FOREWORD This manual covers the service procedures of the TOYOTA TOWING TRACTOR 2TD/2TG20, 25 Series. Please use this manual for providing quick, correct servicing of the corresponding towing tractor models. This manual deals with the above models as of March 1998. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles’ Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL VEHICLE 1DZ ENGINE (No. CE618) REPAIR MANUAL TOYOTA INDUSTRIAL VEHICLE 4Y ENGINE (No. CE602) REPAIR MANUAL TOYOTA INDUSTRIAL VEHICLE 2Z ENGINE (No. CE625) REPAIR MANUAL TOYOTA MOTOR CORPORATIONSECTION INDEX Sealey GENERAL ENGINE AUTOMATIC TRANSMISSION (Up to ‘95. 5) I) AUTOMATIC TRANSMISSION (From '95. 6) w CLUTCH MANUAL TRANSMISSION PROPELLER SHAFT DIFFERENTIAL REAR AXLE FRONT AXLE STEERING BRAKE BODY FRAME ee) APPENDIXGENERAL Page VEHICLE EXTERIOR VIEWS .. 0-2 MODEL LINEUP FRAME SERIAL NUMBER .... ABBREVIATIONS + 0-4 OPERATIONAL TIPS. - 0-4 STANDARD BOLT & NUT TIGHTENING TORQUE . PRECOAT BOLTS HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .... ‘WIRE ROPE SUSPENSION ANGLE LIST .... SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE .... MEMBER WEIGHTS ... PERIODIC REPLACEMENT PARTS & LUBRICANTS ...... 0-10 RECOMMENDED LUBRICANT TYPES & CAPACITIES ... 0-11 LUBRICATION CHART PERIODIC MAINTENANCE0-2 VEHICLE EXTERIOR VIEWS. Vehicle Exterior Views AF26 2, 28MODEL LINEUP Maximum Installed drawoar | Model ae Transmission Remarks pull 3 zroz0 | 10z Clutch + 2000kg |_0227020 | 10z Torque converter t (4400 Ibs) zrez0 | 4¥ Clutch fi o22rez0 | av Torque converter t 2000%g | 42-21b20 | 2 Torque converter Power steering as standard equipment 21025 | _10Z Clutch t 2500 kg [_022TD25 | 10Z Torque converter t (6500 Ibs) 2162s | aY Clutch t czars |__4Y Torque converter t 2500kg | 42202 |Z t t FRAME SERIAL NUMBER Engine Model | Punching format Punching position 27020 0227020 1DZengine 27026-10011 2126 02-2125 27620 0227620 4Y engine 27625-10011 21625 02-21625 42-21020 2Zengine 27025-30011 42210250-4 ABBREVIATIONS Abbreviations used in this manual are as follows: Abbreviation ‘Abbreviation eeu Meaning ‘code Meaning ‘ABDC ‘After button dead center PS Horsepower ASSY Assembly P/S Power steerirg TOC After top dead center RH Right hand ATM Automatic transmission SAE Society of automotive engineers Toc Before top dead center (Usa) u Less ssT Special service tool LH Left hand sTD Standard Lc Long life coolant SUB-ASSY Sub-assembly MIM. Manual transmission T Tightening torque OHV Overhead valve oor Number of teeth (00) OPT Option u/s Undersize ors Oversize wi With’ OPERATIONAL TIPS Safe operation (1). Make sure that correct size wire is used for hoisting a heavy material (2) After jacking up, always support with rigid racks or stands. Preparation of SSTs and measuring tools (1) Prepare SSTs and measuring tools before starting operation Clearing and arrangemen (1) Always keep the workshop n (2) Disass t and orderly for easy operation, mbly of hydraulic equipment shall always be done in a clean place using clean tools. Genuine Toyota pants Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. Repairs on electrical syste Before doing any repairs on the electical system, disconnect the cables from the battery terminals. Be sure to disconnect the negative © cable first. Tightening torque for installation Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque listed in standard bolt & nut tightening torque. Defect status grasp Do not start disassembly and replacement as soon as a defect is found. but first grasp whether the defect requires disassembly and replacement. In the case of torque converter for example, do not attempt torque converter disassembly upon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure.05 STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below. 1. Find outthe type of the bolt from the list below and then find the bolt tightening torque from the table, 2. The nut tightening torque can be judged from the mating bolt type. BOLT STRENGTH TYPE IDENTIFICATION METHOD 1. Identification by bolt shape 2. Identification by part No. ‘Shape and class Hexagon head bolt (43+ Bott head No. - Part No. Hexagon 91611-40625 head bolt Length (mm) a ere av Diameter (mm) Class Hexagon No mark ar flange bolt | iameter Hexagon Two protruding head bolt oO lines Gi ae Hexagon Two protruding | flange bolt lines Stud bolt Hexagon Three head bolt protruding lines | 77 Part No, 92132-40614 Hexagon Four head bolt protruding lines | 8T — Length (mm) Diameter (mm) Class wouaror| ATES | No mark a Stud bolt GroovedHexagon flange bolt 5 32 Specified torque 5 e : sleSegezeegggslseee2 ge s28 sss sses 83\ |< + 2 gel/z FR FR SPSS Bas" SHRSRERSBs gle esse gy £3 gE CHRR wm wMmlo RRR w wloR Bw wloR Flu wmloS WR nu ge lQ@88 8 eee 8 SS ewe She ale SS heres ikee mm Diameter Class TIGHTENING TORQUE TABLE 0-6PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1. Do not use the precoat bolt as it is in either of the following cases. {a) After it is removed. (b) When the precoat bolt is moved (loosened or feats een tightened) by tightness check, ete, Note: For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according to the steps below. 2. Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.) (2) Perfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation. 2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tight- en the fitting. 3, The maximum tightening torque must not exceed twice the standard tightening torque. Nominal diameter Standard tightening torque _N-m (kgf-cm) [ft-lbfl Soe of screw Standard Tightening range ‘mm (in) 7/16 - 20UNF 25 (250) [18.1] 24~26 (240~270) [17.4~19.5] 6 (0.24) 9/16 - 18UNF 49 (500) [36.2] 47~52 (480~530) [34.7~38.3] 9 (0.35) 3/4 - 16UNF ‘59 (600) [43.4] 56~62 (570~630) [41.2~45.6] 12 (0.47) 7/8 - 14UNF 59 (600) [43.4] 56~62 (570~630) [41.2~45.6] 12 (0.47) 7/8 - 14UNF 78 (800) [57.9] 74-82 (760~840) [55.0~60.8) 15 (0.69) 1,1/16 - 12UNF 118 (1200) [86.8] 112~123 (1140~1250) (82.5~90.4] 19 (0.75) 1.5/16 - 12UNF 137 (1400) [101.3] 130~144 (1330~1470) [96.2~106.4] 25 (0.98) PFI4 25 (250) [18.1] 24~26 (240~270) [17.4~19.5] 6 (0.24) PF3/8 49 (500) [36.2] 47-52 (480-530) [34.7~38.3] 9 (0.35) PF1/2 59 (600) [43.4] 56~62 (570~630) [41.2~45.6] 12 (0.47) PF3/4 118 (1200) [86.8] 112~123 (1140~1250) [82.5~90.4] 19 (0.75) PFV 137 (1400) [101.3] 130~144 (1330~1470) [96.2~106.4] 25 (0.98)0-8 WIRE ROPE SUSPENSION ANGLE LIST Suspension Suspension Suspension] ;,,<,9, | compres: | Suspension angie_| Tension method | angle | Tsion | “sion method co | 1.00time | otime | = 90° | 1.41 time | 1.00 time ee SS a ~ a an | 1.04time | 0.27 time | 120° | 2.00 time | 1.73 time we & = 60° | 1.16time | 0.58 time . § SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: _N (ton) [Ib] -__ |Singlo-rope roge | cutting | Sinaler2 Two-rope suspension Four-rope suspension Siameter| load [oe o | 3° | 6 | 90 | o | 30° | 6 | 90° mm | 21380 | 3040 —|~6080 | S880] 5200 | ~a310 | 12160 | 11770 | T0400 | B60 (ozaim)| (2:18) | (0.31) | (0.62) | (0.6) | (0.53) | (0.44) | (1.24) | 11.2) | (1.08) | (0.86) tag07} | (683.6) | (1367) | 11323) | 111691 | 19701 | 12734) | 126461 | 123971 | 119401 gmm | 31480-~ 4410 | 8830 | 8530 | 7650 | 6280] 17650 ] 17060 | 15300 | 12550 (eazm] 220 | (0.45) | (9) | (oar | (o.7—) | (ose) | c1.8) | 1.74) | (156) | (1.28) -S2in)| crore) | 1982.3) | 11986) | 119t8) | 11720) | (1411 | r3969) | 39371 | t2aaoy | 123221 Tomm | 49230 |~ 6860 | 14020 | 13440] 11770 | S810 | 27460] 26480 | 23540 | 19610 orn | 6.02 | (o7n | (ras) | 37 | (1.2) | 0 | 2e) | 27 | ea | 20 -4'n) | tr1069) | 11565.6) | 13183) | (3021) | 126461 | 122051 | 161741 | t5954 | 152921 | 14410) a5 mm) 76880] 10980 | 21670 | 21280 | 18630 | 14710 | 43160 | at190 | 37270 | 29420 Oe 789 | ta fea | en | as | as) | aa | 42 | @e | @o -5'n) | 173871 | 12469.5) | 148511 | 146311 | 141901 | 13308) | 197021 | 192611 | 183791 | 16615) yamm| 96400 | 13730 | 27460 | 26480 | 23540 ] 18630 | 64920 | 52960 | 47070 | 37770 (osom| 989 | 4 | 29) | 27 | ea | iro) | 66) | 164) | (48) | ey -56'n)| 216751 | (3087) _| 16174) | 15954) | 152921 | 14190) | (12348) | 1119071 | :105841 | 1837910-9 Ss MEMBER WEIGHTS av 134 kg (294.8 Ib) {1314 NI Engine ASSY 102 178 kg (387.2 Ib) (1726 NI} 2 240 kg (529.2 Ib) 2354 N} ‘Automatic transmission ASSY 129 kg (283.8 Ib) [1265 NI Manual transmission ASSY 70 kg (154 Ib) 1686.5 NI] Differential cartier ASSY ‘2ID/2TG20, 25 60 kg (132 tb) (586.4 N] Rear axle ASSY 2TD/2TG20, 26 826 kg (717 Ib) (3197 NI Front weight 36 kg (79.2 Ib) [353 NI Rear upper weight 2TD/2TG 20 series 990 kg (2178 Ib) [9709 NI 2TD/2TG 25 series 1445 kg (8180 Ib) 114170 NI Rear lower weight ZID/2TG 20 series 460 kg (1012 Ib) 19511 NI] ZID/2TG 25 series £630 kg (1386 Ib) (6178 NI0-10 PERIODIC REPLACEMENT PARTS & LUBRICANTS = Hem Replacement timing 6 months 1000 hours Engine oit Engine oil filter Coolant (Replace LLC every 2 years) Fuel filter ‘Automatic transmission oil Manual transmission oil Dif erential oil Power steering oil Steering gear box oll Brake Fluid Cluteh fluid Spark plug Trailing arm shi Wreel bearing grease Cyclone air cleaner element PCV valve Breke booster rubber p ‘Wheel cylinder up and seals Breke and clutch hoses Clutch and brake fluid reservoir hose Stop switch Power steering hase Power steering rubber parts Fuel hose Automatic transmission rubber hose0-11 et RECOMMENDED LUBRICANT TYPES & CAPACITIES eae | Tecate cs Feo RY ra SRE (SAE 20incld ‘os Gasoline ‘SD, SE, SF SAE20W-40 (SAE10W-30 in cold oO (1.06 US gal) onal Engine © 6.98 (1.82 US gal) (ian Diesel engine oil 10Z cess [AR | Cae DISA pon cold ae 796 20908 a . ae aoe cd (2.11 US gal) ‘Automatic — ‘ATM vehicle about 106 transmission rd Sere (Up to '95. 5) 12.68 US ga) cayemets thoaad foment nee EnaEe asswbaibonl Aittvatite | bot 118 (From ‘95. 6) (2.9 US gal) ms ant rr er werovenico | 9a UE an Timodes exuanp3200 | nse fe saan” | a0sesoen Aree AP ug [Wid cearoisacesweo | Ms [sz00 anaao00 | 758 Ib models (1.98 US gal) 7 (02) 2TD/2TG 1.88 Powersewingat | ATF GM Deen 1217 woah on 0a ‘Steering gear box oil Gear Oil SAESO. and 5000 Ib 06 £ cise een Clutch reservoir tank SAE J-1703, DOT-3 ‘Clutch models Proper amount jrake reservoir tank Jn -< model 06 e Boke reson tane ae 14708, DOT armoies | @idb,oan = ane Gasoline pea bean Fualtnk 8 19a US gan onal diss noaae | gases ya evan as a SRE roeararant w aze * LLC 30 - 50% mixture (for winter (2.56 US gal) or secat nad Cooling water os * Coolant with rust-inhibitor (for ae (2.2 US gal) Sone sume sa earns a8 a (2.40 US gal) Cog wae ose {reservoir trank) t al esol (0.16 US gal)0-12 LUBRICATION CHART 1 2. 3 4 1. 8 a 2 Trailing arm bearing Steering knuckie king pin Front wheel bearing Brake & clutch ol Rear wheel bearing Differential and sub-transmission Power steering reservoir tank Engine crankshaft Torque converter case Universal joint CO. ea \y I ot m Vv Vv 11. Steering gear box 12. Tilt steering locking mechanism | B-hour (day) inspection I. 40-hour (weekly) inspection IM 170+hour (monthly inspection IV, 1000-hour (month) inspection V. 200¢-hour annually) inspection © Inspection and cil addition © Replacement MP grease Engine oil Hipoyd gear oil Brake fluid GM Dexron@ lt (Automatic vehicle) Gear oi (Clutch vehicle) Lubrication Chant0-13 PERIODIC MAINTENANCE INSPECTION METHOD Inspect M: Measurement. Repair or adjustment if requried ion. Repair or replacement if required. T: Retightening C: Cleaning L: Lubrication Inspection period Ingpec- - Inspection items | tion | Evert | Every 3 | Every 6 | Every 12 method | month | months | months | months ci70)_| (00) | (1000) | (2000) Steering wheel | | 1. Play and looseness: 1 ] ° ° oO Oo 2. Function 1 oO ° oO Oo Gear box 4. Oilleak ° ° oO ° 2. Loaseness of mounting T ° o o ° 3. Relief valve fiter clogging 1 ° ° 4._ Steering gear box oil change L ° Fiod, inks and arm € | 1. Ball joint dust boot cracks and damage \ 2 ° 2 | 2 Looseness and damage 1 ° ° ° ° 2 | 3. Linkage wear and mounting condition ! ° & | Knuckle £ | 1. King pin looseness Oo oO o fe} © | 2. Cracks and deformation ° Steering shaft 1. Wheel alignment M ° 2. Left and right turing angle M ° Power sieeting | 1. Belt looseness and damage M Oo ° Oo Oo 2. Fluid leak and capacity 1 Oo ° oO oO 3. Looseness of mounting 1 Oo Oo oO oO 4, Power steering hose replacement 0(4000) 5, Power steering fluid change Oo ° 6. Replacement of internal rubber parts (4000)0-14 inspect on period Inspeo- - Inspection items tion | Evevt | Every | Every6 | Every 12 | method | month | months | months | months (170)_| 00) | (oon) | (2000) Brake peda 1. Play and floor clearance M ° ° ° ° 2._ Braking effectiveness \ ° 5 © ° Parking brake 1. Margin in pulling distance M ° ° ° ° 2._Braking effectiveness \ ° } ° ° Rod and cable 1. Looseness and damage 9 QO. Hose and piping 1. Leakage, damnage and installation condition ° ° ° ° 2. Brake hose replacement 3 ° 3. Brake fluid reservoir replacement ° 4._Vacuum pump oil hose replacement ° ° Reservoir tank | 1. Amount of fluid ° ° ° % | Master cylinder, wheel cylinder and disk brake & | caliper 2 | 1. Operation. wear and damage ' ° © | 2. Master cylinder and wheel cylinder rubber ' ie) & | Pars replacement (cups, dust sols, otc | including disc brake caliper parts) | 3. Brake fluid change ' | ° 4 Stop switch (hydraulic) replacement \ ° ° Power-assist 1. Air cleaner clogging \ 2 | 0° ° ° 2. Operation \ } o | 0 ° 3. Vacuum hose replacement \ | ° ° 4, Rubber parts replacement \ | ° ° 5. Compressor hose replacement \ ° ° 6._Air pressure gauge hose replacement \ ° ° Brake drum and brake shoe 1. Clearance between drum and lining M ° ° ° ° 2. Wear of shoe sliding portion and lining M ° 3. Drum wear and damage ' °} 4._Loose drum mounting \ } Backing plate 1. Deformation, cracks and damage \ ° 2_Loose mounting \ °0-15 Inspection period Inspec: Inspection items tion | Every1 | Every 3 | Every 6 | Every 12 method | month | months | months | months (170) | (500) | (1000) | (2000) Front axle 1. Cracks, damage and deformation i ° Rear axle 1. Cracks, damage and deformation ‘Wheels Tire inflation pressure Tire cuts, damage and uneven wearing Loose rim and hub nuts Tire groove depth Metal chips, pebbles and other foreign matter trapped in tire grooves Loose wheel nuts and wheel bolts T Rim, side bearing and disc wheel damage 1 ‘Abnormal sound and looseness of front wheel ' bearing 9. Abnormal sound and looseness of rear wheel 1 bearing 10, Front whee! bearing grease replacement L 11. Rear wheel bearing grease replacement L Driving unit eRONS @ 900 900000 © 000 00000 00 9 000 C0000 Chassis springs 1. Damage ' 2. Uneven deflection between left and right t Installation and joints 1. Loosening and damage of installation 1 2. Looseness af joints 1 3._Leat dispiacement I! Suspension arms, 1._Looseness of joints and arm damage It ‘Suspension system ‘Shock absorber 1. Oilleak and damage 1 2._Looseness of installation l oo Jo Jooo Joo Joo o 000 a0000 |o0-16 Inspection items Inspec: Inspection period Every 1 ‘month (170) Every 3 months (500) Every 6 months |_ (1000) Every 12 months (2000) Clutch Pedal play and floor clearance at disengagement 2. Operation 3. Fluid level 4. Cluteh fluid change oo ° ° fo} ° 00 ° 000 ismission system Transmission and automatic transmission 1. Oil leakage and level (transmission) 2. Fluid leakage and level (automatic transmission) 3. Loose operating mechanism Automatic transmission ~ Stall test and oil pressure measurement Transmission - Oil change Automatic transmission - Oil change Automatic transmission - Rubber hose replacement °o 00 00 ° oo 00 00 olommere) 000 Power te Propeller shaft and drive shaft 1. Loose joint 2. Looseness at spline connections 3. Looseness of universal joint 4. Looseness of center bearing 5. Shake of propeller shaft 3__Twisting and cracks of axle shaft 000000 Oil leakage and level Differential 1 2._Differential oil change ° Ignition system Spark plug condition Ignition timing Breaker point condition Operation of advance mechanism Spark plug discontinuity 000 000000 tery Battery fluid level 2. Battery fluid specific gravity 3. Continuation condition of terminal 1 2 3 4 5. Plug cord internal discontinuity 6. Ba Damage of wiring harness 2. Fuses 00 Jooo0-17 —— Inspection period Inspec Inspection items tion | Evert | Every3 | Every 6 | Every 12 method | month | months | months | months (170)_| (600) _| (1000) | (2000) Main body 1, Proper starting and abnormal noise ' ° ° 2 ° 2. Rotating condition at idling and during ' ° ° ° ° acceleration 3. Exhaust condition 1 ° ° ° ° 4. Air cleaner element 1 3 ° ° ° 5. Compression pressure ' ° ° 6. Valve clearance M 0 ° ° 7, Cyclone air cleaner element replacement \ 8. Tightening condition of cylinder head and T ° manifolds Governor 1._ Maximum static speed without load M ° ° ° ° Lubrication system 1. Oilleakage i ° ° ° ° 2. Oil contamination and level ' } 3 ° 3 3. Oil fiter clogging \ ° | 4 Oilchange L ° ° ° ° 2 | 5 Ovtiter change 1 ° ° ° S| Fuel system 1. Fuel leakage ' ° ° &) ° 2. Carburetor linkage operation \ ° 3, Thvotle valve and choke valve operation 1 ° 4. Fuel fiter element clogging 1 ° ° ° ° 5. Injection pressure and spray pattern M ° 6. Injection timing and volume M ° ° 7. Fuel feed pumo operation \ 8. Fuel filter replacement \ ° 8. Fuel hose replacement ' ° 10. Sedimenter water drain \ ° ° Cooling system 1. Water temperature \ ° ° ° 9° 2. Fan belt looseness and damage M ° ° ° ° 3. Water leakage \ 3 ° ° ° 4. Radiator cap operation M ° §, Rubber hose deterioration ' ° ° ° ° 8. Looseness at fan mounting \ ° 3 ° ° 7. Coolant change L ° ° ° 8_ Coolant change (vehicles with LLC) t (4000)0-18 \ Ingpection period inspec Inspection items tion | Every1 | Every3 | Every 6 | Every 12 metiod | month | monthe | months | months (170) | (500) _| (1000) | (2000) Blow-by gas recovery system lz | 1. Metering valve condition ° ° ° ° S| 2. Piping damage ° ° ° ° 2 ®| Fuel evaporative emission control system 2 | 1. Piping damage ° ©) 2 charcoal canister clogging and damage 3 =| 3._Check valve operation ° JE-£| Emission contol system for carbon monoxide, etc. FE 3] 1. Loose mounting and damage of emission con- \ ° 8 trol system (catalytic converter etc.) IS] 2. Secondary air supply unit i ° 22] 3. Piping damage and installation condition ! o 7 a 5 | Heat damage prevention system 1. Loose mounting and installation condition of ° insulating plate Lighting system and turn signal lamps 1. Operaiton I ° ° Hows 1. Operation ° ° ° Back buzzer 1._ Operation ' ° ° ° Wiper, washer, defroster and locks 1. Operation Rear-view mirrors and reflectors 1. Reflecting condition I ° ° ° ° 2. Contamination and damat I ° ° ° ° Instruments Operation ° ° ° 5 | Exhaust pipe and mutter 8 | 1. Looseness and damage at mounting ° & | 2. Mutfler operation ° & | Fuel system for high-pressure gas B | 1. Gas leakage at piping and joint ° ° ° ° | 2. Piping and joint damage ° 3 ° ° 3. Tarin vaporizer ° ¢ ° ° 4. Looseness and damage at gas container ° ° ° 5._Air tightness to the cabin with seats ° Frame and body 1, Door lock operation I ° 2._Looseness and damage I ° Seat 1. Seat belt condition ° Towing device 1._Looseness at draw bar mounting ° ° ° Others 1. Lubricating condition of chassis components ° ° 2_ Steering linkage and universal joint lubrication ° ° °ENGINE Page ENGINE SECTIONAL VIEWS ... 