AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH 40-7

ASSY (U151E/U151F)
4005Z-06

ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion.
(c) Check that the back-up light is on and the reverse warning buzzer sounds only when the shift lever
is set in R position.
If a failure is found, check the park/neutral position switch for continuity.

2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY

Neutral (a) Loosen the 2 bolts of park/neutral position switch and set
Basic Line
the shift lever to the N position.
(b) Align the groove and neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
(d) After adjustment, perform the inspection described in
Groove step 1.
C99453

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY
400H6-02

ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting from P to R position only with ignition switch ON and brake pedal, make sure that the
shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.

2. ADJUST SHIFT LEVER POSITION

(a) Loosen the nut on the control shaft lever.

D25118

(b) Return the control shaft lever 2 notches to N position.

(c) Set the shift lever to N position.
(d) Press the shift cable end toward the inner side of the
cable by less than 10 N force and then release it before
tighten the nut firmly by regular torque.
Torque: 13 N·m (132.6 kgf·cm, 9.5 ft·lbf)
(e) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
D25119 moves rearward when shifting it to R position.

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

SHIFT LEVER ASSY

4011B-02

COMPONENTS
Glove Component Door Assy
Instrument Panel Finish
Panel Sub-assy Lower LH Glove Component Door
Stopper Sub-assy

Floor Carpet Cover Center RH

Floor Carpet Cover Center LH Cowl Side Trim Board RH

Cowl Side Trim Board LH

Instrument Cluster Finish Panel Front Door Scuff Plate RH

Sub-assy Lower Center
Instrument Cluster Finish
Panel Center No.2

Front Door Scuff Plate LH Instrument Cluster Finish

Instrument Cluster Panel Center
Finish Panel
Center No.1 Shift Lever Cap
Shift Lever Knob Sub-assy
21 (214, 15)

Shift Lever Assy

Position Indicator Housing Assy

Transmission Control Cable Assy

N⋅m (kgf⋅cm, ft⋅lbf) :Specified torque

D30702

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

Shift Lever Slide Cover Guide

Position Indicator Slide Cover

Position Indicator Slide Cover No.2

Shift Lock Control Unit Assy

Position Indicator Lamp Bulb

Indicator Lamp Wire Sub-assy

C86301

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40-8
AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

4011G-01

COMPONENTS
4WD
Front Drive Shaft RH Hole Snap Ring

8.4 (86, 74 in.⋅lbf)

Transmission Control
12 (122, 9)
Cable Bracket No.2
Transfer Stiffener Plate RH

Bearing Bracket Hole Snap Ring
Front Drive Shaft Assy RH
13 (133, 10)
34 (350, 25)
Wire Harness Clamp
4WD

32 (330, 24) 34 (350, 25)

46 (470, 34) 69 (700, 51) Transfer Assy

4WD

Automatic Transaxle Assy

64 (650, 47)

48 (489, 35)

X6

37 (377, 27)
Torque Converter Clutch assy

7.8 (80, 69 in.⋅lbf)

78 (800, 58)

Flywheel Housing Under Cover
Front Drive Shaft

LH Hole Snap Ring

Front Drive
Transmission Oil Filler Tube Sub- assy Shaft Assy LH

Oil Cooler Inlet Tube No. 1 ATF Level Gauge

12 (122, 9)

Transmission
Oil Cooler Starter Assy
Control Cable
Outlet Tube
O-ring
Bracket No. 1 9.8 (100, 87 in.⋅lbf)
No. 1 5.5 (56, 49 in.⋅lbf)

5.5 (56, 49 in.⋅lbf) 27 (275, 20)

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Engine Mounting

Non-reusable part 64 (653, 47) Bracket FR 37 (377, 27) G25659

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40-18 AUTOMATIC TRANSMISSION / TRANS - TORQUE CONVERTER CLUTCH AND DRIVE
PLATE (ATM)

TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM)

40063-18

INSPECTION

1. INSPECT TORQUE CONVERTER CLUTCH ASSY

SST
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(2) Install SST so that it fits in the notch of the converter
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)

AT0953

(3) Check that the one-way clutch locks when it is

turned counterclockwise, and rotates smoothly
Hold
clockwise.
Clean the torque converter clutch and retest the one-way
Lock clutch as necessary.
Replace the torque converter clutch if the one-way clutch still
fails the test.
Free
Turn
AT3306

Sample showing minimum amount of (b) Determine the condition of the torque converter clutch
powders in ATF assy.
(1) If the inspection result of the torque converter clutch
assy meets the following conditions replace the
torque converter clutch.
Malfunction item:

Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.

One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch.
(c) Replace the ATF in the torque converter clutch.
Actual Size (1) If the ATF is discolored and/or has a foul odor, stir
D25367 the ATF in the torque converter clutch completely
and drain it with the face for installation facing up.

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 AUTOMATIC TRANSMISSION / TRANS - TORQUE CONVERTER CLUTCH AND DRIVE 40-19
PLATE (ATM)

(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the ATF
is exchanged, clean the oil cooler and oil pipe line.
HINT:

Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from
the inlet hose.

If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
C11090 (2) If the ATF is cloudy, inspect the oil cooler (radiator).

