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AUTOMATIC TRANSAXLE AX-1

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Page 1: Automatic transaxle

AUTOMATIC TRANSAXLE

AX-1

Page 2: Automatic transaxle

DESCRIPTIONGENERAL DESCRIPTIONThe A132L automatic transaxle described in this AX section is a 3-speed automatic transaxlewith a lock-up mechanism developed exclusively for use with transversely-mounted engines.

-AUTOMATIC TRANSAXLE DESCRIPTIONAX-2

Page 3: Automatic transaxle

Number of Discs/Plates Forward Clutch (C1) Direct Clutch (C2) 2nd Brake (B2)1st & Reverse Brake (B3)

DifferentialCapacity liter (US qts, Imp.qts)

Automatic TransaxleCapacity liter (US qts, Imp.qts)

Torque Converter Clutch Lock-up Mechanism

1st Gear 2nd Gear 3rd GearReverse Gear

Torque Converter Clutch Stall Torque Ratio

2nd Coast Brake (B1) Band Width

5.5 (5.8, 4.8)2.5 (2.8, 2.2)

2.8101.5491.0002.298

TotalDrain & Refill

3/32/32/45/4

1.4 (1.5, 1.2)

25 (0.98)

Type of Transaxle

ATF DEXRON® II

Type of Engine

Gear Ratio

ATF Type

Equipped

Transaxle

mm (in.)

A132L

2.5: 1

3E-E

-AUTOMATIC TRANSAXLE DESCRIPTIONAX-3

Page 4: Automatic transaxle

*Down-shift in L position, 2nd gear only-no up-shift.

OPERATIONOPERATION

Shift leverposition

�- --Operating

Gear position

Parking

Neutral

Reverse

* 2nd

2nd

2nd

1st

3rd

1st

1st

-AUTOMATIC TRANSAXLE OPERATIONAX-4

Page 5: Automatic transaxle

These gears change the route through which driving force is transmitted inaccordance with the operation of each clutch and brake in order to increase orreduce the input and output speed.

Prevents outer race of F1 from turning either clockwise or counterclockwise thuspreventing the front & rear planetary sun gear from turning counterclockwise.

When B2 is operating, this clutch prevents the front & rear planetary sun gearfrom turning counterclockwise.

Prevents front & rear planetary sun gear from turning either clockwise orcounterclockwise.

Prevents rear planetary carrier from turning either clockwise or counterclockwise.

Prevents rear planetary carrier from turning counterclockwise.

Connects input shaft and front & rear planetary sun gear.

Connects input shaft and front planetary ring gear.

1. FUNCTION OF COMPONENTS

No. 2 One-Way Clutch

No. 1 One-Way Clutch

1st & Reverse Brake

Planetary Gears

2nd Coast Brake

Forward Clutch

Direct Clutch

Component

2nd Brake

Function

-AUTOMATIC TRANSAXLE OPERATIONAX-5

Page 6: Automatic transaxle

Power from the engine transmitted to the input shaft via the torque converter clutch is thentransmitted to the planetary gears by the operation of the clutch.By the operation of the brake and one-way clutch, either the planetary carrier or the planetarysun gear are immobilized, altering the speed of revolution of the planetary gear unit.Shift change is carried out by altering the combination of clutch and brake operation.Each clutch and brake operates by hydraulic pressure; gear position is decided according to thethrottle opening angle and vehicle speed, and shift change occurs automatically.The conditions of operation for each gear position are shown in the following illustrations:

-AUTOMATIC TRANSAXLE OPERATIONAX-6

Page 7: Automatic transaxle

2. HYDRAULIC CONTROL SYSTEMThe hydraulic control system is composed of the oil pump, the valve body, the solenoid valves,the accumulators, the clutches and brakes, and the governor valve as well as fluid passageswhich connect all of these components.Based on the hydraulic pressure created by the oil pump, the hydraulic control system governsthe hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance.with the vehicle driving conditions.The governor valve produces hydraulic pressure in response to vehicle speed. Governor pressureincreases as vehicle speed increases.

Throttle Cable

OIL PUMP Hydr. pressure control

Fluid passage switching

Governor Valve

CLUTCHES & BRAKES Planetary gear sets

Torque converter clutch

HYDRAULIC CONTROL SYSTEM

-AUTOMATIC TRANSAXLE OPERATIONAX-7

Page 8: Automatic transaxle

PREPARATIONSST(SPECIAL SERVICE TOOLS)

(09351-32010) One-way Clutch Test Tool

(09351-32020) Stator Stopper

(09351-32150) Oil Seal Replacer

09201-6001 1 Valve Guide Bushing Remover & Replacer

(09351-32130) Handle

09350-32014 TOYOTA Automatic Transmission Tool Set

09992-00094 Automatic Transmission Oil Pressure Gauge Set

09043-38100 Hexagon 10 mm Wrench

09921-00010 Spring Tension Tool Speedometer driven gear oil seal

Speedometer driven gear oil seal

09308-00010 Oil seal Puller Side gear shaft oil seal

Oil pan drain plug

Line pressure

-AUTOMATIC TRANSAXLE PREPARATIONAX-8

Page 9: Automatic transaxle

SSM(SPECIAL SERVICE MATERIALS)

Automatic transaxle fluidw/o Differential oilDry fillDrain and refill

08833-00070 Adhesive 1311, THREE BOND 1311 or equivalent

Dial indicator or dial indicator with magnetic base

5.5 liter (5.8 US qts, 4.8 Imp. qts)2.5 liter (2.6 US qts, 2.2 Imp. qts)

Torque converter clutch mountingbolt

Measure inside diameter orpiston stroke.