12 ENGINE PERFORMANCE CURVES .... 15 SPECIFICATIONS .. 18 ENGINE ASSY REMOVAL & INSTALLATION ENGINE SPEED INSPECTION & ADJUSTMENT ... AIR GOVERNOR ADJUSTMENT ACCELERATOR PEDAL .... 1-22 COMPONENTS... 1-22 ACCELERATOR PEDAL ADJUSTMENT. 1-23 AIR CLEANER (UP TO ‘98. 2) .. 1-24 GENERAL .... 1-24 SPECIFICATIONS - 1-24 COMPONENTS .. 1-24 INSPECTION .... 1-25 AIR CLEANER (FROM ‘98. 3) 1-27 GENERAL 127 SPECIFICATIONS 1-27 COMPONENTS .. 1-27 INSPECTION ... 1-281-2 ENGINE SECTIONAL VIEWS DZ Engine Sectional View AFL.4Y Engine Sectional Veiw2zZ Engine Sectional ViewENGINE PERFORMANCE CURVES (17.0/1600 17 16 15 14 13 6 55/2400 5 cf 30} 20! 00 190, 18571400 aK) 10. 1478 22 26 Engine speed (rpm) lee Shoft torque (kgm) Fuel consumption (g/pshh DZ Engine Performance Curves16.5/1800 ) 60 54/2400 (PS) 49 Shaft output (PS) ny w rs a 8 S $ 3 195/2300 | fe 6 10 14 18 22 26 Engine rpm (rpm) x10? 4Y Engine Performance Curves i E -200 & 180 2 \e/psh) Shaft torque (kg-m)17 Shaft output (PS) (os) 70 60 40, 30 22/1600 48 5/2000 209/ 1800 bop 10 14 16 22 Engine rpm (rpm) 26 x108 ko) 23 (a/psh) 180 170 160 150 Shaft torque (kg-m) Fuel consumption (g/psh) 2Z Engine Performance Curves1-8 SPECIFICATIONS cee 4 contusion charter pe Yorextse | brestesion Compression pressure kg/ern*/rpm (kPa/rpml (29/260 [2844/260) 33/260 [3230/260) Fae ovo Peto | s92400 2200 Mesum rae teafen Remvent | Tore ea meta] 220 arm Ting speed om e025 750280 Cylinder liner type Ory ype Intake valve opening & closing timing Open BTDC 16° Oil pump type Gear pump: ‘Trochoid pump Engine oil amount £(USgal) | Oil pan capacity 6.0 (1.58) 8,012.11) ee1-9 Engine model ay Type Gasoline Cycle a No.of cylinders and arrangement In-line 4 cylinders, longitudinal arrangement Starting method Selt-starting Combustion chamber type Wedge type Valve mechanisin OHV, Chain drive Bore * Stroke mm (in) 91.0 * 86.0 (358 x 3.39) Total displacement ec (cu-in) 2287 (136) Compression ratio 88 Compression pressure. kg/cm? (psi)/tom [kPa/epm] 12.6 (178)/250 [1225.8/250} Rated horsepower PS/rom 54/2400 Maximum topque kg-m (ft-lb)/epm [N-m/epm) 16.5 (119)/1800 [181.8/1800] ‘Minimum fuel consumption at full load /ps-h (1pm) 200 (2006), Engine dimensions (length * width * height) mm (in) | _ 676 x 12 x 707 (266 x 20.2 x 27.8) Service weight kg (lb) NJ 134 (295) [1314] ‘Number of piston rings 2 compression rings and oil ring Intake valve timing ead 1z BIDE Close 40" ABDC Open 54° BEDC Exhaust valve timing co Patoe intake 0 (Self adjusting) Vaive clearance Exhaust 0 (Self adjusting) Idle speed om 0+) No-load maximum governed speed rpm 2800 + 0 PCV system type Closed type410 ENGINE ASSY REMOVAL & INSTALLATION The state of the engine ASSY removed iram the vehicle is as follows. Automatic transmission vehicle (Up to '95. 5) .. Automatic transmission vehicle (From ‘95. 6)... Clutch vehicle Engine ASSY wiautomatic transmission . Individual engine ASSY .. Engine ASSY wimenual transmission Operation procedure (Up to ‘95. 5) (No. indicates the removal step No.) Engine ASSY Removal & instalation TarMse REMOVAL (Drain cooling water. [2 Remove the engine hood _ Disconnect the battery terminal and remove the battery [Point 1] Disconnect electrical wiring, uel pining and power steering piping Disconnect the accelerator wire and automatic transmission throttie cable (in ATM vehicle only) on the engine side Disconnect the exhaust pipe. Remove the front grille Remove the radiator ASSY and torque converte Remove the engine mounting bracket set nuts Disconnect the shift lever link rod. oler. [Point 2] Bee88o8a Disconnect the speedometer cable and each switch wiring Disconnect the propeller side an the transmission side Remove the toe board ‘¢ Remove the torque converter drive plate set bolts. [ATM vehicle] [Point 3] «# Disconnect the clutch release cylinder piping. [MTM vehicle] fe Remove the clutch cover and clutch disc, [MITM vehicle} Support the rear part of the transmission with a pantagraph jack. [Point 4] Disconnect the torque converter cooler hose. [Point 5] «# Slightly hoist the engine ASSY w/automatic transmission, [ATM vehicle] [Point 6] «Slightly hoist the engine ASSY w/manual transmission. [MITM vehicle] ‘¢ Remove the automatic transmission rear set bolts. [Point 7] ‘© Remove the manual transmission rear mounting bracket set bolts. ‘@ Remove the engine ASSY w/automatic transmission [Point 8] ‘@ Remove the engine ASSY w/manual transmission. «¢ Separate the engine ASSY from the automatic transmission. [Point 9] «¢ Separate the engine ASSY wi/clutch housing from the manual transmission Remove the flywheel and drive plate housing. [ATM vehicle] Remove the flywheel and clutch housing. [MTM vehicle] aa aaa Boas @ INSTALLATION The installation procedure is the reverse of the removal procedure. Caution: Always operate as follows after engine installation. © Inspect and adjust the engine speeds. (See page 1-12, 1-13) ‘© Bleed air from the power steering system. (See page 9-11) © Drive the vehicle to check the feeling of the automatic transmission.1.12 OPERATION POINTS Point 1 Removal Disconnect the negative © Installation Connect the negative ttery terminal first 5 battery terminal later Point 2 Remove installation Carefu ly operate the prevent the radiator and ‘orque converter fins from damage Point 3 (ATM vehicle) Remave/installation Jse the crank pulley set bolt when rotating the riverter. Installation Tighten the set bolts to the specified torque after stalling all set bolts temporarily T= 15 ~ 2.0 kg-m (10.8 ~ 14.5 ft-lb) [14.71 ~ 19.61 Nem] Point 4 Removal/installation Supply the rear part of the transmission with dantagraph jack. Do not raise the jack exc sively, Disconnecting the Battery © Terminal Removing the Radiator Supporting the Transmission TarS27-12Point 5 Removal Take notes of the tions ;aler hose connecting posi Installation Connect the cooler hoses according to the memos taken at the time of disconnection Point 6 Removal/installation SST 09090-04010 Point 7 [ATM Vehicle] Removal/installation: Four set bolts (two upper and two lower bolts) are used on one side. @ Loosen the mounting set nuts for easier op- eration Installation Align the mounting holes by operating the pantagraph jack Point 8 Removal/insiallation Adjust the length af the chain of SST 09090- 04010 and pay sufficient attention to the sur- rounding area operation. Disconnecting the Cooler Hoses Rear Set Bolts [ATM Vehicle) Removing the Engine ASSY w/ATM114 Operation procedure (From ‘95. 6) (No. indicates the removal step No.) REMOVAL D _ Drain cooling water. Remove the engine hood. Disconnect the battery terminals and remove the battery. [Point 1] Disconnect the electrical wiring, air cleaner hose, fuel piping and power steering pipirg. Disconnect the accelerator wire and automatic transmission throttle cable (only in ATM vehicle) from the engine side. {®) Disconnect the exhaust manifold ‘T) Disconnect the engine hood opener wire and remove the plate, 8) Remove the radiator ASSY. [Point 2] Remove the torque converter drive Oplate set bolts. [Point 3] Remove the engine mounting bracket set nuts. Support the transmission at its front bottom with a pantograph jack. [Point 4]115 t 5] 12] Temporarily hoist the engine ASSY. [Pt [3 Remove the drive plate housing set bolts. Remove the engine ASSY. INSTALLATION The installation procedure is the reverse of the removal procedure. Coution: Always perform the following jobs after installing the engine: © Engine rpm inspection and adjustment (See page 1-18) © Bleed air from the power steering system. (See page 10-11) © Drive the vehicle to check the ATM feeling.1-16 OPERATION POINTS Point 1 Removal Disconnect the battery negative terminal frst. Installation: Connect the negative terminal later. Disconnecting the Battery Negative Terminal Point 2 Removal/instaliation: Carefully operate so as not to damage the radiator and torque converter cooler fins. Point 3 (ATM vehicle) Removal/installation: Use the crank pulley set bolt for rotating the converter. Installation: Tighten the set bolts to the specified torque after temporarily installing all of them, T= 15 ~ 2.0kg-m (10.8 ~ 14.5 ft-lb) (14.71 ~ 19.61 N-m1 Removing the Drive Pate Set Boks Point 4 Removal/installation Support the transmission at its front bottom ‘vith a pantograph jack. Do not raise the jack excessively. t arn ‘Supporting the Transmission atthe Bottom TASTE117 Point 5 Removal/instaliation: SST 09090-040201:18 ENGINE SPEED INSPECTION & ADJUSTMENT (1DZ-22 Engine) IDLING SPEED INSPECTION AND AD- JUSTMENT 1. Warm up the engine, Coolant temperature: 80°C or above Engine oil temperature: 60°C or above 2. Set the tachometer 3. Inspect the idling speed (1) Check the accelerator wire return status, and confirm contact between the inje pump idle adjusting screw and adjusting lever. (2) Idling speed Standard: 650 + 59 rpm (10z) 750 + 50 rpm (22) (From '98. 3) 4, Adjust the idling speed. (1) Loosen the lock nut and turn the adjusting screw for adjustment. 5§ rpm (1DZ) Standard: 650 + ‘780 + 50 rpm (22) (From ‘98. 3) (2). Tighten the lock nut, and inspect the idling speed again, MAXIMUM SPEED INSPECTION AND ADJUSTMENT 1. Warm up the engin 2. Set the tachometer. 3, Inspect the no load static maximum speed (() With the engine in stopped state, depress the accelerator pedal fully and check that the adjusting lever is in contact with the maximum set screw. (2) Start the engine and measure the engine speed when the accelerator pedal is de- pressed fully. Standard: 2600 + 50 rpm (12-22) 4, Adjust the no-load static maximum speed. (/) Unseal the set screw, and tun the set screw for adjustment Standard: 2600 + 50 rpm (102-22) (2) After adjustment, seal the set screw, Ba ‘Adjusting the No:load Static Maximum Speed1:19 (4Y Engine) IDLING SPEED INSPECTION AND AD- JUSTMENT 1. Warm up the engine. Coolant temperature: 80°C or above Engine oil temperature: 60°C or above 2. Set the tachometer and vacuurn gauge (1) Disconnect the connector for inspection from the tachometer measuring cord, and connect the cord to the black wire side (2) Disconnect the intake manifold plug, and set the vacuum gauge 3. Idling speed inspection and adjustment (1) Start the engine. Alternately adjust the throttle adjusting screw @ and idle adjust- ing screw ® to obtain stabilized maximurn degree of vacuum at the specified idling speed (2) tf the idle up actuator rods in contact with the adjusting screw to make lowering of the idling speed difficult loosen the idle up adjusting screw. Standard: Idling speed: 650 + °Q rpm Vacuum: 400 mmbg or above ‘Adjusting the Idling Speed KAN4251-20 AIR GOVERNOR ADJUSTMENT e E Bushing ® Spring @ A219 +03 mm (086 + 0.012 in) B: Effective number of spring winding: 13. ‘Air Governor Adjustment KAIS62 ADJUSTING PROCEDURE FOR EACH PART Lock bolt © Counterclockwise turn ..... Unlocks busing ®. Clockwise turn Locks bushing ®. Bushing @ Counterclockwise turn ..... Decreases the no-load static maximum spee Clockwise turn Increases the no-load static maximum speed, Caution: Fix screw © always with a screwdriver when turning bushing @, Adjusting screw © Counterclockwise turn .... Decreases the relief down at power steering. Retum 1/10 tum clockwise from the state where the relief down is the smallest to correct the torsion of spring ©. Clockwise turn Decreases hunting at the no-load and loaded static maximum speed. Tur the adjusting screw gradually clockwise. Return it by 1/4 tum counterclockwise from the position where hunting is eliminated. Tur it again clockwise by 1/10 turn to correct the torsian of spring @NO-LOAD STATIC MAXIMUM SPEED INSPECTION & ADJUSTMENT Warm up the engine Coolant temperature: 80°C or above Engine oil temperature: 60°C or above 2. Set the tachometer. Adjust the no-load static maximum speed (1) Remove the sealing (2) Loosen the bushing lock bolt. (3) Measure the engine speed when the accel erator pedal is fully depressed (the throttle valve is fully opened) Above the specified maximum speed Turn the bushing counterclockwise @ Below the specified maximum speed Turn the bushing clockwise - @ No-load static maximum speed: 2800 + 50 rpm 4, Adjusting hunting (1) If hunting is generated at the no-load and. loaded static maximum speed as a result of adjustment in steps 3 and 4, adjust it by turning the bushing and adjusting screw. Adjusting screw Hunting adjustment Bushing Maximum speed adjustment Caution: If hunting disappears in a few cycles, it is regarded as no hunting, Repeat steps 3 to 5 above for setting to the standard adjustment value (2) After adjustment, seal the screw. Setting the Tachometer Hunting adjustment KAISOS1-22 ACCELERATOR PEDAL COMPONENTS Aajind sowerejeooy 7B (oursua av) ASsv-ans Aaling suuysng vor jeooy OZ jeo0y OL (ousbu3 za) ‘Accelerator Pedal Components1-23 ACCELERATOR PEDAL ADJUSTMENT | Stopper bolt 0 ~0.5 mm (0~0.0197 in.) ‘Adjusting the Accelerator Pedal TAFS228, 251 1. Pedal height adjustment ‘Adjust the height of the pedal tip end (with pad) from the front floor to 149 mm (5.87 in) by turning the stopper bolt Accelerator pedal height (with pad) 149 mm (5.87 in} Accalerator wire adjustment ‘Adjust the accelerator wire bracket mounting position to make the distance between the accelerator wire clamp and clevis 0 ~ 0.5 mm (0.0197 in) at the idling position.1:24 AIR CLEANER (UP TO '98. 2) GENERAL Air leaner element Ar Cleaner Single) SPECIFICATIONS Single (standard) Double (option) Filtering area em tin) 14200 (2201) Cui aleanL eee) inner: 635 (82.9) Fite medium Filter paper © COMPONENTS ace : \\ 26 EK OG Ne - 1703-295 1703 Air Cleaner Components1-25 INSPECTION Air Cleaner Element Inspection and Cleaning 1, Open the engine hood and remove the air cleaner cap. 2. Remove the element 3. Remove the dust cap and clean the dirt accumulated in the air cleaner cap. 4, Element cleaning (1) For cleaning in ordinary status, blow compressed air (690 kpa (7 kg/cm [100 psil or less} form the inside of the element along the pleets If the element is heavily contemineted, washing is possible (2) Element washing method Dissolve a neutral detergent in tepid water (about 40°C). Immerse the element for about 30 minutes in the washing liquid, and then rinse it thoroughly with clean water. (The water pressure must be 275 Kpa (2.8 kg/cm’) [40 psil or less.) Caution: Carefully protect the filtering paper from damage during washing. After washing, dry it by standing or with a dryer (cold air Caution: Do not use compressed air or hot air for drying. Lee y Cleaning the Air Cleaner Cap we EE \, Element Cleaning the Element Washing the Element1-26 Clogging Warning Inspection 1, Warning lamp inspection (1) Check that the air cleaner warning lamp comes on when the ignition switch is tumed on, and goes off when the engine starts AIR CLEANER Inspecting the Warning Lamp 2. Irdividual inspection 7 (1) Use Mighty Vac and inspect vacuum switch for conduction upon application of a negative pressure. Switch-on pressure | Switch-off pressure -260 ~ -360 mm Aq | -210 ~-340 mm Ag 19.1 ~-26.5 mm Ha | ~15.4 ~-25 mmHg Gasoline 610 ~-790 mm Ag | -870 ~ -780 mm Ag 44.9 ~ -58,1 mm Hg | ~41.9 ~ -67.4 mm Hg Diesel Inspecting the Individual Vacuum Switch 3. Vacuum switch wiring (1) A nonpolar sensor is adopted as the air wt. cleaner clogging sensor (warning lamp sensor} to prevent erroneous wiring. 4 The sensor set pressure is different between gesoline engine vehicles and rw. } diesel engine vehicles. Vacuum Switch Wiring1:27 AIR CLEANER (FROM '98. 3) GENERAL Evacustor valve Ale Cleaner (Single) SPECIFICATIONS Single (STO) Double (OPT) Tyee Cyclone type. = Size. inch = Intake $yp2 Fresh air introduction type = Outer: _18€00 (2883) Fitering area i 14600 (2263 ae clea : J Inner: 510 (79.1) Others With evacuator valve = COMPONENTS 1703 ‘Air Cleaner Components1:28 INSPECTION Air Cleaner Element Inspection and Cleaning 1. Open the engine hood. 2. Remove the element. 1) Element Caution: In case of the double element type (OPT), do not remove the inner element for other than replacement. 3, Clean the element. I) For ordinary cleaning, blow with compressed air [690 kPa (7 kg/ern?) [100 psi] oF less] vertically along the pleats from the inside of the element. If heavily contaminated, washing is possible. 12) Element washing method Dissolve neutral detergent in tepid water (approx. 40°C (104°F)) and immerse the element in it for about 30 minutes. Then, rinse the element well with clear water. [Water pressure: 275 kPa (2.8 kg/cm’) 140 psil or less] After washing, naturally dry the element or dry the element with a dryer (cold air. Caution: ‘Do not damage the element during washing. * Never use compressed air or hot air for drying. 4. Clean the evacuator valve (dust discharge valve) 11) Hold the tip end of the evacuator valve and discharge dust and dirt from the inside of the valve. 5. Inspect the element. 1) After cleaning, place an electric bulb in the element to inspect any damage in the element. If any pinhole, tear or damage is found, replace it with @ new element. 6. Element replacement Replace the element after it is washed six times or generally at intervals of 12 months. Tagpect the ElementClogging Warning Inspection 1, Warning lamp inspection (1) Check that the air cleaner warning lamp comes on when the ignition switch is tumed on, and goes off when the engine stats 2. Individual inspection (1) Use Mighty Vac and inspect vacuum switch for conduction upon application of a negative pressure. = 270 ~ 330 mm Ag Gasoline 199 ~ 233mm Hg ; 706 ~ 820 mm Ag ca 51.7 ~ 60.3 mm Hg 1-29 Inspecting the Warning Lamp Inspecting the Individual Vacuum SwitchAUTOMATIC TRANSMISSION (UP TO '95. 5) Page SECTIONAL VIEW 2-2 SPECIFICATIONS 2-3 COMPONENTS 2-4 INSPECTION & ADJUSTMENT 2-14 ELECTRICAL CONTROL .. 2-26 AUTOMATIC TRANSMISSION (ATM) REMOVAL & INSTALLATION (ENGINE ASSY w/ATM REMOVAL & INSTALLATION) . 2-27 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION (INDIVIDUAL ATM REMOVAL & INSTALLATION) .. 2-29 TORQUE CONVERTER ASSY 2-30 DISASSEMBLY . 2-30 INSPECTION 2-32 REASSEMBLY 2-34 AUTOMATIC TRANSMISSION ASSY DISASSEMBLY .. MANUAL VALVE LEVER & SHAFT OIL PUMP ... + 2-53 TRANSMISSION INPUT SHAFT & OVERDRIVE CASE .. 2-57 FRONT CLUTCH ASSY 2-59 REAR CLUTCH ASSY .. 2-67 CENTER SUPPORT ASSY 2-72 PLANETARY GEAR ASSY & OUTPUT SHAFT . 2-78 FIRST & REVERSE BRAKE ... 2-86 GOVERNOR VALVE ASSY 2-91 VALVE BODY ASSY ...... 2-96 FRONT UPPER VALVE BODY ASSY . 2-104 REAR UPPER VALVE BODY ASSY 2-112 LOWER VALVE BODY ASSY ....... 