Caja Automatica Scoupe 94

AUTOMATICTRANSAXLEReturn To Main Table of ContentsGENERAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TRANSAXLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 51

AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53AUTOMATIC TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . .57

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

FRONT CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 89

REAR CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

END CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

PLANETARY GEAR SET ASSEMBLY . . . . . . . . . . . . . . . . 98

INTERNAL GEAR AND TRANSFER DRIVEGEAR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

TRANSFER DRIVER GEAR ASSEMBLY . . . . . . . . . . . . . . 103

TRANSFER SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 104

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107KICKDOWN SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

SPEEDOMETER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

45-2 GENERAL

GENERAL

SPECIFICATIONS

Type

Torque converterTypeEngine stall speedStall torque ratio

TransaxleType

Gear ratioFirstSecondThirdFourthReverse

Final gear ratioSpeedometer gear ratio

Automatic four speed with damper spring torque converterand integral differential

With damper clutch2,700 ± 200 rpm1.9

Electronically controlled 4-speedfull-automatic

2.8461.5811.0000.6852.1764.029Drive 36/Driven 31

GENERAL 45-3

TIGHTENING TORQUE

Items Nm kg.cm Ib.ft

Oil pan boltsTie rod end to knuckle starter motor mounting boltLower arm ball joint to knuckleTransaxle mounting bracket to transaxleSpecial boltsSelector lever assembly mounting boltsStarter motor mounting boltOil cooler hose clampHose bracketCover to selector knob Selector knob to lever assemblyBell housing cover to engineTransaxle mounting bolt [10 mm (0.40 in.) diameter bolt]Transaxle mounting bolt [8 mm (0.31 in.) diameter bolt]Torque converter to drive plateControl cable to bodyIndicator panelLever assembly to bracket assemblyDrive plate-to-convener tightening boltDrain plugPressure check plugPulse generator mounting boltBearing retainer screwLock plate boltConverter housing boltOne-way clutch outer race boltDifferential drive gear boltManual control lever nutmanual control shaft set screwInhibitor switchSprag rod support boltPump housing-to-reaction shaft support boltOil pump assembly mounting boltValve body boltValve body assembly mounting boltOil filter boltSpeedometer sleeve locking plate boltEnd clutch coverKickdown lock nut

10-12 100-120 7-927-34 270-340 17-2460-72 600-720 43-5260-80 600-800 43-5846-53 460-530 33-389-14 90-140 7-1027-34 270-340 20-254-6 40-60 3-43-5 30-50 2-42.0 or more 20 or more 1.4 or more2.0 or more 20 or more 1.4 or more8-10 80-100 6-743-53 430-530 31-3830-35 300-350 22-259-14 90-140 7-109-14 90-140 7-101.5 or more 15 or more 1.1 or more14-22 140-220 10-1446-53 460-530 34-3830-35 300-350 22-258-10 80-100 6-710-12 100-120 7-917-22 170-220 12-1548-60 480-600 35-4319-23 190-230 14-1623-35 230-350 17-25130-140 1300-1400 94-10117-21 170-210 13-158-10 80-100 6-710-12 100-120 7-920-27 200-270 15-1910-12 100-120 7-919-23 190-230 13-164-6 40-60 3-410-12 100-120 7-95-7 50-70 4-53-5 30-50 2-46-8 60-80 5-615-22 150-220 11-16

45-4 GENERAL

LUBRICANTS

Items Specified lubricant Quantity

Transaxle fluid lit. (U.S. qts., Imp.qts.) DIAMOND ATF SP, GENUINE HYUNDAI ATF 6.0 (6.4, 5.4)AUTOMATIC TRANSMISSION FLUID, OR*MOPAR ATF PLUS TYPE 7176,

Drive shaft oil seal lip Automatic transaxle fluidDEXRON D-II type

As required

Sliding part of bushing Chassis grease SAE J310, NLGI No.0 As required

Selector lever sliding portion Multipurpose grease SAE J310, NLGI No.2 As required

* : Mopar ATF PLUS TYPE 7176 is recommended lubricant.

GENERAL 45-5

SPECIAL TOOLS

GENERAL

SPECIAL TOOLS

GENERAL 45-7

SPECIAL TOOLS

45-8 GENERAL

SPECIAL TOOLS

Tool(Number and name) Illustration Use

09457-22100Transfer bearing outer raceinstaller

Installation of the transfer bearing outer race

GENERAL 45-9

TROUBLESHOOTING Based upon the use of the troubleshooting

Malfunctions of the auto transaxle can lead to other problems, suchas those described below:1. Improper maintenance and/or adjustments2. Electronic control malfunctions3. Mechanical functions4. Hydraulic control5. Engine performance malfunctions

etc.In order to properly troubleshoot the source of these malfunctions,it is first essential to methodically question the owner concerningthe problem. The driver should also be asked whether or not theproblem has occurred more than once.Tests should be conducted troubleshooting, as described at theright.

guide, the probable location of the problemshould be determined.

Checks should be made of fluid levels andthe condition of the ATF, as well as thecondition of the manual control cables;adjustments should then be made if foundto be necessary.

If a presumption has been made that thereis an abnormal condition somewhere in theelectronic-control system, the diagnosistester should be used to estimate the prob-able location by checking the malfunction-indication pattern. If the ignition key wasalready turned to OFF, however, check bymaking a road test.

When the abnormal system is discoveredduring the road test, check each element(sensors, etc.) one by one, and make re-pairs as necessary.

When the abnormal condition is presumedto be in the oil-pressure-control system,check by making oil-pressure test.

When the result of the oil-pressure testdoes not satisfy the specified pressure,check each system at places related to thevalve body, check the oil-pressure pas-sages for leakage, etc.

If the problem is unusually dirty ATF, ab-normal noises, oil leakage, or slippage ofthe clutch or brakes, or an abnormal condi-tion of the transaxle itself, disassemble andrepair the transaxle.

45-10 GENERAL

TROUBLESHOOTING GUIDE

NOTE: X indicates items of high priority during inspection.Abbreviations: TPS = Throttle Position Sensor SCSV = Shift Control Solenoid Valve

GENERAL

PCSV = Pressure control solenoid valveDCCSV = Damper clutch control solenoid valve

GENERAL

DIAGNOSIS AND TESTFLUID LEVEL AND CONDITION

1.2.

3.

4.

5.

6.

Place the vehicle on a level floor.Before removing the dipstick, wipe all dirt from the area aroundthe dipstick.With the selector lever in “P” (Park), and the parking brakesapplied, start the engine.The engine should be running at idle speed. Fluid should be atnormal operating temperature [70-80ºC (160-180ºF)].Move the selector lever sequentially to every position to fill thetorque converter and hydraulic system with fluid, then place theselector lever in “N” (Neutral) position. This operation is neces-sary to be sure that the fluid level check is accurate.Check to see if the fluid level is in “HOT” range on dipstick. Iffluid is low, add automatic transmission fluid until level reachesthe “HOT” range.Low fluid level can cause a variety of conditions because itallows the pump to take in air along with fluid. Air trapped in thehydraulic system forms bubbles, which are compressable.Therefore, the pressure will be erratic.Improper filling can also cause the fluid level to be too high.When transaxle has too much fluid, gears churn up foam andcause the same conditions which occur with low fluid level. Thisresults in accelerated deterioration of the automatic transaxlefluid. In either case, air bubbles can cause overheating, fluidoxidation, and varnishing, which can interfere with normalvalve, clutch, and servo operation. Foaming can also result influid escaping from the transaxle vent, where it may be mis-taken for a leak.Along with fluid level, it is important to check the condition of thefluid. When fluid smells burned, and is contaminated with metalparticles or friction material particles, a complete transaxleoverhaul is needed. Be sure to examine fluid on the dipstickclosely. If there is any doubt about its conditions, drain out asample for a closer check. After fluid has been checked, seatthe dipstick fully to seal out water and dirt.

GENERAL 45-13

MANUAL CONTROL CABLE

Proper manual control linkage adjustment can be determined bychecking whether inhibitor switch is performing well.1.2.3.4.

5.

6.

7.

Apply parking and service brakes securely.Place the selector lever in “R” range.Set the ignition key to “ST” position.Slowly move the selector lever upward until it clicks as it fits inthe notch of the “P” range. If the starter motor operates whenthe lever makes a click, “P” position is. correct.Then slowly move the selector lever to the “N” range by thesame procedure as in the foregoing paragraph. If starter motoroperates when the selector lever fits in “N”, the “N” position iscorrect.Also check to be sure that the vehicle doesn’t begin to moveand the lever doesn’t stop between P-R-N-D.The manual-control cable is properly adjusted if, as describedabove, the starter motor starts at both the “P” range and the “N”range.

45-14 GENERAL

OBTAINING FAULT CODES

1. Connect the voltmeter or multi-use tester to the connector fordiagnosis.

2. Read the output fault codes.Then follow the remedy procedures according to the “FAULTCODE DESCRIPTION” on the following page.