Check torque converter clutchinstallation.

Differential oilw/ Automatic transaxle

1.4 liter (1.1 US qts, 0.9 Imp. qts)

ATF DEXRON® II

EQUIPMENT

LUBRICANT

ATF DEXRON® II

Torque wrench

Straight edge

Ammeter(A)

Classification

Voltmeter

Ohmmeter

CapacityItem

-AUTOMATIC TRANSAXLE PREPARATIONAX-9

Page 10: Automatic transaxle

TROUBLESHOOTINGGENERAL INFORMATION1. Troubles occurring with the automatic transaxle can be caused by either the engine or thetransaxle itself. These 2 areas should be distinctly before proceeding with troubleshooting.2. Troubleshooting should begin with the simplest operation, working up in order of difficulty,but first determine whether the trouble lies within the engine or transaxle.3. Proceed with the inspection as follows:

PRELIMINARY CHECK (See page AX-1 1)(a) Check the tire inflation.(b) Check the idle speed.(c) Check the fluid level and fluid condition.(d) Check the throttle cable mark.(e) Check the shift linkage.(f) Check the park/neutral position switch.

ROAD TEST (See page AX-20 )Confirm if trouble lies within automatic transaxle. If noisy or vibrating, thepossible cause could be with the compressor, engine, drive shaft, tires,etc.

TIME LAG TEST (See page AX-15 )Check the automatic transaxle (each clutch, brake and gear) for wear.

HYDRAULIC TEST (See page AX-16 )Measure the line pressure and make basic check of fluid circuit.

STALL TEST (See page AX-14 )Check the engine and torque converter clutch.

Matrix chart (See page AX-25 )

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-10

Page 11: Automatic transaxle

PRELIMINARY CHECK1. CHECK FLUID LEVELHINT: The vehicle must have been driven so that theengine and transaxle are at normal operating temper-ature.Fluid temperature: 70-80�C (158-176�F)(a) Park the vehicle on a level surface, set the parkingbrake.(b) With the engine idling, shift the selector into eachgear from P position to L position and return to Pposition.(c) Pull out the transaxle dipstick and wipe it clean.(d) Push it back fully into the tube.(e) Pull it out and check that the fluid level is in the HOTrange.If the level is at the low side of the hot range, add fluid.

Fluid type:ATF DEXRON® IINOTICE: Do not overfill.

2. CHECK FLUID CONDITIONIf the fluid smells burnt or is black, replace it.3. REPLACE ATF

NOTICE: Do not overfill.

(a) Using SST, remove the drain plug and drain the fluid.SST 09043-38100(b) Using SST, install the drain plug securely.SST 09043-38100

(c) Add new fluid through the filler tube.Fluid:ATF DEXRON® IICapacity:5.5 liters (5.7 US qts, 4.8 Imp.qts)Drain and refill:2.5 liter (2.6 US qts, 2.2 Imp.qts)

(d) Start the engine and shift the selector into all posi-tions from P through L and then shift into P.(e) With the engine idling, check the fluid level. Add fluidup to the COOL level on the dipstick.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-1 1

Page 12: Automatic transaxle

6. INSPECT AND ADJUST THROTTLE CABLE(a) Depress the accelerator pedal all the way and checkthat the throttle valve opens fully.HINT: If the throttle valve does not open fully, adjustthe accelerator link.(b) Fully depress the accelerator.(c) Loosen the adjustment nuts.(d) Adjust the outer cable so that the distance betweenthe end of the boot and stopper on the cable is thestandard.

Standard boot and cable stopper distance:0-1 mm (0-0.04 in.)

(e) Tighten the adjusting nuts.(f) Recheck the adjustments.

4. REPLACE DIFFERENTIAL FLUID IF NECESSARY(a) Using SST, remove the drain plug and drain the fluid.SST 09043-38100(b) Using SST, install the drain plug securely.SST 09043-38100(c) Remove the filler plug.(d) Add new fluid until it begins to run out of the fillerhole.

Fluid type:ATF DEXRON® II

5. CHECK DIFFERENTIAL FLUID LEVELRemove the filler plug and check differential fluidlevel.

(f) Check the fluid level with the normal fluid temperature70-80 �C (158-176�F) and add as necessary.

NOTICE: Do not overfill.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-12

Page 13: Automatic transaxle

8. ADJUST PARK/NEUTRAL POSITION SWITCHIf the engine will start with the shift selector in anyposition other than N or P position, adjustment isrequired.(a) Loosen the park/neutral position switch bolts and setthe shift selector to the N position.(b) Align the groove and neutral basic line.(c) Hold is position and tighten the bolts.

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

9. INSPECT IDLE SPEED (N POSITION)Idle speed:800 rpm

7. ADJUST SHIFT CONTROL CABLE(a) Loosen the swivel nut on the lever.(b) Push the manual lever fully toward the right side ofthe vehicle.(c) Return the lever 2 notches to the NEUTRAL position.(d) Set the shift lever in N position.(e) While holding the lever lightly toward the ”R” positionside, tighten the swivel nut.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-13

Page 14: Automatic transaxle

STALL TESTThe object of this test is to check the overall performance of the transaxle and engine bymeasuring the maximum engine speeds in D and R positions.NOTICE:• Perform the test at normal operating fluid temperature 50-80 °C (122-176°F).• Do not continuously run this test longer than 5 seconds.MEASURE STALL SPEED(a) Chock the front and rear wheels.(b) Mount an engine tachometer.(c) Fully apply the parking brake.(d) Keep your left foot pressed firmly on the brake pedal.(e) Start the engine.(f) Shift into the D position. Step all the way down on the accelerator pedal with your right foot.Quickly read the highest engine RPM at this time.