(e) Prevent deformation of the torque converter clutch and

OK NG damage to the oil pump gear.
(1) When any marks due to interference are found at
the end of the bolt for the torque converter clutch
The Bottom is and at the bottom of the bolt hole, replace the bolt
Damaged and the torque converter clutch.
(2) All of the bolts must be the same length.
(3) Do not lose the spring washer.
D25368

2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSY

(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is dam-
aged, replace the drive plate.

C81014

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AUTOMATIC TRANSMISSION / TRANS - KEY INTER LOCK SOLENOID

KEY INTER LOCK SOLENOID

4005S-04

INSPECTION

1. INSPECT SOLENOID, KEY INTER LOCK

(a) Disconnect the solenoid connector.
(b) Connect KLS+ (4) terminal to the batteries’ positive (+)
terminal, and KLS- (3) terminal to the battery negative (-)
terminal, and apply about 12V between KLS+ - KLS- ter-
4 3 minals.
(c) Check that operation noise can be heard from the sole-
KLS+ KLS
noid.
D25589 If the solenoid does not operate, replace the solenoid.

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LOCK SOLENOID

SHIFT LOCK SOLENOID

4011C-01

INSPECTION

1. INSPECT SHIFT LOCK SOLENOID

SLS- SLL+ (a) Disconnect the solenoid connector.
(b) Connect SLL+ (2) terminal to the batteries’ positive (+)
terminal, and SLS- (1) terminal to the battery negative (-)
1 2 3 4 terminal, and apply about 12 V between SLL+ - SLS- ter-
mianls.
(c) Check that operation noise can be heard from the sole-
noid.
C97709 D30503 If the solenoid does not operate, replace the solenoid.

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40-2
AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE FLUID (ATM)

AUTOMATIC TRANSAXLE FLUID (ATM)

4005R-05

ON-VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 - 80 °C (158 - 176 °F)

OK if hot (a) Park the vehicle on a level surface and set the parking
brake.
Add if hot
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all positions from P to L position,
and return to P position.
(c) Take out the oil level gage and wipe it clean.
(d) Put it back fully into the pipe.
(e) Take it out and check that the fluid level is in the HOT posi-
D25120 tion.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.

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40-34
AUTOMATIC TRANSMISSION / TRANS - SHIFT LOCK SYSTEM

SHIFT LOCK SYSTEM

40067-05

ON-VEHICLE INSPECTION
1. CHECK SHIFT LOCK OPERATION
(a) Shift the shift lever to P position.
(b) Turn the ignition switch to LOCK.
(c) Check that the shift lever cannot be shifted to any other positions other than P.
(d) Turn the ignition switch ON, depress the brake pedal and check that the shift lever can be shifted to
any other positions.
2. CHECK SHIFT LOCK RELEASE BUTTON OPERATION
(a) Using a small screwdriver, remove the shift lock release cover.
(b) When operating the shift lever with the shift lock release button pressed, check that the lever can be
shifted to any position other than P.
3. CHECK KEY INTERLOCK OPERATION
(a) Turn the ignition switch to ON.
(b) Depress the brake pedal and shift the shift lever to any other position other than P.
(c) Check that the ignition key cannot be turned to LOCK.
(d) Shift the shift lever to P position, turn the ignition key to LOCK and check that the ignition key can be
removed.

4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY

ACC IG (a) Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control unit assembly connec-
tor.

KLS+
E STP C98999

Terminal Measuring Condition Voltage (V)

6 (ACC) - 8 (E) Ignition switch ACC 10 to 14
6 (ACC) - 8 (E) Ignition switch OFF Below 1
7 (STP) - 8 (E) Depress brake pedal 10 to 14
7 (STP) - 8 (E) Release brake pedal Below 1
6. Ignition switch ACC and P position Below 1
12 (KLS+) -8 (E) 7. Ignition switch ACC and except P position 7.5 to 11
8. Ignition switch ACC and except P position (After approx. 1 second) 6 to 9
1 (IG) - 8 (E) Ignition switch ON 10 to 14
1 (IG) - 8 (E) Ignition switch OFF Below 1

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 40-35
AUTOMATIC TRANSMISSION / TRANS - SHIFT LOCK SYSTEM

(b) Using an ohmmeter, measure the resistance at terminal

E (8) and body ground.
HINT:
Do not disconnect the shift lock control unit assembly connec-
tor.