NOTE:o As many as a maximum of ten fault codes, in the

sequence of occurrence, can be stored in the RandomAccess Memory (RAM) incorporated within the controlunit.

o The same fault code can be stored as many as threetimes.

o If the number of stored fault codes or fault patternsexceeds ten, already stored fault codes will be erased,in sequence beginning with the oldest.

o Do not disconnect the battery until all fault codes orfault patterns have been read out. All stored faultcodes or fault patterns will be canceled when thebattery is disconnected.

3. If the fail-safe system is activated and the transaxle is lockedin 3rd gear, the fault code in the Fail-Safe Code Description willbe stored in the RAM.Three of these fault codes can be stored.

4. The cancellation will occur if, with the transaxle locked in 3rdgear, the ignition key is turned to the OFF position, but the faultcode is stored in the RAM.

(Multi-use tester)

GENERAL 45-15

FAULT CODE DESCRIPTION

Faultcode Fault code (for voltmeter) Cause Remedy

21 Abnormal increase of TPS output o Check the throttle position sensorconnector.

o Check the throttle position sensoritself.

o Adjust the throttle position sensor.22 Abnormal decrease of TPS output o Check the accelerator switch (No.28:

output or not).o Check the throttle position sensor

output circuit harness.

23 Incorrect adjustment of the throttle-position sensor system

24 Damaged or disconnected wiring of the o Check the oil temperature sensoroil temperature sensor system circuit harness.

o Check the oil temperature sensorconnector.

o Check the oil temperature sensoritself.

25

26

Damaged or disconnected wiring of o Check the kickdown servo switchthe kickdown servo switch system, or output circuit harness.improper contact o Check the kickdown servo switch

connector.Short circuit of the kickdown servo o Check the kickdown servo switch

switch system itself.

27 Damaged or disconnected wiring of o Check the ignition pulse signalthe ignition pulse pick-up cable system line.

28 Short circuit of the accelerator switch o Check the accelerator switchsystem or improper adjustment output circuit harness.

o Check the accelerator switchconnector.

o Check the accelerator switchitself.

o Adjust the accelerator switch.

31 Malfunction of the microprocessor o Replace the control unit.

45-16 GENERAL

Faultcode Fault code (for voltmeter) Cause Remedy

32 First gear command during high- o Replace the control unitspeed driving

33

41

42

Damaged or disconnected wiring of the o Check the pulse generator B outputpulse generator B system circuit harness.

o Check pulse generator B itself.o Check the vehicle speed reed switch

(for chattering).

Damaged or disconnected wiring of the o Check the solenoid valve connector.shift control solenoid valve A system o Check shift control solenoid valve A

itself.o Check the shift control solenoid valve

A drive circuit harnessShort circuit of the shift-control sole-noid valve A system

4 3 Damaged or disconnected wiring of o Check the solenoid valve connector.the shift control solenoid valve B o Check shift control solenoid valve Bsystem itself.

o Check the shift control solenoid valve

Short circuit of the shift control sole- B drive circuit harness.

noid valve B system44

45

46

Damaged or disconnected wiring of o Check the solenoid valve connector.the pressure control solenoid valve o Check the pressure control solenoids y s t e m valve itself.

o Check the pressure control solenoid

Short circuit of the pressure controlvalve drive circuit harness.

solenoid valve system

47 Damaged or disconnected wiring of o Check the solenoid valve connector.the damper clutchvalve system

control solenoid o Check the damper clutch controlsolenoid valve itself.

o Check the damper clutch controlsolenoid valve drive circuit harness.

48 Short circuit or the damper clutchcontrol solenoid valve system

GENERAL 45-17

Faultcode

4 9

51

52 Second gear non-synchronous

53

54 Fourth gear non-synchronous

Fault code (for voltmeter Cause

Malfunction of the damper clutchsystem

First gear non-synchronous

Third gear non-synchronous

Remedy

o Check the damper clutch controlsolenoid valve drive circuit harness.

o Check the damper clutch hydraulicpressure system

o Check the damper clutch controlsolenoid valve itself

o Replace the control unit.

o Check the pulse generator outputcircuit harness.

o Check the pulse generator connec-tor.

o Check pulse generator A and pulsegenerator B themselves.

o Kickdown brake slippage.

o Check the pulse generator A outputcircuit harness.

o Check the pulse generator A connec-tor.

o Check pulse generator A itself.o Kickdown brake slippage.


o Check the pulse generator connec-tor.

o Check pulse generator A and pulsegenerator B themselves.

o Front clutch slippage.o Rear clutch slippage.


o Check the pulse generator A con-nector.

o Check pulse generator A itself.o Kickdown brake slippage.

45-18 GENERAL

FAIL-SAFE ITEM

CodeNo.

11

12

Output code

Output pattern (for voltmeter)

NoteDescription Fail-safe (relation to

fault code)

Malfunction of the 3rd gear hold When code No. 31 ismicroprocessor generated a 4th time.

First gear command 3rd gear (D) or 2nd When code No. 32 isduring high speed gear (2, L) hold generated a 4th time.driving

13 Damaged or discon- 3rd gear (D) or 2nd When code No. 33 isnected wiring of the gear (2, L) hold generated a 4th timepulse generator Bsystem

14 Damaged or discon- 3rd gear hold When code No. 41 ornected wiring, or 42 is generated a 4thshort circuit, of shift time.control solenoid valveA

15 Damaged or discon- 3rd gear hold When code No. 43 ornected wiring, or 44 is generated a 4thshort circuit, of shift time.control solenoid valveB

16 Damaged or discon- 3rd gear (D) or 2nd When code No. 45 ornected wiring, or gear (2, L) hold 46 is generated a 4thshort circuit, of the time.pressure control sole-noid valve

17 Shift steps non-synchronous

3rd gear (D) or 2nd When code No. 51,gear (2, L) hold 52, 53 or 54 is

generated a 4th time.

GENERAL 45-19

CHECKING THE CONTROL SYSTEM (WHEN A MULTI-USE TESTER IS USED)

No. Description and display data Check conditions Standard value forjudgement

1 Pulse generator A D range (3rd) 50 km/h (31 mph) constant Upper: 1,700 ± 200 rpmo Upper No.19 speed driving Lower: 3rd

Kickdown drum rpmo Lower No.38 D range (4th) 50 km/h (31 mph) constant Upper: 0 rpm

Shift step speed driving Lower: 4th

2 Pulse generator B D range (creep), stop idle Upper: 0 rpmo Upper No.13

Transaxle output shaft rpmLower: 0 km/h (0 mph)

o Lower No.33 D range (4th) 50 km/h (31 mph) constant Upper: 1,800 ± 200 rpmVehicle speed reed switch speed driving Lower: 50 km/h (31 mph)

3 Vehicle speed reed switch P range, idle Upper: 0 km/h (0 mph)o Upper No.33

Vehicle speed reed switcho Lower, no designation D range, speedometer reading 50 km/h (31 Upper: 50 km/h (31 mph)

mph) driving

4 Throttle position sensor Accelerator fully open (engine stopped, Upper: 4.5-5.0Vo Upper No.21 ignition switch : ON) Lower: OFF

TPS outputo Lower No.28 Accelerator fully closed (engine stopped, Upper: 0.25-0.3V

Accelerator switch ignition switch : ON) Lower: ON

5 Kickdown servo switch L range, idle Upper: ONo Upper No.25

Kickdown servo switchLower: 1st

o Lower No.38 D range, idle Upper: OFFShift step Lower: C (creep)

6 Oil temperature sensor Start when transaxle cold, urban driving. Upper: temperature riseso Upper No.24

Oil temperature sensorAfter driving, stop engine and leave as it is. Upper: temperature

o Lower, no designationeventually decreases.

7 Accelerator switch Depress accelerator pedal slowly. Upper: change from ON too Upper No.28 OFF at a throttle-position

Accelerator switch sensor output of about 0.3V.o Lower No.21

TPS output

Release accelerator pedal slowly. Upper: change from OFF toON at a throttle-positionsensor output of about 0.3V.

45-20 GENERAL

No. Description and display data Check conditions Standard value forjudgement

8 Overdrive control switch Overdrive control switch ON Upper: OD-ON

o Upper No.35Overdrive control switch

o Lower, no designation Overdrive control switch OFF Upper. OD-OFF

9 Ignition signal line D range, idle Upper: 750 ± 100 rpmo Upper No.27

Ignition pulseo Lower, no designation D range, tachometer reading 2,500 rpm Upper: 2,500 rpm

10 Inhibitor switch Move shift lever in P-R-N-D-2-L sequence. Upper: changes in P-R-N-D-o Upper No.34 2-L sequence in accordance

Shift lever position with the lever position.o Lower, no designation

11 Power Economy select switch Select power pattern. Upper: ONo Upper No.36

Power Economy selectswitch Select economy pattern. Upper: OFF

o Lower, no designation

12 Air conditioner relay Switch ON the air conditioner switch Upper: ONo Upper No.37 (while idling in D range).

Air conditioner relayo Lower, no designation Switch OFF the air conditioner switch Upper: OFF

(while idling in D range).