2-123 TRANSMISSION ASSY REASSEMBLY 2-134 2-38 2-50SECTIONAL VIEW ‘Automatic Transmission23 SPECIFICATIONS 02-2TD(G)20, 02-2TD23, 02-2TD(G)25 Srelement, T-stage, 2-phase type, hydraulically con- Type trolled planetary gear 3-speed automatic speed changer Torque converter stall-torque 2.86 set specd_| 9078 2nd Forward 1.967 Speed change ratio speed - 3rd xeea | 1900 ; Reverse 2.655 Oil used GM Dexron®ii Oil capacity (US gal) | About 10 12.64) 02-2TD15, 02-2TD18 Sc-element, 1-stage, 2-phase type, hydraulically con Type tolled planetary gear 2-speed automatic speed changer Torque converter stall-torque ratio 2.86 set speed _| 1507 Speed ch a Fost ond Speed change ratio nd | speed _| 100 Reverse 2655 GM Dexron® (US gal) | 10 (2.64)24 COMPONENTS 20 Torque converter No. 1 case SUB-ASSY 21 Speedometer sleeve SUB-ASSY 22 Transmission case SUB-ASSY 30 Oil level gauge SUB-ASSY 45 Oil pan 45A Oil pan packing 458 Drain plug 52 Speedometer driven gear 58 Neutral start switch AD Oil seal AF Gasket AD Magnet Lock plete Cover Oil seat Clip Spacer Clamp it filler tube SUB-ASSY Transmission rear housing Gasket ‘Manual valve lever SUB-ASSY ‘Manual valve lever shaft ‘Transmission corteol shaft lever ‘Automatic Transmission Housiung Components TAFME7.117.118on " 12 4 20 21 23 24 25 26 28 30 3 45, Torque converter ASSY Oil pump ASSY Stator ASSY Pump impelier ASSY Drive plate ring gear ASSY Turbine runner SUB-ASSY il pump drive gear il pump driven gear Pump impeller SUB-ASSY Stator SUB-ASSY Drive cover SUB-ASSY il pump case SUB-ASSY Extension SUB-ASSY Stator hub 458 Thrust washer No.1 ‘50. Oil pump case cover packing 52 Roller 53 Spring 54 Spring cap AQ. Thrust plate AG. Turbine front washer AS. Drive plate spacer AT. Center ring suppor AX. Oil seat AY. Spacer DX_ Front oll pump cover EA Check ball EB Compression spring TAFME®01 Governor body ASSY 40 Governor body 40A Governor body gasket 41 Governor bady suppor AA. Governor oil strainer AB Governor No. 1 valve Governor Components Ac AD AE AG As AK Governor No. 2 valve Compression spring Spacer Governor woight Ring Governor valve No. 2 shaft TAFMS®2 26 404 408 aA a8 cL cr cu cv cw x Clutch No. 2 drum SUB-ASSY Clutch No. 1 shaft SUB-ASSY Front clutch disc Rest clutch dise Front clutch plate Rear clutch plate Thrust bearing Overdrive case SUB-ASSY Thrust bearing ace ‘Thrust bearing race Front clutch piston SUB-ASSY Rear clutch piston SUB-ASSY cy cz DA oB oc op DE DF pe DH DI DJ Compression spring Return spring seat Thrust bearing Thrust bearing race Front eluteh hub Thrust bearing race Compression spring Thrust bearing race Thrust bearing Roar clutch hub Return spring seat Clutch cushion plate ok oN op eM EN ep co ER ES fT eu ev Rear clutch flange Thrust bearing race Input shaft oil seat ring Clutch drum oil seal ring Center support O-ring retainer ‘Transmission input svaft SUB-ASSY Input shaft sleeve ‘Transmission input shaft flange Oil seal ring Thrust bearing race Thrust bearing race Thrust beating | Transmission Components (I) TAFM60, 1929 aoc 40C Clutch disc (for brake) EA. Oil seal ring AIC Brake plate EB Rear planetary sun gear cP Washer EC. Center support ting retainer DQ. 2nd brake piston return spring SUB-ASSY DT Brake No.1 piston DV. Brake No.1 flange DW Front planetary sun gear sub-assy DY Center support SUB-ASSY Torqueconverter Clutch TaRMTal2-10 13 “4 45 51 AK ps. or bu Front planetary gear ASSY Rear planetary gear ASSY ‘-way clutch ASSY (Out put No.1 Shatt ‘Speedometer drive gear Spacer Intermediate shaft Planetary carrier thrust No.1 washer Planetary carrier thrust No.2 washer bv by oz EA EB EC ce EF Front planetary carrier ring gear Rear planetary ring gear Rear planetary ring gear flange Thrust needle roller bearing ‘Thrust needle roller bearing Thrust bearing race Output shatt flange ‘Thrust bearing raco Torqueconverter Gear TARA?211 x HG HH HI HK HL HM HN Hz KA Ke Ko KE KF KI Plug Lockup relay valve Compression spring Lockup relay control valve Lockup relay valve No. 1 sleeve Lockup relay valve No. 2 sleeve Lockup relay valve body plate Lockup relay valve body gasket Primary regulator valve Compression spring Washer Primary regulator valve plunger Primary regulator valve sleeve Manual valve Ball Lo u uw Lo ME Ma Mi NJ MK Ms NE NF NI Ny NY Valve body cover plate Lower modulator vaive Compression spring Low coast shift valve 1-2 telay valve Compression spring 1.2 shift valve Compression spring Second lock valve Valve body No. 2 cover 3-2 kickdown orifice control valve ‘Compression spring ‘Accumulator contro! No. 1 valve Compression spring ‘Apply tube ‘Transmission Components (3) ‘TAFM62AG cy HD HF > HU HY HW HK KV le UF Le u u un Ls u uw Plug Plug Lockup signal valve Compression spring Spring seat Secondary down seat plug SUB-ASSY Compression spring Primary down seat valve SUB-ASSY Compression spring 2.3 shift timing valve plug 2.3 shift timing valve plug sleeve Intermediate modulator valve Compression spring Lower modulator valve Compression spring Throttle valve No. 1 sleave 2-3 shift valve Compression spring Cutback valve Throttle valve No. 2 sleave Transmission Components (8) ma, MB mc. MN. Mo. mp my mw Mx NA NB NC ND NM NP No NT Nu PN Pu Spring Throttle valve Compression spring Intermediate coast shift valve Secondary regulator valve Comprossion spring Third coast valve Overdrive clutch exhaust valve Compression spring Secondary throtte valve Compression spring 2.3 shift timing valve Compression spring Manual down timing valve 3-4 shitt valve Compression spring 3-4 coast shift valve Throttle valve cam ASSY Apply tube Intermediate coast shitt sleeve TAFMES. 121a 16 7 18 ay DR cy oz He Ho HR Hs Transmission cover & valve ASSY Lower valve body ASSY Rear upper valve body ASSY Front upper valve body ASSY Spring Control valve body plate Overdrive brake accumulator piston Front clutch accumulator cover Front clutch accumulator plate Apply tube Oil strainer SUB-ASSY Gasket Transmission Components (5) HT HY KO KP. Ka KR Ks KT. Kx. Nx NY Throttle oil strainer Manual detent spring SUB-ASSY 8-2 accumulator piston Compression spring C-1 accumulator piston Compression spring C-2 accumulator piston Compression spring Ball Detent spring cover Transmission table arply tube 2.132.14 INSPECTION & ADJUSTMENT AUTOMATIC TRANSMISSION FLUID LEVEL CHECK 1. Engine inspection Note: Refer to each engine repair manual for the engine inspection method 1DZ Engine Repair Manual No. CE618 AY Engine Repair Manual No. CE602 1) Inspect the idling speed. Standard +50 102: 650 *80 rpm +50 4¥: 650 +80 rpm 2) Inspect the injection ignition timing (4Y) SST 09275-54010 SST 09240-32880-71 ning (1DZ) and Standard 1DZ: 0° (stationary) BTDC AY: BTDC 7"/rpm 2. Fluid level check ution: © Park the vehicle on a flat ground, © Check the level at the fluid temperature (70° ~ 80°) in normal traveling state. 1) Apply the parking brake. 2), Move the shift lever fully from the N range to the L range with the engine in idling state, and return the lever to the N range. 3) Check that the fluid level is in the HOT range on the level at the N range in idling state. Caution: Inspecting the Injection Timing (102) kans-s Inspecting the Fluid Level 047s © When level check at a low oil temperature (20 ~ 30°C) is necessary for oil replacement or other purpose, adjust to the COOL range on the gauge and check under HOT conditions later. © If the level is different between the front and rear sides of the level gauge, use the lower one for measurement. © Carefully prevent excessive oil as it may cause various troubles. @ If the oil level is insufficient, check oil leakage. Fluid used: GM Dexron®ll volume: About 10 @ (2.64 US gal) The amount of oil to be replaced every 6 months (1,000 hours) is 2.0 t0 2.5 g (0.53 10 0.66 US gal).2-15 THROTTLE CABLE INSPECTION & ADJUSTMENT Throttle cable inspection and adjustment (1) Depress the accelerator pedal fully and push the throttle fever to check full opening. I not fully opened, adjust the accel 2, Throttle cable inspection and adjustment (1) Check that the throttle cable is securely installed to the throttle lever without any bend. (2) Measure distance between the edge of the cable adjustment mark and the cable end face when the throttle valve is fully closed Standard: 0.5 ~ 1.5 mm (0.0197 ~ 0.059 in) If the standard is not satisfied, use the adjusting nut for adjustment. x When a boot is provided, remove the boot and adjust the distance between the cable end face and cable adjustment mark to 0.5 ~ 1.5mm (0.0197 ~ 0.059 in) (3) Inspect the cable stroke when adjusting the injection timing and/or injection pump. (1DZ engine vehicle) Reference value: 33 = 1 mm (1.3 + 0.039 in) Inspect the cable stroke when adjusting the ignition timing or replacing and adjust ing the 1A (4Y engine vehicle) Reference value. 33 + 1 mm (1.3 + 0.039 in) Note: Loosen the throttle cam adjusting nuts and move the throttle cam for adjustment. Caution: Perform inspection in step (2) after the ad- justment. (4) Caulk the lock nut, and fix the nut 33£1 mm (1.3 £0.039 in.) ote ae 05~1.5mm Tos = DF —— Inspecting the Throtle Calbe (12) TAFS23 0.5 ~1.5mm (0.0197 ~0.059 in.) ‘Throttle cam Adjusting bott Ingpecting the Throttle Cable (4Y) ‘TAFS252-16 NEUTRAL START SWITCH INSPEC- TION 2 Functional check () Apply the parking brake (2). Check that the engine starts when the shift lever is shifted to the N range, and does not start in any other range. (3) Be sure that the backup lamp does not come on unless the shift lever is in the range Adjustment (1) Loosen the neutral start switch set bolts (2) Set the shift lever to the N range. (3) Align the cut groove on the switch with the neutral reference line by moving the switch. (4) Tighten the set bolts T= 1.3 kg-m (9.4 ft-lb) [12.75 N-m] ‘Adjusting the N PositionON-VEHICLE INSPECTION Caution: Conduct each test after the end of basic inspec- tion and adjustment. STALL TEST Caution: state. D and R ranges. Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling Do not continue the test over 5 seconds, Wait at least 1 minute between the tests in 7 Inspecting the Oil Temperature ‘TAFS30 1. Carry out measurement according to the illus: trated procedure. Stall speed Standard 1DZ engine: 4Y engine: 2130 ~ 2430 rpm 2100 ~ 2400 rpm AN Shift to the D(R) range. Depress ‘the brake pedal with the left foot. ‘and dapress the accolerator pedal fully with the right foot. Quickly read the maximum engine speed at the time. Note: Estimated defect as a result of stall test ‘Sail Test TAFMT2 When the stall speeds in both ranges are equal but lower than the standard: Throttle valve is not opened fully The engine output is insufficien he stator one-way clutch is detective torque converter dafect may be the reason ifthe stall speed is lower by 600 ( Tpm of more than the standard valve) When the stall speed in the D range is higher than the standard: The front clutch is slipping. Ine-way Clutch No. 21s defective. The line pressure is iow. When the stall speed in the R renge is higher than the standard: The rear clutch is sliping, he Ist & reverse clutch is slipping. fe line pressure is low. When the stall speeds in both ranges are higher than the standard The line pressure is iow. he fluid level is outside the standard (insufficient)2:18 TIME LAG TEST Caution: ‘* Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling state. ‘# Wait at least one minute between tests. ‘* Measure three times, and average the re- sults. {1) Camry out measurement according to the illustrated procedure Time lag Inapecting the Ol Temperature TaFs20 Standard: N-D range 0.7 sec max. N-R range 1.2 sec max. 1.2 seconds 9 or less + 0.7 seconds or less Note: Estimated defect as a result of time lag test, ‘Measuring the Time Lag Wren the N — D time lag is ionger | @ The line pressure is low. than the standard The front clutch is worn Wren the N -+ R time lag is longer than the standard: © The line pressure is low. © The reverse clutch is worn The Ist & reverse brake is worn,2.19 HYDRAULIC PRESSURE TEST Caution: Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state. 1. Governor pressure measurement (1) Cary out measurement ilustrated procedure. Measuring instrument: OPG-100 See the fold out hydraulic circuit dia- gram at the end of this manual. ording to the Inspecting the Oil Temperature TaFS@ Standard Output shat speed rpm] 0 | 500 1000 soo | egea%)_ | ease” Travel- [2nd speed km/h] 0 43 86 123 172 218 Sea _[2respeee ken] 0 Bi 103 14 208 256 Governor pressure kg/cm? “| 05 ~08 22 ~ 27, 3.6 ~ 4.0 53 ~ 6.0 75~ 85 fos] 0 | crea 1i'a | eat? ~ 28) | rst ~ 880) | (753 ~ 882) | i008 ~ 126.2) Ke} {a = ras} | Gre7 = doa | (aoa ase) | (ora ~ Seba | (rose ~ 2096 Remove test plug and install pressure gauge TAFMS Note: Estimated defect as a result of pressure test ro | & The governor valve is defective2-20 2. Line pressure measurement ic illustrated procedure Measuring instrument. Oil pressure gauge Standard sry out measurement according to the Engine speed Idling speed Maximum speed pressure gauge (above neutral start switch). DSO © Note: Estimated defect as a result of the pressure test 4 lating Stall TAFMa2 When the oil pressures in both ranges are higher than the stan. dards ‘© The regulator valve is defective ‘© The throttle valve is detective © The throttle cable adjustment is improper. Wher the oil pressures in both ranges are lower than the standards: © The oil pump is defective © The regulator valve is defective © The throttle valve is detective. @ The throttle cable adjustment is improver When the oil pressures in the D. range are lower than the standards: When the oil pressure in the R. range are lower than the standards: @ Oil is leaking from the D-range hydraulic circuit @ The front clutch is defective Oil is leaking from the R-range hydraulic circuit © The 1st & reverse brake is defective, @ The rear clutch is defective.2-21 DRIVING TEST Caution Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state. 1. D-range test (1) Shift to the D-range and start the vehicle at each valve opening (50% and full open. ing). Check each up-shift and shifting point in conformity with the automatic speed change curves. Note When 1-2 | @ The governor valve is defective. upshift is not | @ The 1+2 shift valve is defec: effected: tive. When 2-93 | eThe 253 shift valve is uoshift is not | defective offected: © The governor valve is defective. Thethvottle cable improper. he throttle valve, 1+2 valve, 2-+3 valve or governor valve is defective, adjustments is improper: (2) Inspect abnormal sound, slipping and shock upon shifting at the time of acceler- ation or deceleration Note: Estimated defect as a result of driving test ‘When the The line pressure is high shock is @ The accumulator is defective excessive’ @ The check ball is defective (3) Carry out kickdown during traveling at each of 2nd and 3rd gear positions to inspect if the limit speed for 2-1, 3-+2 or 3-+1 kickdown matches that on the auto matic speed change curves, = & Throttle valve fully open (100%) ‘Throttle valve “* halfway open (50%) Throttle valve ‘opening (%) Len somt nh ‘Automatic Speed Change Curves TAFMII4 Abnormal noise, slipping ® Shock at shifting Inspection at Acceleation/Deceleration zg i s ‘Throttle valve g halfway open (59%) | 5 Throttle valve Vehicle speed (kin/h} ‘Automatic Speed Change Curves Tars2022-22 (4) Shift to each of the 2- and L-ranges diving driving in the D-range to inspect the en. gine braking effect in each range. Note: Estimated defect as a result of driving test No engine braking om ater tao 2nd brake malfunctioy No engine braking Ist & reverse brake effect in L-range malfunetion (5). Release the accelerator pedal from near 18 km/h (in 3-speed vehicle) while traveling in D-range and shift to the 2-range. Check if the 3 2 down-shift point matches the automatic speed change curve, (6) Release the accelerator pedal from near 9 km/h (3-speed vehicle) or 13 km/h (2- speed vehicle) while traveling in D-range and shift to the L-range. Check if the 2 + 1 down-shift point matches the automatic speed change curve nge test (1) Start the vehicle at each throttle valve opening (50% and full opening) and check if the 1 + 2 up-shift point matches the automatic speed change curve. gnu se i | ES" i ae, suse Wail eed Te rd shift ————+ Actomatie Spend Change Cove aren g EE a) ora socea! ror 2 speed es | { Sooo ‘Automatic Speed Change Curve f) Throttle valve opening (%) Vehicle speed (km/n) ‘Automatic Speed Change Curve o\.< wl h + Qrmneyonn 60%) tv 68. Throttle valve * fully open (100%) —____]3 (2) During traveling at the 2nd gear position, release the accelerator pedal and check the engine brake function. (3) Carry out kickdown from the 2nd gear state, and check if the speed allowing 2 + kickdown matches the automatic speed change curve. (4) Check abnormal sound of slipping during acceleration and deceleration. L-range test. (1) Check no up-shift to the 2nd gear 2:23 (ee Inspecting the Engine Brake Function TAFSZI3 ( z 3. = i F Vehicie traveling speed (km/h) ‘Automatic Speed Change Cue TAFSZI5 ‘sound Deceleration Up-shitt a Down-shift Inspecting Abnormal Sound and Slipping ‘TAFSZI7 )0«e Inspecting Up-shitt, Tarsz92:24 (2) Release the accelerator pedal during trav- ling at the first gear position, and check the engine brake function (3) Check abnormal sound or slipping during acceleration and deceleration. 