Automatic Transaxle.pdf

AX-1

AUTOMATIC TRANSAXLE

AX-2 AUTOMATIC AUTOMATIC TRANSAXLE

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DESCRIPTION

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


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DESCRIPTION

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


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DESCRIPTION

Type of Transaxle

A132L

Type of Engine

3E-E

Torque Converter Clutch Stall Torque Ratio

2.5: 1 Equipped

Torque Converter Clutch Lock-up Mechanism Gear Ratio

Transaxle

2nd Coast Brake (B 1) Band Width

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

Differential Capacity liter (US qts, Imp.qts)

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

25 (0.98) ATF DEXRON® II

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

2.810 1.549 1.000 2.298

Total Drain & Refill

5.5 (5.8, 4.8) 2.5 (2.8, 2.2) 1.4 (1.5, 1.2)


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OPERATION

OPERATION OPERATION

- --Operating

Shift lever position

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


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OPERATION

1. FUNCTION OF COMPONENTS

Component

Function

Forward Clutch

Connects input shaft and front planetary ring gear.

Direct Clutch

Connects input shaft and front & rear planetary sun gear.

2nd Coast Brake

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

2nd Brake

Prevents outer race of F1 from turning either clockwise or counterclockwise thus preventing the front & rear planetary sun gear from turning counterclockwise.

1st & Reverse Brake

Prevents rear planetary carrier from turning either clockwise or counterclockwise.

No. 1 One-Way Clutch

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

No. 2 One-Way Clutch

Prevents rear planetary carrier from turning counterclockwise.

Planetary Gears

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

AX-6 AUTOMATIC TRANSAXLE

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OPERATION

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


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OPERATION

2. HYDRAULIC CONTROL SYSTEM

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

OIL PUMP

Hydr. pressure control

Fluid passage switching Throttle Cable

Governor Valve

CLUTCHES & BRAKES

Planetary gear sets Torque converter clutch


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PREPARATION

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

Oil pan drain plug

09201-6001 1 Valve Guide Bushing Remover & Replacer

Speedometer driven gear oil seal

09308-00010 Oil seal Puller

Side gear shaft oil seal

09350-32014 TOYOTA Automatic Transmission Tool Set

(09351-32010) One-way Clutch Test Tool

(09351-32020) Stator Stopper

(09351-32130) Handle

(09351-32150) Oil Seal Replacer

09921-00010 Spring Tension Tool

Speedometer driven gear oil seal

09992-00094 Automatic Transmission Oil Pressure Gauge Set

Line pressure


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PREPARATION

EQUIPMENT Straight edge

Check torque converter clutch installation.

Dial indicator or dial indicator with magnetic base

Measure inside diameter or piston stroke.

Torque wrench Voltmeter Ammeter(A) Ohmmeter

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

Capacity

Classification ATF DEXRON® II

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

ATF DEXRON® II

SSM(SPECIAL SERVICE MATERIALS) 08833-00070 Adhesive 1311, THREE BOND 1311 or equivalent

Torque converter clutch mounting bolt


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TROUBLESHOOTING

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

PRELIMINARY CHECK (See page AX-1 1) (a) Check the tire inflation. (b) Check the idle speed. (c) Check the fluid level and fluid condition. (d) Check the throttle cable mark. (e) Check the shift linkage. (f) Check the park/neutral position switch.

STALL TEST (See page AX-14 ) Check the engine and torque converter clutch.

TIME LAG TEST (See page AX-15 ) Check the automatic transaxle (each clutch, brake and gear) for wear.

HYDRAULIC TEST (See page AX-16 ) Measure the line pressure and make basic check of fluid circuit.

ROAD TEST (See page AX-20 ) Confirm if trouble lies within automatic transaxle. If noisy or vibrating, the possible cause could be with the compressor, engine, drive shaft, tires, etc.

