP

86

MI

ATSG

Technical Service Information

9. Remove the block, and then the upper separation plate.

1C. Remove the end cover, and then

remove the 1-2 shift
valve, spring, shift control plug and
valve from the upper
valve body.

1.
2.
a
4.

1.2 shift valve

Rear end cover
Shift control plug
Shift control valve
1

11. After removing the end cover,

remove the spring and valve shown in
the figure from the upper valve body.

1. Torque converter control valve

2. Pressure control valve
3.
S
hi
ft
c

ontrol plug 4. Regulator

valve
5. Adjusting screw
6. Front end cover
7. Rear clutch exhaust valve A
8. Rear clutch exhaust valve B
9. 2.3/4-3 shift valve
10. Upper valve body

1
7
5
0
7
8

AUTOMATIC TRANSMISSION SERVICE GROUP

87

ATSG

Technical Service Information

12. Pull out the pin, remove the stopper and then remove
the plug spring and end clutch valve.
i
13. Remove the end cover and then
o
remove the valve and spring shown in
the figure.
n
Note the following when
assembling the valve
body.
Thoroughly clean
each component in
clean automatic
transmission
fluid
before
installation. Do
not wipe them
with a rag.
When inserting
the valve into the
valve body, do not
apply excessive
force.
Tighten all bolts
to the specified
torque using a
torque
screwdriver or
similar tool. All
valve body bolts
are to be
tightened to 4.0-6.0
R
Nm (3.0-4.0 ft.lbs.).
E
A
S
S
E
M
B
L
Y
C
a
u
t

1. Install the valve

springs shown in
illustration to the
upper
valve
body,
install
the front end
cover,
and
tighten the bolt
to 4.0-6.0 Nm
(3.0-4.0 ft.lbs.).
(175078)

1. End clutch valve 2. End

clutch valve plug
3. Stopper
4. Pin
5. Damper clutch control valve
6. Damper clutch valve sleeve
7. End cover
8. N-F1 control valve
9. Reducing valve
10. Adjusting screw

175091

1.Torque converter control valve

2 Pressure control valve
3. Shift control plug
4. Regulator valve
5.Adjusting screw
6. Front end cover
7. Rear clutch exhaust valve A
8. Rear clutch exhaust valve
9.2-3/4-3 shift valve
10. Upper valve body

AUTOMATIC TRANSMISSION SERVICE GROUP

88

ATSG
2.

Technical Service Information

Install the 1-2 shift valve, spring, shift control valve and
plug to the upper valve body, install the rear end cover,
and tighten the bolt to 4.0-6.0 Nm (3.0-4.0 ft.lbs.).

1. 1-2 shift valve

2. Rear end cover
3. Shift control plug
4
.
S
h
i
f
t
c
o
n
t
r
o
l
v
a
l
v
e

3. Install the steel balls (4) and the stopper plate.

4.

Install the upper separation plate and the block to the

intermediate plate, and then temporarily tighten the bolt
(I).

5. Insert the special

tool
guide
pin
(MD998266-01) into
the guide pin hole of
the lower valve body_
6. With the guide pin
as a reference, install
the intermediate
plate upper
separation plate
assembly. After
tightening the bolts
(8), pull out the guide
pin.

89

ATS6
7.

Technical Service Information

Install each of the valve springs to the lower valve body,

install the end cover, and then tighten the bolt.

1.End clutch

valve
2. End clutch
valve plug
3. Stopper
4. Pin
5. Damper
clutch control
valve
6. Damper
clutch valve
sleeve
7. End cover
8.N-R control
valve
9. Reducing
valve
10. Adjusting
screw

175091

8. Install the steel

ball spring and filter
to the intermediate
plate.

9.

Insert the special tool guide pin (MD998266-01) into the

guide pin hole of the intermediate plate.
10. With the guide pin
as a reference, install
the lower separa- tion
plate
lower
valve
body. After tightening
the bolts
(13), pull out the guide pin.

AUTOMATIC TRANSMISSION SERVICE

GROUP
90

ATSG

Technical Service Information

11. Install the N-D control sleeve and valve.

12. Install the valve stopper and clamp.

13. Install the manual valve.

14. After cleaning

the filter part of
each of the solenoid
valves, replace all
0-rings with new ones.