E C98999

Terminal Measuring Condition Specified Value

8 (E) - Body ground Constant Continuity

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 40-1
AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (ATM)

AUTOMATIC TRANSAXLE ASSY (ATM)

400FX-02

PRECAUTION
1. The automatic transaxle is composed of highly precision-finished parts which need careful in-
spection before reassembly therefore even a small nick may cause fluid leakage or may de-
grade the performance. The instructions here are organized in order to work on only one com-
ponent group at a time. This will help you to avoid confusion comes about the similar-looking
parts of the different sub-assemblies being on your workbench at the same time. Inspect and
repair the component groups from the converter housing side. Complete the inspection, repair
and reassembly Complate the inspection, repair and reassembly before proceeding to the next
component group. If a defect is found in a certain component group during reassembly, inspect
and repair this group immediately. If a component group cannot be assembled because the nec-
essary parts are being ordered, be sure to keep all the parts of the group in a separate container
while proceeding with disassembly, inspection, repair and reassembly of the other component
groups.
Recommended ATF: T-IV
2. All the disassembled parts should be washed clean and any fluid passages and holes should
be blown with compressed air.
3. Dry all parts with compressed air. Never use shop rags to dry them.
4. Be careful of ATF or kerosene not to be squirted over your face when using compressed air.
5. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
7. When disassembling the valve body, be sure to match each valve together with the correspond-
ing spring.
8. New discs for the replacement of the brakes and clutches must be soaked in ATF for at least
15 minutes before reassembly.
9. All the oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
10. Replace all the gaskets and rubber O-rings.
11. Do not apply adhesive cements to the gaskets and similar parts.
12. Make sure that the ends of the snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
13. If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be re-
placed.
14. Check the thrust bearings and races for wear or damage. Replace them as necessary.
15. Use petroleum jelly to keep the parts in place.
16. When working with FIPG material, you must follow the procedure below.

Remove all the old packing (FIPG) material from the gasket surface using a razor blade and a
gasket scraper.

Thoroughly clean all the components to remove all the loose material.

Clean both the sealing surfaces with non-residue solvent.

Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY
4011A-03

OVERHAUL
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH (See page 71-10 )
3. REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-10 )
4. REMOVE COWL SIDE TRIM BOARD LH (See page 71-10 )
5. REMOVE COWL SIDE TRIM BOARD RH (See page 71-10 )
6. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER LH (See page 71-10 )
7. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSY (See page 71-10 )
8. REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71-10 )
9. REMOVE FLOOR CARPET COVER CENTER LH (See page 71-10 )
10. REMOVE FLOOR CARPET COVER CENTER RH (See page 71-10 )
11. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER NO.1 (See page 71-10 )
12. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER NO.2 (See page 71-10 )

13. REMOVE SHIFT LEVER KNOB SUB-ASSY

(a) Remove the floor shift lever knob sub-assy.

C86302

14. REMOVE POSITION INDICATOR HOUSING ASSY

Front side of vehicle (a) Using a screwdriver, remove the position indicator hous-
ing assy from the instrument cluster finish panel assy cen-
ter.

C86303

15. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (See page 71-10 )

16. REMOVE SHIFT LEVER CAP

(a) Using a small screwdriver, remove the shift lever cap from
the position indicator housing assy.

C86304

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

17. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY LOWER CENTER (See page
71-10 )

18. DISCONNECT TRANSMISSION CONTROL CABLE

ASSY
Front side of vehicle (a) Using a screwdriver, disconnect the cable end from the
Cable End shift lever assy.
(b) Using a small screwdriver, disconnect the cable outer of
transmission control cable assy from the shift lever assy.

Small Screwdriver

Cable Outer
C86305

19. REMOVE SHIFT LEVER ASSY

(a) Disconnect the 2 connectors.
(b) Remove the 4 bolts and disconnect the shift lever assy
from the vehicle.

C86306

Indicator Lamp Wire Sub-assy 20. REMOVE INDICATOR LAMP WIRE SUB-ASSY
(a) Remove the indicator lamp wire sub assy from the posi-
tion indicator light guide.

C86307

21. REMOVE POSITION INDICATOR LAMP BULB

(a) Remove the shift position indicator lamp bulb from the indicator lamp wire sub-assy.

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40-40
AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

Left-Side-Face:
22. REMOVE POSITION INDICATOR SLIDE COVER
(a) Remove the shift lever slide cover guide from the shift le-
ver assy.

Right-Side-Face:

Shift Lever Slide Cover Guide

Position Indicator Slide Cover

C86308

Position Indicator Slide Cover (b) Remove the position indicator slide cover from the shift le-
ver assy.

C86309

23. REMOVE POSITION INDICATOR SLIDE COVER

(a) Remove the position indicator slide cover No.2 from the
position indicator slide cover.

Position Indicator
Slide Cover No.2
C86310

24. INSTALL POSITION INDICATOR SLIDE COVER

(a) Install the position indicator slide cover No.2 to the posi-
tion indicator slide cover.

Position Indicator
Slide Cover No.2
C86310

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 40-41
AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

Left-Side-Face:
25. INSTALL POSITION INDICATOR SLIDE COVER
(a) Install the position indicator slide cover to the shift lever
assy.
(b) Install the shift lever slide cover guide to the shift lever
assy.
Right-Side-Face:

Shift Lever Slide Cover Guide

Position Indicator Slide Cover

C86308

26. INSTALL POSITION INDICATOR LAMP BULB

(a) Install the shift position indicator lamp bulb to the indicator lamp wire sub-assy.

Indicator Lamp Wire Sub-assy 27. INSTALL INDICATOR LAMP WIRE SUB-ASSY
(a) Install the indicator lamp wire sub-assy to the shift lever
assy.

C86307

28. INSTALL SHIFT LEVER ASSY

(a) Install shift lever assy to the vehicle with the 4 bolts.
Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf)
NOTICE:
Into datum hole of shift lever into datum pin of instrument
lower.
(b) Connect the 2 connectors to the shift lever assy.