Stall speed:2,400±200 rpm

(g) Perform the same test in the R position.EVALUATION(a) If the engine speed is the same for both positions but lower than specified value:• Engine output may be insufficient• Stator one-way clutch is not operating properly(b) If the stall speed at the D position is higher than specified:• Line pressure too low• Forward clutch slipping• One-way clutch No.2 not operating properly(c) If the stall speed at the R position is higher than specified:• line pressure too low• Direct clutch slipping• First and reverse brake slipping(d) If the stall speed in the R and D positions is higher than specified:• Line pressure too low• Improper fluid level

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-14

Page 15: Automatic transaxle

TIME LAG TESTWhen the shift lever is shifted while the engine is idling, there will be a certain time elapse or lagbefore the shock can be felt. This is used for checking the condition of the forward clutch, directclutch and first and reverse brake.NOTICE:• Perform the test at normal operating fluid temperature 50-80 �C (122-176�F).• Be sure to allow 1 minute interval tests.• Make 3 measurements and take the average value.MEASURE TIME LAG(a) Fully apply the parking brake.(b) Start the engine and check the idle speed. (Cooling fan and A/C OFF)

Idling speed:N position 800 rpm

(c) Shift the shift lever from N to D position. Using a stop watch, measure the time it takes fromshifting the lever until the shock is felt.

Time lag:Less than 1.2 seconds

(d) In same manner, measure the time lag for N→R.Time lag:Less than 1.5 seconds

EVALUATION(a) If N→D time lag is longer than specified.• Line pressure too low• Forward clutch worn• Line pressure too low• Direct clutch worn• First and reverse brake worn

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-15

Page 16: Automatic transaxle

HYDRAULIC TEST1. MEASURE LINE PRESSURE(a) Warm up the transaxle fluid.(b) Remove the transaxle case test plug and mount the oil pressure gauge (SST).SST 09922-00094

NOTICE: Perform the test at normal operating fluid temperature 50-80 �C (122-176�F).

(c) Fully apply the parking brake and chock the 4 wheels.(d) Start the engine and check the idle speed.(e) Shift into the D position, step down strongly on the brake pedal with your left foot and whilemanipulating the accelerator pedal with the right foot, measure the line pressure at the enginespeeds specified in the table.(f) In the same manner, perform the test in the R position.

(g) If the measured pressures are not up to specified values, recheck the throttle cable adjustment(See page AX-12 ) and retest.

1,412 -1,648 (14.4 -16.8, 205 - 239)902-1,049 (9.2-10.7,131 -152)

530-706 (5.4-7.2, 77-102)363-422 (3.7-4.3, 53-61)

kPa (kgf/cm2, psi)kPa (kgf/cm2, psi)Line pressure D position R position

Idling

Stall

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-16

Page 17: Automatic transaxle

EVALUATION(a) If the measured values at all positions are higher than specified:• Throttle cable out of adjustment• Throttle valve defective• Regulator valve defective(b) If the measured values at all positions are lower than specified:• Throttle cable out of adjustment• Throttle valve defective• Regulator valve defective• Oil pump defective(c) If pressure is low in the D position only:• D position circuit fluid leakage• Forward clutch defective(d) If pressure is low in the R position only:• R position circuit fluid leakage• First and reverse brake defective• Direct clutch defective

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-17

Page 18: Automatic transaxle

2. MEASURE GOVERNOR PRESSURE(a) Warm up the transaxle fluid.(b) Remove the transaxle case test plug and mount the oil pressure gauge (SST).SST 09992-00094

NOTICE: Perform the test at normal operating fluid temperature 50-80 �C (122-176�F).

(c) Check the parking brake to see that it is not applied.(d) Start the engine.(e) Shift into the D position and measure the governor pressures at the speeds specified in the table.EVALUATIONIf governor pressure is defective:• Line pressure defective• Fluid leakage in governor pressure circuit• Governor valve operation defectiveExcept Puerto Rico

49-127 kPa(0.5-1.3 kgf/cm2, 7-19 psi)

147-226 kPa(1.5-2.3 kgf/cm2, 21 -33 psi)

147-226 kPa(1.5 - 2.3 kgf/cm2, 21 -33 psi)

412-490 kPa(4.2 - 5.0 kgf/cm2, 60 - 71 psi)

412-490 kPa(4.2 - 5.0 kgf/cm2, 60 - 71 psi)

49-127 kPa(0.5-1.3 kgf/cm2, 7-19 psi)

Vehicle speed (Reference)

Vehicle speed (Reference)

105 km/h(65 mph)

30 km/h(19 mph)

27 km/h(17 mph)

96 km/h(60 mph)

49 km/h(31 mph)

Governor pressure

54 km/h(34 mph)

Governor pressure

Puerto Rico

Count drive gear

Count drive gear

1,000 rpm

3,500 rpm

1,800 rpm

3,500 rpm

1.000 rpm

1,800 rpm

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-18

Page 19: Automatic transaxle

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-19

Page 20: Automatic transaxle

ROAD TESTNOTICE: Perform this test at normal fluid temperature,50-80 °C (122-176°F).