4. Rerange test (1) Startthe vehicle with the throttle valve fully ‘opened, and check any slipping. (Tr) ty Engine brake Inspecting the Engine Brake Function 2 Slipping Inspecting Abnormal Sound and Siping —=S«C‘TAPS229 TAFS221 “Acceleration | Deceleration © ‘Throttle full opening | & ‘Slipping Inspecting Sipping TAPSAUTOMATIC SPEED CHANGE CURVES 2:25 ee & $ 8 8 8 g & ° ¢ ¢£ ‘Throttle valve opening (%) o is Tutomatie Speed Change Curves Taras2:26 ELECTRICAL CONTROL CIRCUIT DIAGRAM Circuit Diagram TAFS238 NEUTRAL SWITCH INSPECTION 1. Remove the toe board 2, Inspect continuity between connector termi- nals Standard | Terminal ann clmi|n]es R oo N Inspecting the Switch ~ Tarsz82:27 AUTOMATIC TRANSMISSION (ATM) REMOVAL & INSTALLATION (ENGINE ASSY w/ATM REMOVAL & INSTALLATION) The jobs are the same as in ENGINE ASSY REMOVAL & INSTALLATION. Only the operation procedure is described here. See page 1-10 for the operation points Operation Procedure ‘Automatic Transmission Removal & Installation TAFMES REMOVAL Drain cooling water. Remove the engine hood, Disconnect the battery terminals, and remove the battery. [Point 1] Disconnect the electrical wiring, fuel piping and power steering piping Disconnect the accelerator wire and automatic transmission throttle cable (ATM vehicle only) on the engine exhaust pipe, nt grille. Remove the radiator ASSY and torque converter cooler. [Point 2] Remove the engine mounting bracket set nuts. Disconnect the shift lever link E8888 aaa82-28 8 @ B a o Disconnect the speedometer cable and each switch wiring. Disconnect the propeller shaft on the transmission side Remove the toe bo: ¢ Remove the torque converter drive plate set bolts [ATM vehicle] [Point 3] # Disconnect the clutch release cylinder piping. [MTM vehicle] Support the rear part of the transmission with a pantagraph jack, [Point 4] Disconnect the torque converter cooler hose. [Point 5] « Slightly hoist the engine ASSY w/automatic transmission. [Point 6] @ Slightly hoist the engine ASSY w/manual transmission. @ Remove the automatic transmission rear set bolts. [Point 7] @ Remove the manual transmission rear mounting bracket set bolts. Remove the engine ASSY w/automatic transmission. [Point 8] @ Remove the engine ASSY w/manual transmission. # Separate the engine ASSY from the automatic transmission [Point 9] @ Separate the engine ASSY w/clutch housing from the manual transmission, @ Remove the clutch cover and clutch disc. [MTM vehicle] id GJ Remove the flywheel and drive plate housing. [ATM vehicle) Remove the flywheel and clutch housing [MTM vehicle] INSTALLATION ‘The installation procedure is the reverse of the removal procedure. Caution Operate as follows after installing the automatic transmission. Engine speed inspection and adjustment. (See page 1-12 ~ 1-16) Bleed air from the power steering system. (See page 9-11) Inspect the ATM oil level and add if insufficient. Drive the vehicle to check the ATM feeling2-29 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION (INDI- VIDUAL ATM REMOVAL & INSTALLATION) Auiomatie Tansmision Removal &Tnsilaion Tare REMOVAL Disconnect the battery negative © terminal @ Disconnect the ATM throttle cable on the engine side. Remove the toe board @ Disconnect the ATM electrical wiring and hydraulic piping {© Disconnect the shift lever link rod, [© Disconnect the speedometer cable. {@__ Disconnect the propeller shaft on the ATM side. [B]_ Remove the drive plate set bolts. [Support the engine with a pantagraph jack placed under it. Slightly hoist the ATM. [Remove the ATM housing set bolts, Remove the ATM rear set bolts. {Remove the ATM ASSY. INSTALLATION The installation procedure is the reverse of the removal procedure.2-30 TORQUE CONVERTER ASSY 1. Remove the torque converter ASSY. (1) Torque converter ASSY Caution Drain oil from the converter after removing the torque converter ASSY. DISASSEMBLY 2, Remove the drive cover SUB-ASSY (1) Punch a match mark on the drive cover SUB-ASSY and pump impeller SUB ASSY, (2) Set bolts (3) Drive cover SUB-ASSY Caution If drive cover removal is difficult, blow com. pressed air. The drive cover comes out easily. Be careful not to leak air. 3. Remove the turbine runner SUB-ASSY. (1) Turbine front washer 2) Turbine runner Punching the Match Mark TARz1.29 Removing the Drive Cover TARz-204 6 Remove the stator ASSY. (1) Stator ASSY (2) Thrust bearing race (3) Thrust bearing (4) Thrust bearing race Remove the pump impeller extension. (1) Set bolts (2) Extension Disassemble the stator ASSY. (1) Snap ring (2) Thrust washer No. 1 (3) Thrust plate (4) Snap ring (8) Thrust washer No. 2 (6) Thrust plate Removing the Thrust Washer TAF23.62-32 (G) Clutch hub (8) Roller (9) Spring cap (10)Spring Caution: Carefully remove the roller, spring cap and spring so as not to lose them INSPECTION Caution: Wash each part thoroughly with washing fluid to remove dirt and dust perfectly. 1. Crive cover inspection (1) Crack and damage on cover (2) Damage at contact surface 2. Pump impeller inspection (1) Crack and damage at impeller (2) Crack and damage at blade 3. Pump impeller extension inspection (1) Wear at sliding portion of extension (2) Crack in O-ring Removing the Clutch Hub ee Inspecting the Drive Cover Inspecting the Pump Impell Inspecting the Extension TAF22-10 Tar22-28 TAF22.252-33 4 6 Turbine runner inspection (1) Crack and damage (2) Loose fitting between turbine runner and hub (3) Damage on turbine runner hub Thrust bearing in (1) Crack and damage at cage (2) Damage at roller (3) Rotation status and abnormal sound ‘Thrust bearing race inspection (1) Damage at sliding contact surface Stator ASSY inspection (1) Crack and damage at stator wheel (2) Damage at inner and outer races of one. way clutch (3) Damage, deformation and seizure of thrust washer No. 1 and thrust plate Inspecting the Turbine Runner Inspecting the Thrust Bearing Inspecting the Thrust Bearing Race Inspecting the Stator ASSY (1) aF2223,(4) Vear and damage of roller and spring cap (5) Fatigue and deformation of spring AAARN AA Posse eas Inspecting the Roller and Spring Tarz212 8. Turbine front washer inspection (1) Wear and damage of washer Inspecting the Turbine Front Washet TaR2-19 REASSEMBLY 1. Install the pump impeller extension (1) Coat grease thinly on the O-ring, Installing the Extension (1) rarz2-7 (2) Extension (3) Set bolt T= 0.4 ~ 0.7 kg-m (2.9 ~ 5.1 ft-lb) [39 ~ 67 Nm) Instaling the Extension (2) raz2-23Assemble the stator ASSY Snap ring | FE stator thrust washer J on Short — Cl Turbine runner side (Lump impetier side Spring cap “Thrust plates “!Ut6R hub Assembling the Stator ASSY (1) TAFSI35 Assembling the Stator ASSY (2) Laosa16 Caution: Coat torque converter oil sufficiently on each stator part before reassembly. 1), Clutch hub (2) Spring (3) Spring cap (4) Roller ‘Assembling the Startor ASSY TArn2-29 (8) Installing direction check Check the stator rotation status by rotating it clockwise and counterclockwise. Fix the hub and see that the stator wheel rotates, (in clockwise direction) when a force is applied from outer side of the curved stator wheel blade and that it does not rotate (in counterclockwise direction) when a force is applied from the inner side of the blade. Checking the Installing Direction TAF.2-36 (8) Thrust plate (1) Thrust washer 8) Snap ring 3, _ Install the stator ASSY on the pump impeller 1) Thrust bearing race Thrust bearing (3) Thrust bearing race (4) Stetor ASSY (5) Pay attention to the direction of the stator ASSY at the time of installation. (Check clockwise rotation as viewed from the top.) (6) After stator installation, check no interfer ence by rotating the stator. 4, Install the turbine runner SUB-ASSY. (1) Turbine runner SUB-ASSY Caution When the turbine runner or turbine runner hub is replaced, be sure to link the turbine runner and turbine runner hub securely with a rivet. TAF22.9,8 Direction of Stator ASSY Installing the Turbine Runner TaRD-325. Select the turbine front washer. (1) Place the SST on the turbine runner SST 09230-30151-71 (2) Install the drive cover on the pump impel- ler, and measure clearance (A) at 3 places on the circumference. Caution: Remove the O-ring from the drive cover. Standard clearance between drive cover and pone weerer Installing the SST vars 0.2 ~ 0.5 mm (0.00787 ~ 0.0197 in) (3) Determine the front washer according to the result of clearance (A) measurement and the table below. Front washer | Thickness | Clearance (A) B2-TOIO7T | ZB mm | —__O8~1.1 mm (Artin) | (0.031~0.043 in) 32292-10510-71] 3.1mm | 0.6~0.8 mm (.12im | (0.023~0.031) 32293-10510-71 | 3.4mm 0.5 mm | (0.43 in) (0.0197 in) 32294-10510-71 | 3.7 mm 0.1~0.2 mm (0.15 im\_}(0.0039~0.0079 ind (Example) Select 2.8 mm front washer if clearance (A) is 0.5 Measuring Clearance (A) mm, (4) Front washer 6 Install the drive cover. (1) O-ting Caution: Coat MP grease on the O-ring. (2) Set bolts and nuts T=15 ~ 20kg-m (108 ~ 14.5 ft-lb) (14.7~ 19.6 Nem] Installing the Drive Cover 1922.352-38 AUTOMATIC TRANSMISSION ASSY DISASSEMBLY Caution: ‘© Aways drain fluid before starting disassembly. ‘Store the removed automatic transmission to prevent the load of the transmission from being applied to the oil pan. When the load is applied to the oil pan, receive the load by the whole bottom surface of the oil pan. After installing the transmission on the vehicle, always replace the oil pan gasket. Cean sand or mud from the outer surface of the transmission before disassembly to prevent them from entering inside at the time of disassembly and reassembly. ‘® Work with bare hands or wear vinyl gloves and do not use working gloves or waste cloth. ‘@ When disassembling a joint of light metal alloy parts such as the case, do not pry with a screwdriver but tap them lightly with a plastic hammer for disassembly. @ Arrange and store the disassembled parts in good order. Ey 1. Remove the torque converter. Caution Do not damage the ail seal of the oil pump. 2. Remove the oil level gauge and oil filler tube. Removing the Torque Converter rar2.a2 3. Remove the joint (1) Uncautk the joint (2) Lock nut (3) Washer (4) Joint yoke 4. Remove the control lever. (1) Lock nut and set nut (2) Control shaft lever Caution: Take a note of the lever installation state. Removing the Control Shaft Lever rasa.2:39 5 Remove the network start switch (1) Uneauik the lock washer (2) Nut (3) Lock washer and grommet (4) Neutral start switeh Remove the transmission housing, (1) Throttle cable clamp (2) Set bolts (3)_Transmission housing Setting on the engine stand is recom- ‘mended for operations from here on. Romove the speedometer driven gear. (1), Lock bolt and lock plate (2) Speedometer driven gear ASSY (3) Remove the O-ring from the driven gear after removal Remove the extension housing (1) Set botts (2). Extension housing Caution: Carefully prevent damaging the oil seal. Removing the Neutral Start Switch TAFSIZ Removing the Transmission Housing TAFE Femoving the Driven Gear ase Removing the Extension Housing 33082-40 9. Remove the speedometer drive gear (1) Speedometer drive gear (2) Spacer 10. Remove the governor ASSY. 11, Remove the oil pan (1) Change the direction so as not to place the oil pan on the upper side. Caution: © Do not place the oil pan on the upper side to prevent foreign matters in the oil pan from entering the vaive body. (2) Set bolts (3) Oil pan & gasket 12. Inspect foreign matters in the oil pan (1) If iron particles are found, weer of the bearing, gear or clutch plate is possible. (2) If copper particles are found, wear of the bushing is possible. Removing the Oil Pan e00413. Remove the oil tube. (1) Remove the lockup relay valve body plete. Caution: The pin for the lockup relay valve may fall (2) Use a flat head screwdriver to raise both sides of the ail tube little by litte to remove the tube, (3) Check that the pin for the lockup relay valve is installed, and temporarily install the plate. Caution Use four bolts which are short under the head. 14. Remove the oil strainer. (1) Set bolt (2) Oil strainer (3) Gasket 18. Remove the valve body. (1) Set bolts Caution: Check the position of the reference bolt hav- ing identification mark “8” at the head. 241 Removing the Oil Swainer Refs pote Reference Bolt2-42 (2) Raise the valve body and disconnect the throttle cable from the throttle cam. 16. Remove the transmission case apply gaskets. (1) Apply gaskets (4 pcs.) 17. Disconnect the throttle cable. (1) Throttle cable Caution: Use a 10 mm socket screwdriver and push the retainer portion for easy removal. (2) Remove the O-ring from the throttle cable. 18. Remove accumulator piston C, and spring. (1) Accumulator piston C, Caution: Below compressed air through the oil hole in the transmission case for easy removal. Care- fully operate because the piston and fluid will jet out. (2) Spring Removing the Apply Gaskots TARSI7 Removing Accumulator Position C, ‘arse?2-43 19 20. 2 Remove accumulator piston B, and spring. (1) Accumulator piston B, Caution: Blow compressed air through the oil hole in the transmission case for easy removal. Care- fully operate because the piston and fluid will jet out. (2) Spring Remove accumulator piston C, and spring (1) Front clutch accumulator cover (2) Plate cover (3) Gaskets (2 pes.) (4) Accumulator piston C, Caution: Blow compressed air through the oil hole in the transmission case for easy removal. Care- fully operate because the piston and fluid will jet out. (8) Spring Remove the oil pump. (1) Oil pump set bott TaFSsr Removing the Accumulator Cover Removing the Oil Pump Set Solt44 22 23 (2) Oil pump SST 09350-06140 Ceution: © Use a service bolt of M10 P=1.25. ‘© Do not damage the surface of the shaft bushing. (3) Make the rear side of the oil pump face upward (4) Bearing race (©) O-ring ‘Measure the input shaft installed height (1) Place the SST on the oil pump mounting surface s illustrated, and measure and record the dimension between the SST upper surface and the top surface of the shaft staged portion SST 09360-06090 Remove the overdrive support assembly. (1) Snap ring (2) Thrust bearing and bearing lace Caution: Confirm the mounting direction of the bear- ing and bearing lace. (3) Overdrive support lock bolt "Measuring the Installed Height of Ingut Shaft ‘TAFSSS Removing the snap ring a304 Removing the lock bolt 3062-45 (4) Overdrive support ASSY. SST 09350-06140 (8) O-ring 24. Measure the front clutch installed height. (1) Place the SST on the oil pump mounting surface as illustrated, and measure the di mension between the SST upper surface and the top surface of the front clutch drum. (for checking the installed height of the front clutch.) SST 09350-06090 28. Remove the front clutch ASSY. (1) Front clutch ASSY (2) Thrust bearing and bearing race Caution: Memorize the installing directions of the bearing and bearing race. 26. Remove the rear clutch ASSY (1) Rear clutch ASSY Caution: Hold the clutch hub with fingers at both ends and remove it straight. a6 Removing the Rear Clutch ASSY2-46 27. Remove the center support ASSY (1) Center support lock bolt (2) Center support ASSY SST 09360-06140 28. Remove the planetary gear ASSY & output shaft (1) Snap ring Caution: Wrap the tip end of a screwdriver, and pry the snap ring with it to prevent the case from damage. (2) Planetary gear ASSY & output gear w/one-way clutch (3) thrust bearing and bearing race Caution: Memorize the installing directions of the bearing and bearing race, 29. Remove the transmission rear cover. (1) Transmission rear cover Removing the Transmission Reat Cover aaa,2-47 MAIN PARTS DISASSEMBLY & REASSEMBLY Caution: After washing each part, dry it by air blowing but do not wipe with waste cloth. @ Coat Castle Auto Fluid D-I! or sliding and rotating surfaces before reassembly. Always use new gaskets and O-rings. ‘© Coat petrolatum on the thrust bearing and bearing race before reassembly. ‘© Use the yellow petrolatum grease in the same package when the gasket kit is replaced. ‘© When using a new clutch disc, soak it in Castle Auto Fluid D-II for at least 2 hours. Replacement of Oil Seal for Oil Pump REMOVAL OF OIL SEAL FOR OIL PUMP Caution: The explanation here is for replacement of the oil seal only. 1. Remove the oil seal (1) Oil seat SST 09308-00010 Installation of Oil Seal for Oil Pump 1. Install the oil seal. (1) Coat castle grease No. 2 on the oil seal lip, (2) Oil seal SST 09350-06040 Installing the Oil Seal pase2-48 Replacement of Transmission Output Shaft Bearing REMOVAL OF OUTPUT SHAFT BEARING 1. Ramove the output shaft rear bearing (1) Output shaft rear oil seal Caution: Careful prevent the extension housing from damage. (2) Snap ring Removing the Snap Ring baer (3) Output shaft rear bearing SST 09350-08050 SST 09350-08070 Output Shaft Bearing Installation 1. Install the output shaft rear bearing (1) Rear bearing SST-09350-06050 ‘SST-09350-06080 Caution: Push the bearing in so that the SST does not ‘come into contact with the convex portion of the housing, Removing the Rear Bearing ose(2) Snap ring Caution: © Use @ new snap ring @ Match the snap ring joint with the open- ing in the extension housing (3) Coat MP grease No. 2 on the output shatt rear oil seal (4) Oil seal SST 09350-06040 Caution: Drive the oil seal in until alignment with the housing end surface. Installing the Snap Ring 2-49 oat Instaling the Oi Seal base2-50 MANUAL VALVE LEVER & SHAFT COMPONENTS il sat Manual valve shaft ‘Spacer Manual vaive lever sub-assy ‘Manual Valve Lever & Shaft Components DISASSEMBLY & REASSEMBLY 1. Remove the manual valve lever and shaft, (1) Spacer Caution: Use a flat head screwdriver, and cut the spacer. (2) Use a pin punch and remove the slotted spring pin. TAFM67 Removing the Slotted Spring Pin TARSTS(3) Manual valve lever Caution: Pull the manual valve lever shaft toward the threaded portion. (4) Remove the spacer from the manual valve lever. Replace the oil seal (for manual valve lever shaft) (1) Remove the oil seal Caution: Do not damage the transmission case. (2) Coat MP grease No. 2 on the oil seal li. (3) Install the oil seal. SST 09360-06150 Install the manual vaive lever and shaft. (1) Install a new spacer on the manual valve lever (2) Manual valve lever, spacer, wave washer and shaft. Caution: © Insert the unthreaded portion of the shaft first. © When inserting the shaft, do not damage the oil seal. Removing the Manual Valve Lever ‘TAFST9, 60 Installing the Lever and Shaft ‘TAFSe0252 (8) Align the manual valve lever and shaft holes and drive in a new slotted spring pin for fixing (4) Align the concave portion of the manual valve lever with the hole of the spacer and caulk with @ punch, (5) See that the manual valve lever rotates smoothly Tare cauking2-53 OIL PUMP COMPONENTS Front oil pump body SUB-ASSY it pump riven gear Front oil pump cover SUB-ASSY Compression spring VP Check ball Check valve spring seat (11 Pump Components DISASSEMBLY 1. Install the oil pump on the torque converter. 2. Remove the oil seal rings (2 pcs.) (1) Oil seal rings Caution: ‘@ Do not break the paw! of the oil seal ring ® Do not extend the oil seal ring excessively. 3. Remove the check ball (1) Spring seat SST 09350-06100 (2) Spring and check ball Removing the Oil Seal Ring Removing the Check Ball TAFSSA254 4, Remove the stator shaft. 