C86321

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AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

29. CONNECT TRANSMISSION CONTROL CABLE ASSY

(a) Install the cable outer to the shift lever plate.
Cable End

Projection

Face
Rear

Cable Outer
C86312

(b) When installing the transmission control cable assy on

the shift lever plate, place the projection of the shift cable
FIG. 2 FIG. 3 downward to fit in the groove of the shift lever plate (FIG.
2).
Confirm that the spring in the shift cable outer has moved
to the position (FIG. 3) shown in the illustration.
Confirm that the shift cable is installed on the shift lever
Spring Spring
Projection plate properly.
D30843 NOTICE:

To prevent torsion of the inner cable, the projection
on the eye end should face rear.

Push the cable end to the bottom of the pin.

30. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY LOWER CENTER

31. INSTALL SHIFT LEVER CAP

(a) Install the shift lever cap to the floor shift position indicator
housing assy.

C86304

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 40-43
AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY

32. INSTALL POSITION INDICATOR HOUSING ASSY

Front side of vehicle
(a) Install the position indicator housing assy to the instru-
ment cluster finish panel assy center.

C86303

33. INSTALL SHIFT LEVER KNOB SUB-ASSY

(a) Install the shift lever knob sub-assy.

C86302

34. ADJUST SHIFT LEVER POSITION (See page 40-44 )

35. INSPECT SHIFT LEVER POSITION (See page 40-44 )
36. INSPECT CHECK KEY INTERLOCK OPERATION (See page 40-34 )
37. INSPECT CHECK SHIFT LOCK OPERATION (See page 40-34 )
38. INSPECT CHECK SHIFT LOCK RELEASE BUTTON OPERATION (See page 40-34 )

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 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH 40-3
ASSY (U151E/U151F)

PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F)

4011E-01

REPLACEMENT
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE AIR CLEANER INLET NO.2
5. REMOVE AIR CLEANER BRACKET
6. REMOVE AIR CLEANER INLET NO.1
7. REMOVE INTAKE AIR RESONATOR SUB-ASSY

8. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY

(a) Remove the nut from the control shaft lever.
(b) Disconnect the control cable from the control shaft lever.

D30614

(c) Remove the clip and disconnect the control cable from
the control cable bracket.
NOTICE:
Do not hold the resin guide pipe.

D25415

(d) Disconnect the park/neutral position switch connector.

(e) Remove the nut, washer and control shaft lever.

C99458

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40-4 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH
ASSY (U151E/U151F)

(f) Using a screwdriver, pry out the lock plate.

C99457

(g) Remove the lock nut and lock plate.

G25453

(h) Remove the 2 bolts and pull out the park/neutral position
switch.

C99454

9. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY

(a) Install the park/neutral position switch to the manual valve
shaft.
(b) Temporarily install the 2 bolts.

C99454

(c) Place the lock plate and tighten the nut.

Torque: 6.9 N⋅m (70 kgf⋅cm, 61 in.⋅lbf)
(d) Temporarily install the control shaft lever.

G25453

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 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH 40-5
ASSY (U151E/U151F)

(e) Turn the lever counterclockwise until it stops, then turn it

clockwise for 2 notches.
(f) Remove the control shaft lever.

N D30919

(g) Align the groove with the neutral basic line.

Neutral (h) Hold the switch in position and tighten the 2 bolts.
Basic Line Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)

Groove

C99456

(i) Using a screwdriver, stake the nut with the lock plate.

C99457

(j) Install the control shaft lever, washer and nut.

Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
(k) Connect the park/neutral position switch connector.

C99458

(l) Install the control cable and clip to the bracket.

D25415

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40-6 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH
ASSY (U151E/U151F)

(m) Temporarily install the control cable to the control shaft le-
ver with the nut.

D30614

10. ADJUST SHIFT LEVER POSITION (See page 40-44 )

11. INSPECT SHIFT LEVER POSITION (See page 40-44 )
12. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-7 )
13. INSTALL INTAKE AIR RESONATOR SUB-ASSY
14. INSTALL AIR CLEANER INLET NO.1
15. INSTALL AIR CLEANER BRACKET
16. INSTALL AIR CLEANER INLET NO.2
17. INSTALL AIR CLEANER HOSE NO.1
18. INSTALL AIR CLEANER ASSY
19. INSTALL BATTERY

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40-22
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F)

TRANSMISSION WIRE (U151E/U151F)

400FS-05

REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)

3. REMOVE AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all pan bolts,
and carefully remove the oil pan assembly.

C91925

(b) Remove the 2 magnets from the oil pan.

D30865

(c) Examine particles in the oil pan.

(1) Remove the magnets and use them to collect any
steel chips. Look at the chips and particles in the oil
pan and on the magnet carefully to see the type of
wear which might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear

AT0103

4. DISCONNECT TRANSMISSION WIRE

(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

C91927

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F)

5. REMOVE TRANSMISSION WIRE

(a) Disconnect the transmission wire connectors.
(b) Remove the bolt and transmission wire.