Matrix chart (See page AX-25 )

AX-1 1 AUTOMATIC TRANSAXLE

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TROUBLESHOOTING

PRELIMINARY CHECK 1. CHECK FLUID LEVEL HINT: The vehicle must have been driven so that the engine and transaxle are at normal operating temperature. Fluid temperature: 70-80 C (158-176 F) (a) Park the vehicle on a level surface, set the parking brake. (b) With the engine idling, shift the selector into each gear from P position to L position and return to P position. (c) Pull out the transaxle dipstick and wipe it clean. (d) Push it back fully into the tube. (e) Pull it out and check that the fluid level is in the HOT range. If the level is at the low side of the hot range, add fluid. 

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Fluid type: ATF DEXRON® II NOTICE: Do not overfill.

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

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

(c) Add new fluid through the filler tube. Fluid: ATF DEXRON® II Capacity: 5.5 liters (5.7 US qts, 4.8 Imp.qts) Drain and refill: 2.5 liter (2.6 US qts, 2.2 Imp.qts)

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


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TROUBLESHOOTING

(f) Check the fluid level with the normal fluid temperature 70-80 C (158-176 F) and add as necessary. 

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NOTICE: Do not overfill.

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

5. CHECK DIFFERENTIAL FLUID LEVEL Remove the filler plug and check differential fluid level.

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

(e) Tighten the adjusting nuts. (f) Recheck the adjustments.


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TROUBLESHOOTING

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

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

9. INSPECT IDLE SPEED (N POSITION) Idle speed: 800 rpm


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TROUBLESHOOTING

STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the maximum engine speeds in D and R positions. NOTICE: • Perform the test at normal operating fluid temperature 50-80 °C (122-176°F). • Do not continuously run this test longer than 5 seconds. MEASURE STALL SPEED (a) Chock the front and rear wheels. (b) Mount an engine tachometer. (c) Fully apply the parking brake. (d) Keep your left foot pressed firmly on the brake pedal. (e) Start the engine. (f) Shift into the D position. Step all the way down on the accelerator pedal with your right foot. Quickly read the highest engine RPM at this time. Stall speed: 2,400±200 rpm

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


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TROUBLESHOOTING

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

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Idling speed: N position 800 rpm

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

(d) In same manner, measure the time lag for N →R. Time lag: Less than 1.5 seconds

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


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TROUBLESHOOTING

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

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

D position

kPa (kgf/cm2, psi)

Idling

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

Stall

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

R position

kPa (kgf/cm2, psi)

530-706 (5.4-7.2, 77-102) 1,412 -1,648 (14.4 -16.8, 205 - 239)

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


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TROUBLESHOOTING

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


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TROUBLESHOOTING

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

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(c) Check the parking brake to see that it is not applied. (d) Start the engine. (e) Shift into the D position and measure the governor pressures at the speeds specified in the table. EVALUATION If governor pressure is defective: • Line pressure defective • Fluid leakage in governor pressure circuit • Governor valve operation defective Except Puerto Rico Count drive gear

Vehicle speed (Reference)

Governor pressure

1.000 rpm

30 km/h (19 mph)

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

1,800 rpm

54 km/h (34 mph)

147-226 kPa (1.5 - 2.3 kgf/cm 2, 21 -33 psi)

3,500 rpm

105 km/h (65 mph)

412-490 kPa (4.2 - 5.0 kgf/cm 2, 60 - 71 psi)

Puerto Rico Count drive gear

Vehicle speed (Reference)

Governor pressure

1,000 rpm

27 km/h (17 mph)

49-127 kPa (0.5-1.3 kgf/cm 2, 7-19 psi)

1,800 rpm

49 km/h (31 mph)

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

3,500 rpm

96 km/h (60 mph)

412-490 kPa (4.2 - 5.0 kgf/cm 2, 60 - 71 psi)


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TROUBLESHOOTING


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TROUBLESHOOTING

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

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

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

(c) Run in the 3rd gear of D position, check the abnormal noise and vibration. HINT: Check for cause of abnormal noise and vibration must be made with extreme care as they could also be due to imbalance in the drive shaft, differential, tires, torque converter clutch etc.