11) Stator shaft set bolt 12) Stator shaft 5. Remove the oil pump body. (1) Oit pump body INSPECTION & PARTS REPLACE- MENT 1. Body clearance inspection i1) Push the driven gear fully to one side, and measure the clearance between the driven gear and oil pump body with a thickness gauge Standard: 0.07 ~ 0.15 mm (0.0026 ~ 0.0059 in) Limit: 0.3 mm (0.0118 in) If the limit is exceeded, replace the drive or driven gear. Caution: When replacing the drive or driven gear, select the gear by inspecting the side clear- ance. 2. Tip clearance inspection 1) Measure the clearance between the cres- cent and driven gear with a thickness gauge Standard: 0.14 ~ 0.24 mm (0.0055 ~ 0.0094 in) Limit: 0.3 mm (0.0118 in) If the limit is exceeded, replace the drive or driven gear. Caution: When replacing the drive or driven gear, select the gear by inspecting the side clear- ance. TAFSEG Inapecting the Tip Clearance ‘TAFSe7255 3. Side clearance inspection (1) Measure the clearance between the gear lor shaft mounting surface for the entire circumference with a straight edge and thickness gauge Standard: 0.02 ~ 0.05 mm (0.00078 ~ 0.00197 in) Limit: 0.1. mm (0.0039 in) If the limit is exceeded, replace the drive or driven gear. Note: The drive and driven gears are provided in two thicknesses =0.014 samy an 0.050 18.5 ~O.0%g mm and 18.5_ 9.082 mm 4. Replace the ail seal (1) Use a flat head screwdriver and remave the oil seal Caution: Do not damage the oil pump body. (2) Coat MP grease No. 2 on the lip of anew oil seal (3) Use the SST. and drive in the oil seal unti itis flush with the pump body. SST 09360-06040 REASSEMBLY 1, Install the oil pump body on the torque con- verter. (1) Oil pump body TAFSES Femoving the Oil Seal 229 Installing the Oil Seat 3830 Installing the Oll Pump Body ‘TAFSeS2-56 2. Install the driven and drive gears in the ail pump body, (1) Driven Gear (2) Drive Gear Caution: Coat Auto Fluid D-I1 3. Install the stator shaft. (1) Stator shaft (2) Set bolts T = 0.9 kg-m (two 6 mm bolts) (6.5 ft-lb) [8.826 Nem] T = 2.1 kg-m (six 8 mm bolts) (15.2 ft-lb) [20.6 Nem] 4. Install the check ball (7) Check ball and spring (2) Use the SST to compress the spring, and install the stopper plate from the upper side Caution: Hook the paw! of the stopper plate surely on the oil pump body. 5. Irspect the oil pump operation (1) With the oil pump installed on the torque converter, check if the oil pump is rotated smoothly clockwise and counterclockwise Installing the Driven and Drive Gears Inspecting the Oil Pump Operation TAFSe2 ‘TAFSoa257 TRANSMISSION INPUT SHAFT & OVERDRIVE CASE COMPONENTS Bearing race Shaft sleeve Ino Sor Ot sat ng ye Overdrive case Bearing race Transmission Input Shaft TAFMG® DISASSEMBLY 1. Remove the bearing race. (1) Bearing race Caution: Memorize the bearing race installing direc- tion, 2. Remove the oil seal ring (1) Oil seal ting Caution: @ Do not break the paw! of the oil seal ring © Donotextend the oil seal ring excessively. 3. Remove the O-ring from the overdrive case. Removing the Oil Seal Ring asso2-58 INSPECTION 1. Inspect the input shaft and flange. (1) Bend and crack (2) Damage at spline (3) Damage on flange teeth 2. Thrust bearing and thrust race inspection (1) Wear and damage of thrust bearing (2) Damage of thrust race REASSEMBLY Instalt the oil seal ring (1) Oil seal ring Caution: # Use a new oil seal ring # Coat Auto Fluid D-II before installation # Do not break the pew! of the oil seal ring ‘* Donot extend the oil seal ring excessively. 2. install the O-ring on the overdrive case Caution © Use a new O-ring. © Coat Auto Fluid D-II on the O-ring. 3. Install the bearing race (1) Bearing race Caution: Install the bearing race in the correct direc- tion (with bending portion on the case side). Inspecting the Input Shaft Inspecting the Thrust Bearing and Race Coat auto fluid D-t! TAFSS6 TAFSIS Instaling the Bearing Race ‘TAFSO2-59 FRONT CLUTCH ASSY COMPONENTS. Front clutch plate Piston SUB-ASSY Drum SUB-ASSY Cushion plate Clutch disc | Return spring Compression eee eee | spring Front clutch hub Rear clutch hub Thrust bearing Bearing race Front Clutch ASSY Components e256 DISASSEMBLY 1. Install the front clutch ASSY to the overdrive case, Setting the Front Clutch ASSY to the Drive Case TAFSI8# 2. Remove the rear clutch hub, (1) Snap ring (2) Rear clutch hub Removing the Rear Clutch Hub ‘TAFSTES2-60 3 Remove the front clutch hub (1) Thrust bearing (2) Bearing race Caution: Memorize the installing directions of the bearing and bearing race. (3) Front clutch hub Remove the thrust bearing and bearing race, (1) Thrust bearing (2) Bearing race Caution: Memorize the installing directions of the tearing and bearing race. Front clutch piston stroke inspection (1) Let the rear clutch hub float. Use the SST and install a dial gauge on the front clutch ASSY SST 09350-06110 Caution: ¢ Bring the SST into vertical contact with the piston. © Do not let the SST be in contact with anything other than the piston. ‘TAFSIOS Removing the Front Clutch Hub ‘TAFST06 Tarsie7 Instaling the Dial Gauge ‘TaFSIBe2-61 (2) Install the rear clutch hub and the snap ring Caution: Do not install the front clutch hub. (3) Set the dial gauge as illustrated. Blow compressed ait at 4 ~ 8 kg/cm? (56.8 ~ 113.8 psi) through the cil hole in the overdrive case shown in the illustration to inspect the front clutch piston stroke and sliding status. Standard: 3.93 ~ 4.23 mm (0.155 ~ 0.166 in) Limit: 4.43 mm (0.174 in) Caution: Inspect at a few points and average the measured values. Note: As the invisible portion of the SST is parallel with the visible portion, use it as the guide at the time of setting, Remove the rear clutch hub, clutch discs, clutch plates and clutch cushion plate. (1) Snap ring (2) Rear clutch hub (3) Cluteh discs and plates (4) Cluteh cushion plate Caution: Memorize the cushion plate installing direc- tion. Remove the spring seat and springs. (1) Snap ring ‘SST 09350-06010 ‘SST 09905-00012 (2) Spring seat (3) Springs (22 pos.) Measuring the Piston Stroke TARSIEO If the limit is exceeded, replace the clut or clutch plates as follows ® Replace the clutch discs with new ones. ® Inspect the piston stroke again. ® ifthe standard is not satisfied after steps O and @, replace the clitch plates with selected ones to make the piston stroke satisfy the standard. ses Not The plates are provided in 4 thickness: 1.8 + 0.05, 2.0 = 0.05, 2.2 + 0.05 and 2.4 + 0.05 mm. Removing the Snap Ring ‘TAFS1992-62 8. Remove the front clutch piston, (1) Front clutch piston Caution: Blow compressed air through the oil hole in the overdrive case. (2) O-ring 9. Remove the input shaft oil seal ring. (1) Oil seal ring Caution: Use a flat head screwdriver. Front Clutch Inspection 1. Front clutch piston inspection (1) Shake the piston to inspect that the check ball is not sticking (2) Apply compressed air at a low pressure to check if air leaks from the valve. 2. Compression spring inspection (1) Inspect the free length of the spring Standard: 30.5 mm (1.2 in) Removing the Clutch Piston TAFSION NN ‘TaFSt92 Inspecting the Clutch Piston aaa Inspecting the Spring 2a,REASSEMBLY Install the input shaft oil seal ring (1) Coat Auto Fluid D-I! on a new cil seal ring (2) Contract the oil seal ring as illustrated be- fore installation (3) Install the oil seal ring on the input shaft Install the front clutch piston (1) Coat Auto Fluid D-II on a new O-ting (2) Install the O-ring on the front clutch piston (3) Install the piston to the clutch drum, Caution ‘© Install the O-ring without being twisted or trapped. ‘© Push the piston in evenly. Install the springs and spring seat (1) Springs (22 pes.) (2) Spring seat (3) Snap ring (Use a new snap ring.) SST 09360-06010 Caution: © Install the springs without inclination or tilting. ‘@ Do not align the snap ring joint with the stopper of the spring seat. ‘© Fit the snap ring firmly to the stopper portion of the spring seat. 2-63 Installing the Oil Seal Ring TAFSION Installing the Clutch Piston TARSI95 TAFSI9G Instaling the Sanp Ring TAFSIO7264 4. Install the clutch cushion plate, clutch disc and rear clutch hub. (1) Clutch cushion plate Caution: Install the cushion plate with the convex portion on its internal circumference on the piston side. (2) Clutch plates (6 pcs.) and clutch discs (6 pes.) Caution: Install alternately in the order of the plate and disc. Front clutch piston stroke inspection (1) Let the rear clutch hub float. Use the SST and install the dial gauge on the front clutch ASSY, SST 09350-06110 Caution: © Bring the SST into vertical contact with the piston. ¢ Do not let the SST be in contact with anything other than the piston. (2) Install the rear clutch hub and the snap. ring. Caution: Do not install the front clutch hub. (2) Set the dial gauge as illustrated, Blow compressed air at 4 ~ 8 kg/cm? (56.8 ~ 113.8 psi) [39.2 ~ 78.5 kPa} through the oll hole in the overdrive case shown in the illustration, and inspect the front clutch piston stroke and sliding status. Standard: 3.93 ~ 4.23 mm (0.155 ~ 0.166 in) Limit: 4.43 mm (0.174 in) Caution: Inspect at a few points, and average the ‘measured values. Installing the Cushion Plate Installing the Dial Gauge 358 ‘Measuring the Piston Stroke e259If the limit is exceeded. replace the clutch discs or plates as follows ® Replace the clutch discs with new ones @ Inspect the piston stroke again. © If the standard is not satisfied after steps © and ® above, replace the Flange thickness Thickness mm (in) eerie 5078) 0.197 *Bo030) None 82287 (0208 *B o039) 1 547810213 Booa) 2 5.6 7B (0.22078 039) Removing the Return Spring ase2-74 5. emove the brake No. 1 piston (1) Blow compressed air through the illus trated oil hole and remove the brake No. 1 piston, 2) O-ring 6 Remove the oil seal ring (1) Oil seal ring Caution: * Do not break the pawl of the O-ring, # Donotextend the oil seal ring excessively. 7. Remove the O-rings. 1) O-rings (3 pcs.) Center Support ASSY Inspection 1. Compression spring inspection {1) Inspect the free length of the spring with the spring seat. Standard 22.75 mm (0.896 in) Removing the Oil Seal Ring a2ee, Inspecting the Compression Spring ates.2-75 Center Support ASSY Reassembly 1. Install the O-rings (1) Coat Auto Fluid D-I! on three new O and install them at the oil hole in the center support case. 2. Install the oil seal rings, (1) Coat Auto Fluid D-II on two new oil seal rings and install them on the center sup. port. Caution: Surely set both ends of the oil seal ring ‘# Do not break the paw! of the oil seal ring, ‘® Donot extend the oil seal ring excessively. 3. Brake No. 1 piston installation (1) Coat Auto Fluid D-II on two new O-rings, and install them on the brake No. 1 piston, (2) Coat Auto Fluid D-Il on the brake No. 1 piston and install it on the center support. Caution: © Install the O-rings without being twisted or trapped. ‘© Insert the piston evenly. 4, Install the second brake piston return spring ASSY. (1) Spring seat ASSY (2) Snap ring SST 09360-06020 Caution: @ Install the springs without inclination or tilting, ¢ Do not match the snap ring joint with the notched portion of the center support. ease Installing the Snap Ring 4267 2402276 5. Install the brake plates, clutch dises and brake No. 1 flange (1) Brake plates (4 pes.),Clutch discs (4 pes.) Caution: Install the brake plate and clutch disc in this order. (2) Brake No.1 flange Caution Install the brake No. 1 flange with its cham- fered or staged portion on the disc side. Installing the Brake Plate and Clutch Dise paaro (3) Snap ting Caution Do not match the snap ring joint with the notched portion of the center support. 6 Biake No. 1 piston stroke inspection (1) Seta dial gauge. SST 09360-06120 Caution: © Bring the SST into vertical contact with the piston. © Do not let the SST be in contact with anything other than the piston. (2) Blow compressed air at 4 ~ 8 kg/cm? (86.8 ~ 1138 psi) (39.2 ~ 78.5 kpa] through the illustrated oil hole, and inspect the brake No. 1 piston stroke and sliding status Standard: 1.60 ~ 1.80 mm (0.063 ~ 0.071 in) Limit: 1.90 mm (0.075 in) Inspecting the Piston Soke 3400 Caution: Inspect at a few points, and average the —_‘Flange thickness eeu identification Thickness mm (in) ae Ifthe limit is exceeded, replace the clutch - discs or clutch flange as follows 1(0.197 8.9939) pone @® Replace the clutch discs with new 1 (0.205 “9. 0039) _ 1 aoe 5.4781 (0.213 oos9) 2 Inspect the piston stroke again 5570, 02207Baey 3 @ If the standard is not satisfied after 58781 (0220 "Boose eS steps © and ® above, replace the clutch flange with the ane selected to satisfy the standard piston stroke7. Install the planetary sun gear. (1) Planetary sun gear (2) Snap ring SST 09905-00012 Caution: Confirm that the snap ring is securely fit in the shaft groove. Instaling the Planetary Sun Gear baa782-78 PLANETARY GEAR ASSY & OUTPUT SHAFT COMPONENTS Rear planetary gear ASSY Front planetary Fing gear” Thrust bearing 2 5\@09 y Thrust washer, No. 1 One-way clutch, No. 2 ‘Thrust washer, No. 1 Bearing race 2 Planetary * sun gear ‘Theust washer No.2 Thrust bearing v Soop ina orgs Lap » (Output shaft SUB-ASSY Bearing race Rear planetary Intermediate shaft ring gear @Non-reusable parts Planetary Gear ASSY & Output Shaft Components, 1Das00 DISASSEMBLY ” ~ | 1. Remove the front planetary gear. (1) Planetary gear 2. Front planetary carrier thrust washer No. 1 (1) Thrust washer No. 1 Removing the Carrior Thrust Washer sees, 034062-79 3. Remove one-way clutch No. 2 (1) One-way clutch No. 2 ASSY Caution: Memorize the installing direction of the one- way clutch 4. Remove output shaft thrust washer No. 2 (1) Thrust washer No. 2 Caution: Memorize the installing direction of the thrust washer, 5. Remove the planetary sun gear (1) Planetary sun gear 6 Remove the front planetary ring gear (1) Contract the snap ring. (2) Ring gear Removing One-way Clutch No. 2 4268 Lo Removing Thrust Washer No. 2 ose? Removing the Ring Gear azo2:80 7. Remove the rear planetary (1) Rear planetary gear AS 8. Remove the reer planetary ring gear. (1) Rear planetary w/intermediate shaft (2), Thrust bearing and bearing race Caution: Memorize the installing directions of the bearing and bearing race. (3) Thrust bearing and bearing race Removing the Rear Planetary Gear ASSY 3409 Removing the Rear Planetary Gear 4370 Removing the Thrust Beating basis | Removing the Thrust Bearing ‘34902:81 (4) Oil seal ing Removing the Oil Seal Ring coe (5) Rear planetary ring gear SST 09905-00012 sst \ / Removing the Rear Planetary Ring Gear sez (6) Snap ring (7) Planetary gear flange Caution: Memorize the installing direction of the plan- etary gear flange. Removing the Planetary Gear Flange aaa2-82 Planetary Gear w/Output Shaft Reas- sembly 1, Install the rear planetary ring gear. (1) Rear planetary gear flange Caution: Install the planetary gear flange in the correct, direction. (2) Snap ring (3) Rear planetary ring gear (4) Snap ring SST 09905-00012 (5) Coat Auto Fluid D-II on the oil seal ring (6) Oil seal ting (7) Thrust bearing and bearing race Caution: Install the bearing and bearing race in correct directions. a2 Installing the Thrust Beering(8) Thrust bearing and bearing race Caution: Install the bearing and bearing race in correct directions. Instaling the Theust Bearing baste (8) Rear planetary ring gear w/intermediate shaft Installing the Rear Planetary Ring Gear paa7o 2. Install the rear planetary gear ASSY. (1) Rear planetary gear ASSY 3. Install the front planetary ring gear (1) Contract the snap ring (2) King gear Caution: Fit the snap ring securely in the groove. Installing the Front Planetary Ring Gear a2ee2-84 4. Install the planetary sun gear (1) Planetary sun gear 5. Install output shaft thrust washer No. 2. (1) Thrust washer No. 2 Caution: Install the thrust washer in the correct direc- tion. 6. Install one-way clutch No. 2 (1) One-way clutch Caution: Install the one-way clutch in the correct direction. 7. Install the front planetary carrier thrust washer No.1 (1) Thrust washer No. 1 Theust Washer No. 1 aes, 034068, Install the front planetary carrier. (1) Front planetary cartier Instaling the Front Planetary Carrier ames2:86 FIRST & REVERSE BRAKE COMPONENTS Brake plate Radial ball bearing Cluteh dise 1st & reverse brake piston Snap ring cy Breke return spring O-ring SUB-ASSY Transmission case @Non-reusable parts First & Reverse Brake Components ‘TAFMIO DISASSEMBLY r | 1. First & reverse brake piston stroke inspection 1) Set a dial gauge. SST 09350-06120 SST 09350-06130 Caution ¢ Bring the SST into vertical contact with the piston. Do not let the SST be in contact with anything other than the piston. Setting the Diesel Gauge asso 2) Blow compressed air at 4 ~ 8 kg/cm? (568 ~ 1138 psi) (39.2 ~ 78.5 Koa] through the illustrated oil hole, and inspect the front clutch piston stroke and sliding status Standard: 3.30 ~ 3.80 mm (0.130 ~ 0.150 in) Limit: 4,00 mm (0.157 in) Caution: Inspect at a few points, and average the measured values. Inspecting the Piston Stroke asa2-87 if the limit is exceeded, replace the clutch Reference discs or brake No.1 flange as follows: Flange thickness © Replace the clutch dises with new ones Thickness eG lenifeaion ® Inspect the piston stroke again. mar ® If the standard is not satisfied after 6.65 “1 (0.262 *B 9039) ‘None steps © and ®@ above, replace the 7.05781 10278 Boose) 1 brake No. 1 flange with the one se- + ; 74578 (0.293 2 lected to satisfy the standard. 