Technical Service Information INTRODUCTION ACURA INTEGRA 1990 The Acura transmission is a computer controlled 4 speed front wheel drive transaxle with one reverse speed and a converter clutch. The electronic control system consists of an automatic control unit, sensors, and 4 solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The teardown - assembly and trouble - shooting is covered in detail in this manual. We thank the Honda Motor Corporation for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA HOTLINE TECHNICIAN HOTLINE TECHNICIAN ED KRUSE LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161 1INDEX ACURA INTEGRA 1990 POWER FLOW... ELECTRONIC CONTROL .. REMOVAL... TEAR DOWN .. VALVE BODY .. COMPONENT DISASSEMBLY/ASSEMBLY... TRANSMISSION ASSEMBLY Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami, FL 33156 (305) 661-4161Information Technical Service ‘The Automatic Transmission is a combination of a 3-element torque converter and a triple-shaft electronically controled ‘automatic transmission which provides 4 speeds forward and 1 speed reverse, The entire unit is positioned in line with the engine, TORQUE CONVERTER, GEARS AND CLUTCHES The torque converter consists of a pump, turbine and stator, assembled in a single unit, They are connected to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converter assembly serves as a flywheel while transmitting power to the transmission mainshaft The transmission has three parallel shafts, the mainshaft, the countershaft and the secondary shaft. The mainshaft isin fine with the engine crankshaft. ‘The mainshaft includes the clutches for 1st. and 4th, and geors for 3rd, 4th, Reverse and 1st (3rd gear is integral with the mainshaft, while reverse gear is integral with 4th gear) The countershaft includes 3rd clutch and gears for 2nd, 3rd, and Ath, Reverse and 1st The secondary shaft includes 2nd clutch, the secondary deve gear, and 2nd geer. The 4th and reverse gears can be locked to the countershaft at its center, providing 4th gear or Reverse, depending on which way the selector is moved. The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears in the transmission are engaged by the clutches, power is transmitted from the mainshaft to the countershatt to provide (Sq). [Sd. (0). 2) and B. Contrat lectronic control system consists of an automatic control unt, sensors, and 4 solenoid valves. Shifting and lock-up ‘are electronically controlled for comfortable driving under all conditions. The A/T control unit is located below the dash to the left of the steering column HYDRAULIC CONTROL The valve assembly includes the main valve body, secondary valve body, servo valve body, and reguiatar valve body. ‘They are bolted to the torque converter case as an assembly “The main valve body contains the manval valve, 1-2 shift valve, 2-3 shift valve, 2-8 shift valve, cooler relief vaive, 3rd orifice control valve, lock-up shift valve, lock-up control valve, 3-2 kickdown valve, pressure reef valve and oil pump gears. ‘The secondary valve body includes the 4th exhaust valve, 3rd kickdown valve, modulator valve, 2nd modulator valve, servo control valve and the 2nd orifice control valve. ‘The servo valve body contains the sccumulator pistons T/C check valve, and servo valve. The regulator valve body contains pressure regulator valve and lock-up timing valve. Fluid from the regulator passes through the manu valve to the vanous control valves. ‘The 1st, 3ed and 4th clutches receive oil from their respective feed pipes SHIFT CONTROL MECHANISM. Input from various sensors located throughout the car determines which shift contto! solenoid vaive the AIT contral unit wil activate. Activating a shitt control solenoid valve changes modulator pressure, causing 9 shift valve to move. This pressurizes a line to one of the clutches, engaging that clutch and its corresponding gear. LOCK-UP MECHANISM or [D), in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through an oil passage, causing the lock-up piston to be held agsinst the torque converter cover, AS this takes place, the mainshaft rotates at the same speed as the engine crenkshaft. Together with hydraulic control, an electronic control unit optimizes the timing of the lack-up mechanism, The lock-up valves control the range of lock-up according to lock-up control solenoid valves A and B, and theottie valve B When lock-up control solenoid valves A and B activate, modulator pressure changes. Lock-up control solenoid valves A and 8 are mounted on the torque converter housing, and ate controlled by the A/T control unit (cont'ahTechnical Service Information GEAR SELECTION Bo sleeve a pose TP ARK, ET AEVERSE [I NEUTRAL, [BoE] rouoh Anger noe, CE] ‘st through 3rd gear ranges, and [2] 2nd gear. Position Description —_—— | TEIPARK Front wheels locked: parking pawl engaged with parking gear on countershafi. All clutches released. [reverse | Reverse; reverse selector engaged with countershaft reverse gear and 4th gear clutch locked. [neutaat | at clutches released. D orive 's off in Ist, shifts automatically to 2nd, 3rd, then 4th, speed and thrattle position. Downshifts through 3rd, 2nd and 1st on deceleration to stop comes into operation in 2nd, Grd and 4th when the sports ion at highway speeds and general driving: starts off in Tst, shifts (1 through 3, | nd, then 3rd (3, and then 4th (a) depending on vehicle speed and oa) throttle position. Downshifs through lower gears on deceleration to stop. (second | For engine braking or better traction starting off on loose or slippery sutaces; stays in 2nd | gear, does not shift up or down, | weutra-safety switch, Starting is possible only in [BJ and [through use of a slide-type, POSITION INDICATOR ‘A position indicator in the instrument panel shows what gear has been selected without having to look down at the console. AIT SPEED PULSER 2ND CLUTCH PARKING GEAR SRD CLUTCH Toraue CONVERTER Lock.UP CONTROL, SOLENOID VALVE ASSEMBLY ast ewurcH SHIFT CONTROL SOLENOID VALVE ASSEMBLY 4TH CLUTCHTechnical Service Information {1st chem The tet clutch is on the ight end ofthe malnshat. nthe [5]. 6. or 5] range, constant hydraull pressure is aplied 10 the mainehett through the Ist clutch to the mainshaft 1st gear. “The elutch plate is mounted on the clutch drum, while the clutch disc is fited tothe mainshaft 1st gear The {st gears are attached tothe malnghaft and courtershet through neetlo bearings, one Tor each ge. When aoe lover is placed in the ls [Sd or [0] range,hydraullc pressure Is applied from the right sige cover through the meinshott, and thus tothe clutch drum; asthe pressure rises, the clutch piston presees te clutch plate ang clutch tise, thus causing the clutch to engage Power is ansmitted fom the meinsheft 1st gear, through the countershaft 1st gear, tothe one-way clutch, parking ‘ear, and finaly tothe countershaft. The one-way clutch locks in the forward direction svhen in tt gear nthe (Sa, [Sl ‘or [D] range, all others besides 1st gear are not engaged, thus transmitting no power. (2nd Clutch] ‘The 2nd clutch is on the secondary shaft, and is the same construction as the Tst clutch. The secondary shaft 2nd drive gear uses a needle bearing. The countershaft 2nd gear is splined to the countershaft In 2nd gear of 2, (Sa) [Se]. oF[D), hydraulic pressure is applied to the clutch drum from the secondary shaft, thus transmitting ower from the mainshaft 3rd gear, countershaft 3rd gear, secondary shaft 2nd gear, 2nd drive gear to the countershatt 2nd gear, {Grd Clutehi The 3rd cluteh is on the left end of the countershatt. ‘The clutch hub is joined to the countershaft 3rd gear, on the countershaft, supported by a single needle bearing. In 3d gear of [Sd (Se. or 0). hydraulic pressure Is applied to the 3rd clutch on the countershaft, thus causing the clutch to engage, and transmitting power. [4th Clutehi The 4th clutch ison the center