1. D POSITION TESTShift into D position and while driving with the accel-erator pedal held constant at the throttle valve fullopen, check on the following points:(a) Check to see that the 1 -2 and 2-3 up-shifts takeplace and also that the shift points conform to thoseshown in the automatic shift schedule.(See page AX-24 )EVALUATIONIf there is no 1-2 up-shift:• Governor valve is defective• 1-2 shift valve stuckIf there is no 2-3 up-shift:• 2-3 shift valve stuckIf the shift point is defective:• Throttle cable out-of adjustment• Throttle valve. 1-2 shift valve, 2-3 shift valve,

etc. defective

(b) In the same manner, check the shock and the slip at 1-2 and 2-3 up-shifts.EVALUATIONIf the shock is severe:• Line pressure is too high• Accumulator is defective• Check ball is defective

(c) Run in the 3rd gear of D position, check the abnormalnoise and vibration.HINT: Check for cause of abnormal noise and vibra-tion must be made with extreme care as they couldalso be due to imbalance in the drive shaft, differen-tial, tires, torque converter clutch etc.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-20

Page 21: Automatic transaxle

(d) While running in the 3rd gear of D position, check tosee that the possible kick-down vehicle speed limitsfor the 3-1 and 3-2 kick-down conform to thoseindicated in the automatic shift schedule.(See page AX-24 )EVALUATIONIf the possible kick-down vehicle speed limit is de-fective:• Throttle cable out-of adjustment• Throttle valve, 1- 2 shift valve, 2-3 shift valve,

etc. defective(e) Check the abnormal shock and slip at kick-down.

2. INSPECT LOCK-UP MECHANISM(a) Drive in D position at a steady speed (Lock-up ON) ofabout 80 km/h (50 mph).(b) Lightly depress the accelerator pedal and check thatthe engine speed does not change abruptly.If there is a big jump in engine RPM, there is no lock -up.

3. 2 POSITION TEST(a) While running in 2 position, 2nd gear, release theaccelerator pedal and check the engine braking effect.EVALUATIONIf there is no engine braking effect:• Second coast brake is defective

(f) While running about 60 km/h (37 mph) in the 3rd gearof D position, release your foot from the acceleratorpedal and shift into L position. Then check to see ifthe 2 - 1 down - shift point conform to those in-dicated in the automatic shift schedule.(See page AX-24 )

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-21

Page 22: Automatic transaxle

(b) While running in L position, release the acceleratorpedal and check the engine braking effect.EVALUATIONIf there is no engine brake effect:• First and reverse brake is defective

(b) Check the abnormal noise during acceleration anddeceleration.(c) Check the shock at up-shift and down-shift.

4. L POSITION TEST(a) While running in L position, check to see that there isno up-shift to 2nd gear.

5. R POSITION TESTShift into R position and, while running at full throttle,check the slipping.

(c) Check the abnormal noise during acceleration anddeceleration.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-22

Page 23: Automatic transaxle

6. P POSITION TESTStop the vehicle on a gradient (more than 9%) and,after shifting into P position, release the parkingbrake. Then check to see that the parking lock pawlprevents the vehicle from moving.

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-23

Page 24: Automatic transaxle

Throttle valve fully opened 1→2 2→3 3→2 2→1Throttle valve fully closed Lock-up ON Lock-up OFF

Throttle valve fully opened 1→2 2→3 3→2 2→1Throttle valve fully closed Lock -up ON Lock-up OFF

AUTOMATIC SHIFT SCHEDULESHIFT POINTExcept Puerto Rico

47-59 (29-37)90-100 (56-62)84-99 (52-62)34-41 (21 -25)70-77 (43-48)66-72 (41 -45)

51-64 (32-40)98-1 11 (61- 69)92-107 (57-66)37-45 (23-28)77-84 (48-52)72-79 (45-49)

Throttle valve fully opened

Throttle valve fully opened

Vehicle speed km/h (mph)

Vehicle speed km/h (mph)

40-48 (25-30)

Puerto Rico

36-44 (22-27)

Shifting point

Shifting pointShift position

Shift position

D position

D position

L position

L position

2→1

2→1

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-24

Page 25: Automatic transaxle

TROUBLESHOOTING MATRIX CHARTUse the table below to help you find the cause of the problem.The numbers indicate the priority of the likely cause of the problem. Check each part in order. Ifnecessary, replace these parts.

Does not move in any forward positionor reverse position

Does not move in any forward position

Does not move in reverse position

Shift point too high or too low

1st a

nd r

ever

se b

rake

(B

3)

No.

1 o

ne-w

ay c

lutc

h (F

1)

No.

2 on

e-w

ay c

lutc

h (F

2)

Low

coa

st m

odul

ator

val

ve

2nd

coas

t mod

ulat

or v

alve

1st → 2nd(”D” position)

1st → 2nd(”2” position)

Thr

ottle

mod

ulat

or v

alve

Torq

ue c

onve

rter

clu

tch

Prim

ary

regu

lato

r va

lve

2nd

coas

t bra

ke (

B1)

Suspect Area

For

war

d cl

utch

(C

1)

Harshengagement

Fro

nt p

lane

tary

gea

r

Rea

r pl

anet

ary

gear

Sec

ond

brak

e (B

2)

Par

king

lock

paw

l

Dire

ct c

lutc

h (C

2)

1st → 2nd → 3rd

C1

accu

mul

ator

B2

accu

mul

ator

Gov

erne

r va

lve

1-2

Shi

ft va

lve

2-3

Shi

ft va

lve

No-down shift

Thr

ottle

val

ve

2nd → 3rd

Man

ual v

alve

No-up shift

“N”→ “L”

2nd → 1st

1st → 2nd

3rd → 2nd

2nd → 3rd

3rd → 2nd

Symptom

See page

AX

-41

AX

-34

“N”→ “R”

“N”→ “D”

-AUTOMATIC TRANSAXLE TROUBLESHOOTINGAX-25

Page 26: Automatic transaxle

�: R

efer to ’94 A131L, A

132L Autom

atic Transaxle Repair M

anual.