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TROUBLESHOOTING

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

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

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

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


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TROUBLESHOOTING

(b) Check the abnormal noise during acceleration and deceleration. (c) Check the shock at up-shift and down-shift.

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

(b) While running in L position, release the accelerator pedal and check the engine braking effect. EVALUATION If there is no engine brake effect: • First and reverse brake is defective

(c) Check the abnormal noise during acceleration and deceleration.

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


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TROUBLESHOOTING

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


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TROUBLESHOOTING

AUTOMATIC SHIFT SCHEDULE SHIFT POINT Except Puerto Rico Shift position

Vehicle speed km/h (mph)

Shifting point Throttle valve fully opened

D position

Throttle valve fully closed

L position

Throttle valve fully opened

1 →2 2→3 3→2 2→1 Lock -up ON Lock-up OFF

2→ 1

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

40-48 (25-30)

Puerto Rico Shift position

Vehicle speed km/h (mph)


D position

Throttle valve fully closed

L position


1 →2 2→3 3→2 2→1 Lock-up ON Lock-up OFF

2→1

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

36-44 (22-27)


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TROUBLESHOOTING

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

See page

1 4 X A

4 3 X A

) 2 F (

Suspect Area

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

Harsh engagement

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

1st → 2nd → 3rd 2nd → 3rd 3rd → 2nd

) 3 B (

h e c t h r r k u ) l c a a a 1 t r c l u e e b ) l C r w g ( 2 g c e a e t e e e h C y y s y r r p r r ( v v v t c l e a a e l l h a t v k e a t u v a a c w n c l v v v l e v - e n n e o a r t t c t o l r e u v l a a c f l i f i d l d l e r c n n p o e g h h p n a t n a r u i r a e S S w c 2 t k u q . n a t n v r e r r r o - 3 - o i o r e s o a a o 2 T P M G 1 2 F D N F R 1

) 1 F (

e e v v l l a a e e v v v l v ) h l r r a c 1 t a v o o t ) B v t r u 2 ( l a a r l o c l t B o e r u r u a ( k t y o d l o d a t o t a l e a u o r w l a k b u a d e l v m a t m l g u r t u t o a e e b s n m s m s m v r a o u a e e y d a c o u r o l l n o c c c t t c c t t a o c 1 a . o a o c d o m r r i 1 w 2 d e n n h h r o S 2 N C L B 2 T T P

A X - 2 6

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: R e f e r t o ’ 9 4 A 1 3 1 L , A 1 3 2 L A u t o m a t i c T r a n s a x l e R e p a i r M a n u a l .

N o l o c k u p

P o o r a c c e l e r a t i o n

N o k i c k d o w n

N o e n g i n e b r a k i n g 2 n d ( ” 2 ” p o s i t i o n )

S l i p

1 s t ( ” L ” p o s i t i o n )

3 r d

2 n d

1 s t

” R ” p o s i t i o n

F o r w a r d & R e v e r s e

S y m p t o m

S u s p e c t A r e a

Torque converter clutch

S e e p a g e

AX-41

Forward clutch (C1) No. 2 one-way clutch (F 2) 1st and reverse brake (B 3) Second brake (B2) No. 1 one-way clutch (F 1) Pressure relief valve Oil strainer

AX-27

Second coast brake (B1) 1-2 Shift valve 2-3 Shift valve Lock-up relay Lock-up signal valve


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T R A N S A X L E -

Direct clutch (C2)

N

A U T O M A T I C

VALVE BODY

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

T R O U B L E S H O O T I N G


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VALVE BODY

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

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

5. REMOVE OIL TUBES (a) Remove the 2 bolts and apply tube bracket.

(b) Pry up the both tube ends with a large screwdriver and remove the 4 tubes.