ofthe msinsaft. The clutch hub joined tothe mainshaft 4th gear and reverse ger, supported by two needle earings In 4th gear of (Sd. or [B], hydraulic pressure is generated within the mainshett, applying pressure tothe 4th clutch on the mainshat. ‘one-way clutch dsengages 1st gear when in 2nd, 3 and 4th gear ranges. The clutch i epined to the countrshatt between Ist gear and the poring gear, with spag elements and the retainer which support the cena section between the toroge en coumteahatt Tot gee foetes cackwise tna parking gor counterclockwise, the aprags incline to the tight locking the gears together, When shifting from 1st 02nd nthe [Sd [Sa or] range, the higher ato ot 2nd gear Chises tne Courearanett fo rnste clockwise ato speed greet tan the of Tak gear The parking gear than rotates Slockwise: andthe sprags move sway rom the locing postion. n il. Eo [De higher rato of Sr gear prevents the snags tom locking Keoing 1x goer Suengegeds COUNTERSHAFT 18T GEAR ‘SPRAG = locks ener PARKING GEAR Automatic Transmission Service Group 6A Technical Service Information MAINSHAFT 3RD Gear COUNTERSHAFT =) 20 Gear =F | COUNTERSHAFT 2ND GEAR MAINSHAFT 4TH/REVERSE GEAR aTH CLUTCH MAINSHAFT 1ST GEAR ast cLuTcH ] REVERSE SELECTOR ONE-WAY CLUTCH COUNTERSHAFT SELECTOR HUB PARKING GEAR COUNTERSHAFT 1ST GEAR Lock.UP cLUTCH ‘SECONDARY SHAFT RD CLUTCH COUNTERSHAFT REVERSE GEAR COUNTERSHAFT 4TH GEAR } ano cturcH '2ND DRIVE GeaR SECONDARY SHAFT 2ND GEAR, FINAL DRIVEN GEAR Automatic Transmission Service Group 7, Technical Service Information —E TST GEAR [IND GEAR] SAD GEAR BRAT cua] TORQUE AR F PARKING convener |1Sreturcn ONEWAY) | 2ND, 380 MQeAR | GEAR | RANGE clutcH | cuutcH | cLuTcH | GEAR CLUTCH ital o x x x x x x x o : 3 x x x ex oO ml ea mal a = 3 x x a wo 3 3 x xox [kp x pe 20] 0 70) XO HOOK KX 3n0[ 0} 70 x x ox xf ke ati aio o o x x xX x [x zo 6) 70 x o Xxx ex &) pee 70) x x a ne aS [ero ro x x ee efx (itz —o 73 x © xO xX Gr Operates, X- Doesn't operate, *: Although the 1st clutch engages, ving powers not wanemitted as the one-way clutch sips. MaINsHarT ano ciuren Sno GEAN rw clurcH REVERSE 10Le Gene ainswart COUNTERSHAFT Reverse ean / saiswart 187 GEAR MAINSHAFT eee ‘1ST CLUTCH eA i MAINSHAFT — TI B Lor| counrenswarr Bs |i) ji tsreean | | courte Shar 7 SMAET PARKING GEAR l 5 ¥ cee Surber Bly ra CoUNTERSHAFT ] TORQUE CONVERTER: 1 eee Bl 5 cturen ca aril fi [| Parnine paw Final Driven ——— I as CCOUNTERSHAFT eran a Sevense ‘SECONDARY | riverse SAR SHAFT | SELECTOR seconpanystart CouNTensHarT Sno tan gounrens 2ND RIVE GEAR ‘SERVO VALVE 2ND CLUTCH Automatic Transmission Service Group 8Technical Service Information Electronic Control System The electronic contral system consists of the automatic control unit, sensors. and 4 solenoid valves. Shifting and lock-up {are electronically controlled for comfortable driving under all conditions. ‘The automatic control unit is below the dash to the left of the steering column, < Getting @ signal from each sensor, the automatic control unit detects the appropriate gear shifting and activates shift control solenoid valves A and/or 8. ‘The combination of driving signals to shift control solenoid valves A and 8 is shown in the table below. Shirk control sok vale | Range ies) ce ae [OFF ow 10 59 B3)'2na ‘ON ‘ON [BEI Eee [oN OFF (Esse) OFF OFF From sensor input signals, the automatic control unit detects whether to turn the lock-up ON or OFF and activates lock: ‘up control solenoid valve A and/or B accordingly. ‘The combination of driving signals to lock-up control solencid valves A and 8 is shown in the table below. Solenoid vane Cockup condition a e Lock-up OFF OF OFF Lock-up, sight ON OF Lock-up, Ralf ON, ON Lock-up, full ON_| ON Lock-up ‘on | Duty operation during deceleration Offa eON Automatic Transmission Service Group 9Technical Service Information A/T CONTROL UNIT ir Conditioner Signa Vehicle Speed Signal Throttle Angie ‘Shite Contra! Signal Solenoid Valve A ‘Shit Contr P eae ‘Shit Contr! Solenoid Valve & R LK Lockup Gonvol Sclonod Valve A D ‘Lock-up_ m= Sonat eck Conra ster —{ senor Valve —— 5 . 2 58 indicate Light — ’ Grane Laie Swntch Sorat Goolane Temperature Signal Engine APM |__| Shift Position Signal ‘Set-Diagnosis| Indiator “aemospher Proseure Signal Automatic Transmission Service Group 10|; Technical Service Information Circuit Diagram and Terminal Location IGNITION swiTcH + as : ae THROTTLE a Tae |- COOLANT TEMP. 4 ‘SENSOR SOLENOID VALVE A T_atmosprenic ® traobune re BUFR RETRY *17 suirr contmou _ ts 6 il LOCK-UP CONTROL \axmon _ [rerum ruuiee co} oe [ a | Fanceereusen * Lot 4 ara BRAKE LIGHT SWITCH Arc conTROL $ ad SHIFT POSITION switch SHIFT CONTROL unt Automatic Transmission Service Group uTechnical Service Information WAN FUSE 80x parent [pease ONS wt /oan 4 wir/aaw. mae ol ean - ae 8at-4(O> oumon eet vesrjony HABA UCHT =) ae = cout Vv 7 ao ee Sas (104) G (154) CRUISE CONTROL UNT eee L KEY INTERLOCK SOLENOID. BUK/YEL LII. ora BLK/YEL- LT vol ule en A seule el dy “pape a t | GRN/WHT ‘RED/BLK | & }—O—— GRN / WHT ES ;o ’ ; wre. AE Pa a See a ea ea Automatic Transmission Service Group 12Technical Service Information Pour ecu _} cave) [rere] | | fen Vv me [ee somal sensor | | SENSOR en Lorex 2 ay = veclou) aw] xtc RED /AT “cr | BRN /eLK ete 4 le ste cule ae obs ae RoE ale EB pooce Pe ae size tea Ee som ake ok ‘aa [a7] a8 [a5 ‘aejas]az}ar) (os]e«] [5] fes]ezjer asalar7jarelas[are]arayar2|ansfaro] ae] [arzlenr] [ee] se 7 |e6 Automatic Transmission Service Group 13ATSG] Technical Service Information ‘TW SENSOR THROTTLE ANGLE SENSOR ACT SPEED PULSER Lock-uP controt SOLENOID VALVES, SHIFT CONTROL SOLENOID VALVES AUT CONTROL UNIT BRAKE SWITCH PA SENSOR ‘s, SWITCH PaM-Ft ecu ‘SHIFT POSITION Console SWITCH ‘Automatic Transmission Service Group 14Technical Service Information ‘The A/T Control Unit has a built-in self-diagnosis function. The Ss indiestor light in the gauge assembly and LED display fon the A/T control unit blink when the A/T control unit senses an abnormality in the input or output systems. The number Of Blinks from the LED display varies according to the problem, which can be diagnosed by counting the number of blinks. For problem diagnosis count the number of blinks from the LED display as shown on the Symptom-to-Component Chart fon page 14-36. If no abnormality is found from your inspection, refer to the hydraulic system Symptom-to-Component Chart on page 14-60. LED DISPLAY So INDICATOR ust When the ignition switch is turned ON, the Ss indicator light comes on for about two seconds regardless of whether there is @ problem. The Ss indicator light will also come on when in S2 mode. It there is a system problem, the $2 indicator light will come on and continue to blink until the ignition key is turned OFF. When the ignition key is turned ON again, the Sa indicator light will not blink again for the original problem. But if the A/T Control unit senses the original abnormality again with ignition switch ON, the Sa indicator light will link again for the ‘riginal problem. Therefore, even though the Ss indicator light does not come on whan turning the ignition key ON, check the LED display for automatic transmission problem diagnosis. ‘Since the LED problem code is retained in memory. it will Bink again whenever the ignition key is turned on. If the LED problem code is not memorized, check the following causes: '© Check the Alternator Sensor fuse (10A) in the under-hood relay box '© Check for an open circuit in the WHT/YEL wire between the Alternator Sensor fuse (10A) and A/T contral unit & 12 terminal After making repair, disconnect the Alternator Sensor fuse (10A) in the under-hood relay box for more than ten seconds to reset LED display memory. Automatic Transmission Service Group 15. Technical Service Information Number of LED | Sr indeator Hier te sae Symetom | Probable Cause SSR SE TBs eecp Gan ET | “Bekcup euteh does not eaengege. | "valve A connector 1 Binks | « Frequant engin saling + Open oF shor lock-up conto! solenoid waive A wre, _ Faulty lekoup conto solencid valve A. ~Lockup dutch doesnot engage. | -Disconnecied lock-up contol solenod] | ‘ave 8 connector 2 Binns = Gpen_or short in lock-up contol solenoid valve B wire, | + Fauly lock-up control solenoid valve 8. | ~Tedkcup clutch does not engage. | » Disconnected throttle angle sensor con- Blinks nector. | 3 or + Open/short in throttle angle sensor OFF wire, + Faulty throttle angle sensor. “Tockup cluteh does not engage. | » Disconnected speed pulser connector 4 Blinks + Open of short in speed pulser wire __| + Faulty speed pulser. | “Fails to shi other than 2nd=dth| Short in shift position console switch 5 Binks | gear. wire Lock-up clutch does not engage. | « Faulty sift position console switch. TFails to shift other than 2nd=ath| - Disconnected shift position console ‘gear. switch connector. 