1st and reverse brake (B3)

No. 1 one-way clutch (F1)

No. 2 one-way clutch (F2)

Second coast brake (B1)

Torque converter clutch

Forward clutch (C1)

Lock-up signal valve

Forw

ard & R

everse

2nd (”2” position)

Pressure relief valve

No engine braking

Second brake (B2)

Direct clutch (C2)

1st (”L” position)

Poor acceleration

1-2 Shift valve

2-3 Shift valve

Lock-up relayN

o kick-down S

uspect Area

”R” position

No lock-up

Oil strainer

See

page

Sym

ptom

AX-27

AX-41

1st

2nd

3rd

NS

lip

-A

UTO

MAT

IC T

RA

NS

AX

LET

RO

UB

LES

HO

OT

ING

AX

-26

Page 27: Automatic transaxle

VALVE BODYVALVE BODY REMOVAL1. CLEAN TRANSAXLE EXTERIORTo help prevent contamination, clean the exterior ofthe transaxle.2. DRAIN TRANSAXLE FLUIDUsing a heagon wrench, remove the drain plug anddrain the fluid into suitable container.

3. REMOVE OIL PAN AND GASKETNOTICE: Some fluid will remain In the oil pan. Remove allpan bolts, and carefully remove the oil pan assembly.Discard the gasket.

4. REMOVE OIL STRAINERRemove the 3 bolts, and the oil strainer.

NOTICE: Be careful as some oil will come out with the strainer.

(b) Pry up the both tube ends with a large screwdriverand remove the 4 tubes.

5. REMOVE OIL TUBES(a) Remove the 2 bolts and apply tube bracket.

-AUTOMATIC TRANSAXLE VALVE BODYAX-27

Page 28: Automatic transaxle

9. REMOVE SECOND BRAKE APPLY GASKET ANDGOVERNOR OIL STRAINER

(b) Disconnect the throttle cable.(c) Remove the valve body.

7. REMOVE MANUAL VALVE AND VALVE BODY

8. REMOVE VALVE BODY(a) Remove the 14 bolts.

6. REMOVE MANUAL DETENT SPRING

-AUTOMATIC TRANSAXLE VALVE BODYAX-28

Page 29: Automatic transaxle

3. PLACE MANUAL VALVE AND BODY ON TRANS-AXLE(a) Align the manual valve with the pin on the manualvalve lever.(b) Install the valve body into place.(c) Finger tighten the 4 bolts first. Then tighten them witha torque wrench.

Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

4. INSTALL DETENT SPRING(a) Finger tighten the 2 bolts first. Then tighten them witha torque wrench.

Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

(b) Check that the manual valve lever is in contact withthe center of the roller at the tip of the detent spring.

2. INSTALL VALVE BODY(a) While holding the cam down with your hand, slip thecable end into the slot.(b) Bring valve body into place.

NOTICE: Be careful not to entangle the kick - downswitch and solenoid wire.

VALVE BODY INSTALLATION1. INSTALL GOVERNOR OIL STRAINER AND SECONDBRAKE APPLY GASKET

(c) Finger tighten all the bolts first. Then tighten themwith a torque wrench.

Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

-AUTOMATIC TRANSAXLE VALVE BODYAX-29

Page 30: Automatic transaxle

5. INSTALL OIL TUBES(a) Tap the tubes with a plastic hammer to install theminto the positions indicated in the illustration.

NOTICE: Be careful not to bend or damage the tubes.

8. INSTALL OIL PAN WITH GASKETNOTICE: Make sure that the magnet does not interferewith the oil tubes.Torque: 4.9 N-m (50 kgf-cm, 43in.-Ibf)

(b) Install the apply tube bracket.

7. INSTALL MAGNETS IN PAN

6. INSTALL OIL STRAINER

-AUTOMATIC TRANSAXLE VALVE BODYAX-30

Page 31: Automatic transaxle

9. INSTALL DRAIN PLUG WITH NEW GASKETUsing SST, install the drain plug with a new gasketand tighten it.

Torque: 49 N-m (500 kgf-cm, 36 ft-lbf)

SST 09043 - 38100

10. FILL TRANSAXLE WITH ATFAdd only about 2 liters of ATF.

NOTICE: Do not overfill.Fluid type:ATF DEXRON® II

11. CHECK FLUID LEVEL(See page AX-1 1)

-AUTOMATIC TRANSAXLE VALVE BODYAX-31

Page 32: Automatic transaxle

3. IF THROTTLE CABLE IS NEW, STAKE STOPPER ONINNER CABLEHINT: New cables do not have a cable stopper staked,(a) Bend the cable so there is a radius of about 200 mm(7.87in.).(b) Pull the inner cable lightly until a slight resistance is felt,and hold it.(c) Stake the stopper, 0.8 - 1.5 mm (0.031 - 0.059 in.)from the end of outer cable.