13 Amount of damper clutch D range tachometer reading 1,500 rpm Upper: 250 ± 50 rpm

slippage TPS output approx. 0.7V Lower: 0.7Vo Upper No.47

Amount of damper clutch D range tachometer reading 2,500 rpm Upper: 0 rpm

slippage TPS output approx. 1.0V Lower: 1Vo Lower No.21

TPS output

14 Transaxle gear position D range, idle Upper: C (creep)o Upper No.38 Lower: 0.25-0.3V

Shift stepo Lower No.21 Economy pattern D range (overdrive pos- Upper: 1st-2nd-3rd-4th

TPS output sible condition) Lower: 2.5VAccelerate to 100 km/h (62 mph) with fixedthrottle position sensor output of 2.5V

GENERAL 45-21

Check conditions Standard value forjudgementNo. Description and display data

D range tachometer reading 1,500 rpmThrottle-position sensor output approx. 1.0V

15 DCCSV controlo Upper No.49DCCSV control dutyo Lower No.21TPS output

Upper: 0%

Lower: 1.0V

D range tachometer reading 2,500 rpmThrottle position sensor output approx. 1.0V

Upper: 0-60% changeaccording to load

Lower: 1.0V

ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER

45-22 GENERAL

SHIFT PATTERNS

Two shift patterns are pre-stored in the control unit of this transaxle.One is the Normal pattern (for more powerful performance), and theother is the Economy pattern (for improved fuel consumption andquieter operation).The driver can select and switch to the desired pattern by using thenormal/economy select switch on the center console.The solid lines shown in these shift patterns indicate up-shifts, andthe broken lines indicate down-shifts. The reason why there is adifference between the shift points for up-shifts and for down-shiftsis so that up-shifts and down-shifts will not occur intermittentlywhen driving at a speed close to that of the shift point.When the vehicle is stopped, there is a shift to 2nd gear in order toobtain a suitable “creeping”. Then when the accelerator pedal isdepressed, the vehicle starts off in 1st gear.

GENERAL 45-23

Normal range

VEHICLE SPEED V km/h (FINAL GEAR RATIO 4.029 TIRE RADIUS 0.279 m)

Economy range

VEHICLE SPEED V km/h (FINAL GEAR RATIO 4.029 TIRE RADIUS 0.279 m)

45-24 GENERAL

INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS

GENERAL 45-25

GENERAL

GENERAL

GENERAL

GENERAL

GENERAL

GENERAL 45-31

OIL PRESSURE TESTS

1. Completely warm up the transaxle.2. Raise the front of the vehicle 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 (09452-21500) and the

adapter (09452-21002) to each oil-pressure outlet port.When the reverse pressure is to be tested, the 3,000 kPa (400psi) type of gauge should be used.

5. Measure the oil pressure under various conditions. Check to besure that the measured results are within the standard valuerange shown in the “Standard oil pressure table” below.If the oil pressure is not within the specified range, check andrepair as described in the section “Preliminary Steps If OilPressure Is Not Normal” on the next page.

Standard Oil Pressure Table

NOTE:- must be 9.8 kPa (1.4 psi) or less.SW-ON : Switch ON the overdrive control switch.SW-OFF : Switch OFF the overdrive control switch.* : Hydraulic pressure is generated, but not the standard value.

45-32 GENERAL

Preliminary Steps If Oil Pressure Is Not Normal

Trouble symptom Probable cause Remedy

1. ‘Line pressures are all a. Restriction on oil filter a. Visually inspect the oil filter; replace thelow (or high). oil filter if it is restricted.NOTE b. Improper adjustment of oil pressure b. Measure line pressure 2 (kickdown brake*“Line pressures” (line pressure) regulator valve pressure); if the pressure is not the stan-refers to oil pressures 2, dard value, readjust the line pressure, or3, 4 and 5 in the “Stan if necessary, replace the valve body as-dard oil pressure table” sembly.on the previous page. c. Sticking of regulator valve c. Check the operation of the regulator valve;

repair if necessary, or replace the valvebody assembly.

d. Looseness of valve body tightening part d . Tighten the valve body tightening boltand installation bolt.

e. lmproper oil pump discharge pressure e. Check the side clearance of the oil pumpgear; replace the oil pump assembly ifnecessary.

2. Improper reducingpressure

a. Improper line pressure a. Check the 2 kickdown brake pressure(line pressure); if the line pressure is notthe standard value, check as describedin item 1 above.

b. Clogging of the filter (L-shaped type) b. Disassemble the valve body assemblyof the reducing-pressure circuit and check the filter; replace the filter if it

is restricted.c. Improper adjustment of the reducing c . Measure the 1 reducing pressure; if it is

pressure not the standard value, readjust, or replace the valve body assembly.

d. Sticking of the reducing valve d. Check the operation of the reducingvalve; if necessary, repair it, or replacethe valve body assembly.

e. Looseness of valve body tightening e. Tighten the valve body tightening boltpart. and installation bolt.

3. Improper kickdownbrake pressure

a. Malfunction of the D-ring or seal ring a. Disassemble the kickdown servo andof the sleeve or kickdown servo piston. check whether the seal ring or D-ring is

damaged.If it is cut or has scratches, replace theseal ring or D-ring.

b. Looseness of valve body tightening b. Tighten the valve body tightening boltpart. and installation bolt.

c. Functional malfunction of the valve c. Replace the valve body assembly.body assembly.

GENERAL 45-33

Trouble symptom

4. Improper front clutchpressure

5. Improper end clutchpressure

6. Improper low-reverse brakepressure

7. Improper torqueconverter pressure

Probable cause Remedy

a. Malfunction of the D-ring or seal ring of thesleeve or kickdown servo piston.

b. Looseness of valve body tightening partc. Malfunction of the valve body assembly.d. Wear of the front clutch piston or retainer,

or malfunction of the D-ring.(Refer to the figure on the next page.)

a. Malfunction of a D-ring, seal ring of the endclutch or O-ring of the pipe (Refer to thefollowing figure.)

b. Looseness of valve body tightening part.c. Malfunction of the valve body assembly

a. O-ring between valve body and transaxledamaged or missing

b. Looseness of valve body tightening partc. Malfunction of the valve body assemblyd. Malfunction of the O-ring of the low-

reverse brake piston or the O-ring of theretainer (Refer to the following figure.)

a. Sticking of the damper clutch control sole-noid valve (DCCSV) or the damper clutchcontrol valve.

b. Clogging or leaking of the oil cooler and/orlines.

5. Damaged seal ring of the input shaft (Refer tothe following the figure)

3. Malfunction of the torque converter

a. Disassemble the kickdown servo andcheck whether the seal ring or D-ring isdamaged.If it is cut or has scratches, replace theseal ring or D-ring.

b. Tighten the valve body tightening boltand installation bolt.

c. Replace the valve body assembly.d. Disassemble the transaxle itself and

check whether or not there is wear ofthe front clutch piston and retainerinner circumference, or damage of theD-ring. If there is any wear or damagereplace the piston, retainer, D-ring andor seal ring.

a. Disassemble the end clutch and checkthe seal ring, D-ring of the piston, sealring of the retainer, etc.; replace ifthere are cuts, scars, scratches ordamage.

b . Tighten the valve body tightening boltand installation bolt.

c. Replace the valve body assembly.

a. Remove the valve body assembly andcheck to be sure that the O-ring at theupper surface of the upper valve bodyis not missing or damaged; install orreplace the O-ring if necessary.

b. Tighten the valve body tightening boltand installation bolt.

c Replace the valve body assembly.d. Disassemble the transaxle itself and

check the O-ring for damage; replaceif there are cuts, scars, scratches ordamage.

a. Check the operation of the damperclutch system and the DCCSV.

b. Repair or replace, as necessary, thecooler and/or lines.

c. Disassemble the transaxle itself andcheck for damage of the seal ring;replace the seal ring if there is dam-age.

d. Replace the torque converter.

45-34 GENERAL

Oil seal

Seal ring

GENERAL 45-35

CONVERTER STALL TEST

Stall test consist of determining maximum engine speed obtainedat full throttle in “D” and “R” positions. This test checks torqueconverter stator overrunning clutch operation, and holding ability oftransaxle clutches and low-reverse brake.

Warning:During this test, make sure that no one stand in front of orbehind vehicle.

1.

2.3.4.5.6.

7.

Check transaxle fluid level. Fluid should be at normal operatingtemperature [70-80°C (160-180°F)]. Engine coolant shouldalso be at normal operating temperature [80-95°C (176-205°F]).Apply chocks to both rear wheels.Attach an engine tachometer.Apply the parking and service brakes fully.Start the engine.With the selector lever in the “D” position, depress the accelerator pedal fully to read maximum engine rpm. Do not hold thethrottle wide open any longer than is necessary to obtainmaximum engine rpm reading, and never longer than 5 sec-onds at a time. If more than one stall test is required, operatethe engine at approximately 1,000 rpm in neutral for 2 minutesto cool the transaxle fluid between tests.