9=B 10299 “Hoos 2. Remove the brake flange, clutch discs, brake plates and brake cushion plate (1) Snap ring (2) Brake flange. clutch discs, brake plates. and brake cushion plate Caution: ‘Memorize the installing direction of the cush- ion plate. Removing the Brake Flange, ee asst 3. Remove the first & reverse brake piston return spring ASSY. (1) Snap ting SST 09360-06030 sst (2) First & reverse brake piston return spring ASSY if Romoving the Piston Retin Spring coy 4, Remove the first & reverse brake piston. (1) Blow compressed air through the illus- trated oil hole, and remove the first & reverse brake piston (2) O-ring Femoving the Brake Piston aes788 First & Reverse Brake Inspection Compression spring inspection (1) Inspect the free length of the spring with the spring seat Standard: 23.9 mm (0.941 in) Output Shaft Front Bearing Replacement 1. Remove the output shaft front bearing (1) Front bearing SST 09360-06050 SST 09350-06070 2. Install the output shaft front bearing (1) Front bearing Caution: © Use a new bearing ‘© Check smooth rotation of the bearing after installation. First & Reverse Brake Reassembly Install the fist & reverse brake (1) Coat Auto Fluid D-II on the O-ring (2) First & reverse brake piston Caution: ¢ Install the O-ring without bearing twisted or trapped @ Insert the piston evenly. ‘Spring seat | Inspecting the Spring pases Instaling the Brake Piston 103500Install the first & reverse brake piston return spring ASSY. (1) First & reverse brake return spring ASSY (2) Snap ring SST 09350-06030 Caution: Do not incline or tilt the spring. Install the brake cushion plate, brake plates. clutch dises and brake flange (1) Install the brake cushion plate in the illus trated direction. Caution: Install the cushion plate with its convex por- tion on the internal circumference on the piston side. (2) Brake plates (6 pes.) and clutch dises (6 pes.) Caution: Install alternately in the order of the brake plate and clutch disc. (3). Brake flange Caution: Install the flange with its chamfered or staged, portion on the disc side. (4) Snap ring Caution: Match the snap ring joint with the opening of the transmission case. 2-89 TIN | Wa@m Ss) Cushion plate | Trang “) UPR ane | SS I ; — | \ ‘Snap ring Instaling the Snap Ring ass2-90 4 First & reverse brake piston stroke in 1) Seta dial gauge SST 09350-06120 SST 09350-06130 Caution: * Bring the SST into vertical contact with the piston. ¢ Do not let the SST be in contact with anything other than the piston, (2) Blow compressed air at 4 ~ 8 kg/cm? (68 ~ 1138 psi) through the illustrated «il hole, and inspect the front clutch piston stroke and sliding status. Standard: 3.30 ~ 3.80 mm (0.130 ~ 1.50 in) Limit: 4.00 mm (0.157 in) Caution: Inspect at a few points, and average the measured values. If the limit is exceeded, replace the clutch discs or brake No. 1 flange as follows: ® Replace the clutch discs with new ones ® Inspect the piston stroke again. @ If the standard is not satisfied after steps © and ® above, replace the brake No. 1 flange with the one se- lected to satisfy the standard stroke. Seiting the Dial Gauge Inspecting the Piston Stroke Reference Flange thickness Thickness mm (in) Identification mark 6.65 °9; (0.262 “8 ooa9) None 7.08 *8; (0.278 8 0039) 1 7.48 *8 1 (0.283 *Yoo39) 22-91 GOVERNOR VALVE ASSY COMPONENTS Governor oi G2 Eing ae snoion OX : Governor body support Compression spring Governor valve No. 2 shaft Ve snap ring @Non-reusable parts “Governor Valve ASS¥ Components TAFMI28 Governor valve No. 1 Gasket DISASSEMBLY 1, Remove the governor body. (1) Governor body (2) Gasket 2. Remove the oil seal rings. (1) Oil seal rings (3 pes) Caution: Do not extend the oil seal rings excessively. Removing the Oil Seai Ring ‘o3so22:92 3. Remove governor valve No. 1 (1) Hold the governor weight down. (2) Snap ting (3) Snap ting (4) Governor valve No. 1 jove governor valve No. 2 ) E ring Spacer (3) Ering (4) Weight &) Snap ring2-93 (6) Governor valve No. 2 shaft (7) Spring (8) Governor valve No. 2 5. Remove the governor oil strainer. (1) Oil stainer Governor Valve ASSY Reassembly 1. Install the governor oil strainer. (1) Oil strainer 2, Install governor valve No. 2. (1) Coat Auto Fluid D-II on the governor valve No. 2 shaft (2) Governor vaive No. 2 (3) Spring (4) Governor valve No. 2 shaft Caution: Check the governor valve for smooth motion. Installing Governor Valve No.22-94 (5) Snap ring (6) Governor valve No. 2 shaft Note: It is recommended to match the snap ring joint with the notched portion of the gover- nor body. (2) Install the weight to governor valve No. 2 (8) Ering Caution: Make the chamfered side of the E ring face the spacer. (9) Spacer (10)E ring 3. _ Install governor valve No. 1 (1) Coat Auto Fluid D-II on governor valve No. (2) Governor valve No.1 Caution: Check smooth movements of the governor valve and shaft, (3) Snap ring Installing Governor Valve No.1 Shaft snap ring Installing the Snap Ring ‘TAFSo72-95 Install the oil seal rings y (1) Coat Auto Fluid D-II on oil seal rings (2) Oil seal rings (3 pes.) Caution: Do not extend the oil seal ring excessively. Installing the Oi! Seal Ring 3610 Install the governor body. (1) Coat Auto Fluid D-II on the gasket (2) Gasket (3) Governor body suppor (4) Temporarily install the governor body on the governor body support (5) Insert a 0.01 mm (0.00038 in) thickness gauge between the top of the output shaft and the governor body. and temporarily tighten the bolts ‘Temporariy Installing the Governor Body Support 3613 (6) After temporary tightening, check uniform clearance between the output shaft and governor body. and tighten 8 bolts. T= 1.0 kg-m (7.23 ft-lb) [9.8 N-m] ‘Tightening the Governor Body Support, asta6 VALVE BODY ASSY Caution Chack no burr before reassembly, Do not use the valve body which has been dropped. As many similar parts are used, arrange the disassembled parts in good order for proper inspection and reassembly. Since many types of bolts are used, do not mistake their positions. The positions are shown on the next ° ° ° page. COMPONENTS __ 70.55 t (40) (5.4) Lock up signal valve 2 — apply tube i gq 10.55 i (4.0) [5.4N) => | ‘Signal apply tube 7} | Rear upper valve i | body ASSY | Q}-——Line pressure tube 70.55 J eo, —Rear upper valve body ---0—Stee! ball Valve body No. 1 O— gasket —Valve body plate Valve body No. 2 gasket Lower valve body ASSY << soncer Manual detent spring SUB-ASSY | ea Manual detent spring sover Sy 0 0) NEES Traaminion le aoty Lock up relay valve body gasket Lock up relay valve body plate MS: T=0.55 (4.0) [5.4] MB: T=1.0 (7.2) [9.8] @Non-reusable parts T=kg-m (ftto.) [Nem] Valve Body Components aaee2-97 VALVE BODY SET BOLT No] PARTS NO. t [aw al s0i05.05007 | is| 5 | | | s0r05.05015 | 60 | 2 c] so1s.0so16 | ss | ¢ o[ 9010505017 | a7 | 5 e| 9010505023 [iz | ie | 9010s.05028 [a9s| 7 G| 010506058 | 64 | 3 |] 90105-06060 | s7 | 5 i [90105-05002 | a5 | 4 | s{ 90105-05020 | 25 | 1 x] 90105-05027 [aos] 1 | | | 90105-05028 | 39 | 1 m{ 9010505030 | 43 | 1 nu] 90r0s.06069 | 22 | 1 of so10s.06072 | a2 | 4 P| 9010506025 | 36 | 2 a] sorososos: | a5 | 3 rn] _90105.06070 | a1 | 1 s| 90105-06073 | 45 | 1 +] 90106-06071 | 57 | 2 v{|__s0r0s.06064 | 16 | 2 Jk: Standard bolt WAVE WASHER PARTSNO. [QTY 94541-00500 | 37 Valve Body Set Bolt Mounting Positions ARM2:98 DISASSEMBLY 1 4 Remove the detent spring (1) Spacer (2) Detent spring (3) Detent spring cover Caution: Memorize the installing sequence and direc- tions. Remove the manual valve, (1) Manual vaive Caution: Memorize the manual valve installing direc- tion. Remove the line pressure tube (1) Line pressure tube Caution Memorize the tube installing direction. Remove the transmission loop apply tube and signal apply tube. (1) Clamp (2) Tubes (2 pes.) Removing the Detont Lever baara Removing the Manual Valve Removing the Apply Tubes2-99 5, Remove the front upper valve body. (1) Set bolts (2) Set bolts Caution: Memorize the positions of reference bolts (2 pes.) each with identification mark “8” on the head. (3) Reverse the valve body. (4) Front upper valve body. Caution: Do not loose the check ball and spring. (5) Oil stainer Caution: Memorize the oil strainer installing direction. 6. Memorize the positions of the front upper valve body stopper and pin Caution: Do not lose the stopper and pin. Stopper and Pin Positions asaz 7. Remove the rear upper valve body. (1) Reverse the valve bady ASSY. (2) Set bolts (16 pes.) Caution: Memorize the positions of reference bolts (2 pcs.) each with identification mark “8” on the head. Removing the Set Bolts aso2-100 (8) Push the valve body plate and gasket ‘against the lower valve body, and separate the lower valve body and rear upper valve body. 8. Remove the rear upper valve body check balls. (1) Check balis (7 pes } Caution: Do not lose check balls. 9. Memorize the rear upper valve body pin and seat positions. Caution: Note that the gasket shapes are different between the lower side and upper side 10. Remove the lower valve body gasket and plate. Caution: Note that the gasket shapes are different between the lower side and upper side. REASSEMBLY 1. Install the lower valve body gasket and plate. Caution: Do not use the upper gasket by mistake. Lower Valve Body Gasket are2-101 (1) Temporarily fasten the plate and gasket by three bolts, Note: It is recommended to use oil strainer set bolts having shot length under head (2) Place a new upper gasket on the plate. Caution: Do not use the lower gasket by mistake. Upper Gasket ase Install the rear upper valve body check balls (1) Check balls (7 pes.) Caution: Install in correct positions. Install the rear upper valve body. (1) Check the pin and seat positions. (2) Lower vaive body Setting the Lower Valve Body asoa2-102 (3) Temporarily tighten the set bolts (16 pes.) Caution: «Install two reference bolts each with iden- tification mark “8” on the head 4 Install bolts in correct positions. 4. Install the front upper valve body (1), Reverse the valve body ASSY, and remove the two bolts fastened temporarily in step 2. Caution Do not break or damage the gasket. (2) Oil strainer Caution: Install in the correct direction. (3) Place the lower valve body on the front upper valve body. Caution: Do not let the stopper, pin and strainer fall Setting the Lower Vaive Body east (4) Temporarily tighten the set bolts ‘Temporarily Tightoning the Set Bolts asza(5) Reverse the valve body. (6) Temporarily tighten the set bolts (7 pcs.) Tighten the upper valve body set bolts (1) Set bolt lightening torque T = 0.55 + 0.05 kg-m (4.0 + 0.36 ft-Ib) Caution: © Tighten the reference bolts first. ighten the bolts uniformly in several steps. Install the transmission loop apply tube and signal apply tube. (1) Tubes Caution: Do not deform the tubes. (2) Clamp T = 0.55 kg-m (4.0 ft-lb) Install the line pressure tubes. (1) Line pressure tubes (2 pcs) Install the manual valve (1) Manual valve Caution: Install the manual valve in the correct direc- tion. Install the detent spring (1) Detent spring cover (2). Detent spring and spacer (3) Set bolt T = 0.55 kg-m (4.0 ft-lb) [5.4 Nem] Caution: Install the detent spring in cortect direction and order. 2-103 Reference bolt, Installing the Upper Valve Body ears Instaling the Tubes bears Installing the Detent Spring bere2-104 FRONT UPPER VALVE BODY ASSY COMPONENTS S&— 11.0 7.2) 19.8) Primary down shift plug SUB-ASSY Secondary down shift Throttle valve, No. 1 sleeve a_i ee c 4 a q eee” rom Throttle valve No. 2 sleeve Compression ~~. spring = Compression Front upper valve orn body pring @ SQ ave sy Mauiator Primary throttle valve \ Secondary throttle valve Secondary regulator valve Front Upper Valve Body Components ~ TARMTDISASSEMBLY 1. Remove the throttle cam ASSY (1) Set bolts (2 pes.) (2) Throttle cam ASSY (3) Shims Caution: © Note the number of shims used. ‘© Do not lose the shims. 2. Remove the secondary regulator valve and spring. (1) Push the plug with a finger, and extract the seat by using 2 magnet hand. (2) Remove the plug, secondary regulator valve and spring 3. Remove the primary throttie valve. (1) Valve vibrating stopper (2) Push the primary down shift plug with a finger, and extract the pin by using a mag- net hand. 2-105 Removing the Secondary Regulator Valve ‘4406, TAFSION Removing the Pin Removing the Stopper2-106 (3) Primary throttle valve (4) Spring (6) Primary down shift plug (6) Throttle valve No. 1 sleeve @) Spring (8) E-rings: Caution: Check the number of E-rings after removal. 4, Remove the secondary throttle valve. (1) Valve vibrating stopper (2) Push the secondary shift plug with a finger, and extract the pin by using a magic hand. (3) Secondary throttle valve (4). Spring () Secondary down shift plug (6) Spring (7) Throttle valve No. 2 sleeve Removing the Stopper Removing the Secondary Throttle Valve ass?(8) Remove the spring and E-rings from the rear side of the body Caution: Check the number of E-rings after removal VALVE SPRING INSPECTION 1. Free length inspection (1) Inspect the free length of each spring eae ] indicates the inside diameter. cea Saou a] Feat (1) Secondary regulator valve 73310528 | 443(17a) (4) Primary thotie valve 78031 253110), (5) Secondary thot valve 182 (0717 wan | (6) Tote valve No.2 sieve ye2orm | 108 oes | Throttle Upper Valve Body Reassembly Install the secondary throttle valve (1) Secondary throttle valve (2) Push the secondary throttle valve with a finger, and install the E-rings. Caution: Install as many E-rings as the number checked at the time of removal. 2-107 Removing the Spring Inspecting the Spring 07046 Installing the Secondary Throttle Valve Instaling the E-rings esas2-108 (3) Push the secondary throttle valve with a finger, and install the spring Caution: © Install the spring securely. © Do not drop any E-ring (4) Valve vibrating stopper Caution: Go not use the primary side stopper by mis- take. (8) Spring (8) Secondary down shift plug (7) Throttle valve No. 2 sleeve (8) Push the secondary down shift plug with a finger and install the pin. Instaling the Spring beats Installing the Stopper aes Installing the Secondary Down Shift Plug passe Installing the Pin Desa2-109 2 Install the primary throttle valve (1) Primary throttle valve (2) Push the primary throttle valve with a fin ger. and install the E-rings. Caution: Install as many E-rings as the number checked at the time of removal. (3) Push the primary throttle valve with a fin. ger and install the spring Caution: ¢ Install the spring securely. ¢ Do not drop any E-ring. (4) Valve vibrating stopper Caution: Do not use the secondary side stopper by mistake. Installing the Primary Throtle Valve bans Installing the E-ing pane Installing the Spring baai7 Installing the Stopper aaes2-110 6) Spring (6) Primary down shift plug (7) Throttle vaive No. 1 sleeve (8) Push the primary down shift plug with a finger. and install the pin 3. Install the secondary regulator valve. 1) Spring (2) Secondary regulator valve 3) Plug ‘4) Push the plug with a finger, and install the seat, Installing the Primary Throttle Valve ase lnstalling the Pin Instaling the Seat panaInstall the throtlle cam ASSY. (1) Install the shims and throttle cam ASSY in the valve body so that the down shift plug roller is positioned at the center of the cam Caution: © Use the number of shims checked at the time of removal. ‘© Do not lose shims. (2) Set bolt T= 1.0 kg-m (7.23 ft-lb) [9.8 Nem] Caution: The bolt shall not ride on the valve body comer Tightoning the Set Bolt ese2112 REAR UPPER VALVE BODY ASSY COMPONENTS Compression spring Tey intermediate cows shit valve 2.3 shift valve © a entree | Compression spring: < Low modulator “~—> Lock up signal valve— Spring seat —> 77 ¢ Compression spring yz © Cy, $§ spring =| Sage shit timing valve | 233 shift timing plug ‘Sleeve CB A coast valve 3-4 coast shift valve fT cra a a Overdrive clutch | exhaust valve Comprestion spring Manual down timing valve iate modulator valve 3-4 shift valve = Lockup signal valve ’ O/D exhaust valve i = Manual down. timing valve Intermediate | modulator valve LS |) Fear Upper Valve Body Components ‘TAFNMT90. 181DISASSEMBLY 1. Remove the 2-3 shift valve, (1) Push the valve with a finger, and extract the seat by using a magic hand. (2) Plug (3) Spring (4) Intermediate coast shift valve (5) Sleeve (6) 28 shift valve (7) Push the plug on the opposite side of the valve body with a finger, and extract the pin by using a magic hand. (8) Remove the plug and 2 shift valve plug Removing the Seat 2-113 Removing the 2 ~ 3 Shift Valve Plug aaa2114 2. Remove the 2~3 shift timing valve (1) Push the 2-3 shift timing valve plug sleeve with a finger, and extract the pin moving the Pin peaze (2) 2-8 shift timing valve plug sleeve (3) 2-8 shift timing plug (4) 2-3 shift timing valve (5) Spring 3. Remove the 3-4 shift valve, (1) Push the plug with a finger, and extract the seat by using @ magnet hand. lomoving the Seat esos (2) Plug (3) Third coast valve (4) 3—4 coast shift valve ) Spring Removing the Third Coast Valve115 4 (6) Remove the pin an the opposite side of the valve body by using the magnet hand. (2) Plug (8) 3-4 shift valve Remove the detent regulator valve. (1) Push the plug with a finger, and remove the seat by using the magnet hand. (2) Plug (3) Low modulator valve (4) Spring Removing the Pin ze Removing the 3-4 Shift Valve bao Removing the Seat eea0 Removing the Low Medulator Valve be116 ©. Remove the lockup signal valve (1) Push the lockup signal valve sleeve with a finger, and extract the pin by using the magic hand (2) Lockup signal valve sleeve (2) Lockup signal valve plug (4) Spring (8) Spring seat (6) Lockup signal valve 6 Remove the cutback valve, () Seat (2) Plug (3) Cutback valve FRomoving the Pin aasz Removing the Lockup Signal Valve aaa Removing the Seat aaa Removing the Cutback Valve asa,2-117 7. Remove the overdrive clutch exhaust valve. (1) Seat ov (2) Plug (3) Spring (4) Overdrive clutch exhaust valve baw? 8. Remove the manual down timing valve (1) Seat Removing the Seat pass (2) Plug (3) Manual down timing valve Femoving the Manual Down Timing Valve pase2-118 9. Remove the intermediate modulator valve, (1) Seat (2) Plug (3) Intermediate modulator valve (4) Spring VALVE SPRING INSPECTION (1) Inspect the free length of each spring. Sanaa) t ] indicates the inside diameter. ey sera | aaa rr waaay aaa ReneS ECCT EXT Dae woiaerane | Bao201 | enc (Omen cr abamre | tevoz09) | 303 Resins NTCT oxy [za] Removing the Seat Removing the Intermediate Modulator Valve Lec S T \ Inspecting the SpringREASSEMBLY 1 Install the intermediate madulator valve (1). Spring (2) Intermediate modulator valve (3) Plug (4) Seat Install the manual down timing valve (1), Manual down timing valve (2) Plug (3) Seat Install the overdrive clutch exhaust valve. (1) Overdrive clutch exhaust valve (2) Spring (3) Seat Install the cutback valve (1) Cutback valve (2) Plug (3) Seat2-120 5. Install the backup signal valve. (1) Lockup signal valve spring seat (2) Lockup signal valve (3) Spring seat (4) Spring (5) Lockup signal valve sleeve Caution: Check that a plug exists in the sleeve. (6) Pin C3 © Installing the Spring Seat passa Instaling the Lockup Signal Valve passa.2-121 6 8 Install the detent regulator valve (1) spring (2) Low modulator plug (3) Plug (4) Seat Install the 3—4 shift valve, (1) 3-4 shift valve (2) Plug (3) Pin (A) 3-4 coast shift valve () Third coast valve (6) Plug (7) Seat Install the 2~3 shift timing valve (1) 2—3 shift timing plug (2) Spring (3) 2~3 shift timing valve and sleeve Caution: Check that a plug exists in the sleeve. (4) Pin Install2-122 9. Install the 2 3 shift valve, (1) 2-3 shift valve plug (2) Plug (3) Pin (4) 2-3 shift valve (6) Intermediate coast shift valve (6) Spring (7) Plug Caution: Do not attempt valve stroke operation with- out installing the 2-3 shift valve plug be- cause the valve body will be damaged to adversely affect sliding motion. (8) Seat Installing the 2-3 Shift Valve esa2-123 LOWER VALVE BODY ASSY COMPONENTS 3-2 kick-down orifice 2 shift valve primary requatorwane Mg BQ toms 1:2 shift valve competion ina tea eae 1 qq Sen 2a sore Oy 1© —— ! 1 Oey — Soin a 09 Og Accumulator | Vor ~ aie 1 eg, erin ver | Lock relay valve regulator | Control ort —— 2a valve Spring sora BH ‘ave ‘ave rimarycepultor valve 3:2 kicksdown once e a " control valve Lower valve body cover Lockup relay valve \ Oil strainer Manual valve Low modulator valve Lower Valve Body Components TAFMI322.124 DISASSEMBLY 1. Remove the lockup relay valve. (1), Lockup relay valve body plate (2) Gasket (3) Push lockup relay valve sleeve No. 1 with a finger. and extract the pin by using the magnet hand. (4) Lockup relay valve sleeve No.1 (©) Lockup relay valve (© Lockup relay control valve () Spring (8) Pin ee ARS Ne Ade Se ey fonovrae Pr as Rama sas ar a = Removing the Pin2-125 (9) Lockup relay valve sleeve No. 2 2. Remove the primary regulator valve. (1) Push the pressure regulator valve sleeve with a finger, and extract the seat by using the magnet hand, (2) Pressure regulator valve sleeve (3) Primary regulator valve plunger (4) Spring (8) Plate washer (6) E-rings (7) Primary regulator valve Caution: Check the number of E-rings after removal. 3, Remove the 1 ~2 shift valve, (1) Pin Removing the Pin Removing the Seat paso ast Daass26 4. (2) Plug (3) 1-2 shift valve tow plug (4) 1-2 shift valve 6) Spring Caution: Memorize the low plug installing direction. (6) Seat (7) Plug (8) Low coast shift valve Remave the lower valve body cover, (1), Lower valve body cover (2) Gasket (3) Plate Removing the 1 ~ 2 Shift Valve pasar Removing the Seat ease 4 8 Removing the Low Coast Shift Valve aces Removing the Body Cover aae25. Remove the lower valve body check balls. (1) Lower valve body check balls (2 pes.) Caution: Do not lose the check balls. 