2. REMOVE PARK/NEUTRAL POSITION SWITCH(a) Disconnect the transaxle control cable from the trans-axle control shaft lever.(b) Remove the transaxle control shaft lever.(c) Remove the park/neutral position switch.3. REMOVE VALVE BODY(See page AX-27 )

THROTTLE CABLE INSTALLATION1. INSTALL CABLE INTO TRANSAXLE CASE(a) Be sure to push it in all the way.(b) Install the retaining plate and bolt.2. INSTALL VALVE BODY

(See page AX-29 )

THROTTLE CABLETHROTTLE CABLE REMOVAL1. DISCONNECT THROTTLE CABLE FROM ENGINEDisconnect the cable from the throttle linkage.

4. REMOVE THROTTLE CABLE(a) Remove the retaining bolt and plate.(b) Pull out the cable from the transaxle case.

-AUTOMATIC TRANSAXLE THROTTLE CABLEAX-32

Page 33: Automatic transaxle

6. INSTALL PARK/NEUTRAL POSITION SWITCH(a) Install the park/neutral position switch.(b) Adjust the park/neutral position switch.(See page AX-13 )(c) Install the transaxle control shaft lever.(d) Connect the transaxle control cable.7. TEST DRIVE VEHICLE

4. CONNECT THROTTLE CABLE TO ENGINE5. ADJUST THROTTLE CABLE(See page AX-12 )

-AUTOMATIC TRANSAXLE THROTTLE CABLEAX-33

Page 34: Automatic transaxle

5. INSTALL GOVERNOR BRACKET6. CONNECT LH DRIVE SHAFT

(See page SA-26 )7. INSTALL TRANSAXLE DUST COVER8. ADD FLUID TO DIFFERENTIAL IF NECESSARY

(See page AX-1 1)

Fluid type:ATF DEXRON® II

GOVERNOR VALVE INSTALLATION1. INSTALL GOVERNOR BODY ADAPTOR2. INSTALL PLATE WASHER3. INSTALL GOVERNOR BODY WITH THRUSTWASHER4. INSTALL GOVERNOR COVER WITH O-RING

4. REMOVE GOVERNOR COVER WITH O-RING5. REMOVE GOVERNOR BODY WITH THRUST WASHER6. REMOVE PLATE WASHER7. REMOVE GOVERNOR BODY ADAPTOR

GOVERNOR VALVEGOVERNOR VALVE REMOVAL1. REMOVE TRANSAXLE DUST COVER2. DISCONNECT LH DRIVE SHAFT(See page SA-22 )

3. REMOVE GOVERNOR BRACKET

-AUTOMATIC TRANSAXLE GOVERNOR VALVEAX-34

Page 35: Automatic transaxle

2. INSTALL RH SIDE OIL SEAL(a) Using SST and a hammer, drive in a new oil seal untilits surface is flush with the case surface.SST 09350-32014 (09351-32150, 09351-32130)

Oil seal drive in depth:0±0.5 mm

(b) Coat the oil seal lip with MP grease.3. INSTALL LH AND RH DRIVE SHAFT(See page SA-26 )4. INSTALL ENGINE UNDER COVER5. FILL TRANSAXLE WITH ATF(See page AX-1 1)

NOTICE: Do not overfill.Fluid type:ATF DEXRON® ll

6. CHECK FLUID LEVEL

DIFFERENTIAL OIL SEALDIFFERENTIAL OIL SEALS REMOVAL1. DRAIN TRANSAXLE FLUIDRemove the drain plug and drain the fluid into asuitable container.2. REMOVE ENGINE UNDER COVER3. REMOVE LH AND RH DRIVE SHAFTS(See page SA-22 )

4. REMOVE LH AND RH SIDE OIL SEALSUsing SST, drive out the both side oil seals.SST 09308-00010

DIFFERENTIAL OIL SEALS INSTALLATION1. INSTALL LH SIDE OIL SEAL(a) Using SST and a hammer, drive in a new oil seal.SST 09350-32014 (09351-32150, 09351-32130)

Oil seal drive in depth:0 mm (0 in.)

(b) Coat the oil seal lip with MP grease.

-AUTOMATIC TRANSAXLE DIFFERENTIAL OIL SEALAX-35

Page 36: Automatic transaxle

SPEEDOMETER DRIVEN GEAR OILSEAL INSTALLATION2. INSTALL SPEEDOMETER DRIVEN GEAR OIL SEALSST 09201 -60011

Drive in depth:19 mm (0.75 in.)

SPEEDOMETER DRIVEN GEAR OILSEALSPEEDOMETER DRIVEN GEAR OILSEAL REMOVAL1. REMOVE SPEEDOMETER DRIVEN GEAR OIL SEALUsing SST, pull out the oil seal.SST 09921-00010

-AUTOMATIC TRANSAXLE SPEEDOMETER DRIVEN GEAR OIL SEALAX-36

Page 37: Automatic transaxle

ASSEMBLY REMOVAL ANDINSTALLATIONRemove and install the parts, as shown below.

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-37

Page 38: Automatic transaxle

TRANSAXLE REMOVALCAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is disconnected from the battery.