Stall speed : 2,500-2,900 rpm

Place the selector lever in the “R” position and perform the stalltest by the same procedure as previously described.

Stall Speed Above Specification in “D”If stall speed is higher than specification, rear clutch or overrunningclutch of transaxle is slipping. In this case, perform hydraulic testto locate cause of slippage.

Stall Speed Above Specification in “R”If the stall speed is higher than specification, the front clutch of thetransaxle or low-reverse brake is slipping. In this case, perform thehydraulic test to locate the cause of slippage.

Stall Speed Below Specification in “D” and “R”If the stall speed is lower than specification, insufficient engineoutput or a faulty torque converter is suspected. Check for enginemisfiring, improper ignition timing, or valve clearance etc. If theseare good, the torque converter is faulty.

45-36 GENERAL

E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL COMPONENTS

D

Name Symbol Name Symbol

4 A/T control unit

M.P.I. control unit

G Pulse generator A, B AH Accelerator switch I

M.P.I. throttle position sensor B Self-diagnosis check connector EOil temperature sensor C Vehicle-speed sensor DNormal (NORM)/Economy (ECO) switch F

GENERAL 45-37

45-38 GENERAL

SERVICE ADJUSTMENT PROCEDURES

TRANSAXLE FLUID LEVEL INSPECTION

1. Drive the vehicle until the fluid temperature reaches normaloperating the usual temperature ]70-80ñC (160-180ñF)[.

2. Place the vehicle on a level floor.3. Move the selector lever sequentially to every position. This will

fill the torque converter and hydraulic system with fluid, thenplace lever in “N” (Neutral) position.

4. Before removing the dipstick, wipe all contaminate from areaaround the dipstick. Then take out the dipstick and check thecondition of the fluid.The transaxle should be overhauled under the following condi-tions.o If there is a “burning” odor.o If the fluid color has become noticeably blacker.o If there is a noticeably excessive amount of metal panicles

in the fluid.5. Check to see if the fluid level is in the “HOT” range on dipstick.

If fluid level is low, add automatic transaxle fluid until the levelreaches the “HOT” range.

Transaxle fluid :GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSIONFLUID, MOPAR ATF PLUS TYPE 7176, OR DIAMOND ATFSP.

Low fluid level can cause a variety of abnormal conditionsbecause it allows the pump to take in air along with fluid. Airtrapped in the hydraulic system forms bubbles which arecompressable. Therefore, pressures will be erratic, causingdelayed shifting, sliping clutch and brakes, etc.Improper filling can also raise fluid level too high. When thetransaxle has too much fluid, gears churn up foam and causethe same conditions which occur with low fluid level, resultingin accelerated deterioration of automatic transaxle fluid.In either case, air bubbles can cause overheating, and fluidoxidation, which can interfere with normal valve, clutch, andservo operation. Foaming can also result in fluid escaping fromthe transaxle vent where it may be mistaken for a leak.

6. Be sure to examine the fluid on the dipstick closely.

TRANSAXLE FLUID REPLACEMENT

Refer to GROUP 10-Lubrication and Maintenance.

GENERAL 45-39

SELECTOR LEVER OPERATION CHECK

1. Shift the selector lever to each range and check to see that thelever moves smoothly and is controlled. Check to see that theposition indicator is correct.

2. Check to be sure that the selector lever can be shifted to eachposition (by button operation as shown in the illustration).

3. Start the engine and check to see if the vehicle moves forwardwhen the selector lever is shifted from “N” to “D”, and movesbackward when shifted to “R”.

4. When the shift lever malfunctions, adjust the control cable andthe selector lever sleeve. Check for worn shift lever assemblysliding parts.

INHIBITOR SWITCH ADJUSTMENT

INHIBITOR SWITCH

1. Place selector lever in “N” (Neutral) position.2. Loosen the manual control lever flange nut to free up the cable

and lever.

3. Place the manual control lever in the “N” (Neutral) position.4. Turn the inhibitor switch body until the 12 mm (.47 in.) wide end

of the manual control lever aligns with the switch body flange[12 mm (0.472 in.) wide portion].

5. Tighten the attaching bolts (2 pcs.) to the specified torque.Inhibitor Switch Attaching Bolt:10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

NOTEWhen setting up the switch body, be careful O-ring not todrop from the switch body.Tighten the attaching bolts carefully.

45-40 GENERAL

6. Make sure that the selector lever is in the “N” (Neutral) position7. Adjust the flange nut so that there is no slack in the control cable

and make sure that the selector lever operates smoothly.8. Run the vehicle and confirm that the transaxle is set in each

range when the selector lever is shifted to each position.

KICKDOWN SERVO ADJUSTMENT

1. Completely remove all dirt and other contaminating materialsadhered around the kickdown adjust screw.

2. Loosen the lock nut.

3. Loosen and tighten the adjust screw two times by torque of 5Nm (3.6 Ib.ft)

4. Again loosen the adjust screw 3 to 3-1/3 turns.

5. Tighten the lock nut to the specified torque.

Lock nut: 15-25 Nm (15-25 Nm (150-250 kg.cm, 11-18 Ib.ft)

NOTEBefore assembly, apply sealant (DC780) to center portionof the adjust screw.

LINE PRESSURE ADJUSTMENT

1. Drain out the automatic transaxle fluid.2. Remove the oil pan.3. Remove the oil filter.4. Remove the oil-temperature sensor.

GENERAL 45-41

5. Press the tab of the solenoid valve harness grommet and pushin.

6. Remove the valve body assembly. The manual valve cancome out, so be careful not to drop it.

7. Turn the adjustment screw of the regulator valve and adjust sothat the line pressure (kickdown brake pressure) reaches thestandard value.When the adjustment screw is turned clockwise, the linepressure becomes lower; when it is turned counter-clockwise,it becomes higher.

Standard value :860-900 kPa (122-129 psi, 8.77-9.18 kg/cm)Oil pressure change for each turn of adjustment screw : 38kPa (5.4 psi, 0.39 kg/cm)

8. Check to be sure that the O-ring is installed on the uppersurface of the valve body at the place shown in the figure.

9. Replace the O-ring of the solenoid valve connector with a newone.

10. Install the valve body assembly to the case and then insert thesolenoid valve connector into the case. Be sure, at this time,that the notched part of the connector faces as shown in thefigure.Also be careful that the lead wiring isn’t caught.

GENERAL

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

A: 25 mm (0.709 in.) longB: 35 mm (0.984 in.) longC: 40 mm (1.575 in.) long

12. Install the oil filter.13. Install a new oil pan gasket with the oil pan.14. Pour in the specified amount of Automatic transaxle fluid.15. Make the oil pressure test. Readjust if necessary.

REDUCING PRESSURE ADJUSTMENT(If the Multi-Use Tester is not available)

1. Remove parts up to the oil filter in the same way as foradjustment of the line pressure. The valve body need not beremoved.

2. Turn the adjustment screw of the lower valve body and adjustso that the reducing pressure is the standard value.When the adjustment screw is turned to the right, the reducingpressure becomes lower; when it is turned to the left, itbecomes higher.

NOTE:When adjusting the reducing pressure, aim for the centervalue (425 kPa, 60 psi) of the standard value allowance.

Standard value :420±20 kPa (60±1 psi, 4.3±1 kg/cm)Oil pressure change for each turn of the adjustmentscrew: 22 kPa (4.3 psi, 0.3 kg.cm)

3. Install the oil filter and oil pan in the same way as for adjustmentof the line pressure.

4. Make the oil pressure test. Readjust if necessary.

(If the Multi-Use Tester is used)1. Adjust the PC solenoid so that the kickdown brake pressure is

the standard value when activated to 50% duty by the Multi-UseTester.

Standard value :320-130 kPa (39±1 psi, 2.8±1 kg/.cm)Oil pressure change for each turn of the adjustmentscrew: 30 kPa (3 psi, 0.2 kg/cm)

2. Check to be sure that the reducing pressure (after the adjust-ment is completed) is within the range of 370-490 kPa (53-70psi, 3.8-5.0 kg/cm)

GENERAL 45-43

Caution:This adjustment should be made at an oil temperature of70-80°C (160-180°F).If the adjustment is made at a temperature that is too high,the line pressure will drop during idling, with the result.that it might not be possible to make the correct adjust-ment.

THROTTLE-POSITION SENSOR ADJUSTMENT

Refer to FUEL SYSTEM-Service Adjustment Procedures.

DRIVE SHAFT OIL SEALS REPLACEMENT

1. Disconnect the drive shaft from the transaxle. (Refer toFRONT SUSPENSION-Drive Shaft)

2. Using a flat-tip (-) screwdriver, remove the oil seal.

3. Using the special tool (09431-21200), tap the drive shaft oil sealinto the transaxle.

4. Apply a coating of the transaxle fluid to the lip of the oil seal.

45-44 GENERAL

SPEEDOMETER CABLE REPLACEMENT

1. Correctly insert the adapter into the instrument panel, andfasten the new speedometer cable.

2. Install the grommet so that, as shown in the illustration, thecable attachment part and the projection part are horizontal.