6 oft — | -Lock-up clutch does not engage. | « Open in shift position console switch ‘Lock-up clutch engages and. dis-| wire i |_ engages siternstely, + Faulty shift postion console switch f ~ Falls to shift other than Tst--dth, 2nd] » Disconnected shift control solenoid valve | | sth, oF 2nd--3rd gears. A connector. | 7 Blinks | + Fails to shift (stuck in 4th gear). | = Open or short in shitt control solenoid valve A wice = Faulty shift control solenoid valve A. Falls to shift (stuck in Tt gear or 4th | » Disconnected shift control solenoid valve 902). B connector. + Open or short in shift control solenoid | valve 8 wire + Faulty shift control solenoid valve B. “Todicup cuieh does not engage. | = Disconnected A/T speed pulser. * Open or short in A/T speed pulser wire + Faulty A/T speed pulser “Tack ciah doe not engage. | = Disconnected coolant tenuate a> «Sper or ator a coolunt temperate | | _ Fou ool temperture sensor a Blinks 9 Blinks 10 Blinks TT Lockcup clutch does not engage, | » Disconnected ignition coll connector. oFF Open or short in ignition coil wire {Faulty ignition coil “Tate locicup clutch engagement ~ Disconnected PA sensor connector | open or short in PA sensor wire [Li Faulty PA sensor 1a | Blinks NOTE © If a customer describes the symptoms for codes 3, 6 oF 11, yet the LED is not blinking, it will be necessary to recreate the symptom by test driving, and then checking the LED with the ignition stil ON, If the LED display Dlnks 12 or more than 1 times, the contro unit is faulty. {© Ss indicator light and engine warning light may come on simulteneousl. If s0, check the PGM-FI system according to the number of blinks on the PGM-F! ECU self-diagnosing indicator, then reset the memory by removing the alternator sensor fuse (10A) inthe under-hood celay box for more than 10 seconds, Drive the vehicle for several minutes at speed over 30 mph, then recheck the lights Automatic Transmission Service Group 16ATSG], Technical Service Information If the self-diagnosis LED indicator does not blink, perform an inspection according to the table listed below. ‘Symptom Probable Cause Ss ight is not on for 2 seconds attr ignition is first turned on, Check S4 switeh signal. Does not change 10 Ss mode. Lock-up clutch does nat have duty operation (ON-OFF). | Check A/C signal with operation A/C. | Lock-up clutch does not engage. | Check brake light switch signal Shift lever eannot be moved from @) range Check shift lock switch signal No.| DESCRIPTION Jno. DESCRIPTION NO. DESCRIPTION INO. DESCRIPTION, OF nesoune SF oneeaune OF pReeOURE a i une @ | Moouaton | 30] sro ciuten [es] ou coouen TRODUCATOR TORGUE is Ne ro) ssrewten [so] emewren”[os)wenicarion os TORQUE | [une 20) anocuuren [ai] atwcuuren of YES | Bapale the PEMLFL NO Tur the ignition switch OFF Disconnect the 18P and 12P View toom wire side ‘connectors from the contol unit Technical Service Information BLK/RED “Turn the ignition switch ON. Measure the voltage between the ‘ais AIS (BLU/WHT) and etuiwar ts) 81 [BLK/RED) terminals eee Repair open or short im BLU/WHT wire be: the voltage 4 Ve SNO_] twoen the A1S termi. << isine vonage 4.75525 7S ween the A1S term ‘minal of the PGM-FI ves eu ‘Tura the ignition switch OFF La ‘Connect the 18° and 12P con Pectors to the conta! unit. aLK/RED Tum ne anion swien ON] Measure the voltage between the ‘AIT IRED/WHT) and 81 (BAN/ REO/WHT RED) terminals. Is the volage 2, 76-296 V 7" nd the PA sensor ves (Check for foose control unit connectors. If Scbstiate a Control unit and recheck: + 210% Automatic Transmission Service ~ ~'0 34TSG], Technical Service Information —— Inepection of the A/C signal ———— ‘Start the engine | Turn te Bower wich ON. | Push the A/C switch ON. Does A/C compressor clutch \NO r engage? YEE Stop the engine Disconnect the 12P and 16P con rector from the conta unt ‘See Air Conditioner inspection. aucneo J, | ) yee A ‘Stan the engine pe t ‘Measure the votage berween AD | tvetl ang 61 (8UK/AED) term nals. (A/C compressor OFF) te there battery voltage? —_| YES OK. ] ‘Repair opan in YEL wire berwoen AS torminal_ and atch a3 & 0. Automatic Transmission Service Group 35Information Service , Technical Inspection of the shiftlock switch signal Depress the brake pedal and sten fora elcking noise trom the sht- fock solenoid valve. © Repair the shite. Jock soloncid valve Is solenoid vate operating pro- \\NO. cireui pec? © Check solenoid ves ‘Turn the ignition switch aff Tem ion swith OW “Sh : i ~ ena i My Depress the brake pedal and accel- trator pedal simultaneously and I measure voltage between the AG (WHT/RED) and 81 (BLK/RED) Disconnect the 18P and 12P con- nectors from the contol unt [check for toose contot Gam comectr, He nse ves ve tere vonage ? isery. subcinte 8 beset Sown-good contol NO ‘unit “snd recheck [shite tek switch signal ie OX. ee Automatic Transmission Service Grov1o 36Test: 1, Apply the parking brake, biock the rear wheels, and jack up the front of the car 2. Disconnect the A/T speed pulser 2P connector. 3, Rotate the front wheels and be sure that continuity ‘and no continuity appear alternately between the two terminal. AIT SPEED PULSER 1 2 Technical Service Information pRemoval/inspection- Remove the 6 mm bolt from the transmission hous: ing and remove the A/T speed pulser assembly O-RING Replace A/T SPEED PULSER 61.0 mm T2Nem (1.2 kgm, 9 Ibe Bring a magnet close to the A/T speed pulser assembly and check for continuity MaGner ‘Alt SPEED PULSER ASSEMBLY AIT speed pulser assembly is in good condition if there is + Continuity with a magnet close to the pulser assembly. + No continuity with @ magnet away from the pulser assembly. WW the A/T speed pulser is normal, go to Rotor Disassembly/Inspection Replace the Oving with a new one before reassembling the AIT speed pulser CAUTION: Carefully inspect the A/T speed pulser before installing. Do not install if it shows signs of being dropped or improperly handled, 7Test NOTE: Lock-up control solenoid valves A and 8 must be removedireplaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. NOTE: Do not remove the lock-up control solenoid valve A/B stay. 2. Measure the resistance between the No.1 terminal (SOL. V A) of the lock-up control solenoid valve ‘connector and body ground and between the No. 2 terminal (SOL. V B) and body ground. STANDARD: 12-240 View fom terminal side Logk-uP CONTROL — SOLENOID VALVE ‘ASSEMBLY 3, Replace the lock-up control solengid valve ‘assembly if the resistance is out of specification, 4. Connect the No.1 terminal of the lock-up control solenoid valve connector to the battery positive t ‘minal. Connect the No.2 terminal to the battery posi- tive terminal ‘A clicking sound should be heard each time the ‘connection is made. 5. If not, check for continuity between the A/T control unit 83 or BB harness and body ground 6. Replace the lock-up control solenoid valve assembly if there is continuity between the A/T Control unit 83 or BB harness and body ground. Technical Service Information Replacement 1. Remove the four mounting bolts and lock-up con {10l solenoid valve assembly, NOTE: Be sure to remove or replace the lock-up control solenoid valves A and 8 as an assembly. 