D30866

6. INSTALL TRANSMISSION WIRE

(a) Coat an O-ring of the transmission wire connector with
ATF.

D30867

(b) Install the transmission wire and bolt.

Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)

D30866

7. CONNECT TRANSMISSION WIRE

(a) Coat an O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor with the lock plate and
bolt.
Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)
(c) Connect the 7 shift solenoid valve connectors.

C91927

8. INSTALL AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply the seal packing or the equivalent to the 18 bolts.
Seal packing:
THREE BOND 1344 or equivalent

D30865

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F)

(c) Install a new gasket, oil pan and 18 bolts to the transaxle
case.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
NOTICE:
Apply the seal packing or equivalent to the bolts and tight-
en them within 10 minutes after application because the
bolts should be seal bolts.

C91925

9. INSTALL ENGINE UNDER COVER NO.1

10. RESET MEMORY (See page 05-533 )

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

TRANSMISSION VALVE BODY ASSY (U151E/U151F)

400FT-05

REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)

3. REMOVE AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all pan bolts,
and carefully remove the oil pan assembly.

C91925

(b) Remove the 2 magnets from the oil pan.

D30865

(c) Examine particles in the oil pan.

(1) Remove the magnets and use them to collect any
steel chips. Look at the chips and particles in the oil
pan and on the magnet carefully to see the type of
wear which might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear

AT0103

4. DISCONNECT TRANSMISSION WIRE

(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

C91927

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

5. REMOVE VALVE BODY OIL STRAINER ASSY

(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful that some fluid will come out of the oil strainer.

C91931

(b) Remove the O-ring from the oil strainer.

C91932

6. REMOVE TRANSMISSION VALVE BODY ASSY

(a) Support the valve body assy and remove the 17 bolts and
the valve body assy.
NOTICE:
Be careful not to drop the check valve body, spring and ac-
cumulator piston.

C91933

(b) Remove the check ball body and spring.

C50017

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

(c) Remove the 5 bolts and 7 shift solenoid valves.

D30644

7. INSTALL TRANSMISSION VALVE BODY ASSY

(a) Install the spring and check ball body.

C50017

(b) Install the 7 shift solenoid valves with the 5 bolts.

B Torque:
Bolt A, B: 11 N·m (110 kgf·cm, 8 ft.⋅lbf)
Bolt C, D: 6.6 N·m (67 kgf·cm, 58 in. lbf)
A Bolt length:
B Bolt A: 16 mm (0.63 in.)
Bolt B: 57 mm (2.20 in.)
C Bolt C: 23 mm (0.90 in.)
C Bolt D: 12 mm (0.47 in.)

D30644

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

(c) Align the groove of the manual valve with the pin of lever.
(d) Install the 17 bolts.
C Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)
A NOTICE:
B

B
 Push the valve body against the accumulator piston
B
B C spring and the check ball body to install it.
A

 Tighten those bolts marked by
in the illustration
B first temporarily because they are positioning bolts.
C C C Bolt length:
C91933

Bolt A: 41 mm (1.614 in.)

Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)

8. INSTALL VALVE BODY OIL STRAINER ASSY

(a) Coat an new O-ring with ATF.
(b) Install the O-ring to the oil strainer.

C91932

(c) Install the oil strainer with the 3 bolts.

Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)

C91931

9. CONNECT TRANSMISSION WIRE

(a) Coat an O-ring with ATF.
(b) Install the ATF temperature sensor with the lock plate and
bolt.
Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf)
(c) Connect the 7 shift solenoid valve connectors.

C91927

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AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F)

10. INSTALL AUTOMATIC TRANSAXLE OIL PAN

SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to 18 bolts.
Seal packing:
THREE BOND 1344 or equivalent

D30865

(c) Install a new gasket, oil pan and 18 bolts to the transaxle
case.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
NOTICE:
Apply the seal packing or equivalent to the bolts and tight-
en them within 10 minutes after application because the
bolts should be seal bolts.

C91925

11. INSTALL ENGINE UNDER COVER NO.1

12. RESET MEMORY (See page 05-533 )

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151E)

FRONT DIFFERENTIAL OIL SEAL (U151E)

40066-07

REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
4. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30-18 )
5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-18 )

6. REMOVE TRANSAXLE HOUSING OIL SEAL

(a) Using SST, pull out the oil seal.
SST
SST 09308-00010

D25831

7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

SST OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010

D25832

8. INSTALL TRANSAXLE HOUSING OIL SEAL

SST (a) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.

D25833

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151E)

9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST
D25834

10. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-18 )

11. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30-18 )
12. INSTALL FRONT WHEELS
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
13. ADD AUTOMATIC TRANSAXLE FLUID
14. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-2 )
15. INSTALL ENGINE UNDER COVER NO.1
16. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS WITH EBD SYSTEM (See pege 05-386 )
(b) ABS WITH EBD & BA &TRAC VSC & SYSTEM (See pege 05-435 )

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
400ZO-02

REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-33 )
2. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-18 )
SST 09520-01010, 09520-24010 (09520-32040)
3. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See page 30-18 )
4. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See page 30-18 )
SST 09520-01010, 09520-24010 (09520-32040)

5. REMOVE TRANSMISSION CONTROL CABLE

BRACKET NO.2
(a) Remove the bolt and transmission control cable bracket
No.2.