6. Remove the secondary lock valve, (1) Push the plug with a finger, and remove the seat by using the magnet hand. (2) Plug (3) Second lock valve 7. Remove the 3-2 kickdown orifice control valve (1) Push the plug with a finger, and remove the seat by using the magnet hand. Removing the Check Balls, ease Removing the Seat Removing the Second Lock Valve ase2 Removing the Seat ‘paso2-128 (2) Plug (3) 3-2 kickdown orifice control valve (4 Spring 8 Remove the accumulator control valve. (1) Push the plug with a finger, and remove the seat by using the magnet hand. (2) Plug (3) Spring () Accumulator control valve 9. Remove the low modulator valve. (°) Push the plug with a finger, and remove the seat by using the magnet hand. Removing the Orifice Control Vaive Removing the Seat pao Removing the Seat2-129 VALVE SPRING INSPECTION (2) Plug (3) Spring (4) Low modulator valve (1) Inspect the free length of each spring ‘Standard £1 incicates te inside diameter REASSEMBLY 2 Install the low modulator valve. (1) Low modulator valve (2) Spring (3) Plug (4) Push the plug with a finger. and install the seat Install the accumulator control valve. (1) Accumulator control valve (2) Spring (3) Plug (4) Push the plug with a finger, and install the seat, a oe =2-130 3 Install the 3-2 kickdown orifice control valve, (1) Spring (2) 3-2 kickdown orifice control valve (3) Push the plug with a finger, and install the seat Install the second lock valve. (1) Spring 2) Second lock valve @) Plug (4) Push the plug with a finger. and install the seat Install the lower valve body check balls. (1) Lower valve body check balls (2 pcs.) Caution: Do not lose the check balls. Install the lower valve body cover. (1) Two gaskets (new gaskets) Caution: Set the gasket with holes at check balls on the valve body side of the valve body cover plate. (2) Lower valve body (3) Lower valve body cover Installing the Check Balls,2-131 7 (4) Set bolt T = 0.55 kg-m (4.0 ft-lb) Install the 1 2 shift valve (1) Low coast shift valve (2) Plug (3) Seat Install the primary regulator valve. (1) Primary regulator valve plunger (2) Primary regulator valve (3) E-tings and plate washer (4) Spring (5) Primary regulator valve sleeve Caution: Install as many plungers as the number checked at the time of removal. Make the pawl of the E-ring face the rear side. ‘© Check that the plunger exists in the sleeve. (6) Push the pressure regulator valve sleeve with a finger, and install the seat. an the Set Bolt - pas2 Installing the _ ‘Shift ave as | tL Instaling he Plunger ase installing the Primary Regulator Valve ess2-132 9. Install the lockup relay valve (1) Install the lockup relay spring on valve sleeve No. 2 trol valve and (2) Install the lockup relay valve on valve sleeve No. 1 (2) Lockup relay valve sleeve No. 2 (4) Lockup relay valve sleeve No. 1 (6) Pin (for sleeve No. 2) oe Installing the Valve and Spring ases Installing the Lockup Relay Valve as67 Instaling Valve Sleeve No. 1 as692-133 (6) Install the pin with lockup relay valve sleeve No. 1 in the illustrated direction. Note: Place the hole at the sleeve end surface on the rear side of the valve body, a7 (7) Lockup relay valve body plate _ (8) Gasket (new) (8) Set bolts (3 pes.) ‘Tempoarily Tightening the Ser Bolts aseo2-134 TRANSMISSION ASSY REASSEMBLY Caution ‘Work with bare hands or wear vinyl gloves, and never use working gloves or waste cloth. Prevent entrance of foreign matters such as sand or dust. Coat Auto Fluid D-II on sliding and rotating parts before reassembly. Do not use bond for gaskets Always use new gaskets and O-rings. Coat petrolatum on the trust bearing and bearing race before reassembly. When the gasket kit is replaced, use the yellow petrolatum grease in the same package. ‘© Install the thrust bearing and bearing race in the positions and directions shown in the illustration below. ry tnnereia. [27,0 veo) fanig|2®8# [2080] 6.5 |r. 15] 7. a4]. 75 rs [oer a7 |z.2 |478] 7. |. | 3219 |32.75 | 3.75 ouer a, 13.0 [46.15] 46.15] 51,70 50.15 | 51.95 [51.70] 90.40 81.95/51.70| 50.40 50.40.70 51.98 |. 7| 50. | 50.40 [51.70 (=) “Thrust Bearing and Bearing Race Mounting Positions TART2-135, REASSEMBLY 1, Install the transmission rear cover. (1) Transmission rear cover (2) Gasket (new) (3) Set bolts (3 pes) (4) Screws (6 pes.) T = 0.8 kg-m (58 ft-lb) [7.8 N-m] 2. Install accumulator piston C, and the spring (1) Inspect the accumulator piston outside di- ameter. and spring outside diameter and tee length ie S_7 Standard ‘orn | Free : Fitna soe | i, KZ dew | tn) = 70 vo 72307 i | 2007S og 11760-90024) ae) | (2) Coat Auto Fluid D-II on the new O-ring (3) Install the O-ring on accumulator piston C (4) Spring (8) Accumulator piston C, (6) Install gaskets No. 1 and No. 2 on the plate. Installing Accumulator Cy aso Installing Gaskets No. 1 and No.2 4805,2-136 (D) Front Clutch accumulator cover (®) Set bolts T = 0.8 kg-m (6.8 ft-lb) [7.8 N-m] 3. Install the planetary gear ASSY & output shaft. (1) Planetary gear ASSY & output shaft (2). Install the service bolt to the boithole in the one- way clutch drum, Note: User a bolt whose thread diameter is 6 mm. and thread pitch is 1.0 mm. (3) One-way clutch ASSY Caution: Match with the notch in the transmission case, (4) Rotate the one-way clutch clockwise by using the service bolt, and install the drum on the transmission case. Note: If the one-way clutch drum is not rotated clockwise, the one-way clutch installation may be incorrect. Installing the One-way Clutch ASSY Datos(8) Snap ring Caution: Match the snap ring joint with the opening in the case, 4, Install the center support ASSY. (1) Center support ASSY Caution: Align the oil hole and bolt hole in the center support with those of the transmission case. (2) Lock bolt T = 2.5 kg-m (18.1 ft-lb) [24.5 Nem) Caution: Do not coat sealant on the bolt as it is installed temporarily. ©. Install the governar ASSY (1) Governor ASSY 6. Install the speedometer drive gear. (1) Spacer and speedometer drive gear Intaling the Speedometer Drive Gear aves,2138 7. Extension housing installation 1) Gasket (new part) (2) Extension housing |3) Bolts (10 pes.) T = 3.8 kg-m (27.5 ft-lb) [373 Nem] Caution: ‘¢ Install the bolts in correct positions. ‘# Do not damage the oil seal. 8. Install the output flange. (1) Output flange (2) Lock nut T= 13 kg-m (94 ft-lb) [127.5 N-m] Caution: Do not caulk the lock nut as it is temporarily installed for inspection and adjustment of the transmission 9, Inspection and adjustment of center support axial clearance (1) Push the output shaft toward the front side of the transmission with a force of 5 ~ 10 kg (11 ~ 22 Ib) [49 ~ 98N]. (2) Pull the center support toward the front side of the transmission with a force of 5 ~ 10 kg (11 ~ 22 Ib) [49 ~ 98N] (3) Bring the SST into contact with the top surface of the center support case, Use verniar calipers to measure the distance between the top surfaces of the SST and one-way clutch drum, and check the value obtained by deducting the thickness of the Sst. SST 09350-06090 Cautio Measure the thickness of the SST, too. Installing the Extension Housing 386 Inataling the Output Fange oat 510 ke 11~22 1b) to~0en) Ke S| = (1~220) Center ESI (49~98n)| Sipoere Preparing for Inspection and Adjustment of Centger Support 8495, Sst AY SS ‘Measuring the Dimension from the Top Surface of Center Support Case to Top Surface of One-way Clutch Drum 4496(4) Remove center support lock bolts (3 pcs.) (5) Center support ASSY SST 09350-06140 (6) Reverse the center support and place it on. a surface plate. Measure the dimension from the washer mounting surface to the ‘end surface af the center support case (7) Subtract the dimension (6) from the di- mension measured in step (3) Note: This dimension is the clearance between the center support washer mounting surface and ‘one-way clutch drum upper surface. (8) Select the washer to make the clearance between the center support and one-way Clutch satisfy the standard by referring to the dimension obtained in (7). Standard: 03 ~ 0.7 mm (0.0118 ~ 0.2756 in) Limit: 0.9 mm (0.0354 in) Note: ‘© Washers are provided in four thickness: 1.8 + 0.05 mm (0.071 + 0.00197 in), 2.1 + 0.05 mm (0.083 + 0.00197 in) 2.4 + 0.05 mm (0.094 + 0.00197 in) and 2.6 + 0.05 mm (0.102 + 0.00197 in) @ If the measured thickness of a used washer is within the standard above, it may be used gain. (9) Install the washer selected in (8) to the center support. (10)Coat Auto Fluid D-II on the O-rings (3 pes.) (11)Align the oil hole and bolt hole in the center support ASSY with those of the transmission case, and install the center support to the transmission case. 2-139 Installing the Center Support 3399 ‘Measuring the Dimension from Washer Nounting Surface to Support Case End Surface rd Selecting the Washer Installing the Center Support ASSY2-140 10. (12)Clean the lock bolt and bolt hole. Caution: Use a nylon brush. (13) Degrease with white gasoline and dry by blowing ait (14)Coat sealant (Locktite §72) in the illus- trated position Caution: Keep the bottom surface ® of the bolt free from the sealant, (15)Center support ASSY (16)Lock bolt T = 2.5 kg-m (18.1 ft-lb) (24.5 Nim] Install the rear clutch ASSY. (1) Rear clutch ASSY Caution © Align clutch disc pawls. ‘© Check that the bearing race is installed. Install the front clutch ASSY. (1) Front clutch ASSY Caution Confirm secure installation. Coating Lock Bolt Sealant asg9 ‘TAFSI03 asoe Installing the Front Clutch ASSY2-141 12 13. (2) Spacer (3) Bearing race Note: Use the originally installed spacer again for inspection. Front clutch installation height inspection (1) Place the SST on the oil pump mounting surface as illustrated. Measure the dimen- sion between the SST upper surface and front clutch drum upper surface to check if itis the same as that before removal ‘SST 09350-06090 Install the overdrive support ASSY. (1) Align the overdrive support ASSY oil hole and bolt hole with those of the transmis sion case, and install the overdrive support. (2) Lock bolt T= 2.5 kg-m (18.1 ft-lb) [24.5 N-m) Caution: Do not coat sealant as the bolt is installed temporarily. (3) Push the output shaft toward the front side of the transmission with a force of § ~ 10 kg (11 ~ 22 Ib) [49 ~ 98 NJ. (4) Pull the overdrive support toward the front side of the transmission with a force of 5 ~ 10 kg (11 ~ 22 ib) [49 ~ 98 N} Installing the Overdrive Support 3406 5~10 ka = (11~22 iv) [49~98N} Preparing for Inspection and Adjustment cf ‘Overctive Suppor ‘Tarstos2-142 (5) Set a dial gauge ‘SST 09350-06130 (6) Inspect the input shaft axial play to see that itis within the standard Standard: 03 ~ 0.7 mm (0.0118 ~ 0.2756 in) Limit: 0.9 mm (0.0354 in) If the limit is exceeded, replace the front clutch spacer with the one selected as follows: @ Measure the thickness of the ori installed spacer ® Select the spacer to satisfy the stan- dard play by referring to the thickness measured in © above. inally Note: Spacers are provided in five thicknesses: 0.9 + 0.05 mm (0.035 + 0.00197 in), 1.2 + 0.05 mm (0.0472 + 0.00197 in), 1.5 + 0.05 mm (0.0590 + 0.001 in), 1.8 + 0.05 mm {0.0708 + 0.00197 in), and 2.1 + 0.05 mm (0.0827 + 0.001 in) (7) Remove the overdrive support lock bolt. (8) Remove the overdrive support ASSY. SST 09350-06140 (9) Coat Auto Fluid D-II on the O-rings (3 pes.) (10)Align the oil hole and bolt hole in the overdrive support ASSY with those in the \ransmission case, and install the overdrive support on the transmission case. Ingpecting the Input Shaft Axial Play 307 Installing tho Overdrive Support ASSY 306(11)Clean the lock bolt and bolt hole Caution Use a nylon brush. (12)Degrease with white gasoline and dry by blowing air (13)Coat sealant (Locktite 672) in the illus trated position. Caution: Keep the bottom surface ® of the bolt free from the sealant. (14)Overdrive support ASSY T= 25 kg-m (18.1 ft-lb) [24.5 Nm) (15)Bearing race Caution Install the bearing race in the correct direc- tion, (16)Coat yellow petrolatum grease or petrola: tum on the thrust bearing (17) Thrust bearing (18)Input flange (19){nstall the snap ring at the flange (20)Sleeve Coating Lock Bolt Sealant 5S 3 Installing the Thrust Bearing 3296 TAFSIOS Installing the Input Flange TAFSIOS2-144 14, 16. 16. Install the input shaft. (1) Input shaft Input shaft installation height inspection (1) Place the SST on the oil pump mounting surface as illustrated, and measure the di- mension between the SST upper surface and the top surface of the input shaft staged portion to see that itis the same as that before disassembly. SST 09350-06090 (2) Thrust washer (3) Needle bearing Install the oil pump ASSY. (1) Bearing race Caution: Install the bearing race in the correct direc- tion, (2) Align the oil pump bolt hole and transmis~ sion case bolt hole (2) Oil pump Assy Caution: Tap the upper surface of the oi! pump with a plastic hammer along the whole circumfer- ence. (4) Pump set bolts T= 2.1 kg-m (15.2 ft-lb) Installing the Input Shaft ‘TAFSIO7 Installing the input Shaft installation Height TAFSIOR Installing the Olt Pump TAFSIO9 Installing the Oil Pump17. Input shaft looseness inspection (1) Push the input shaft toward the rear side of, the transmission with a force of 5 ~ 10 kg (17 ~ 22 Ib) [49 ~ 98N) (2) Set a dial gauge on the input shaft as illustrated (3) Inspect to see ifthe input shaft axial loose- ress is within the standard, Standard: 0.3 ~ 0.7 mm (0.0118 ~ 0.2756 in) Limit: 0.9 mm (0.0354 in) If the limit is exceeded, replace the cil pump bearing race with the ane selected as follows: @® Measure the thickness of the originally installed bearing race @® Select the bearing race to satisfy the standard by referring to the thickness measured in ©. Note Bearing races are provided in three thicknesses: 0.8 8-8) mm (0.0315 3.98038 in), 1.0 0.05 mm (0.0394 + 0.00197 in) and 1.4 + 0.05 mm (0.055 + 0.00197 in) (4) Oil pump set bolts (5) Oil pump ASSY SST 09360-06140 2-145 Input shaft > 510 kg (1122 tb) [49~98 N} f Preparing for Input Shaft Looseness Inspection ‘TAFSINO Inspecting the Input Shaft Looseness pasio Removing the Oil Pump ASSY 33002-146 (6) Coat Auto Fluid D-II on the O-ring (new) and instal it on the oil pump. (7) Install the bearing race selected in step (3) on the oll pump ASSY Caution: Install the bearing race in the correct direc- tion. (8) Clean the bolt and bolt hole. Caution Use a nylon brush. (8) Install the gasket (new) on the transmis. sion case by aligning the oil hole. (10)Match the bolt holes of the oil pump and transmission case. (11)0il pump ASSY (12)Degrease the bolts and bolt holes with white gasoline and dry by ait blowing (13) Coat sealant (Locktite 572) on the bolts. Caution Do not smear the bottom surface of the bolt with the sealant. (14)Set bolts T = 2.1 kg-m (15.2 ft-lb) (20.6 N-mj 18. Install accumulator pistons C2, Bo and B, and the springs Installing the Bearing Race on Coating Sealant on the Bolts aso2 Installing the Ol Pump am (1) Inspect each piston outside diameter and each spring outside diameter and free length. ge ® cy Bo Standard | ' mS Pace | Piston outsie | Spring outsice | Free tengin B gu sed | fhm ony at ime tn) = = G_| sara | 218 0088) | e015) | rT 8 _| 2987(0.176) | 207 (0815) | 6305 (2.48) | a BD B, a] 3087 1670) | 24910800) | 650255 | Ba 3,2} 99.87 (1570) | 110(0493) | 289(7.19) = ~ Inspecting the Accumulator Pistonsand Springs —‘TARSHI22-147 19 20. a (2) Coat Auto Fluid D-II on the O-rings (new) and install them on pistons. (3) Springs (4) Accumulator pistons Install the throttle cable. (1) Coat Auto Fluid D-11 on the O-ring (new) and install it on the throttle cable. (2) Throttle cable Caution: Make sure that the cable retainer portion is fitted securely. Install the transmission case apply gaskets. (1) Coat Auto Fluid D-II on the apply gaskets (4 pes.) (2) Apply gaskets Install the valve body, (1) Valve body (2) Connect the throttle cable to the throttle cam. (3) Set bolts T= 1.0 kg-m (7.23 ft-lb) (9.8 N-m) Caution: ‘© Reference bolts have identification mark “8” on the head. ‘© Install the reference bolts first. TAFSINS bolt Installing the Apply Gaskets Reference ‘TaFSt4 Reference boit Reference bolt Installing the Set Bolts2-148 22. Install the oil strainer and gasket. (1) Gasket (new) (2) Oil strainer (3) Set bolts MS: T= 0.55 kg-m (3.98 ft-lb) [5.4 N-m] M6: T= 1.0 kg-m (7.23 ft-lb) [9.8 N-m] 23. Install the oil tube. (1) Remove lockup relay valve body plate set bolts. Caution Do not let the pin for the lockup relay valve fall (2) Oil tube Caution «Lightly tap both ends with a plastic ham- mer. @ Do not deform the oil tube. (3) Gasket (new) (4) Lockup relay valve body pl (5) Set bolts MS: T= 0.55 kg-m (3.98 ft-Ib) [5.4 Nem] M6: T= 1.0 kg-m (7.23 ft-lb) [9.8 N-m} 24, Install the oil pan (1) Magnet Caution: Install the oil pan so as not to come into contact with the oil tube. (2) Gasket (new) 20 mm (0.787 in.) 120 mm (4.72 in.) 20 men (0.787 in.) Installing the Magnet Asoo(3) Oil pan (4) Set bolts T = 0.7 kg-m (5.1 ft-Ib) [6.9 N-m] 2, install the speedometer driven gear ASSY. (1) Coat Auto Fluid D-II on the O-ring, and install iton the driven gear. (2) Speedometer driven gear (3) Lock plate (4) Set bolt T= 1.3 kg-m (9.4 ft-lb) (12.7 Nm] 26. install the transmission housing. (1) Transmission housing set bolts T = 6.5 kg-m (47 ft-lb) [63.7 N-m] (2) Throttle cable clamp 27. Install the neutral start switch (1) Neutral start switch (2) Align the neutral reference line and the groove cut on the shaft (3) Bolt T= 1.3 kg-m (9.4 ft-lb) [12.7 Nem] Installing the Neutral Switen ‘TAFSS22-150 (4) Lock nut T= 07 + 0.1 kg-m (5.1 + 0.7 ft-lb) [6.9 + 0.98 N-m] (8) Caulk the lock washer paw! 28. Irstall the control shaft lever. (1) Control shaft lever (2) Nut T=1.3kg-m (9.4 ft-lb) [12.7 Nem] 29. Irstall the oil level gauge and oil filler tube. (1) Coat Auto Fluid D-Ii on the O-ting (new) and install it on the oil filler tube (2) Oil filler tube (3) Level gauge 30. Install the torque converter ASSY. (°) Torque converter ASSY Caution: ‘¢ Match the notch in the torque converter ASSY with the paw! of the oil pump. * Do not damage the oil seal on the oil pump. (2) Inspect the torque converter installed di mension Standard: 4.5 mm (1.77 in) Installing the Torque Convertor ‘TAFSNS TAFSS Instaling the Torque Converter TaFS240AUTOMATIC TRANSMISSION (FROM '95. 6) Page SECTIONAL VIEW 32 SPECIFICATIONS 33 COMPONENTS ... 34 INSPECTION & ADJUSTMENT 3-14 ELECTRICAL CONTROL 3-26 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION ..... 3-27 TORQUE CONVERTER ASSY 3-29 AUTOMATIC TRANSMISSION ASSY DISASSEMBLY 3-30 MANUAL VALVE LEVER & SHAFT OIL PUMP . TRANSMISSION INPUT SHAFT & OVERDRIVE CASE FRONT CLUTCH ASSY 3-51 REAR CLUTCH ASSY CENTER SUPPORT ASSY PLANETARY GEAR ASSY & OUTPUT SHAFT . 3-70 FIRST & REVERSE BRAKE . 