2. Check the lock-up control solenoid vaive oil passages for dust or dirt and replace as an assembly, if necessary. BASE GASKET Replace, ys i savages ee Looe-ur sor wether (1.2 kgm. 9) 3. Clean the mounting surface and oil passages of the lock-up central solenoid valve assembly and install ‘a new base gasket 4. Check the connector for rust, dirt or oll and recon- rect it securely 38Test NOTE: Shift control solenoid valves A and B must be removed/replaced as an assembly. 1 Disconnect the connector from the shift control sole- roid valve A/B. NOTE: Do not remove the shift control solenoid valve AB stay. ‘Measure the resistance between the No.1 terminal (SOL. V A) of the shift contro! solenoid valve con- rector and body ground and between the No.2 termi- ral (SOL. V B) and body ground. STANDARD: 12-26 0 2 ‘SHIFT CONTROL SOLENOID VALVE ‘ASSEMBLY Replace the shift control solenoid valve assembly f the resistance is out of specification. Connect the No.1 terminal of the shift control solenoid valve connector to the battery positive terminal. Con- ‘ect the No.2 terminal to the battery positive terminal A clicking sound should be heard each time the Connection is made. not, check for continuity between the A/T control Unit B4 or B5 harness and body ground. Replace the shift control solenoid valve assembly if there is continuity between the A/T contol unit B4 or BS harness and body ground. Technical Service Information 1 Replacement: Remove the four mounting bolts and shift contro! solenoid vaive assembly NOTE: Be sure to remove or replace the shitt control solenoid valves A and 8 as an assembly. Check the shift control solenoid valve oil passengers for dust or dirt and replace as an assembly, if neces- sary. SHIFT CONTROL BASE GASKET SOLENOIO Replace vaLve ASSEMBLY 3 mounting surface tnd ol possages, Bour a2Nem (12 kgm, 9b Clean the mounting surface and oil passages of the shift control solenoid valve assembly and install a new base gasket, Check the connector for rust, dirt or oil and recon- rect it securely. 39< ° = o E x ° - < o ° > z o o © ° c = °° o F TestTechnical Service Information RSS RTT ‘SYMPTOM FSO ellen PROBABLE CAUSE Engine ene, but car Goes nt move in any Gear [1,2,3.6,7,8,|K,L,R,| 1. ATF level too low 39,44 S'""'|2. Oi pump seized, gear damaged, foreign matter [Car moves in 2, but not in S or D 7,9,10,11 [CMO], suckin gear 7 s/damages SFE AAT jeguator valve stuck oF spring weak/damage: [Car moves in Sor D,butnotin2 47.12.13 _ |__| 4. Servo shaft stuck [Car moves §, D of 2, but notin R 4,7,14,23, |E.N.O]s° Seq genre worn/ damaged 36.60 6. Mainshaft damaged Poor acceleration 7 Shift cable msadjustee oF eut: end pin discon Engine races when stating of in c nected ~Stall rom high in S, D and 2 1.2.3.7. [Kt |e. Final gear worn/camaged 24,47 9 Countersnatt and one-way clutch seized/ Stall . STEEL BALLS pressure RELIEF waive NN RoLeR—af} Lock-uP SHIFT- valve vatve: 3-2 KICK-DOWN VALVE cap route SuEEVE SPRING ag — MANUAL VALVE Lookup CONTROL VALVE SPRING yaiN VALVE BODY Inspect for scoring or cemage. 2.3 SHIFF-VALVE SHIFT SPRING: VALVE COVER’ FB euan & R 5 mm BOLT ROLLER 8 Nem (0.8 kom, 6 Ib) SPRING ‘Automatic Transmission Service Grovr 69Technical Service Information NOTE: Coat a parts with ATF before assembling 4. Install the manual valve, 6 x 16 mm rollers and spring 1. Place the shift spring in the shift valve, then sip it into the valve body and install the valve cove ROLLER SPRING 2.3 SHIFT VALVE VALVE covER pe 2.3 SHIFT SPRING ROLLERS MANUAL VALVE 5 mm BOLTS 8 Nem (0.8 kg-m, 6 i-A) 2. Install the 3-4 shift valve, 3-4 shift valve spring and 5. Set the kick-down spring in the 3:2 kick-down valve shift cap in the main valve body and secure with the land install tin the main valve body. roller. 6. Push the spring in with a screwativer, then install the ROLLER spring seat ‘SPRING SEAT 9-4 SHIFT VALVE VALVE SPRING vawve Serine SCREWORIVER 3. Install the 1-2 shite valve, lock-up shift valve and lock= 7. Install the ortice control valve, cooler ralief valve and Lup control valve in the main valve body in the same relief valve in the main valve body in the same manner procedure as for 3-6 shift valve deseribed in step 6 Automatic Transmission Service Group 70Technical Service Information 1. install he pump gests and shat inthe main valve 2. Install the oll pump shalt and measure the side voy * Slearance ofthe cive and dewen gear a (o.coe0.0104'n) namie sid 008 Driven gear 0.098--0,060 mm fade) (o:00%4~-0.0028 0.) seporator plate co MAIN VALVE BODY onvecean nivel cean AN sake oz Z Z y ZA. Zi LiL, Ale ee Inapact teeth for weer or damage: vatve aooy 2. Measure the thrust clearance of the driven ‘gear-to-valve body. Drive/Driven Gear Thrust (Axial) Clearance: Standard (New): 0.03—0.05 mm {0.001—0.002 in.) Service Limit: 0.07 mm (0.0028 in.) OW PUMP DRIVEN srralGHT EDGE GEAR Automatic Transmission Service Group n, Technical Service Information Note: © Clean all parts thoroughiy in solvent or carburetor cleaner, and dry with compressed air, Blow out all passages © Check all valves for free mavemént. If any fall to slide freely, ‘See Section 3 for spring specifications © Replace as assembly if any parts are worn or damaged sPRiNe sear noun NY SPRING ( MODULATOR past vatve seo ruven a Renin, srhina vawe cap ‘STEEL BALL ano/xick DOWN \ ROLLER: VALVE SERVO CONTROL ; wae arm cust ES tie ZS IR soniva SOS sonmo A vawe SPRING CaP . (h~nouen ZX, i Pn 0 2ND ORIFICE ‘CONTROL VALVE SPRING sieeve VALve’SPRING car Automatic Transmission Service Group 72, Technical Service Information Nore: © Clean all parts thoroughly in solvent or carburetor cleaner. ¢ Replace valve body as assembly if any parts are worn or damaged, © Check all vaives for free movement: if any fal to slide freely, See Section 3 for spring specifications. ‘© Coat all parts with ATF betore reassembly. Hold the retainer in place while removing the lack bolt. Once the bolt is removed, release the retainer slowly. 2. Reassembly is in the reverse order of disassembly. NOTE: Align the bole in the retainer with the hole inthe valve body, then press the retainer into the valve body and tighten the lock bolt. FILTER Lock BoLT SPRING A Replace. 42 Nem (1.2 ko-m, SPRING 8 check BOLT RETAINER 18 Nem (1.8 kgm, 19 T/C CHECK VALVE SEALING WASHER” Replace ‘STATOR REACTION ‘SPRING SPRING REGULATOR VALVE Vatve cover 5 mm BOLTS 8 Nim (0.8 kgm. 6 iA) REGULATOR VALVE BODY Inspect for wear, seratches or scoring, Lock-uP TIMING valve ‘SPRING cap CaLve SPRING ‘Automatic Transmission Service Group 73TSG] Technical S Note: {© Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. (© Check all valves for free movemem. If any fil to slide fre © See Section 3 for spring specifications. 1ST ACCUMULATOR SPRING 4TH ACCUMULATOR ‘SPRING SPRING ‘SERVO BODY o-RINGS: Replace, 4TH ACCUMULATOR PISTON O-RINGS: Replace ast accumuLaTon’ PISTON. o-RINGS Repisce SRD ACCUMULATOR PISTON ‘ACCUMULATOR ervice Information Ate ACCUMULATOR ‘STRAINER cover Replace teen. SERVO VALVE (SHIFT FORK SHAFT) Inspect for scoring ‘or camage (© After disassembling the ATF strainer, check that it niet ‘opening is not clagged and in good condition. Replace | the strainer with a new one if iti clogged. © The strainer can be reused iit not clogged. Clean the inlet opening thoroughly with compressed air etc. before reinstaling it ATR STRAINER, INLET OPENING “Replace if clogged. Clean wah compressed ar ‘not clogged. befor inataling ‘Automatic Transmission Service Group 74ATSG] Technical Service Information Note: © Cleon all parts thoroughly in solvent or carburetor cleaner. and dry with compressed air. Blow out all passages. heck all valves for free movefient. If any fail to slide freely, © See Section 3 for spring specifications ArT SPEED PULSER ROTOR Magner Inapeet for demage ‘O-RINGS, Replace, shart Inspect for wear or damage ‘2ND ACCUMULATOR PISTON WASHER. O-RING Inspect for Repisce wear of damage, 2ND ACCUMULATOR ING PRI -2ND ACCUMULATOR ‘BODY WASHER Inspect for wear or damage. cIRCUP Replace Automatic Transmission Service Group 5ATSG]| Technical Service Information NOTE: This repair is only necessary if one or more of the valves in a valve body do not side smoothly in their bores. You may use this procedure t3 free the valves in the main valve body, regulator valve body, lock-up shift valve body, and servo valve body. DO NOT use this procedure 10 free the valves inthe governor; if any ‘governor valves are stuck, the governor must be re- placed as an assembly. 