1. REMOVE BATTERY2. REMOVE AIR DUCT3. REMOVE THROTTLE CABLE FROM ENGINE

4. DISCONNECT SPEEDOMETER CABLE5. REMOVE UPPER SIDE MOUNTING BOLTS6. REMOVE STARTER(a) Disconnect the cable and connector.(b) Remove the starter with the 2 bolts.7. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

8. REMOVE UNDER COVERS9. DRAIN TRANSAXLE AND DIFFERENTIAL OIL

11. DISCONNECT RIGHT DRIVE SHAFT(See page SA-22 )

HINT: Suspend the drive shaft with cord.

10. DISCONNECT LEFT DRIVE SHAFT(See page SA-22 )

HINT: Suspend the drive shaft with cord.

12. DISCONNECT CONTROL CABLE(a) Remove the clip from the control cable.

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-38

Page 39: Automatic transaxle

14. REMOVE FRONT EXHAUST PIPE(a) Remove the 3 bolts from engine.(b) Disconnect the oxygen sensor connector.

15. DISCONNECT PARK/NEUTRAL POSITION SWITCHCONNECTOR

(c) Remove the 2 bolts from rear exhaust pipe.

(b) Disconnect the control cable from the lever.

13. DISCONNECT OIL COOLER HOSE FROM PIPE

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-39

Page 40: Automatic transaxle

16. REMOVE TORQUE CONVERTER CLUTCH MOUNT-ING BOLTS(a) Turn the crankshaft to gain access to each bolt.(b) Hold the crankshaft pulley nut with a wrench andremove the 6 bolts.

19. REMOVE ENGINE REAR MOUNTING BRACKET(a) Hold the engine and transaxle with 2 jacks, or a chainblock and jack.

(b) Remove the 3 bolts and disconnect the rear mountingbracket from the body.

17. DISCONNECT BOND CABLE FROM LH ENGINEMOUNTING BRACKET

18. DISCONNECT LH ENGINE MOUNTINGRemove the 2 mounting bolts.

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-40

Page 41: Automatic transaxle

TORQUE CONVERTER CLUTCH AND DRIVEPLATE INSPECTION1. INSPECT ONE-WAY CLUTCH(a) Install SST in the inner race of the one-way clutch.SST 09350-32014 (09351-32010)(b) Install SST so that it fits in the notch of the converterhob and outer race of the one-way clutch.SST 09350-32014 (09351-32020)

2. MEASURE DRIVE PLATE RUNOUT AND INSPECTRING GEARSet up a dial indicator and measure the drive platerunout.If runout exceeds 0.20 mm (0.0079 in.) or if the ringgear is damaged, replace the drive plate. If installing anew drive plate, note the orientation of the spacersand tighten the bolts.

Torque: 88 N-m (900 kgf-cm, 65 ft-lbf)

TORQUE CONVERTER CLUTCH CLEANINGIf the transaxle is contaminated, the torque converterclutch and transaxle cooler should be thoroughly flu-shed with ATF.

(c) With the torque converter clutch held up right, theclutch should lock when turned counterclockwise,and should rotate freely and smoothly clockwise.If necessary, clean the converter and retest the clutch.Replace the converter if the clutch still fails the test.

20. REMOVE TRANSAXLE MOUNTING BOLTS21. REMOVE TORQUE CONVERTER CLUTCH FROMTRANSAXLE

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-41

Page 42: Automatic transaxle

3. MEASURE TORQUE CONVERTER CLUTCH SLEEVERUNOUT(a) Temporarily mount the torque converter clutch to thedrive plate. Set up a dial indicator.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

If runout exceeds 0.30 mm (0.0118 in.) try to correctit by reorienting the installation of the converter. Ifexcessive runout cannot by corrected, replace thetorque converter clutch.HINT: Mark the position of the converter to ensurecorrect installation.(b) Remove the torque converter clutch from the driveplate.

3. ALIGN TRANSAXLE AT INSTALLATION POSITION(a) Align the 2 knock pins on the block with the converterhousing.(b) Temporarily install 1 bolt.4. INSTALL TRANSAXLE HOUSING MOUNTINGBOLTSInstall the transaxle housing mounting bolts.

Torque: 12 mm 64 N-m (650 kgf-cm, 47 ft-lbf)

TRANSAXLE INSTALLATION1. INSTALL TORQUE CONVERTER CLUTCH IN TRA-NSAXLEIf the torque converter clutch has been drained andwashed, refill with new ATF.

Fluid type:ATF DEXRON® II

2. CHECK TORQUE CONVERTER CLUTCH INSTALLA-TIONUsing calipers and a straight edge, measure from theinstalled surface to the front surface of the transaxlehousing.

Correct distance:More than 13.4 mm (0.528 in.)

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-42

Page 43: Automatic transaxle

7. INSTALL TORQUE CONVERTER CLUTCH MOUNT-ING BOLTS(a) First, install the gray bolt and then the 5 black bolts.(b) Tighten the bolts evenly.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

5. CONNECT LH MOUNTING BRACKET(a) Install the LH engine mounting bracket with 2 bolts.Torque the 2 bolts.

Torque: 43 N-m (440 kgf-cm, 32 ft-lbf)

(b) Connect the bond cable with the bolt.

