Assignment

1

1. Reverse Clutch Snap Ring

Inspection

Check that the clearance between the snap ring and clutch reaction plates is within the standard value. When measuring the clearance, press the clutch reaction plate by force of 5 kg (50N) evenly. If not within the standard value, select a snap ring to adjust

Standard Value:

Result:

Remarks:

2. Overdrive Clutch Snap Ring Inspection

Check that the clearance between the snap ring and clutch reaction plates is within the standard value. If not within the standard value, select a snap ring to adjust.

Standard Value:

Result:

Remarks:

3. Underdrive Clutch Snap Ring

Inspection

Check that the clearance between the snap ring and clutch reaction plates is within the standard value. When measuring the clearance, press the clutch reaction plate by force of 5 kg (50N) evenly. If not within the standard value, select a snap ring to adjust

Standard Value:

Result:

Remarks:

4. Reaction Plate End Play Inspection

Replaced the pressure plate of the low reverse brake with special tools, and then install the brake disc and plate.

Move the special tool to measure the end play and than replace the snap ring to adjust the end play to standard value

Standard Value:

Result:

Remarks:

5. Low reverse Brake Pressure Plate end play Inspection

Replaced the pressure plate of the second brake with special tools, and then install the brake disc and plate as shown in the figure.

Install the return spring, second brake piston and snap ring

Move the special tool to measure the end play

Standard Value:

Result:

Remarks:

6. Second Brake Pressure Plate end play Inspection

Reverse the transmission

Move the special tool to measure the endplay.

Standard Value:

Result:

Remarks:

7. Output shaft Pre load Inspection

Move the output shaft to measure operating amount (A) and then replace the spacer installed in step (2) with a new one which thickness is within the following value

(A /Operating Amount) + (B / thickness of the old spacer) + 0.07 mm to (A /Operating Amount) + (B / thickness of the old spacer) + 0.09 mm

Standard Value:

Result:

Remarks:

8. Under Drive Sun Gear End Play Inspection

Install the used trust race No 8 at the rear cover

Measure endplay of the underdrive sun gear. Replace the thrust race to adjust the play to the standard value.

Note: Installing the underdrive clutch hub to makes is easy to measure

Standard Value:

Result:

Remarks:

9. Input Shaft End Play Inspection

Measure end play of input shaft. Replace the thrust washer installed to adjusted the play to the standard value.

Standard Value:

Result:

Remarks:

10. Differential End Play Inspection

Install the 1.25 mm thick spacer. Place a solder (B) approximately 10 mm in length, 3mm diameter on the differential

Measure used micrometer the thickness (T)

(T-0.45mm) to (T-o.165mm)

Standard Value:

Result:

Remarks:

11. Inhibitor Switch Inspection

Inhibitor Indicator

Continuity Check

Remarks

P

Terminal 3 & 8

Terminal 9 & 10

R

Terminal 7 & 8

N

Terminal 4 & 8

Terminal 9 & 10

D

Terminal 1 & 83

Terminal 5 & 82

Terminal 2 & 81

Terminal 6 & 8

12. Solenoid Valve Inspection

Measure the resistance between terminals 1 and 2 of each solenoid valve.

Name

Resistance

DAMPER clutch Solenoid Valve

Low Reverse Solenoid Valve

Second Brake Solenoid Valve

Underdrive Solenoid Valve

Overdrive Solenoid Valve

Hydraulic Pressure Test

(1) Warm up the engine until the automatic transmission fluid temperature is 80--100C.

(2) Jack up the vehicle so that the wheels are free to turn.

(3) Connect the special tools (2,942-kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900]) to each pressure discharge port.

(4) Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table, and check that the measured values are within the standard value ranges.

(5) If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.

Standard Hydraulic Pressure Test

Measurement ConditionStandard Hydraulic Pressure kPa

Selector Lever PositionShift PositionEngine Speed (RPM)UD Clutch PressureREV Clutch PressureOD Clutch PressureLRB Pressure2Nd Brake Pressure

P2,500

RReverse2,500

N2,5002,500

D1 gear2,500

2 gear2,500

3 gear2,500

4 gear2,500

Service Data Reference Table

Item NoCheck ItemCheck RequirementNormal ValueActual Value

11Throttle Position SensorEngine: Stopped Selector Lever Position PAccelerator Pedal Release

Accelerator Pedal Halfly depressed

Accelerator Pedal Depressed

15Oil Temperature sensorWarming UpAccelerator Pedal Release



21Crank Angle SensorEngine: Idling Selector Lever Position PAccelerator Pedal Release



22Input Shaft Speed sensorSelector Lever Position 3Driving at constant speed 50km/h at 3rd gear


23Output Shaft Speed sensorSelector Lever Position 3Driving at constant speed 50km/h at 3rd gear

26Stop lamp SwitchIgnition switch: ON

Engine: StoppedBrake pedal: Depressed

Brake Pedal Release

29Vehicle Speed SensorSelector Lever Position 3Idling with 1st gear (Vehicle Stooped)

Driving at constant speed of 50 km/h in 3rd gear

31Low and Reverse Solenoid Duty%Select lever position L, 2, 3, D10 km/h 1 gear

32Underdrive Solenoid Duty%30 km/h 2nd gear

33Second Brake Solenoid Duty%50 km/h 3rd gear

34Overdrive Solenoid Duty%70 km/h in 4th gear

36DCCSVSelector lever position 3Driving at 50km/h in 3rd gear with acc released


36DCCSVSelector lever position 3Driving at 70km/h in 3rd gear with acc released

54Control Relay Output VoltageIG SW:OFFIG SW: ON - OFF

61Inhibitor SwitchIG SW: ON

Engine StoppedLever: P

Lever: R

Lever: N

Lever: D

Lever: 3

Lever: 2

Lever: 1

63 Shift PositionSelect Lever Position: L., 2, 3, DDriving at constant speed 10km/h at 1st gear

Driving at constant speed 30km/h at 2nd gear

Driving at constant speed 50km/h at 3rd gear

Driving at constant speed 70km/h at 4th gear

Remarks:

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WAJA 1.8 DPO TRANSMISSION

1. Adjusting The Leaf Spring Lever

Hold the mulfunction switch lever in the extreme position (1st gear hold) using a plastic clip and a bolt in the mechanism housing.

Removed the Bolt (c)

Position the leaf spring lever by placing the roller (A) in the hollow of sector (B) corresponding to 1st gear hold.

By Used Fit tool B.Vi. 1462 instead and in place of bolt (C) screw the tool in fully whist holding the leaf spring lever.

Tighten bolt (D) to correct torque.

Remove the tool and refit bolt (C).

Remarks:

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2. Malfunction Switch Inspection

Placed the gear lever position in the Neutral position

Place Multimeter to the two electrical terminals on the position control tabs

Check the resistance of malfunction switch (MFS) by turn the MFS switch

Standard Value: Resistance at contact Terminal = 0(

Result:

Remarks:

3. Anti Start Relay Inspection

Check the continuity between terminal 1 and 2

By give power supply to terminal 1, check the continuity between terminal 3 and 4

Caution:

Wrong give power supply to terminal will damage the relay

Continuity between terminal 1& 2

Continuity between terminal 3& 4

Remarks:

3. Solenoid Valve Inspection

Check the resistance of the electro valve.

ElectrovalveStandard ValueActual Value

EVM & EVLUP Approx. 1ohm

EVCApprox. 40 ohm

Remarks:

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