1. Soak a sheet of #800 abrasive paper in ATF for about 30 minutes. 2. Carefully tap the valve body so the sticking valve drops out of its bore CAUTION: It may be necessary to use a small screwdriver to pry the valve free. Be careful not to seratch the bore with the screwdriver 3. Inspect the valve for any scuff marks. Use the ATF soaked 4600 paper to polsh off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air 4. Rll up half a sheet of ATF-soaked paper and insert it in the vaive bore of the sticking vate. ‘Twist the paper slighty, so that it unrolls and fits the bore tightiy, then polish the bore by twisting the paper a you puth tin and out, CAUTION: The valve body is aluminum and doesn't require much polishing to remove any burrs. ATF soaked 1600 abrasive paper 7. Remove the #800 paper and thoroughly wash the entire vaive body in solvent, then dry with compressed Coat the valve with ATF then drop it into its bore. It should drop to the bottom of the bore under its own ‘weight. If not, repeat step 4, then retest vawe Remove the valve and thoroughly clean it ana the valve body with solvent. Dry all parte with compressed air then reassemble using ATF as @ Wbricant Automatic Transmission Service Group 76Technical Service Information Note: © Lubricate al parts with ATF during reassembly. © Install thrust needle bearings with unolled edge of bearing retainer facing washer Ingpect thrust needle bearings for galling and rough movement Locknut 0-70 ibs) CAUTION: Lat-hand threads. Fa é @® )sr owes SNAP RING Replace, THRUST WASHER MAINSHAFT NEEDLE BEARING Cetin see aruetan Check bearing surtace for oe Sing seta resin = NEEDLE BEARING am Sage czonm games necour eeanna C= THRUST wasnen Baas x24 mm couar 4TH GEAR COLLAR THRUST NEEDLE BEARING ‘THRUST WASHER 4TH CLUTCH O-RINGS. Repace pe RING Automatic Transmission Service Group 7Technical Service Infor NOTE: © Lubricate all parts with ATF during reassembly. © Install thrust neadie bearings with unrolled edge of bearing retainer fecing washer. © Inspect thrust needle and needle bearings for galling and rough movement, a REVERSE GEAR COLLAR a REVERSE GEAR REVERSE GEAR SELECTOR REVERSE SELECTOR Hus NEEDLE BEARING COUNTERSHAFT Check splines for excessive wear or damage, CCheck bearing surface for sconng, scratches or excessive wear ATH GEAR (Seleesve) 2nd GEAR THRUST NEEDLE BEARING SRO GEAR ‘THRUST NEEDLE BEARING NEEDLE BEARING DISTANCE COLLAR 35 x81 x 25 mm (Selective) 3R0 CLUTCH O-RINGS, Replace, Automatic Transmission Service Group 78 mation Locknut Repisce 140--0-~140 Nem (14.0-0-14.0 kom, 1020-102 Ibs} PARKING GEAR, One-way cLuTcH 1ST GEAR NEEDLE BEARING 1ST GEAR COLLARTSG], Technical Service Information Removal 1 Using a hydraulic press, press out the countershatt while supporting the 3rd clutch drum. NOTE: Place an attachment between the hydraulic press and countershaft to prevent damage to the shaft COLLAR = couensnaer COUNTERSHAFT 2ND GEAR COUNTERSHAFT 3RD GeaR 79PEP] Technical Service ‘Assemble the 3rd clutch assembly, distance collar (Al ‘thrust needle bearing (small), needle bearing, counter- shaft 3rd. gear, thrust needle bearing large) and ‘countershaft 2nd gear without instaling the counter- shaft With the 3rd clutch assembly held stationary, hold the Ccountershaft 2nd gear against the 3rd clutch assembly with a force of 5=10 kg (11-12 Ib). Spin the countershatt 3rd gear by hand to check for Clearances. The clearances are considered normal iit turns freely without binding. If the Sed gear binds, or turns but sluggishly. the Clearances are too small and should be adjusted Replace the distance collar (A) with (B), and repeat the steps (1) thru (3) above. If the gear stil binds, repeat the steps (1) thru (3) again with the distance collar (C) installed ‘The clearances are excessive if there is play in the shaft direction when you perform the step (3) Cheek the countershaft 3rd gear, countershaft 2nd ear, distance collar (Al, thrust needle bearings (large Sand smal), and needle bearing for wear, and replace any worn parts NOTE: After replacing parts, repeat the steps (1) thru (3) with the distance collar (A) installed Parts No. [__ 80501—PRO—000 [-_90811=PRO—000 '90512—PRO—000 [ air Width ns) 25 985 (1.0290) 26 015 (10902) 26 045 10958) | Information _— COUNTERSHAFT 2ND GEAR THaUST NEEDLE (tar COUNTERSHAFT RO GEAR qHRUsT NEEDLE BEARING (Smal) NEEDLE BEARING SHAFT DISTANCE COLLAR (a8, ch ‘|R0 CLUTCH ASSEMBLY 8-10 kg (1112 1b) J COUNTERSHAFT 2NO GEAR COUNTERSHAFT 3RD GEAR {Cheek tor smooth ‘Automatic Transmission Service Group 8011, Remove the countershaft bearings from the transmis ‘on housing 2. Assemble the countershatt including bearing and all parts 3. Hold the parking gear on the countershatt with your hand and torque the countershaft locknut to 30 Nem (3.0 kg-m, 22 ib-t). sembly. 4. Hold the selector hub firmiy against the countershaft 4th gear, the insert 2 feeler gauge between the Ccountershatt reverse gear and selector hub to keep the ‘nub in contact with the countershaft 4th gear 5. Measure the clearance of the countershatt 2nd gear with a Feeler gauge Pars No Thickness fms a 30803-PRO-01O | 23.10 0.8098) 3050¢-eno-010_| 28.18 (0.9114)__| | s0s0s—pno-o10 | _23.2010.9138) 30508=FRO 23.26/(0.8154) | 7 23.30 (0.9173) | [sosoe=FA0mo70) 23.9510 8199, 80509=PRO=010 | 28.40 0.8213) Fec.er GAUGE counTensHar? 2ND GEAR Technical Service Information Take measurements at least three locations equally Take the average as the actual gear clearance. Standard: 0-0.08 mm (0—0.0031 in) If out of specs, measure the length of the distance collar used, then select the one which will bring the clearance within the specified limits After replacing the distance collar, repeat the steps (4) thru (6) to make sure that the end play is within the specified limits. It the end play sil exceeds the service limit even when the shortest distance collar is installed, check the countershaft 2nd gear ana distance collar 29 mm for ‘wear, and replace any worn part. After replacing parts, perform the steps (4) theu (8) 10 make sure that the clearance ig held within the speci= fied valves. NOTE: Measure the length of the old distance collar to determine the required length of new distance collar. COUNTERSHAFT tn GEAR DISTANCE COLLAR 23 mm (Selective Fit) "= Press fry against courtershatt 2na sear FeeLen GAUGE ‘Use gauge of maximum COUNTERSHAFT REVERSE GEAR BALL BEARING SELECTOR HUB *Preasfrmly sgainst 28 mm distance color byinserting thikness gauge between MUD tnd counter reverse gear ‘Automatic Transmission Service Group 81NOTE: Lubrieat parts with ATF during reassembly. 1, Install two new O-rings on the courtershatt NOTE: Before instaling the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. 