C83203

6. REMOVE WIRE HARNESS CLAMP

(a) Disconnect the wire harnesses from the clamps.
(b) Remove the 3 bolts and 2 clamps.

D30465

7. DISCONNECT WIRE HARNESS

(a) Remove the bolt and wire harness.

G25456

8. REMOVE STARTER ASSY

(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.

D30464

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

9. DISCONNECT CONNECTOR
Transmission
Wire Connector
(a) Disconnect the 2 transmission wire connectors.
(b) Disconnect the park/neutral position switch connector.
(c) Disconnect the 2 transmission revolution sensor connec-
tors.

Park/neutral Position Switch Connector

Transmission Revolution
Sensor Connectors

D30864

10. REMOVE TRANSMISSION CONTROL CABLE

BRACKET NO.1
(a) Remove the bolt and oil cooler tube clamp.
(b) Remove the 2 bolts and transmission control cable brack-
et No.1.

D30467

11. REMOVE TRANSMISSION OIL FILLER TUBE

SUB-ASSY
(a) Remove the ATF level gauge.
(b) Disconnect the wire harnesses 2 clamps from the oil filler
tube.
(c) Remove the 2 bolts and oil filler tube.
(d) Remove the O-ring from the oil filler tube.

D30468

12. REMOVE OIL COOLER INLET TUBE NO.1

SST
(a) Using SST and spanner, disconnect the oil cooler inlet
tube No.1.
SST 09023-12701
13. REMOVE OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, disconnect the oil cooler outlet
tube No.1.
SST 09023-12701
D30469

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

14. REMOVE ENGINE MOUNTING BRACKET FR

(a) Remove the 3 bolts and engine mounting bracket FR.

D30470

15. REMOVE AUTOMATIC TRANSAXLE ASSY (2WD

DRIVE TYPE)
(a) Remove the 2 bolts and flywheel housing under cover.

D30471

(b) Turn the crankshaft to gain access and remove the 6 bolts
while holding the crankshaft pulley bolt with a wrench.

D30472

(c) Remove the 8 bolts.

U151E
(d) Separate and remove the automatic transaxle.

D30511 D30668

16. REMOVE TRANSFER STIFFENER PLATE RH (4WD

DRIVE TYPE)
(a) Remove the 5 bolts, nut and transfer stiffener plate RH.

D30512

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

17. REMOVE AUTOMATIC TRANSMISSION

W/TRANSFER (4WD DRIVE TYPE)
(a) Remove the 2 bolts and flywheel housing under cover.

D30471

(b) Turn the crankshaft to gain access and remove the 6 bolts
while holding the crankshaft pulley bolt with a wrench.

D30472

(c) Remove the 8 bolts.

U151F
(d) Separate and remove the automatic transaxle w/transfer.

D30511 D30669

18. REMOVE TRANSFER ASSY (4WD DRIVE TYPE) (See page 31-9 )
19. REMOVE TORQUE CONVERTER CLUTCH ASSY
20. INSPECT TORQUE CONVERTER CLUTCH ASSY (See page 40-18 )
SST 09350-32014 (09351-32010, 09351-32020)
21. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic trans-
axle.

(b) Using vernier calipers, measure the dimension ”A” be-

tween the transaxle fitting part the converter fitting part of
the drive plate.

A D30868

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

(c) Using vernier calipers and a straight edge, measure the

dimension ”B” shown in the illustration and check that ”B”
is greater than ”A” measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of straight edge.

Dimension B C65911

22. INSTALL TRANSFER ASSY (4WD DRIVE TYPE) (See page 31-9 )

A 23. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER

U151F A
(4WD DRIVE TYPE)
A
A (a) Install the automatic transaxle w/transfer and 8 bolts to
the engine.
Torque:
B Bolt A: 64 N⋅m (650 kgf⋅cm, 47 ft⋅lbf)
Bolt B: 46 N⋅m (470 kgf⋅cm, 34 ft⋅lbf)
A Bolt C: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
D30511
C C D30669 (b) Apply a few drops of adhesive to each of 2 threads on the
tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent

(c) Install the 6 torque converter clutch mounting bolts.

Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf)
HINT:
First install green colored bolt and then the 5 bolts.

D30472

(d) Install the flywheel housing under cover to the automatic

transaxle with the 2 bolts.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in⋅lbf)

D30471

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

24. INSTALL TRANSFER STIFFENER PLATE RH (4WD

DRIVE TYPE)
(a) Install the transfer stiffener plate RH and 5 bolts to the
transfer and engine mounting bracket RR.
Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf)

D30512

A
25. INSTALL AUTOMATIC TRANSAXLE ASSY (2WD
U151E A
A
DRIVE TYPE)
A (a) Install the automatic transaxle and 8 bolts to the engine.
Torque:
A
Bolt A: 64 N⋅m (652 kgf⋅cm, 47 ft⋅lbf)
Bolt B: 46 N⋅m (469 kgf⋅cm, 34 ft⋅lbf)
Bolt C: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
B
(b) Apply a few drops of adhesive to each of 2 threads on the
C
D30511 C G25660 tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent

(c) Install the 6 torque converter clutch mounting bolts.

Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf)
HINT:
First install black colored bolt and then the 5 bolts.

D30472

(d) Install the flywheel housing under cover to the automatic

transaxle with the 2 bolts.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in⋅lbf)

D30471

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

26. INSTALL ENGINE MOUNTING BRACKET FR

(a) Install the engine mounting bracket FR and 3 bolts to the
automatic transaxle.
Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf)

27. INSTALL TRANSMISSION OIL FILLER TUBE

SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler
C91739 tube.

(b) Install the oil filler tube and bolt to the automatic transaxle.
Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf)
(c) Connect the 2 clamps to the oil filler tube.
(d) Install the ATF level gauge.

28. INSTALL OIL COOLER INLET TUBE NO.1

(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
D30700

(c) Install the oil cooler tube clamp and bolt.

Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf)
HINT:
Install the oil cooler tube clamp and bolt so that the oil cooler
tube cushion is positioned as illustrated.

D30699

(d) Using SST and spanner, tighten the oil cooler inlet tube
No.1.
SST SST 09023-12701
Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf)
29. INSTALL OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, tighten the oil cooler outlet tube
No.1.
SST 09023-12701
D30469 Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf)

30. INSTALL TRANSMISSION CONTROL CABLE

BRACKET NO.1
(a) Install the control cable bracket No.1 and 2 bolts.
Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf)

D30467

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

31. CONNECT CONNECTOR

Transmission
Wire Connector
(a) Connect the 2 transmission with connectors.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 transmission revolution sensor connec-
tors.

Park/neutral Position Switch Connector

Transmission Revolution
Sensor Connectors

D30864

32. INSTALL STARTER ASSY

(a) Install the starter assy and 2 bolts.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
(b) Connect the connecter.
(c) Install the starter wire and nut.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

D30464

33. INSTALL WIRE HARNESS

(a) Install the wire harness and bolt.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)

G25456

34. INSTALL WIRE HARNESS CLAMP

(a) Install the 3 bolts and 2 clamps.
Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf)
(b) Connect the wire harnesses to the clamps.

D30465

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AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F)

35. INSTALL TRANSMISSION CONTROL CABLE

BRACKET NO.2
(a) Using the detent, install the transmission control cable
bracket No.2 with the bolt.
Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf)

C83203

36. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-18 )

37. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See page 30-18 )
38. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See page 30-18 )
39. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-33 )
40. RESET MEMORY (See page 05-533 )

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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151F)

FRONT DIFFERENTIAL OIL SEAL (U151F)

4011H-02

REPLACEMENT
HINT:
When replacing the front differential oil seal (LH) or (RH), perform step 1 to 13 or 14 to 27 respectively.
1. REMOVE FRONT WHEEL
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
4. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-18 )

5. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

SST OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010

D25832

6. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST

D25834

7. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-18 )

8. INSTALL ENGINE UNDER COVER NO.1
9. INSTALL FRONT WHEEL
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
10. ADD AUTOMATIC TRANSAXLE FLUID
11. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-2 )
12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-7 )
13. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS WITH EBD & BA &TRAC VSC & SYSTEM (See pege 05-435 )
14. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-33 )
15. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-18 )
16. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30-18 )
17. REMOVE TRANSFER STIFFENER PLATE RH (See page 40-9 )
18. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (See page 40-9 )
19. REMOVE TRANSFER ASSY (See page 31-9 )
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AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151F)

20. REMOVE TRANSAXLE HOUSING OIL SEAL

(a) Using a screw driver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the housing.

D30693

21. INSTALL TRANSAXLE HOUSING OIL SEAL

A (a) Using SST and a hammer, drive in a new oil seal.
Oil seal drive in depth:
6.0
0.5 mm (0.236
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST 09649-17010, 09950-70010 (09951-07200)
SST

D30913

22. INSTALL TRANSFER ASSY (See page 31-9 )

23. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (See page 40-9 )
24. INSTALL TRANSFER STIFFENER PLATE RH (See page 40-9 )
25. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30-18 )
26. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-18 )
27. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-33 )
SST 09670-00010

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40-20 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION REVOLUTION
SENSOR (U151E/U151F)

TRANSMISSION REVOLUTION SENSOR (U151E/U151F)

4011F-01

REPLACEMENT
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE AIR CLEANER INLET NO.2
5. REMOVE AIR CLEANER BRACKET
6. REMOVE AIR CLEANER INLET NO.1

7. REMOVE TRANSMISSION REVOLUTION SENSOR

(NT SENSOR)
(a) Disconnect the transmission revolution sensor connector.
(b) Remove the bolt and transmission revolution sensor.

C90569

8. REMOVE TRANSMISSION REVOLUTION SENSOR

(NC SENSOR)
(a) Disconnect the transmission revolution sensor connector.
(b) Remove the bolt and transmission revolution sensor.