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VALVE BODY

6. REMOVE MANUAL DETENT SPRING

7. REMOVE MANUAL VALVE AND VALVE BODY

8. REMOVE VALVE BODY (a) Remove the 14 bolts.

(b) Disconnect the throttle cable. (c) Remove the valve body.

9. REMOVE SECOND BRAKE APPLY GASKET AND GOVERNOR OIL STRAINER


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VALVE BODY

VALVE BODY INSTALLATION 1. INSTALL GOVERNOR OIL STRAINER AND SECOND BRAKE APPLY GASKET

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

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

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

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

(b) Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.


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VALVE BODY

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

(b) Install the apply tube bracket.

6. INSTALL OIL STRAINER

7. INSTALL MAGNETS IN PAN

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


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VALVE BODY

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

SST 09043 - 38100

10. FILL TRANSAXLE WITH ATF Add only about 2 liters of ATF. NOTICE: Do not overfill. Fluid type: ATF DEXRON® II

11. CHECK FLUID LEVEL (See page AX-1 1)


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THROTTLE CABLE

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

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

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

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

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


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THROTTLE CABLE

4. CONNECT THROTTLE CABLE TO ENGINE 5. ADJUST THROTTLE CABLE (See page AX-12 )

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


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GOVERNOR VALVE

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

3. REMOVE GOVERNOR BRACKET

4. REMOVE GOVERNOR COVER WITH O-RING 5. REMOVE GOVERNOR BODY WITH THRUST WASHER 6. REMOVE PLATE WASHER 7. REMOVE GOVERNOR BODY ADAPTOR

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

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

Fluid type: ATF DEXRON® II


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DIFFERENTIAL OIL SEAL

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

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

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

2. INSTALL RH SIDE OIL SEAL (a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 09350-32014 (09351-32150, 09351-32130) Oil seal drive in depth: 0±0.5 mm

(b) Coat the oil seal lip with MP grease. 3. INSTALL LH AND RH DRIVE SHAFT (See page SA-26 ) 4. INSTALL ENGINE UNDER COVER 5. FILL TRANSAXLE WITH ATF (See page AX-1 1) NOTICE: Do not overfill. Fluid type: ATF DEXRON® ll

6. CHECK FLUID LEVEL


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SPEEDOMETER DRIVEN GEAR OIL SEAL

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

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


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ASSEMBLY REMOVAL AND INSTALLATION

ASSEMBLY REMOVAL AND INSTALLATION Remove and install the parts, as shown below.


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

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

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

11. DISCONNECT RIGHT DRIVE SHAFT (See page SA-22 ) HINT: Suspend the drive shaft with cord.

12. DISCONNECT CONTROL CABLE (a) Remove the clip from the control cable.


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(b) Disconnect the control cable from the lever.

13. DISCONNECT OIL COOLER HOSE FROM PIPE

14. REMOVE FRONT EXHAUST PIPE (a) Remove the 3 bolts from engine. (b) Disconnect the oxygen sensor connector.

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

15. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR


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16. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS (a) Turn the crankshaft to gain access to each bolt. (b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.

17. DISCONNECT BOND CABLE FROM LH ENGINE MOUNTING BRACKET

18. DISCONNECT LH ENGINE MOUNTING Remove the 2 mounting bolts.

19. REMOVE ENGINE REAR MOUNTING BRACKET (a) Hold the engine and transaxle with 2 jacks, or a chain block and jack.

(b) Remove the 3 bolts and disconnect the rear mounting bracket from the body.


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20. REMOVE TRANSAXLE MOUNTING BOLTS 21. REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE

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

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

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


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

If runout exceeds 0.30 mm (0.0118 in.) try to correct it by reorienting the installation of the converter. If excessive runout cannot by corrected, replace the torque converter clutch. HINT: Mark the position of the converter to ensure correct installation. (b) Remove the torque converter clutch from the drive plate.