2. Assemble the 3rd clutch, distance collar (selected), small thrust needle bearing, 3rd gear, large thrust needle bearing, and 2nd gear 3. Inetall the above assembly on the countershaft. ‘ard CLUTCH DISTANCE COLLAR, Piney neo — Beanie een shah 3rd GEAR THRUST NEEDLE BEARING (large) ‘2nd GEAR (Press feed) Service Information 4, With the shaft splines aligned with those of the 2nd ‘gear, press the countershaft into the 2nd gear in 3 hydraulic press NOTE: © Also align the shaft splines with those of the 3rd Clutch when pressing the countershaft into the 2nd gear © Use an old collar between the shaft end and hydra lie press to prevent damage to the countershaft. © Stop pressing the countershaft when the 3rd clutch contacts the final rive get couLAR FINAL DRIVE GEAR 2nd GEAR COUNTERSHAFT ‘Automatic Transmission Service GroupTechnical Service Information Nore: © Lubricate all parts with ATF during reassembly © Install thrust neecle bearings withwunrolled edge of bearing retainer facing washer Ingpect thrust needle and needie bearings for galing and rough movement DISTANCE COLLAR 25 mm 1 Sateen THRUST WASHER onines, Replace SECONDARY SHAFT Cheek spines for excessive wear or damage (Check bearing surface for scoring, seratches oF exc SEAL RINGS NEEDLE BEARING THRUST NEEDLE BEARING .2ND DRIVE GEAR THRUST NEEDLE BEARING SECONDARYSHAFT 2ND GEAR COTTER 26 mm (Selective *Noed the one se ony. y COTTER RETAINER y= sar nine Automatic Transmission Service Group 83Technical Service Information Installation Removal 1. Remove the snap ring, cotter retainer and cotter from the secondary shaft. 2. Rest the secondery 2nd gear on a pair of guides as shown: on the CAUTION: Do not rest the 2nd deive gf guides. 3. Press the torque converter end of the secondary shaft down with a hydraulic press until the secondary 2nd ‘gear is clear of the shaft to use a pad between the sec- 1088 to provent damage CAUTION: Be aur ondary shaft and hydraulic to the shaft 4, Remove the remaining parts. ATTACHMENT SECONDARY ae ‘SHAFT ‘SECONDARY DRIVE GEAR SECONDARY nd Gear’ HOLDERS 1. Install the needle bearing, thrust needle bearing, 2nd rive gear and thrust needle bearing on the secondary shah. 2. Install the secondary 2nd gear on the secondary shaft and align their splines. 3. Place the secondary shaft upright on a holder with the ‘transmission end down, then press the secondary gear ‘onto the shaft unti bottoms using the Driver and ‘Attachment as shown CAUTION: Do not use excessive load to install the secondary 2nd gear on the shaft. | 077460030100 ATTACHMENT, 36 mm 077460030460 SECONDARY a and GEAR ‘TRANSMISSION HOUSING END 84, Technical Service Information Selection 1 Axial Clearance. Measure 2nd drive gear axialearance. NOTE: Measure the clearance at three places 120° apart, and take the average as the actual clearance, Standard: 0—0.08 mm (0—0.0031 in.) Service Limit: 0.10 mm (0.0039 in.) Replace the two needle bearings ff any readings are out of tolerance, and recheck the clearance, NOTE: It is recommended to replace the thrust needle bearings if any readings exceed the standard limits. Replace the 2nd drive gear and secondary shaft as 2 set if the service limite are still exceeded with new thrust needle bearings: ‘Also check thet the axial clearance is held within the standard limits [0—0.08 mm (0—0.0031 in.) if any ‘other parts are replaced Note: (© Adjust the 2nd drive gear axial clearance before selecting the cotters © Check that the 2nd drive gear is pressed to the shoulder fon the secondary shat fully, 1. Before selecting, measure the thickness of each cot- ter, and keep them in order. CAUTION: Never use cotters of drifferent thicknes- ‘0s on @ shatt. Thickness (mm, inl PartNo, '90428—PRO—000 2.00 (0.0787) '90829—PRO—000 2.03 (0.0788) '90430—PRO—000 2.06 (0.0871) [_s0aso~PRomo0o fae) '90431—PRO—O10 72.08 (0.0823) 2. Select the two cotters which are thickest for the ‘rooves in the shaft starting with the thickest cotters measured, Seat the selected cotters in the groove propery. ‘SECONDARY SHAFT 2ND GEAR, ae pf Select the thickest (conr'a 853, Measure the clearance between the secondary 2nd ‘gear and cotter using @ 0.04 mm (070016 in.) feeier gauge. Standard: __0—0.08 mm (0-0.0016 Service Limit: 0.06 mm (0.0024 in.) THICKNESS GAUGE 0.04 mm (0.0096 in.) SECONDARY SHAFT ‘SECONDARY 2nd GEAR, 4, The clearance should be rechecked with @ 0.06 mm (0.0026 in.) feeler gauge ifthe 0.04 mm (0.0016 in.) gauge goes in 5. The clearance is out of tolerance if the 0.06 mm (0, (0026 in) gauge goes in 6. Remove the cotters and select cotters which will bring the clearance within tolerance. NOTE: Its recommended to adjust the clearance if it ‘exceeds 0.08 mm [0.0018 in.) ; Technical Service Information ‘Assemble the secondary shaft assembly (page 14- 105) Select and install the shortest distance collar 25 mm (standara) Part No. Width (mm, in '90520—PRO—000 76.85 (0.6634) '90521—PRO—000 | 16.90 10.6654) {90522—PRO—000 16.95 (0.6673) {90513—PRO—000 -00 (0.6693) 90514—PRO—000 17.05 (0.6713) ‘B0515—PRO—000 | _17.10 10.6732) '90516—PRO—000 17.48 (0.6752) '90517—PRO—000 17.20 0.6772) | ~90518—PRO—000 | 17.25 (0.6791) _ '30519—PRO—000 17.30 (0.6811) Install the secondary shaft assembly in the torque converter housing NOTE: It is not necessary to install the countershaft, mainghaft, etc. at this time Place 2 new packing on the torque converter housing, and install the transmission housing. NOTE: Check that ll shafts and gearings in the torque converter and transmission rotate freely without bind- ing. Automatic Transmission Service Group 86Technical Install 4—5 bolts around the secondary shaft and tighten them to the specified torque. ‘Specified torque: 55 Nem (5.6 kg-m, 40 lb) Install the set ring 25 men Place the transmission upside down, Measure the clearance between the set ring 25 mm and secondary shatt ball bearing. ‘Standard: 0-0.06 mm (0—0.0024 in.) Service Limit: 0.08 mm (0.0031 in.) STANDARD COLLAR BALL BEARING SET RING 25 mm Caloulate the required thickness of the collar using the following formu: (Clearance measured) (Standard (0—0.08 mm (0 =0,0024 in.}}+ (width of standard collar) = Thickness of collar required Service Information (Example) {0.12 mm) (0 mm) +(16.99 mm)=(17.11 mm) (0.12 mm)=(0.08 mm)-+(18.99 mm)=(17.05 mm) (17.05—17.11 mm)=(17.07—17.10 mm) Coliar 10. Replace the existing collar with the collar selected, and repeat the step 3 thru 8. CCheck that the clearance is below 0.06 mm (0.0024 in SET RING 25 mm Automatic Transmission Service Group 87Technical —1.Remove the snap ring. > =2)Remove the end plate, clutch discs and plates. END PLATE ‘SNAP RING ‘SCREWDRIVER cLuTCH DRUM cuuTcH vise 2. Tetand 2nd elutch only Remove the spring washer. 1ST and 2NO ‘SPRING WASHER y =a cuuTcH DRUM Service Information NOTE: Steps 3 theu 7 are forall clutches, 3. Install the clutch spring compressor as shown and compress the cluteh return spring. CAUTION: If either end of the compressor attach- ‘ment is set over an area of the retainer which is un: ‘supported by the spring, the retainer may be dam- aged. CLUTCH SPRING COMPRESSOR ATTACHMENT et, 3rd and ath (O7HAE~PLS0100 2 '07960-6120101 ‘SET HERE RETAINER 0 Nor SET HERE CLUTCH SPRING COMPRESSOR BOLT (Retainer unsupported O7GAE~PG40200° by spring! ‘st, Sed and 4th: CLUTCH SPRING 1S... COMPRESSOR ATTACHMENT 079606120101 CLUTCH spRING COMPRESSOR BOLT ASSEMBLY o7GaE-PGs0200 Automatic Transmission Service Group 88.(97960-6120100 TAGHMENT GE ATTACHMENT See = ‘O7HAE—PL50100 BOLT ASSEMBLY ‘7Gaé—PGa0200 Compress the clutch return spring CLUTCH SPRING BOLT ASSEMaLY (O7GAE-PGs0200 (CLUTCH RETURN SPRING Technical Service Information 6. Remove the snap ring. Then remove the special tool, spring retainer and spring, 7. Wrap a shop rag around the clutch drum and app pressure tothe oll passage to remove the piston. Place 2 finger tip on the other end while applying air pres- lL PASSAGE COMPRESSED AIR Hose NOZZLE ‘Automatic Transmission Service Group 89. Technical Service Information 3 ‘et Church: END PLATE SPRING. RETAINER SNAP RING ae SEG vd, a ae / AG i pisces c RING SPRING RETURN cpa WASHER E PISTON O-RING 4th Clutch: Replace O-RING Replace PISTON SPRING RETAINER, END PLATE RETURN SPRING snap RING cLutcH oiscs SNAP RING Automatic Transmission Service Group 90Technical Service Information 3rd Clutch RETURN SPRING snap RING cuurcH biscs PISTON /p ome é, oom RING PISTON cLutcH RUM ‘Automatic Transmission Service Group a1NOTE: © Clean all parts thoroughly in solvent, and dry with compressed air. Blow out all passages. © Lubricate all parts with ATF before reassembly. 