Caution:The cable arrangement should be made so that the radiusof the cable bends is 150 mm (5.9 in.) or more.

3. At the transaxle end of the speedometer cable, the key jointshould be inserted into the transaxle, and the nut should besecurely tightened.

Caution:If the cable is not correctly and securely connected, it maycause an incorrect reading on the speedometer, or abnor-mal noise. Be sure to connect it correctly.

ACCELERATOR SWITCH CHECK ANDADJUSTMENT

1. After warming up the engine, make sure that the acceleratorswitch is on with the accelerator pedal in the free state.

NOTECheck to see that the accelerator switch is on or off bychecking the voltage between the G wire and the groundwire at the accelerator switch connector (2-pin)

When the accelerator switch is ON : 0VWhen the accelerator switch is OFF : 12V

2. Measure stroke B, as shown in the illustration, at the point whenthe accelerator switch goes from ON to OFF when the pedal isdepressed.

Standard value: 4-8 mm (0.16-0.31 in.)

3. If the figured stroke B deviates from the standard value, adjustit by the adjusting bolt.

GENERAL

45-46 TRANSAXLE CONTROL

T R A N S A X L E C O N T R O L

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

TRANSAXLE CONTROL

REMOVAL

1. Remove the console box assembly. (Refer to Body Group).2. Remove the knob installation screws.3. Disconnect the overdrive switch connector and then remove

the knob.

4. Disconnect the position indicator light connector.5. Remove the shift lever indicator assembly.

6. Remove self lock pin from the link.

7. Remove the clip, nut from the shift lever side.

8. Remove the bolt-washer assembly located on dash panel.

TRANSAXLE CONTROL

9. Remove the clip, flange nut from the transaxle side.10. Remove the transaxle control cable assembly.

INSPECTION

1. Check the control cable for function and for damage.2. Check the bushing for wear or damage.3. Check the spring for damage or deterioration.4. Check the overdrive switch for continuity.

NOTE

*Color code Color of wire *Color code Color of wire

R Red B Black

W White L Blue

5. Check the E/N switch for continuity.

Terminal1 2 3 4 5

Position

ECO

NORMAL

TRANSAXLE CONTROL 45-49

INSTALLATION

1. Apply a coating of the specified grease to the interior of thebushing.

Specified grease : Chassis grease SAE J310, NLGI No.0

2. Move the shift lever and the inhibitor switch to the “N” position,and install the control cable.

3. When connecting the control cable to the transaxle mountingbracket, install the clip until it contacts the control cable, inposition switch in the figure.

4. Install the bolt-washer assembly, nut.

5. Install the clip pin, self lock pin.(shift lever side).

45-50 TRANSAXLE CONTROL

6. Connect the position indicator light connector, the O/D switchconnector, the parking position switch connector, and the shiftlock solenoid connector.

7. Install the shift lever indicator assembly.

8. Apply the specified grease at the place shown in the figure.

Specified grease : Multipurpose grease SAE J310,NLGI No.2

9. Place the shift lever in the “N” position, and then turn the camadjusting so that the clearance between the cam adjusting andthe lever assembly end in within the standard value.

Standard value (A) : 15.2-15.9 mm (0.598-0.625 in.)

NOTEBe sure to face B of the adjusting cam to the push button(driver’s side).

10. Install the selector knob.11. Install the console box. (Refer to BODY GROUP).

ADJUSTMENT OF CONTROL CABLE

1. Eliminate slack from the control cable with the adjusting flangenut and check that the select lever operates smoothly.

2. Driving the car, check that the transaxle is set in the properrange when the select lever is shifted to each position.

SHIFT LEVER ASSEMBLY 45-51

SHIFT LEVER ASSEMBLY

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

INSPECTION

o Check the detent place for wear.o Check the bushing for wear or damage.o Check the spring for damage or deterioration.o Check the pin at the end of rod assembly for wear.

ASSEMBLY

1. Apply a coating of grease to the sliding part of the bushing.

Specified grease : Chassis grease SAE J310, NLGI No.0

SHIFT LEVER ASSEMBLY

2. Apply the specified grease at the places shown in the figure.

Specified grease : Multipurpose grease SAE J310,NLGI No.2

AUTOMATIC TRANSAXLE 45-53

AUTOMATIC TRANSAXLE

COMPONENTS

45-54 AUTOMATIC TRANSAXLE

REMOVAL AND INSTALLATION

1. Remove the drain plug and drain out the transaxle fluid.2. Disconnect and remove the air cleaner assembly.

3. Loosen the mounting clamps and disconnect the return andsupply hose.

NOTETo prevent to entry of dust and foreign matter, plug thedisconnected hoses and the transaxle fitting part.

4. Remove the control cable.5. Remove the speedometer cable.

6. Separate the pulse generator connector, inhibitor switch con-nector, kickdown servo switch connector, solenoid valve con-nector, and the oil temperator switch connector.

7. Remove the transaxle-to-engine bolt from the upper portion ofthe transaxle.

AUTOMATIC TRANSAXLE 45-55

8. Remove the transaxle mounting bracket

9. While supporting the lower pan of the transaxle by using a jack,remove the center member mounting bolts.

CAUTION:Support a wide area of the transaxle so that an excessiveamount of pressure is not applied to the oil pan.

10. Remove the bell housing cover.11. Remove the six special bolts connecting the converter to the

drive plate.

NOTETo remove the special bolts of torque converter, turnengine crankshaft with a box wrench to bring one of thebolts to the position appropriate for removal. After remov-ing the bolt, turn the crankshaft in the same manner asabove and remove all remaining bolts one after another.Bring the transaxle shift lever into the “N” (Neutral) posi-tion.

12. After removing the special bolts, re-install the center memberassembly.

13. Remove the lower arm ball joint (Refer to DRIVE SHAFTGROUP)

14. Remove the remaining engine connecting bolts while at thesame time supporting the transaxle with a floor jack.

INSTALLATION

1. Attach the torque converter on the transaxle side and mount thetransaxle assembly onto the engine.

CAUTIONIf the torque converter is mounted first on the engine, theoil seal on the transaxle side may be damaged. Therefore,be sure to first assemble the torque converter to thetransaxle.

45-56 AUTOMATIC TRANSAXLE

2. Install the transaxle control cable and adjust as follows.1) Move the shift lever and the inhibitor switch to the “N”

position, and install the control cable.2) When connecting the control cable to the transaxle mount-

ing bracket, install the clip until it contacts the control cable.(as shown in the illustration)

3) Remove any free-play in the control cable by adjusting nutand then check to see that the selector lever movessmoothly.

4) Check to see that the control cable has been adjustedcorrectly.

AUTOMATIC TRANSAXLE ASSEMBLY 45-57

DISASSEMBLY

Caution:Because the automatic transaxle is composed of componentparts of an especially high degree of precision, these partsshould be very carefully handled during disassembly andassembly so as not to scar or scratch them.A rubber mat should be placed on the workbench, and itshould 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 usepaper towels.All disassembled parts must be thoroughly cleaned. Metalparts may be cleaned with ordinary detergents, but must bethoroughly air dried.Clean the clutch disc, resin thrust plate and rubber parts byusing ATF (automatic transaxle fluid), being very careful thatdust, dirt, etc. do not adhere.If the transaxle main unit is damaged, also disassemble andclean the cooler system as well.

1. Clean away any sand, mud, etc. adhered around the transaxle.2. Place the transaxle assembly on the workbench with the oil pan

down.3. Remove the torque converter.4. Measuring input shaft end play before disassembly will usually

indicate when a thrust washer change is required (except whenmajor parts are replaced).

Standard value : 0.3-0.1 mm (0.012-0.004 in.)

Thrust washers are located between the reaction shaft supportand rear clutch retainer, and between the reaction shaft supportand front clutch retainer.Mount a dial indicator to the converter housing with the dialindicator support.Make sure that the indicator plunger is seated against the endof the input shaft.When checking end play, pull out or push in the input shaft withpliers. Be careful not to scratch the input shaft. Record indicatorreading for reference when reassembling the transaxle.

5. Remove the pulse generators “A” and “B”.

6. Remove manual control lever, then remove the inhibitor switch.

45-58 AUTOMATIC TRANSAXLE ASSEMBLY

7. Remove the snap ring and kickdown servo switch

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

9. Remove the fiber thrust washer.

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

11. Remove the thrust bearing


12. Remove the clutch hub.

13. Remove the thrust race and bearing.

14. Remove the kickdown drum.

15. Remove the kickdown band.

16. Remove the snap ring.


17. Attach the special tool (09453-21310) on the center support.Holding the handle of the tool, pull the center support straightupward.