3-78 GOVERNOR VALVE ASSY . 3-83 TRANSMISSION ASSY REASSEMBLY 3-88 ‘See pages 2-96 to 2-150 for the valve.32 SECTIONAL VIEW ‘Automatic TransmissionSPECIFICATIONS 02-2TD(G)20, 02-2TD(G)25, 42-2TD20, 42-2TD25 S-element, 1-stage, 2-phase type, hydraulically con- Type trolled planetary gear 3-speed automatic speed changer Torque converter stall-torque ratio 2.68 — J tset A speed Forward | 296 1.548 Speed change ratio speed 3rd 1 speed oo _ Reverse 2.657 Oil used GM Dexron®l Oil capacity (US gal) | About 1112.9)3-4 COMPONENTS Torque converter No. 1 case SUB-ASSY ‘Speedometer sieeve SUB-ASSY Transmission case SUB-ASSY Oil level gauge SUB-ASSY Oil pan Oil pan packing Drain plug ‘Speedometer driven gear Neutral start switch Oil seal Gasket Magnet Lock plate Cover Oil seat Clip Spacer Clamp Oil fillor tube SUB-ASSY Transmission ree housing Gasket Manual valve lever SUB-ASSY Manual valve lever shaft Transmission conteol shaft lever ‘Automatic Transmission Housiung Components TAPMGT. 7.118oO " 20 23 28 30 ‘Torque converter ASSY Oil pump ASSY Drive plate ring gear ASSY Oil pump drive gear Oil pump driven gear il pump case SUB-ASSY 30A O-ring 50 AL AR AS AT aX Ay il pump case cover packing Bolt Bott Drive plate spacer Center ring support Oil seat Spacer oz x EA EB Check valve spring seat | Front oil pump cover Check ball Compression spring “Torque Converter ComponentsQ 01 Governor body ASSY 40 Governor body 40A Governor body gasket 41 Governor body support AA Governor oil strainer AB Governor No, 1 valve ‘Governor Components ac AD AE AG AS AK Governor No. 2 valve Compression spring Spacer Governor weight Ring Governor valve No. 2 shaft ARMs21 Clutch No. 2 drum SUB-ASSY 24 Clutch No. 1 shaft SUB-ASSY 40A Front clutch disc 408 Rear clutch disc 41A Front clutch plate 41B Rear clutch plate CL Thrust bearing CU. Thrust bearing race CV Thrust bearing race CW Front clutch piston SUB-ASSY CX Rear clutch piston SUB-ASSY CY Compression spring cz DA DB oc Do DE oF ob DH ol Du OK Transmission Components (I) Return spring seat Thrust bearing Thrust bearing race Front clutch hub Thrust bearing race Compression spring ‘Thrust bearing race ‘Thrust bearing Rear clutch hub Return spring seat Clutch cushion plate Rear clutch flange DN oP —M EN EP £0 EQ ER ES ET eu ‘Thrust bearing rece Input shaft oll seal ring Clutch drum oil seal ring Center support C-ring retainer Transmission input shaft SUB-ASSY O-ring Input shaft sleeve Transmission input shaft flange Oil seat ring Thrust bearing race Thrust bearing race Thrust bearingaoc eB 40€ Clutch dise (for brake) EA. Ol seal ring 41C Brake plate EB Rear planetary sun gear cP Washer EC. Center support ring retainer DQ. 2nd brake piston return spring SUB-ASSY DT Brake Not piston DV Brake Not flange DW Front planetary sun gear sub-assy DY Center support SUB-ASSY Torqueconverter Clutch TAFMIA3-10 ED 13. Front planetary gear ASSY 14 Rear planetary gear ASSY 15 1-way clutch ASSY 45 Out put No.1 Shaft 45A No.1 bearing 458 No2 bearing 45C O-ring AN O-ring AK Spacer AL Snap ring AP. Snap ring AX. Snap ring BT Nut Ds oT bu bv Dw Dx by Dz EA £8 eD EE EF Intermediate shaft Planetary carrier thrust No.1 washer Planetary carrier thrust No.2 washer Front planetary carrier ring gear Hole snap ring Intermediate shaft oil seal Rear planetary ring gear Rear planetary ring gear flange Thrust needle roller bearing Thrust needle roller bearing Hole snap ring Output shaft flange Thrust bearing race Torqueconverter Gearx HG HH HI HK HL HM HN Hz kA KB KD KE KF Ki Plug Lockup relay valve Compression spring Lockup relay control valve Lockup relay valve No. 1 sleeve Lockup relay valve No. 2 sleeve Lockup relay valve body plate Lockup relay valve body gasket Primary regulator valve Compression spring Washer Primary regulator valve plunger Primary regulator valve sleeve Manual valve Ball Transmission Components (3) Lo u wu Lo ME MG Mi NJ mK ms NE NF NI Ny NY Valve body cover plate Lower modulator valve Compression spring Low coast shift valve 1-2 velay valve Compression spring 1-2 shift valve Compression spring Second lock valve Valve body No. 2 cover 3-2 kickdown orifice control valve Compression spring ‘Accumulator control No. 1 valve Compression spring Apply tube TaFM62RESGECCESRS Plug Plug Lockup signal valve Compression spring ‘Spring seat ‘Secondary down seat plug SUB-ASSY Compression spring Primary down seat valve SUB-ASSY Compression spring 2-3 shift timing valve plug 2-3 shift timing valve plug sleeve Intermediate modulator valve ‘Compression spring Lower modulator valve Compression spring Throttle valve No, 1 sleeve 2-3 shift valve Compression spring ‘Cutback valve Throttle valve No. 2 sleeve “Transmission Components (8) MA MB Mc. MN. Mo. mp my mw mx NA NB Ne ND NM. NP No NT NU PN PU Spring Throttle valve Compression spring Intermediate coast shift valve ‘Secondary regulator valve Compression spring Third coast valve Overdrive clutch exhaust valve Compression spring ‘Secondary throtle valve Compression spring 2.3 shift timing valve Compression spring Manual down timing valve 3-4 shift valve Compression spring 3-4 coast shift valve Throttle valve cam ASSY Apply tube Intermediate coast shift sleeve TAFMED, 1213-13 o1 16 "7 18 AY oR cy cz He Ha HR HS ‘Transmission cover & valve ASSY Lower valve body ASSY Rear upper valve body ASSY Front upper valve body ASSY Spring Control valve body plate Overdrive brake accumulator piston Front clutch accumulator cover Front clutch accumulator plate Apply tube Oil strainer SUB-ASSY Gasket “Transmission Components (5) HT HY KO KP Ka KR. Ks KT NX NY Torottle oil strainer Manual detent spring SUB-ASSY B-2 accumulator piston Compression spring C-1 accumulator piston Compression spring C-2 accumulator piston Compression spring Ball Detent spring cover ‘Transmission table apply tube ‘TAFMG14 INSPECTION & ADJUSTMENT AUTOMATIC TRANSMISSION FLUID LEVEL CHECK 1. Engine inspection Note: Refer to each engine repair manual for the engine inspection method, 1DZ Engine Repair Manual No. CE618 4Y Engine Repair Manual No. CE602 2Z Engine Repair Manual No. CE625 (1) Inspect the idling speed Standard 1DZ: 650 *50 rpm 0 4Y: 650 *80 rpm : +50 2z: 750 +80 rpm 2) Inspect the injection timin: ignition timing (AY) SST 09275-54010 SST 09240-32880-71 Standard 1DZ-2Z: 0° (stationary) BTDC : 4Y: BTDC 7°/rpm 2. Fluid level check (1DZ) and Inspecting the Injection Timing (102) KANS-8 Caution: ‘¢ Park the vehicle on a flat ground. ¢ Check the level at the fluid temperature (70° ~ 80°) in normal traveling state. | (1) Apply the parking brake. | (2) Move the shift lever fully from the N range to the L range with the engine in idling state, \d return the lever to the N range Inspecting the Fluid Level 047s (3) Check that the fluid level is in the HOT range on the level at the N range in idling state Caution: «When level check at a low oil temperature (20 ~ 30°C) is necessary for oil replacement or other purpose, adjust to the COOL range on the gauge and check under HOT conditions later. «If the level is different between the front and rear sides of the level gauge, use the lower one for measurement. Carefully prevent excessive oil as it may cause various troubles, If the oil level is insufficient, check oil leakage. Fluid used: GM Dexron®lt volume: About 10 @ (2.64 US gal) The amount of oil to be replaced every 6 months (1,000 hours) is 2.0 to 2.5 £ (0.53 to 0.86 US gall3-15 THROTTLE CABLE INSPECTION & ADJUSTMENT 1. Throttle cable inspection and adjustment (1) Depress the accelerator pedal fully and push the throttle lever to check full opening If not fully opened, adjust the accelerator wire. 2. Throttle cable inspection and adjustment (1) Check that the throttle cable is securely installed to the throttle lever without any bend (2) Measure distance between the edge of the cable adjustment mark and the cable end face when the throttle valve is fully closed, Standard: 0.5 ~ 1.5 mm (0.0197 ~ 0.059 in) If the standard is not satisfied, use the adjusting nut for adjustment. x When a boot is provided, remove the boot and adjust the distance between the cable end face and cable adjustment mark to 0.5 ~ 1.5 mm (0.0197 ~ 0.059 in) (3) Inspect the cable stroke when adjusting the injection timing and/or injection pump. (1DZ - 22 engine vehicle) Reference value: 33 £ 1. mm (1.3 + 0.039 in) Inspect the cable stroke when adjusting the ignition timing or replacing and adjust- ing the IA (4Y engine vehicle) Reference value: 33 + 1: mm (1.3 + 0.039 in) Note: Loosen the throttle cam adjusting nuts and move the throttle cam for adjustment. Caution: Perform inspection in step (2) after the ad justment. (4) Caulk the lock nut, and fix the nut 33¢1mm, (1.3 £ 0.039 in.) 0.5~1.5mm (0.0197 ~ 0.089 in.) Inspecting the Throttle Calbe (1DZ) TAFS23 05~1.5. nm (0.0197 ~ 0.069 in.) Throttle cam Adjusting bolt Inepecting the Throttle Cable (4Y) TAFS56 NEUTRAL START SWITCH INSPEC- TION 1. Functional check (1) Apply the parking brake (2) Check that the engine starts when the shift lever is shifted to the N range, and does not start in any other range. (3) Be sure that the backup lamp does not come on unless the shift lever is in the R range, 2. Adjustment (1) Loosen the neutral start switch set bolts. (2) Set the shift lever to the N range. (3) Align the cut groove on the switch with the neutral reference fine by moving the switch, (4) Tighten the set bolts T = 1.3 kg-m (9.4 ft-tb) (12.75 N-m] Neutral datum line Cut groove} Adjusting the N Position ‘TAFS293.17 ON-VEHICLE INSPECTION Caution: Conduct each test after the end of basic inspec: tion and adjustment. STALL TEST Caution: Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling state. © Do not continue the test over 5 seconds. @ Wait at least 1 minute between the tests in D and R ranges, Inspecting the Ot Temperature ‘TAFS20 1. Carry out measurement according to the illus: trated procedure. Stall speed Standard ‘1DZ engine: 2080 ~ 2380 rpm 4Y engine: 2050 ~ 2350 rpm 2Zengine: 2250 ~ 2350 rpm Shift to the B(R) range. Depress ‘the brake pedal with the lft foot and depress the accelerator pedal fully with the right foot, Quickly read the maximum engine speed at the time Stall Test ‘TaFNNT2 Note: Estimated defect as a result of stall test "e The throtle valve is not opened fully. ¢ The engine output is insufficient ¢ The stator one-way clutch is defective. (2 torque converter defect may be the reason ifthe stall speed is lower by 600 rpm or more than the standard valve.) When the stall speeds in both ranges are equal but lower than the standard: ' The front clutch is sipping ‘¢ One-way clutch No. 2 is detective The line pressure is low. '¢ The rear clutch is sipping The Ist & reverse clutch is sipping, 18 The line pressure is low When the stall speed in the D range is higher than the standard: When the stall speed in the R range is higher than the standara When the stall speeds in both ranges | The line pressure is low. are higher than the standard: Le The fluid level is outs he standard (insufficient)3-18 TIME LAG TEST Caution ‘© Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling state. © Wait at least one minute between tests. ‘@ Measure three times, and average the re- sults. C) Carry out measurement according to the illustrated procedure. Time lag Inspecting the Ol Temperature TAFS90 Standard: N-D range 0.7 sec max. N-R range 1.2 sec max. 1.2 seconds or tess 7 0.7 seconds or less a ‘Measuring the Time Lag TARM28 Note: Estimated defect as a result of time lag test When the N + D time lag is longer ] @ The line pressure is low. ther the standard: The front clutch is worn. ‘¢ The line pressure is low. @ The reverse clutch is worn, @ The 1st & reverse brake is worn, When the N + R time lag is longer thar the standardHYDRAULIC PRESSURE TEST Caution: Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state. 1. Governor pressure measurement (1) Carry out measurement according to the illustrated procedure. Measuring instrument: OPG-100 3-19 See the fold out hydraulic circuit gram at the end of this manual. Inspecting the Oil Temperature ‘TAFSIO Standard ae (Reference! | (Reference) Output shaft speed rpm! 0 500 1000 1500 000 2600 Travel- [2nd speed km/h] 0 43 86 129) 172 218 ing speed [3rd speed km/h] 0 BA 103 154 205 25.6 Governor pressure kg/em™ o5~08 | 22~27 | 36~40 | 63~60 | 75~85 (osi)| 0 | (71 ~ 11.4) | (31.2 ~ 383) | (51.1 ~ 56.8) | (75.3 ~ 86.2) | (106.5 ~ 170.7) [kPa] (49 ~ 78.5) | (216.7 ~ 2648} | (383 ~ 3923) | (518.8 ~ 9884) | [738.5 ~ 8336) Remove test plug and install pressure gauge Note: Estimated defect as a result of pressure test TAFMA van the gow ig im. | © The line pressure is defective. When the governor pressure is im |. Gir is jeaking from the governor pressure hydraulic circuit. proper # The governor valve is defective.3-20 2. Line pressure measurement (1) Carry out measurement according to the illustrated procedure. Measuring instrument: Oil pressure gauge ‘Standard Engine speed | _D-range Rerange 1 sage | se itingsooed | GREY, | (fib > Bly imum | taste? | 9 —venin? | Maxien (1876 ~ 1931 psi) (198.8 ~ 2414 psi) seve OBS TSAR | SIRES ROAR Remove test plug and install pressure gauge (above neutral start switch) Note: Estimated defect as a result of the pressure test When the oil pressures in both | @ The regulator valve is defective, ranges are higher than the stan- | e The throttle valve is defective, dards: ¢ The throttle cable adjustment is improper. ‘© The oil pump is defective When the oll pressures in both | @ The regulator valve is defective ranges are lower than the standards: | The throttle valve is defective. @ The throttle cable adjustment is improver range are lower than the standards: | @ The front clutch is defective When the oil pressures in the D- | @ Oilis leaking from the D-range hydraulic circurt, When the oil pressure in the R range are lower than the standaras. | & The 1st & reverse brake is defective The rear clutch is defective ¢ Oil is leaking from the R-range hydraulicDRIVING TEST Caution: Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state D-range test (1) Shift to the D-range and start the vehicle at each valve opening (60% and full open- ing). Check each up-shift and shifting point in conformity with the automatic speed change urves, Note When 1-52 | @ The governor valve is detective. upshift is not | e The 12 shift valve is defec- effected: tive When2+3 |The 2-3. shift valve is upshift is not | defective. effected, 1 The governor valve is defective. ‘¢ The throttle cable adjustment is ‘When the improper. shifting point | @ The throttle valve, 1-+2 valve. 's improper 2-43 valve or governor valve is defective (2) Inspect abnormal sound, slipping and shock upon shifting at the time of acceler ation or deceleration Note’ Estimated defect as a result of driving test ‘When the @ The line pressure is high shook is @ The accumulator is defective excessive: @ The check ball is detective (3) Carry out kickdown during traveling at each of 2nd and 3rd gear positions to inspect if the limit speed for 241. 3-+2 or 31 kickdown matches that on the auto: matic speed change curves. 3-21 Throttle valve fully open (100%) Throttle valve “* halfway open (50%) ‘opening (%) Vehicle speed (km/h) —_ TARMNS4 ‘Automatic Speed Change Curves @® ‘Abnormal noise, slipping Shock at shifting Inspection at Acceleration /Deceleration on ® © halfway open (50%) Throttle valve fully open (100%) Vehicte speed (kmin) ‘Automatic Speed Change Curves ‘Tars2023-22 (4). Shift to each of the 2- and L-ranges diving driving in the D-range to inspect the en- gine braking effect in each range. Note: Estimated defect as a result of driving test No engine braking 2 malfuncti effect n2-range 2nd brake malfunction Ist & reverse brake No engine braking malfunction effect in L-range (6) Release the accelerator pedal from near 15 km/h (in 3-speed vehicle) while traveling in D-range and shift to the 2-range. Chet if the 3 + 2 down-shift point matches the automatic speed change curve. Release the accelerator pedal from near 9 km/h (3-speed vehicle) or 13 km/h (2- speed vehicle) while traveling in D-range and shift to the L-range. Check if the 2 + 7 down-shift point matches the automatic 6 speed change curve 2. Zerange test (1) Start the vehicle at each throttle vaive opening (60% and full opening} and check if the 1 + 2 up-shift point matches the automatic speed change curve Throttle valve ‘opening (%) tend Vehicle speed tken/h) 3rd. shite * “ ‘Automatic Speed Change Curve Throttle valve opening (%) Throttle valve > yminronn DS" & Throttle Throttle valve opening a Vehicle speed (km/h) ‘Automatic Speed Change Curve fully open (100%) Tars207 TAFs200 (50%) TARSIn3 3-23 (2) During traveling at the 2nd gear position, release the accelerator pedal and check the ‘engine brake function (3) Cary out kickdown from the 2nd gear state. and check if the speed allowing 2 + 11 kickdown matches the automatic speed change curve. (4) Check abnormal sound or slipping during acceleration and deceleration L-range test (1) Check no up-shift to the 2nd gear. (Nee Inspecting the Engine Brake Funcion area ) @&°® ® fo. He F Vehicle traveling speed (km/h) sutonate Speed Ghange Gave Taraz Inspecting Abnormal Sound and Slipping Oe @® Upshift ‘een j @).00% TARS217 = (7) 0«®e Inspecting Up-shift, ‘TAFSZI3:24 (2) Release the accelerator pedal during trav- eling at the first gear position, and check the engine brake function (3) Check abnormal sound or slipping during acceleration and deceleration. 4, Ferange test (1) Start the vehicle with the throttle valve fully opened, and check any slipping, ) ES Engine brake Inspecting the Engine Brake Function TARS221 i: Slipping Inspecting Abnormel Sound and Slipping Tarsz23 ‘Acceleration Deceleration Inspecting Slipping | CF) Throttle full opening + Slipping TAFS2ISAUTOMATIC SPEED CHANGE CURVES 3-25 & ? g | lo g 8 3 3 a ° Throttle valve opening (%) * — Automatic Speed Change Curves TAFMI38.3-26 ELECTRICAL CONTROL CIRCUIT DIAGRAM Circuit Diagram TAFSZ0 NEUTRAL SWITCH INSPECTION 1. Remove the toe board. As 2. Inspect continuity between connector termi- nals. Standard Terminal Shift Oo-0 | N oo Inspecting the Switch TAFS293-27 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION 6 ‘Automatic Transmission Flemoval & Installation TAFMGS REMOVAL [_ Disconnect the battery negative © terminal. [Point 1] [2 Disconnect the ATM throttle cable on the engine side, (Remove the toe board. @ Disconnect the ATM electrical wiring and hydraulic piping {]_ Disconnect the shift lever link rod Disconnect the speedometer cable. Remove the propeller shaft. Remove the drive plate set bolts. [Point 2] []_ Support the engine with a pantagraph jack placed under it. [Point 3] Slightly hoist the ATM. @ Remove the ATM housing set bolts. {Remove the ATM rear set bolts. {3 Remove the ATM ASSY. [Point 4] INSTALLATION ‘The installation procedure is the reverse of the removal procedure