4, ed and 4th clutch. =1, Install a new O-ring on the clutch piston. Be sure that the disc spring is securely staked. CLUTCH PISTON one Bl ‘SPRING WASHER O-RING o-nne Piston SPRING WASHER onING Technical Service Information 2. Install the piston in the clutch drum, Apply pressure and rotate to ensure proper seating NOTE: Lubricate the piston O-ring with ATF before installing CAUTION: Do not pinch O-ring by installing the piston with force. PISTON —3. Install the return spring and retainer. =4. Position the snap ring an the spring retainer. cLuTcH ORUM SNAP RING RETURN SPRING Automatic Transmission Service Group 92. Technical Service Information 2. Yt and 2nd clutch. =1. Install new O-ring on the clutch piston. CLUTCH PISTON. one Bal ‘SPRING WASHER O-RING =2, Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating NOTE: Lubricate the piston O-ring with ATF before instaling. CAUTION: Do not pinch O-ring by installing the piston with force PISTON curcxonum =| =3. Install the spring washer. NOTE: Note the spring washer direction. ‘SPRING WASHER 1ST and 2D = 4, Install the return spring and retainer =8. Position the snap ring on the spring retainer RETURN SPRING ! (con's) Automatic Transmission Service Group 93Technical NOTE: Step 3 thru 12 are for all clutches. 3. Install the special tools on the clute! drum and com- press the clutch return spring, CAUTION: If either end of the compressor attach- ment is set over an area of the retainer which is un- supported by the spring, the retainer may be damaged. CLUTCH SPRING COMPRESSOR ATTACHMENT 1ST, 3AD and 4TH: O7HAE—PL50100 2ND: (07960~6120101 SPRING 00 NOT SET HERE (Retainer unsupported by spring! ‘st, Sed and 4th CLUTCH SPRING COMPRESSOR ATTACHMENT ‘7HAE—PLSO100 VY CLUTCH SPRING COMPRESSOR ATTACHMENT (079606120101 (07960-6120100 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY o7Gae~PGa0200 Service Information 2nd: CLUTCH SPRING COMPRESSOR ATTACHMENT (07860-6120101 o (979606120100, CLUTCH SPRING ‘COMPRESSOR ATTACHMENT (O7HAE~PL50100 + ctu spring COMPRESSOR BOLT ASSEMBLY o7GAE~PG40200 4. Compress the clutch retuen spring CLUTCH SPRING BOLT ASSEMBLY (07GAE—PG80200 CLUTCH RETURN SPRING ‘Automatic Transmission Service Group 94Technical Service Information 5. Install the snap ring. 9. Install the snap ring 6. Remove the special tools.» SNAP RING SCREWDRIVER SNAP RING 10. Check the clutch engagement by blowing air into the oil passage in the clutch drum hub. Remove the air pressure and check that the clutch releases, 7. Soak the clutch dises thoroughly in automatic trans CLUTCH ASSEMBLY Nozzue mission fluid for a minimum of 30 minutes. 8, Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the side NOTE: Before instaling the plates and dises, make sure the inside ofthe clutch drum is free of dit or other foreign matter. Discs ANo PLATES. END PLATE Automatic Transmission Service Group 95. Technical Measure the clearance between the clutch end plate tnd top dise with a dial indicator ‘Zero the dial indica tor with the clutch end plate lowered and lift up to the snap ring. Distance where the clutch end plate moves is the clearance between the clutch end plate and top disc NOTE: Measure at thee locations. n Service 12 Information It the clearance isnot within the service limits, select 3 new cluten end plate from the following table. NOTE: If the thickest clutch end plate is installed but the clearance is stil over the standard, replace the cluten dises end clutch plates. End Plate-to-Top Disc Clearance: PIN [PLATE NO | THICKNESS mm fn} Service Limit | |22581-PF4—000] 3 2.1 (0.082) | | |22552-pF4—o0o| 2 2:2 (0.086) asx | 0.65-0.85mm | (0.026~-0.039 in.) 22553-PF4—000/ 3 2'3 (0.080) 2nd | 0.80-0.70 mm | (0.020-0.028 in.) | g| 22854—PF4—000| 4 2.4 (0.084) 3r¢ | 0:40-0'80mm | (0.016-0.024 in.) | $| 22555—Pr—000| 5 2:5 (0.088) ain | 0.40-0.80mm | (0.018-0.024 in.) | 3 | 22556—Pr2—000] 6 2.6 (0.102) 3] 22587—pra—o00| 7 2.7 0.108) —___—_! 3] 22558—Pr4—000| 8 2.8 0.110) ©) 22558-Pr4—o00| 9 2.9 (0.114) END PLATE | 22860—Pra—000/ 10 3.0 (0.118) oP pisc | 22561—PF4-000) 11 3.1 10.122) 22562—PF4—000| 12 3.210.126) | |22563-Pr4—000| 13 3.3 (0.130) |__| z2se4Pr4—000) 14 314 (0.134) 22631—PRO-013)— 1 3.1 (0.122) 22632—PRO-013| 2 3.2 10.126) |22632-PR0—013) 3 3.3 (0.130) | 22634—PRO—013 4 3.4 (0.134) 5) 22635—PRO-013) No mark | 3.5 (0.138) 2) 22638—PRo-013| 6 316 (0.182) 22637—PRO—013/ 7 3.7 (0.148) 22638-PRO-013, 8 318 (0.150) 22639—PRO—013, 9 3.9 (0.154) NUMBER —= END PLATE Automatic Transmission Service Group 96Technical Service Information Replacement 1. Remove the differential assembly. 2. Remove the countershaft bearing 3. Replace the oil guide piste. Commercaly Avaibie 3/8 x 16 akde Hammer. ‘COUNTERSHAFT NEEDLE BEARING Fepiace with new bearing i removed ~\ apsustasie BEARING REMOVER (25-40 rom) (07736~A010000 4. Drive the new bearing into the housing using the special tools oniver Bye = fx = HOUSING OWL GUIDE PLATE Replace ATTACHMENT 62 « 68 mm 07748-0010500 Replacement 1. Drive out the mainshatt bearing and oil seal using the special tools onIver J_-— 077480010000 ATTACHMENT € ToRaUe CONVERTER as HOUSING Drive in the new mainshaft bearing unti it bottoms in ‘the housing, using the special tools. paiver (07748-00100, ATTACHMENT 62 x 68 mm (07746~0070500 (cont) 7x Technical Service Information [Replacement (cont'd) 3. Install the oil seal flush with the housing using the ‘special tools. paiver 07743~0010000 BEARING DRIVER ATTACHMENT & 079476340201 1 Replacement Remove the secondary shaft bearing. By heating the torque converter housing to 100°C (212°F) with a heat gun turn the hesting outer race top on the mark side of the bearing ar CAUTION: Do not heat the housing in excess of 100°C (212°F). Drive the new bearing flush with the housing using the special tools. oRIveR (07748-00100 ATTACHMENT 62x68 mm (0746~0010500 98Technical Service Information 1. To remove the mainshaft, countershaft and secondery. | 2. Expand each snap ring with snap ring pilers, insert the shaft bearings from the transrfssion housing, expand new bearing part-way into it, then release the pliers feach snap ring with snap ring plies, then push the Push the bearing down into the transmission unt the bearing out. fing snaps in place around it NOTE: Do not remove the snap rings unless it's neces- sary f0 clean the grooves in the housing ‘COUNTERSHAFT a tsa Toa MAINSHAFT BEARING ven ‘Automatic Transmission Service Group 991, Assemble the reverse idler bearing holder. NOTE: Align the hole in the shaft with the spring REVERSE IDLER BEARING HOLDER GEAR SHAFT RETAINING STEEL BALL oe 27 Nem (2.7 kg-m, 20 tof) 2. Install the reverse idler gear. NOTE: Install the reverse idler gear so that the larger ‘chamfer on the shaft bore faces the torque converter housing. REVERSE IDLER GEAR Insect teeth for weae CChamfored and 3. Install the needle bearing into the idler gear 4, Install the reverse idler bearing holder into the trans- mmission housing Technical Service Information 5. Tighten the reverse idler bearing holder bolts 6. Install the spring and then tighten the retaining bolt and washer, 6x10 mm AZ Nem (1-2 kgm, 9 bf) IDLER BEARING REVERSE IDLER GEAR TRANSMISSION HOUSING Automatic Transmission Service Group 100Technical Service Information 1. Reassemble the transmission in the folowing numbered sequence: ¥, @, ©, @. BD, ®. @. @ Boks : 12.Nem (1.2 kom, 8 Ib-f) =DBolts Note: 18 Nem (1.8 kg-m. 13 Ib-A) Make sure the pump drive gear rotates smoothly in the o ‘normal operating direction and the pump shaft moves, earOn re cores roca Gs reece to, Smoothly in the axial and normal operating directions. rea Seer EST eSTae lie stalin te Sore CAUTION: If the pump gear and pump shaft do not * * | a G01 Boks) He (2 Bots) move freely, loosen the valve body bolts. the shaft, and thon retighten to the specified 10 align the in seized pump gear or pump shaft. 