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

19. Remove the planet carrier assembly and thrust bearing.

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

21. Remove the end clutch cover mounting bolts, the cover holder,and the end clutch cover.

AUTOMATIC TRANSAXLE ASSEMBLY

22. Remove the end clutch assembly.

23. Remove the thrust plate.

24. Remove the end clutch hub and thrust bearing

25. Pull out the end clutch shaft.

26. Remove the oil pan and gasket


27. Remove the oil filter from the valve body.

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

29. Press the tab of the solenoid valve harness grommet and pushin.

30. Remove the 10 valve body bolts. Remove the valve body.

31. Using an impact driver, loosen the bolt.If an impact driver is not available, use a punch or somethingsimilar


32. Remove the bearing retainer.

33. Remove the snap ring from the bearing.

34. Loosen the rear cover mounting bolt and remove the rearcover.

35. Unstake the transafer shaft lock nut stopper.

36. Place lever in “P” position.


37. Remove the locking nut.

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

39. Remove the taper roller bearing outer race.

40. Remove the snap ring

41. Remove the transfer shaft and taper roller bearing.


42. Move the manual control lever from the "P" position to “N”position

45-65

43. Remove the stopper plate.

44. Using the special tool or presser, remove the output flange anddrive gear.

45. Remove the speedometer sleeve.

46. Remove the differential cover and the gasket.


47. Before removal of the differential gear, measure the end playof the differential gear with a dial gauge.

48. Remove the 5 differential bearing retainer mounting bolts.

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

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

51. Remove the differential assembly.


52. Remove two bolts and the parking sprag rod.

53. Remove the set screw and the manual control shaft assembly.Remove the steel ball, the seat and the spring together at thistime.

54. Remove the kickdown servo snap ring.

55. Remove the kickdown piston assembly.


ASSEMBLY

CautionDo not reuse gaskets, oil seals and rubber parts. Replacethem with new ones at every reassembly. The O-ring of the oillevel dipstick need not be replaced.Do not use grease other than petrolatum or industrial vaseline.Apply automatic transaxle fluid to friction elements, rotatingparts, and sliding parts before installation. New clutch discsshould be immersed in automatic transaxle fluid for a mini-mum of two hours before installation.Do not apply sealer or adhesive to gaskets.When bushings must be replaced, replace their completeassembly which.Do not use shop towels during disassembly and reassemblyoperation.The oil in the cooler should also be replaced.

1. Insert manual control shaft into the transaxle case and push ittoward the manual control lever.At this time, do not install the larger one of the two O-rings onthe manual control shaft.

NOTEIf installed before inserting the shaft, the O-ring willinterfere with shaft set screw hole.

2. After installing the new O-ring on manual control shaft, drawshaft back into case. Install the set screw and gasket. Install thedetent steel ball, seat and spring at the same time.

3. Install the parking sprag rod to the detent plate (manual controlshaft).Install the sprag rod support and tighten the two bolts.

Sprag rod support bolts:20-27 Nm (200-270 kg.cm, 15-19 Ib.ft)


4. Insert the annulars gear, output flange transfer drive gear andbearing assembly into the case.

5. Before assembly of the transaxle, measure the end play of thelow-reverse brake, and select a pressure plate to be used sothat the end play will be the standard value.1) Install the brake reaction plate, brake plate and brake disc

to the transaxle case.

Caution:If new brake discs are used, be sure to immerse themin ATF for a minimum of two hours.

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

Caution:Be sure that the return spring is installed so that itfaces in the correct direction.

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

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


5) Install the snap ring.

6) Install the special tools (09454-21400, 09453-33100) and adial gauge at the transaxle case.

Caution:Install the dial gauge so that it contacts the brakereaction plate at a right angle from the transfer idlershaft hole.

7) Using a manual pump, pump air (5 kg/cm) in from theposition shown in the illustration. Read the dial indicatorgauge, and select the pressure plate that will provide thestandard value.

Standard value: 0.675-6.987 mm (0.0307-0.043 in.)

6. Install the transfer shaft, and press-fit the bearing outer race tothe transaxle case.


7. Install the transfer shaft snap ring.

8. Insert the spacer on the transfer shaft.

9. Install the bearing cage on the case.

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

11. Tighten the lock nut to the specified torque.

Transfer lock nut:200-230 Nm (2000-2300 kg.cm, 146-166 Ib.ft)


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

Transfer shaft end play: 0-0.06 mm (0-0.002 in.)

13. Using a punch, lock the lock nut to prevent rotation.

14. Install the transfer drive gear assembly.

15. Install the special tool at the rear side of the transaxle case.

16. Using the special tool (09452-33100), insert an assembly of theannulars gear into the transfer drive gear.


17. Install the stopper plate.

18. Apply specified sealant to the rear cover.

Specified sealant : THREE BOND 1216

19. Install the rear cover assembly.

Tightening torque :17-22 Nm (170-220 kg.cm, 12.3-15.9 Ib.ft)

20. Install snap ring.

21. Install the bearing retainer. Tighten the screws to the specifiedtorque. Apply a 5 mm (0.2 in.) width of sealant (3M Stud LockingNo. 1303). Sealant should not stick out of screw head.

Screw: 17-22 Nm (170-220 kg.cm, 13-15 Ib.ft)


identification of thrust bearings, thrust races and thrust washers Unit: mm (in.)


23. Install the planetary carrier to the case.

22. Apply a coating of petroleum jelly to thrust bearing #12 andattach to the planetary carrier.

24. Assemble the reverse sun gear and the forward sun gear in thefollowing order:1) Attach the seal ring and the snap ring to the reverse sun

gear. When attaching, squeeze the seal ring as shown inthe figure.

2) Attach thrust race #9 to the reverse sun gear.3) Attach thrust race #10 to the reverse sun gear.

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

25. Install both of the previously assembled sun gears inside theplanetary carrier.


26. Install the brake disc and brake plate

27. install the selected brake pressure plate.

28. Install the return spring

29. Apply a coating of petroleum jelly to the wave spring and attachit to the center support.

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


31. After applying a coating of ATF to the O-rings, install the specialtool (09453-21310) to the center support, and install into thecase.

CAUTIONBe sure that the wave spring is not out of position.

32. Install the snap ring.

CAUTION:The mating hole of the snap ring must be aligned with theinstallation hole of pulse generator A.

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

34. Press the kickdown servo and sleeve in by using the valvespring compressor (09222-28000), install the snap ring.

35. Install the end clutch shaft. Be sure to install the longer splinetoward the front as shown.


36. Fit the thrust washer toward the return spring at the end clutchside.

37. Install the end clutch hub to end clutch.

38. Attach, using petroleum jelly, thrust bearing #13 to the endclutch hub.

39. Install the end clutch assembly.

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

CAUTION:Install so that the D-ring is not twisted.Apply a sufficient amount of automatic transaxle fluid tothe bearing.


41. Attach the end cover and fasten it with four bolts

CAUTION:When installing the end cover, be sure the screw hole iscorrectly aligned. If the end cover is turned (after it isinstalled) in order to align with the screw hole, the O-ringand/or the D-ring may be twisted as a result.

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

43. Apply a coating of petroleum jelly to thrust bearing 8, and thenattach to the kickdown drum.

44. Apply a coating of petroleum jelly to thrust race 7, and thenattach to the rear clutch hub.

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


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

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

48. Combine the rear clutch and the front clutch assemblies.

49. Install the entire clutch assembly.

50. If end play which was measured and recorded at disassemblyis not within standard value, adjust to specification by selectingthrust race #3.


When the thrust race is replaced with that of a differentthickness, also replace thrust washer #1 located between theoil pump and front clutch. Use a washer of proper correspond-ing thickness corresponding to thrust race.Find correct pair of thrust races (metal) and thrust washers(fiber) from following table.


Thrust race #3 (metal) Thrust race #1 (fiber)

Thickness mm (in.) Thickness mm (in.)

1.4 (0.055) 1.0 (0.039)

1.4 (0.055) 1.2 (0.047)1.8 (0.071) 1.4 (0.055)1.8 (0.071) 1.6 (0.063)2.2 (0.087) 1.8 (0.071)2.2 (0.087) 2.0 (0.079)2.6 (0.102) 2.2 (0.087)

2.6 (0.102) 2.4 (0.095)

Example:When a different thickness thick thrust race is selected, acorresponding thrust washer must be paired with it.

51. Attach the reused thrust washer #1, or the one selected in step50 to the front clutch by using petroleum jelly.

52. Install the special tool (09452-21401) to the case.

53. Attach the reused thrust race #3 or the one selected in step 50to the oil pump by using petroleum jelly.

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


55. Install a new O-ring in the groove of the oil pump housing andlightly apply automatic transaxle fluid to the outside surface ofthe O-ring.

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

57. Check the input shaft end play. Readjust if necessary (see step51)


58. Install the O-ring at the center of the top of the valve bodyassembly (brake oil pressure passage).Install the valve body assembly to the case, fitting the detentplate (manual control shaft) pin in the slot of the manual valve.