C90570

9. INSTALL TRANSMISSION REVOLUTION SENSOR

(NC SENSOR)
(a) Coat an O-ring with ATF.
(b) Install the transmission revolution sensor with the bolt.
Torque: 11 N⋅m (115 kgf⋅cm, 8 ft⋅lbf)
HINT:
Make sure of the manufacturer’s name.
(c) Connect the transmission revolution sensor connector.
C90570

10. INSTALL TRANSMISSION REVOLUTION SENSOR

(NT SENSOR)
(a) Coat an O-ring with ATF.
(b) Install the transmission revolution sensor with the bolt.
Torque: 11 N⋅m (115 kgf⋅cm, 8 ft⋅lbf)
HINT:
Make sure of the manufacturer’s name.
(c) Connect the transmission revolution sensor connector.
C90569

2005 SIENNA REPAIR MANUAL (RM1163U)

Author
: Date
: 2844

 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION REVOLUTION 40-21
SENSOR (U151E/U151F)

11. INSTALL AIR CLEANER INLET NO.1

12. INSTALL AIR CLEANER BRACKET
13. INSTALL AIR CLEANER INLET NO.2
14. INSTALL AIR CLEANER HOSE NO.1
15. INSTALL AIR CLEANER ASSY
16. INSTALL BATTERY
17. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS WITH EBD SYSTEM (See pege 05-386 )
(b) ABS WITH EBD & BA &TRAC VSC & SYSTEM (See pege 05-435 )

2005 SIENNA REPAIR MANUAL (RM1163U)

Author
: Date
: 2845

 40-47
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM)

TRANSMISSION CONTROL CABLE ASSY (ATM)

4011D-02

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH (See page 71-10 )
3. REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-10 )
4. REMOVE COWL SIDE TRIM BOARD LH (See page 71-10 )
5. REMOVE COWL SIDE TRIM BOARD RH (See page 71-10 )
6. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER LH (See page 71-10 )
7. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSY (See page 71-10 )
8. REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71-10 )
9. REMOVE FLOOR CARPET COVER CENTER LH (See page 71-10 )
10. REMOVE FLOOR CARPET COVER CENTER RH (See page 71-10 )
11. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER NO.1 (See page 71-10 )
12. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER NO.2 (See page 71-10 )
13. REMOVE SHIFT LEVER KNOB SUB-ASSY (See page 71-10 )
14. REMOVE POSITION INDICATOR HOUSING ASSY (See page 71-10 )
15. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (See page 71-10 )

16. REMOVE TRANSMISSION CONTROL CABLE ASSY

(a) Remove the nut from the control shaft lever.
Control Shaft Lever (b) Disconnect the transmission control cable assy from the
control shaft lever.

D25414

(c) Remove the clip and disconnect the transmission control

Control Cable Bracket cable assy from the control cable bracket.

D25415

(d) Disconnect the transmission control cable assy from the

Transmission Control transmission control cable bracket No.2.
Cable Bracket No.2

D25416

2005 SIENNA REPAIR MANUAL (RM1163U)

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: Date
: 2871

40-48
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM)

(e) Remove the 2 nuts and disconnect the transmission con-

trol cable assy from the vehicle.

Front side of vehicle C86313

(f) Using a screwdriver, disconnect the cable end from the

shift lever assy.
Front side of vehicle (g) Using a small screwdriver, disconnect the cable outer of
transmission control cable assy from the shift lever assy.
Cable End (h) Pull out the control cable from the vehicle.
17. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Pull in the control cable to the body.

Small Screwdriver

Cable Outer
C86305

(b) Install the cable end, as shown in the illustration.

Cable End

Projection

Face
Rear

Cable Outer
C86312

2005 SIENNA REPAIR MANUAL (RM1163U)

Author
: Date
: 2872

 40-49
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM)

(c) When installing the transmission control cable assy on

the shift lever plate, place the projection of the shift cable
FIG. 2 FIG. 3 downward to fit in the groove of the shift lever plate (FIG.
2).
Confirm that the spring in the shift cable outer has moved
to the position (FIG. 3) shown in the illustration.
Confirm that the shift cable is installed on the shift lever
Spring Spring
Projection plate properly.
D30843 NOTICE:

To prevent torsion of the inner cable, the projection
on the eye end should face rear.

Push the cable end to the bottom of the pin.

(d) Install the transmission control cable assy and 2 nuts.

Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf)

Front side of vehicle C86313

(e) Connect the transmission control cable assy to the trans-

Transmission Control mission control cable bracket No.2.
Cable Bracket No.2

D25416

(f) Temporarily install the transmission control cable assy to

Control Cable Bracket the control shaft lever with the nut.

D25415

2005 SIENNA REPAIR MANUAL (RM1163U)

Author
: Date
: 2873

40-50
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM)

(g) Install the transmission control cable assy and clip to the
bracket.
Control Shaft Lever

D25414

18. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (See page 71-10 )
19. INSTALL POSITION INDICATOR HOUSING ASSY (See page 40-38 )
20. INSTALL SHIFT LEVER KNOB SUB-ASSY (See page 40-38 )
21. ADJUST SHIFT LEVER POSITION (See page 40-44 )
22. INSPECT SHIFT LEVER POSITION (See page 40-44 )

2005 SIENNA REPAIR MANUAL (RM1163U)

Author
: Date
: 2874