6 Bors) . _ replace a (. d. 9] cwogecn fre CT TLD onmencean Bw Soo Automatic Transmission Service Group 1016 Technical Ser number © through @ on the mainshatt Install parts number @ through @ on the countershatt ‘Set the countershaft, mainshaft and secondary shaft in place as ‘an assembly. NOTE: Do not tap on the shafts with a hammer to drive in Install parts number @ through @ on the countershaft NOTE: Install the reverse gear selector with its flat facing up. Install the reverse shift fork over the servo valve stem. Align the hole in the stem with hole in fork as shown, and install the bott ‘and new lock plate. Bend the lock tab against the bolt head, Instat parts number ® through @ on the countershatt 1 Automatic Transmission 102 vice Information ‘ORK BOLT HOLE 14 Nom (1.4 gem, 11 Io) SECONDARY SHAFT Service GroupTechnical Service Information 9. Assemble the transmission in the following numbered sequence, 27 Nem (2.7 kg-m, 20 lb-ft) 12 Nem (1.2 kg-m, 9 tot) J ital he bates inthe locations shown 55 Nem (5.5 kgm, 40 It) Automatic Transmission Service Group 103, Technical Service Information 10. Assemble the transmission in the following numbered sequence, {end of the parking paw releade spring fits into the hole in the parking pawi, the other end into the hole in the ransmission housing as shown. (© The release spring should put clockwise tension on the pawl, forcing it away from the parking gear 514 Nem (1.4 kgem, 11 b-A) 2140 14,0 kgm, 1020-102 lb-ft) 9.5 kg-m, 70-070 ib-f) A) 42 Nem (1.2 kg-m, 9 tof) 55 Nem (5.5 kg-m, 40 Io-ft) Q @ ° @ @ @CAUTION: Lock ‘nut has left. hand thread, Replace be \ ¥ FVLP Automatic Transmission Service Group 10411, Shift to PARK, 12, Install and torque the new countershaft locknut. Tighten to specified torque, then loosen and retighten to same torgue Torque: 140-0140 Nem (14.0--0--14,0 kg-m, 1020-+102 +t) 13. Stake the locknut flange at two places into the gear grooves using @ 3.8 mm punch. 3.5 mm (0.14 in.) ‘TORQUE CONVERTER HOUSING Technical Service Information 15. Install and torque the new mainshaft locknut. Tighten to specified torque, then loosen and retighten to same torque. Torque: 95--0--95 Nem {9.50-9.5 kgem, 70--0— 70 tof} CAUTION: Locknut has left-hand thread. 16, Stake the locknut flange into the groove in the Tst Point 0 be stake. Automatic Transmission Service Group 105Technical Service Information 1. Set the parking shift arm in the PARK position Measure the distance between tae outer face of the parking pawl shaft and outer face of the parking shift arm roller pin. Distance: 55.8—56.8 mm (2.197~2.236 in.) 14 Nem (1.4 kgm yA Lock WASHER DISTANCE: PARKING GEAR PARKING PAWL SHAFT 3. If the measurement is out of specification, select the appropriate parking brake stopper using the table below. and install it fon the parking shift arm [No.[ PARTS NUMBER | [24s3-pa9-003] 24838-729-003| 24599-743-003 Automatic Transmission Service Group 106Technical Se With feed pipes assembled, align lugs on the collars with slot in end cover. Install the snap ring. Install the feed pipes in the end cover, aligning the lugs of the 1st clutch feed pipe with the grooves of the end Install the snap ring ATH CLUTCH FEED PIPE 187 CLUTCH FEED PIPE tues R, SIDE COVER, .. Intail the A. Side cover, Torque: 12 Nem (1.2 kg-m, 8 Ib-f} Information rvice Install the control lever and new lock plate on the other fend of shaft. Tighten the bolt to the torque shown, then bend the tab over against the Bolt head. 6 Lock WASHER 12.Nem (1.2 Kem, 8 voc Automatic Transmission Service Group 107Technical Service Information 1, Start the engine. Shift to reverse to see ifthe reverse 4. Check that the hole in the adjuster is perfectly aligned ‘Gear engages. If not, refer to Troubleshooting with the hole in the shift cable 2. With the engine off, remove the console. 3. Shift 10 I or [H position, then remove the lock pin from the cable adjuster ADJUSTER ‘SHIFT CABLE cob cabie Bact Too Short Too tong Aigrment NOTE: There are two holes in the end of the shift cable. They are positioned 80° apart to allow cable pose adjustments in 1/4 turn increments 5. If not perfect aligned, loosen therloek nut on shift cable and adjust as required 6. Tighten the lock nut 7. Install the lock pin on the adjuster. NOTE: If you feel the lock pin binding as you reinstall SHIFT CABLE it, the cable is stil out of adjustment and must be readjusted. Lock NuT T Nom (0.7 kgm. 5 I-A) ADJUSTER 8. Start the engine and check the shift lever in all gears If any gear does not work properly, Automatic Transmission Service Group 108(© Make sure jacks and safety stands are placed prop- erty and hoist brackets are attached to correct positions on the engine. © Apply parking brake and block rear wheels, so car ‘wal not rll off stands and fal on you while working Under it. Remove the front console. Technical Service Information Remove the front and rear engine stiffeners. Remove the torque converter cover and cable holder Remove the shift cable by removing the cotter pin ‘control pin and control lever roller from the contro! lever CAUTION: Take care not to bend the cable when removing Ml lathe Kaolin taeh 8, Install the shift cable inthe reverse order of removal Remove the bolts, then remove the cable bracket and NOTE: On reassembly, check the cable adjustment cable guide, Remove the center beam and header pipe ‘CONTROL PIN conTROL COTTER PIN cane Replace 8 1.25 mm 27 Nem (2.7 kgm, 20 bo) /7 Lock PIN ADJUSTER | FRONT ENGINE | STIFFENER 58 Nem 5.8 kgm, 42 by ToRave CONVERTER COVER I~ REAR ENGINE STIFFENER ST 28 Nem (2.4 kgm, 17 Ib 198 Nim (6.8 kgm, 42 Ib-h) 24 Wem (2.4 kgm, 17 bf) CABLE BRACKET CABLE GUIDE Automatic Transmission Service Group 109(Eaatse), technical Service Information oo Nore the vacuum modulator is faulty or the throttle B pres sures out of specs, perform the folowing inspections. 1. Stop the engine, intake manifold tube nd apply a vacuum of ing) 2, Connect a vacuum pump to (of the vacuum modulator v 500—600 mmHg. (18.7— VACUUM TUBE ‘Check for cracks or vacuuM MoDULATOR other do. VALVE ASSEMBLY mage. ATMOSPHERIC PRESSURE TUBE "Check for clogaing. Nore: (© Ge sure that the atmospheric pressure tube is not logge © Before checking, be sure that the vacuum tube is not damaged, and in good condition 3, Ifthe vacuum is not maintained, replace the modulator valve as an assembly. the vacuum is maintained, remove the vacuum ‘modulator valve assembly by removing the three 6 x 41.0 mm bolts. NOTE: Do not loosen or remove the three bolts fasten- ing the vacuum body cover. asker Replace o-ring When s- Replace when assembled sassembles VACUUM MODULATOR ASSEMBLY 6x 1.0mm BOLTS. AZ Nem (1.2 kom. or (cont'd) Automatic Transmission Service Group 110Technical Service r— Inspection/Replacement (cont'd) 5. Apply a vacuum of 500-600 mmg (19.7-23.6 inkl) to the intake manifold vacuum tube again to cheek that the modulator valve is moved. ‘Also check that the modulator valve moves in the ‘opposite direction by releasing the vacuum. Repeat the above steps 2—3 times. NOTE: You can see the movements of the valve ‘through the oll passage in the attaching surface of the modulator valve assembly. 6. If the valve binds, or is moved but sluggishly, replace the vacuum modulator as an assembly. VACUUM MODULATOR ASSEMBLY artachine Ol PASSAGE SURFACE vacuum MODULATOR VALVE VACUUM PUMP/GAUGE _*The valve is moved in 0-30 intig the arrow rection (A973X—041—2000X, wahen vacuum is applied TWshould be maved in when vacuum f released. 1 Information