59. Replace the O-ring of the solenoid valve connector with a newone.

60. Tighten the valve body assembly mounting bolts to 10-12 Nm(100-120 kg.cm, 7-9 Ib.ft)A : 25 mm (0.984 in.) longB : 35 mm (1.378 in.) longC : 40 mm (1.575 in.) long

61. Install the oil filter. Tighten the four oil filter mounting bolts to 5-7 Nm (50-70 kg.cm, 4-5 Ib.ft)


62. Install five magnets into the five depression provided in the oilpan.

63.

64.

Install a new oil pan gasket and oil pan. Tightening 12 bolts to10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

Install a new D-ring to the kickdown servo switch. Press into thecase and secure using the proper snap ring.

65. Install the inhibitor switch and manual lever.Adjust the inhibitor switch.

Tightening torque:10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

66. Install the pulse generator A and B


67. lnstall the differential cover assembly and gasket.

68. Install the speedmeter sleeve.

69. After applying automatic transaxle fluid to the outside surfaceof the oil pump-side cylindrical portion of the torque converter,install the torque converter carefully so as not to damage theseal lip. Make certain that the torque converter is in mesh withoil pump drive gear.

70. Measure the distance between the ring gear end and theconverter housing end. The torque converter has been properlyinstalled when measurement is approximately 12 mm (0.47 in.)

OIL PUMP ASSEMBLY 45-85

OIL PUMP ASSEMBLY

COMPONENTS Bolt (5)

O-ring

DISASSEMBLY

1. Place the oil pump body on the torque converter.2. Remove the two seal rings and O-ring.

3. Remove five volts and remove reaction shaft support fromhousing.

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

5. Make reassembly alignment marks on drive and driven gear.6. Remove oil pump drive and driven gears from pump housing.7. Remove the steel ball from housing.

45-86 OIL PUMP ASSEMBLY

8. Remove the snap ring and the oil seal from the oil pump drivegear.

INSPECTION

1. Measure the side clearance of the oil pump gear. If theclearance exceeds the standard value, or if an inspection of thesurface area (of the oil pump housing) that contacts the oilpump gear reveals indications of interference, replace theentire oil pump assembly.

Standard value: 0.03-0.05 mm (0.0012-0.0020 in.)2. Check the surface of the reaction shaft support that contacts

the oil pump gear. If there are indications of interference,replace the entire oil pump assembly.

3. Using a dial indicator, measure the inside diameter of the oilpump body bushing.

Max inside diameter: 43.01 mm (1.69 in.)

If the inside diameter is greater than the maximum, replace theoil pump body.

4. Check oil pump drive gear rotation.

ASSEMBLY

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

OIL PUMP ASSEMBLY 45-87

2. Install the snap ring.

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

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

5. Install the steel ball in the hole as shown in the illustration.

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

7. Make sure that oil pump gear turns freely.8. Install a new O-ring in the groove provided in the circumference

of the pump housing and apply petroleum jelly to the circumfer-ence of the O-ring.

9. Loosely install the reaction shaft support on the pump housing.Tighten the five bolts fingertight.

10. With the reaction shaft support properly positioned on the pumphousing, using special tools (09452-21401, 09452-21301)tighten the five bolts to 10-12 Nm (100-120 kg.cm, 7-9 Ib.ft).

OIL SEAL REPLACEMENT1. Pry off the pump housing oil seal using a screwdriver.

45-88 OIL PUMP ASSEMBLY

2. Using the special tool (09452-21200), install the oil seal to thepump housing. Apply a thin coat of automatic transaxle fluid tothe lip of the oil seal before installation.

FRONT CLUTCH ASSEMBLY 45-89

FRONT CLUTCH ASSEMBLY

COMPONENTS

Clutch reaction platethickness 3.8 mm (0.150 in.)

Clutch disc

D-ring

45-90 FRONT CLUTCH ASSEMBLY

DISASSEMBLY

1. Remove the snap ring from the clutch retainer.2. Take out the three clutch reaction plates and two clutch discs.

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

3. With return spring compressed with the special tool (09453-24000), Spring Compressor, remove snap ring, then springretainer and return spring.

4. Remove the piston from the retainer.5. Remove the D-section rings from the inner and outer circumfer-

ences of the piston.

INSPECTION

1. Check to see if the sliding surface of the disc, plate are wornor burnt, if necessary, replace then.

NOTE:If the lining of the disc is peeling off or discolored, replaceall discs.

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

ASSEMBLY

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

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

3. Install the return spring and spring retainer.4. Compress the return spring with the special tool (09453-24000)

and install the snap ring.

FRONT CLUTCH ASSEMBLY 45-91

5. Install the three clutch reaction plates and two clutch discs.Prior to installation, apply automatic transaxle fluid to them.

Caution:When new clutch discs are used, they should be im-mersed in automatic transaxle fluid a minimum of twohours prior to installation.

6. After installing the snap ring, check to see if there is a 0.4-0.6mm (0.0157-0.0236 in.) clearance between the snap ring andthe clutch reaction plate.To check clearance, hold the entire circumference of the clutchreaction plate down with 50 N (11 lb.) force. If clearance is outof specification, adjust the clearance by selecting the propersnap ring.

Shear drop

REAR CLUTCH ASSEMBLY

REAR CLUTCH ASSEMBLY

COMPONENTS

Clutch pressure plate

REAR CLUTCH ASSEMBLY 45-93

DISASSEMBLY

1. Remove the snap ring and thrust race.2. Remove the input shaft from the rear clutch retainer.3. Remove the snap ring from the clutch retainer.4. Remove the clutch reaction plate, three clutch plates, two

clutch discs and clutch pressure plate from the retainer.

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

ASSEMBLY

1.

2.

3.4.

Install the D-section rings in the grooves in the outside andinside surfaces of the piston.After applying automatic transaxle fluid to the outside surfaceof the D-section rings, push the piston into the rear clutchretainer by hand.Install the return spring on the piston.Compress the return spring with the snap ring, by pushingdown with a screwdriver and setting the snap ring in itsgroove.

5. Install clutch pressure plate, two clutch discs, clutch plate andclutch reaction plate into the rear clutch retainer.When the reaction plate, clutch plate and clutch disc areremoved, reinstall them by reversing the order of disassembly.Prior to installing, apply automatic transaxle fluid to the platesand discs.Caution:When new clutch discs are used, immerse them in auto-matic transaxle fluid for a minimum of two hours prior toinstallation

6. Install the snap ring. Check to see that the clearance betweenthe snap ring and clutch reaction plate is 0.3-0.5 mm (0.0118-0.0197 in.). To check clearance, hold the entire circumferenceof the clutch reaction plate down with 50N (11 Ibs.) force. Ifclearance is out of specification, adjust by selecting the propersnap ring. Snap rings are the same as those used for the frontclutch.

7. Insert the input shaft into the clutch retainer.

45-94 REAR CLUTCH ASSEMBLY

8. Install the thrust race, and snap ring.9. Install the three seal rings to the grooves in the input shaft.

END CLUTCH ASSEMBLY 45-95

END CLUTCH ASSEMBLY

COMPONENTS

End clutch retainer

45-96 END CLUTCH ASSEMBLY

DISASSEMBLY

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

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

3. Remove the piston. If it is difficult to remove, face the piston sidedownward, and, with the retainer on a base, blow air in throughthe 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.

ASSEMBLY

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

2. After applying a coating of automatic transaxle fluid to the D-section rings outer circumference, manually press the pistoninto 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

(09453-33000), install the retainer. Push the snap ring as fardown on the guide as possible.Attach the installer and press until the snap ring enters thegroove. Do not press more than necessary. The places indi-cated by arrows in the illustration (center projections) are notto be supported.

5. Install the clutch plate, clutch disc and reaction plate to the endclutch retainer.If the reaction plate, clutch plate and clutch disc are reused,install them in the same order they were disassembled. Applya coating of automatic transaxle fluid.

CautionWhen a new clutch disc is used, soak it in automatictransaxle fluid for 2 hours before using it.

END CLUTCH ASSEMBLY 45-97

6. Install the snap ring. Check that the clearance between thesnap ring and the clutch reaction plate is 0.4-0.65 mm (0.016-0.026 in.).To check the clearance, hold the circumference of the clutchreaction plate down with 50N (11 lb.) force.If clearance is out of specifications, adjust the clearance byselecting the proper snap ring.

45-98 PLANETARY GEAR SET

PLANETARY GEAR SET

COMPONENTS

Thrust washer front (6)

Outer race

Overrunning clutch

B

DISASSEMBLY

1. Remove three bolts.

2. Remove the overrunning clutch outer race assembly. Removethe overrunning clutch end plate.

3. Remove the shaft of only one short pinion.4. Remove the spacer bushing and two front thrust washers.5. Remove the pinion. Do not drop the 17 roller bearings in the

pinion.