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

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

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


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

(b) Connect the bond cable with the bolt.

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

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

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

(b) Install the bolts . Torque: 62 N-m (630 kgf-cm, 46 ft-lbf)

(c) Connect the oxygen sensor connector. 10. CONNECT PARK/ NEUTRAL POSITION SWITCH CONNECTOR


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11. CONNECT OIL COOLER HOSE TO PIPE

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

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

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

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


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21. INSTALL AND ADJUST THROTTLE CABLE 22. INSTALL AIR DUCT 23. INSTALL BATTERY AND CONNECT 24. NEGATIVE BATTERY TERMINAL

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

26. CHECK FLUID LEVEL (See page AX-1 1)


SHIFT LOCK SYSTEM COMPONENT

WIRING DIAGRAM

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SHIFT LOCK SYSTEM


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SHIFT LOCK SYSTEM

SHIFT LOCK SOLENOID INSPECTION INSPECT SHIFT LOCK SOLENOID

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

(c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid.

SHIFT CONTROL ECU INSPECTION INSPECT SHIFT LOCK CONTROL ECU

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

Connector

Terminal ACC -E IG - E STP-E

Measuring condition

Voltage (V)

Ignition switch ACC position

10- 14

ignition switch ON position

10- 14

Depress brake pedal

10- 14

(1) Ignition switch ACC position and P position KLS - E

(2) Ignition switch ACC position and except P position (Approx-after one second)

8 - 14 6-9

(1) Ignition switch ON position and P position SLS (+)

- SLS (-)

(2) Depress brake pedal

8.5- 13.5 (Approx-after 20 seconds)

5.5 - 9.5

(4) Except P position P1 - P P2-P 1

(1) Ignition switch ON, P position and depress brake pedal (2) Except P position

9 - 13.5

(3) Ignition switch ACC position and P position

9 - 13.5

(4) Except P position


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SHIFT LOCK SYSTEM

KEY INTER LOCK SOLENOID INSPECTION 1. INSPECT KEY INTER LOCK SOLENOID

(a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5-16.5 

(c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid.

2. INSPECT SHIFT LOCK CONTROL SWITCH

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

Specified value

P position (Release button is not pushed)

P-P 1

Continuity

R position (Release button is pushed)

P-P 1 P-P 2

Continuity

R, N, D, 2, L position

P-P 2

Continuity

Shift position


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SERVICE SPECIFICATIONS

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

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

Line pressure (wheel locked)

Engine idling D position R position

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

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

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

0.5-1.3 kgf/cm2 1.5 - 2.3 kgf/cm 2 4.2 - 5.0 kgf/cm 2

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

363-422 kPa 530-706 kPa

3.7 -4.3 kgf/cm 2 5.4-7.2 kgf/cm2

53-61 psi 77-102 psi

9.2-10.7 kgf/cm2 14.4-16.8 kgf/cm 2

131-152 psi 205 - 239 psi

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

AT stall (Throttle valve fully opened) D position R position

902 -1,049 kPa 1,412-1,648 kPa

Engine stall revolution Time lag

2,400±200 rpm N position N position

→ D

position → R position

Less than 1.2 seconds Less than 1.5 seconds

Engine idle speed (Cooling fan and A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Torque converter clutch sleeve runout Drive plate runout

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

Limit Limit

0.30 mm 0.20 mm

0.0118 in. 0.0079 in.

SHIFT POINT Except Puerto Rico Shift position


D position Throttle valve fully closed

L position


Vehicle speed km/h (mph) 1 →2 2→3 3→2 2→1 Lock-up ON Lock -up OFF 2→1

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

Puerto Rico Shift position


D position Throttle valve fully closed

L position


Vehicle speed km/h (mph) 1 →2 2→3 3→2 2→1 Lock -up ON Lock -up OFF 2→1

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

Automatic Transaxle.pdf

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