AUTOMATIC TRANSMISSION SERVICE GROUP

91

ATSG

Technical Service

Information
15. Install the solenoid valves.
Use the shape and lead wiring colors to identify so that the

installation positions are not mistaken.

Solenoid valve

Lead wiring color

Damper clutch control solenoid valve (DCCSV)

Red

Shift control solenoid valve A (SCSV-A)

Orange

Shift control solenoid valve B (SCSV-B)

Yellow

Pressure control solenoid valve (PCSV)

Blue

KICKDOWN SERVO PISTON ASSEMBLY

COMPONENTS
Washer assembled screw (2)
K
i
c
k
d
o
w
n

s
e
r
v
o

s
w
i
t

c
h

S
n
a
p

r
i
n
g
Kickdown servo cover
Snap ring
11:07c)
0-ring
Seel ring
D-ring
Nut

Adjust rod assembly

Kickdown
servo
sleeve

Coil spring

Kickdown servo piston

D-ring

(((ir,

172028-A

REASSEMBLY
1. Insert the adjust rod assembly into
kickdown servo piston, and then screw
the nut.
2. Install new D-rings and Seal ring to
piston.
3. Apply automatic transmission fluid to
D-rings and Seal ring.

Seal ring

D-ring
Adjust
rod
assembly
Seal ring

Kickdown servo piston

AUTOMATIC TRANSMISSION SERVICE

GROUP
92

ATSG

Technical Service Information

COMPONENTS

0-ring

0-ring

Gear

172002

DISASSEMBLY
Drive spring pin out,
and gear and sleeve
can be disassembled.
Caution
Do not reuse 0-rings and spring pin.

REASSEMBLY
Spri
ng
pin

1. Install a new 0-ring to the shaft part

of the gear, and
coat a small amount of ATF onto the 0ring.
2. Insert the gear into the sleeve, and

Speedom
eter
driven
gear

align the pin hole

and the groove of the gear's shaft.
3. Tap a new spring pin into the sleeve.

When tapping it
in, be sure that the slit is not at the gear
side.

4. Install a new 0-ring into the outer groove

of the sleeve,
and then apply a coating of a small
amount of ATF to
the outer circumference of the 0-ring.

0ring
0-ring Sleeve

rA

LA
Speedom
eter
driven
gear

u,
Spring
Sleeve

a
pin

Section A A

160038

AUTOMATIC TRANSMISSION SERVICE GROUP

93

AT5G

Technical Service

Information

COMPONE
NT
SERVICECASE
ASSEMBLY
(AUTOMAT
IC
TRANSAXL
E)
COMPONENTS

0.ring

Plug
pressu
re

170182

REASSEMBLY
Using Special Tool
MD998325-0 I and

MB990938-0I, drive
two drive shaft oil
seals into transaxle
case

AUTOMATIC TRANSMISSION SERVICE

GROUP
94

AT5G

Technical Service Information

COMPONENTS

B
e
a
r
i
n
g

o
u
t
e
r

r
a
c
e

S
p
a
c
e
r

Dowel pin

Housing

Oil seal

170183

REPLACEMENT OF OUTER TAPER ROLLER BEARING

When
replacing
taper roller bearing
outer
race
(press
fitted in
converter
housing),
use
Special
Tools
MD998346-01,
MD998347-01
and
MB99091R-01.

M099834701
M8990938-01

AUTOMATIC TRANSMISSION
SERVICE
95

1711128

ATSG

Technical Service Information

MAKE YOUR OWN AUTOMOTIVE ELECTRONICS

12 VOLT

L.E.D. TESTER

(
probe lead -

20 milliampere L.E.D.
(Can be Red, White or Green),

41

Solder to test)
4
(Annode longest leg is +)

1
Encase in suitable
OHM
plastic tube

Solder 560

Resistor

{
[
C
o
v
e
r
b
a
r
e
w
i
r
e
w
i
t
h
i
n
s
u
l
a
t
i
n
g
s
l
e

e
v
e
o
r
t
a
p
e
)

N
(
S
o
l
d
e
r
t
o
t
e
s
t
p
r
o
b
e
l
e
a
d

/Solder to alligator

(
+
)

clip or hook (-)

T
E
S
T
P
R
O
B
E
L
E
A
D
S
M
A
Y
B
E

A
N
Y
L
E
N
G
T
H
D
E
S
I

R
E
D

AUTOMATIC TRANSMISSION SERVICE

GROUP
96