PLANETARY GEAR SET 45-99

6. Remove the thrust bearing.

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

ASSEMBLY

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

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

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

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

Rear thrust washer

45-100 PLANETARY GEAR SET

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

6. Install the end plate in the outer race

7. Press the overrunning clutch into the outer race. Be sure thatthe arrow on the outside circumference of the cage is pointingupward as shown in the illustration when the overrunning clutchis installed.

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

INTERNAL GEAR AND TRANSFER DRIVE GEAR SET ASSEMBLY 45-101

INTERNAL GEAR ASSEMBLY

COMPONENTS

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

INTERNAL GEAR AND TRANSFER DRIVE GEAR SET ASSEMBLY

TRANSFER DRIVE GEAR ASSEMBLY

COMPONENTS

Snap ring

Rear bearing

Front bearing

Drive gear

DISASSEMBLY

1. Using special tool (09433-21000), pull off the front bearing andthe rear bearing from transfer drive gear.

REASSEMBLY

1. Using special tool (09433-21000), press the front bearing andthe rear bearing onto the transfer drive gear.

TRANSFER DRIVEN GEAR ASSEMBLY 45-103

TRANSFER DRIVEN GEAR ASSEMBLY

COMPONENTS

Transfer ‘driven gear

Tapered roller bearing

DISASSEMBLY.

1. Using special tool (09433-21000), pull off tapered roller bearingfrom the transfer driven gear.

REASSEMBLY

1. Using special tool (09432-33800), press tapered roller bearingonto the transfer driven gear.

45-104 TRANSFER SHAFT ASSEMBLY

TRANSFER SHAFT ASSEMBLY

COMPONENTS

Transfer shaft

Outer raceTapered roller bearing

DISASSEMBLY

1. Using special tool (09433-21000), remove the bearing from thetransfer shaft.

REASSEMBLY

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

DIFFERENTIAL 45-105

DIFFERENTIAL

COMPONENTS

DISASSEMBLY

1. Remove the drive gear retaining bolts and drive gear from thedifferential case.

2. Remove the bearing with the special tool (09433-21000).

3. Drive out the lock pin with a punch inserted in hole “A”.4. Remove the pinion shaft, pinion gears and washers5. Remove the side gears and spacers.

Do not mix the gears and spacers between the left and rightsides.

45-106 DIFFERENTIAL

ASSEMBLY

1. With the spacers installed on the back of the differential sidegears, install the gears into the differential case. If reusingparts, install them in their original positions noted duringdisassembly.If using new differential side gears, install medium thicknessspacers 1.0mm (0.039in.).

2. install the washers on the back of the pinion gears. Install gearsinto the differential case, then insert the pinion shaft.

3. Measure the backlash between the side gear and the piniongear.Backlash should be 0.025-0.150 mm (.0010-.0059 in) and theright and left hand gear pairs should have equal backlash. If thebacklash is out of specification, disassemble and reassembleusing different spacers for the correct backlash.

Standard value: 0.025-0.150 mm (.0010-.0059 in.)

4. Install the pinion shaft lock pin in the direction specified in theillustration. After installation, check that the projection is lessthan 3 mm (.118 in.).

CautionThe lock pin must not be reused.

5. Press the bearings onto both ends of differential case. Press onthe inner race when installing the bearings Do not apply load toouter race.

6. Install the differential drive gear onto the case.

7. Apply ATF to the bolts and tighten the bolts to the specifiedtorque in the sequence shown in the illustration.

Tightening torque:130-140 Nm (1300-1400 kg.cm, 94-101 Ib.ft)

VALVE BODY

DISASSEMBLY

1. Remove the 4 solenoid valves and the oil temperature sensorbracket.

2. Remove the manual valve.

3. Remove the valve stopper and clamp.

4. Remove the bolts (13), and then remove the lower valve body

5. Remove the separating plate

45-108 VALVE BODY

6. Remove the relief spring, two steel bails and oil filter from theintermediate plate.

7. Remove the bolts (7), and then remove the intermediate plateand upper separation plate.

8. Remove the block.

9. Remove the upper separating plate.

10. Remove, from the upper valve body, the three steel balls, theteflon ball, and the two stopper plates.

VALVE BODY 45-109

11.

12.

13.

Remove, from the upper valve body, the seven bolts; thenremove the front end cover and the adjustment screw.

CautionWhen removing the bolts, be sure to firmly press the frontend cover (as shown in the illustration) so as to prevent thespring from causing the adjustment screw to pop out.

Remove the pressue control spring and the pressure controlvalve.

Remove the torque converter control spring and the torqueconverter control valve.

14. Remove the regulator spring and the regulator valve

15. Remove the shift-control spring and shift-control plug A

VALVE BODY

16. Remove rear clutch exhaust valves A and B as well as the rearclutch exhaust spring.

17. Remove the 2-3/4-3 shift spring and the shift valve.

18. Remove, from the rear side of the upper valve body, the N-Dcontrol sleeve and the N-D control valve

19. Remove the four bolts. and then remove the rear end cover.

20. Remove the 1-2 shift spring and the 1-2 shift valve

VALVE BODY 45-111

21. Remove shift-control plug B.

22. Remove the shift-control valve.

23. Using a magnet, extract the pin from the lower valve body, andthen remove the stopper.

24. Remove the end clutch valve plug, end clutch spring, and endclutch valve.

25. Remove the three bolts from the lower valve body, and thenremove the end cover, adjustment screw, and reducing spring

45-112 VALVE BODY

26. Remove the reducing valve

27. Remove the N-R control/accumulator valve and the N-R control/accumulator spring.

28. Remove the damper clutch control sleeve, damper clutchcontrol valve, and the damper clutch control spring.

Damper clutch control sleeve

VALVE BODY 45-113

VALVE INSTALLATION POSITIONS

Upper Valve Body

45-114 VALVE BODY

Lower Valve Body

Damper clutchcontrol valve!

Damper clutchcontrol sleeve

Reducing valve

Adjustment screw

VALVE BODY 45-115

ASSEMBLY

1. Install in the lower valve body, the damper clutch control spring,damper clutch control valve, and the damper clutch controlsleeve.

2. Install the N-R control/accumulator spring and the N-R control/accumulator valve.

3. Install the reducing valve.

4. Install the reducing spring, adjustment screw, and end coverTighten the bolts to the specified torque.

Tightening torque: 4-6 Nm (40-60 kg.cm, 29-43 Ib.ft)

5. Install the end clutch valve, end clutch spring, and end clutchplug.

45-116 VALVE BODY

6. Install the stopper and secure it with the pin.

7. Install the 1-2 shift-control valve to the upper valve body.

8. Install the 1-2 shift-control plug.

9. Install the 1-2 shift valve and 1-2 shift spring

10. Install the rear end cover.

VALVE BODY 45-117

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

12. Install the 2-3/4-3 shift valve and the 2-3/4-3 shift spring.

13. Install the rear clutch exhaust spring and rear clutch exhaustvalves A and B.

14. Install the shift-control valve and shift control spring

15. Install the regulator valve and regulator spring

45-118 VALVE BODY

16. Install the torquecontrol spring.

converter control valve and torque convener

17. Install the pressure control valve and pressure control spring

18. Install the adjustment screw and front end cover. Tighten thebolts to the specified torque.

19. Install, in the upper valve body, the three steel balls, the teflonball, and the stopper plate.

20. Install the upper separating plate

VALVE BODY

21. Install the block.

22. Install the special tool (09456-21000). Then, securing theupper separating plate and the intermediate plate with the eightinstallation bolts, remove the special tool.

23. Install to the intermediate plate, the oil filter, the two steel balls,and the spring.

24. Install the special tool (09456-21000) to the intermediate plate.

25. Install the separating plate.

45-120 VALVE BODY

26. After securing the lower valve body using the 13 installationbolts, remove the special tool.

27. Install the valve stopper and clamp.

23. Install the manual valve.

29. Secure the four solenoid valves using the installation bolts.

KICKDOWN SERVO 45-121

KICKDOWN SERVO

COMPONENTS

Kickdown servo sleeve

Kickdown servo rod

ASSEMBLY

1. Install the rod and nut to the kickdown servo piston.2. Install two new D-rings (one large and one small) around the

circumference of the piston, and then apply a coating of ATFto the D-rings.

3. Install the kickdown servo piston in the sleeve.4. Install a new O-ring around the circumference of the sleeve,

and apply a coating of ATF to the O-ring.

45-122 SPEEDOMETER SLEEVE

SPEEDOMETER SLEEVE

COMPONENTS

Sleeve

Gear

DISASSEMBLY

Drive the spring pin out, and disassemble the gear and sleeve.

Caution:Do not reuse the O-rings and spring pin.

ASSEMBLY1. Install a new O-ring to the shaft part of the gear, and apply ATF

to the O-ring.2. Insert the gear into the sleeve, and 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 O-ring into the outer groove of the sleeve, and

apply a coating of ATF to the outer circumference of the O-ring.

Documents

Caja Automatica Scoupe 94