(b) Install the bolts.Torque: 62 N-m (630 kgf-cm, 46 ft-lbf)

(c) Connect the oxygen sensor connector.10. CONNECT PARK/ NEUTRAL POSITION SWITCHCONNECTOR

6. CONNECT REAR MOUNTING BRACKETInstall the rear mounting bracket with 3 bolts.Torque the bolts.

Torque: 73 N-m (740 kgf-cm, 54 ft-lbf)

8. INSTALL ENGINE REAR END PLATE9. INSTALL FRONT EXHAUST PIPE(a) Install the bolts.

Torque: 62 N-m (630 kgf-cm, 46 ft-lbf)

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-43

Page 44: Automatic transaxle

16. FILL DIFFERENTIALFluid Type:ATF DEXRON® llDifferential Fluid Capacity:1.4 liters (1.5 US qts, 1.2 Imp.qts)

17. CHECK DIFFERENTIAL FLUID LEVEL(See page AX-12 )

12. CONNECT CONTROL CABLE(a) Connect the control cable to the lever.(b) Install the clip to the control cable.13. CONNECT PARK / NEUTRAL POSITION SWITCHCONNECTOR

18. INSTALL STARTER(a) Install the starter with 2 bolts.(b) Connect the 2 connector.19. INSTALL UPPER SIDE MOUNTING BOLTS20. CONNECT SPEEDOMETER CABLE

14. INSTALL DRIVE SHAFT(See page SA-26 )

15. INSTALL ENGINE UNDER COVER

11. CONNECT OIL COOLER HOSE TO PIPE-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION

AX-44

Page 45: Automatic transaxle

25. FILL TRANSAXLEFluid type:ATF DEXRON® llAutomatic Transaxle Fluid Capacity:5.5 liters (5.8 US qts, 4.8 Imp.qts)

21. INSTALL AND ADJUST THROTTLE CABLE22. INSTALL AIR DUCT23. INSTALL BATTERY AND CONNECT24. NEGATIVE BATTERY TERMINAL

26. CHECK FLUID LEVEL(See page AX-1 1)

-AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONAX-45

Page 46: Automatic transaxle

SHIFT LOCK SYSTEMCOMPONENT

WIRING DIAGRAM

-AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEMAX-46

Page 47: Automatic transaxle

SHIFT LOCK SOLENOID INSPECTIONINSPECT SHIFT LOCK SOLENOID(a) Disconnect the solenoid connector.(b) Using an ohmmeter, measure the resistance betweenterminals.

Standard resistance:30-35 �

SHIFT CONTROL ECU INSPECTIONINSPECT SHIFT LOCK CONTROL ECUUsing a voltmeter, measure the voltage at each termi-nals.HINT: Do not disconnect the ECU connector.

(c) Apply battery positive voltage between terminals.Check that an operation noise can be heard from thesolenoid.

(1) Ignition switch ON, P position and depress brake pedal

(2) Ignition switch ACC position and except P position

(3) Ignition switch ACC position and P position

(1) Ignition switch ACC position and P position

(1) Ignition switch ON position and P position

Ignition switch ACC position

(2) Depress brake pedal

ignition switch ON position

(Approx-after one second)

(Approx-after 20 seconds)

(2) Except P position

(4) Except P position

(4) Except P position

Depress brake pedal

Measuring condition

SLS (+) - SLS (-)

Voltage (V)

8.5- 13.5

Connector

5.5 - 9.5

9 - 13.5

9 - 13.5

10- 14

ACC -E

Terminal

P2-P 1

10- 14

10- 14STP-E

KLS - E

P1 - P

8 - 14

IG - E

6 - 9

-AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEMAX-47

Page 48: Automatic transaxle

KEY INTER LOCK SOLENOID INSPECTION1. INSPECT KEY INTER LOCK SOLENOID(a) Disconnect the solenoid connector.(b) Using an ohmmeter, measure the resistance betweenterminals.

Standard resistance:12.5-16.5 �

(c) Apply battery positive voltage between terminals.Check that an operation noise can be heard from thesolenoid.

2. INSPECT SHIFT LOCK CONTROL SWITCHCheck whether there is continuity between each ter-minal.

P position (Releasebutton is not pushed)

R position (Releasebutton is pushed)

Tester condition toterminal number

R, N, D, 2, L position

Specified value

P-P 1P-P 2

Shift position

Continuity

Continuity

ContinuityP-P 2

P-P 1

-AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEMAX-48

Page 49: Automatic transaxle

Throttle valve fully opened 1→2 2→3 3→2 2→1Throttle valve fully closed Lock -up ON Lock -up OFF

Throttle valve fully opened 1→2 2→3 3→2 2→1Throttle valve fully closed Lock-up ON Lock -up OFF

(Vehicle speed reference) Except Puerto Rico 30 km/h (19 mph) 54 km/h (34 mph) 105 km/h (65 mph) Puerto Rico 27 km/h (17 mph) 49 km/h (31 mph) 96 km/h (60 mph)

Governor PressureCounter drive gear1,000 rpm1,800 rpm3,500 rpmCounter drive gear1,000 rpm1,800 rpm3,500 rpm

SERVICE SPECIFICATIONSSERVICE DATA

47-59 (29-37)90-100 (56-62)84-99 (52-62)34-41 (21 -25)70-77 (43-48)66-72 (41 -45)

Between boot and face and inner cable stopper 0-1 mm 0-0.04 in.

51 -64 (32-40)98-1 11 (61- 69)92-107 (57-66)37-45 (23-28)77-84 (48-52)72-79 (45-49)

Engine idle speed (Cooling fan and A/C OFF) N position

Torque converter clutch sleeve runoutDrive plate runout

Throttle cable adjustment (Throttle valve fully opened)

SHIFT POINTExcept Puerto Rico

0.5-1.3 kgf/cm2

1.5 - 2.3 kgf/cm2

4.2 - 5.0 kgf/cm2

0.5-1.3 kgf/cm2

1.5-2.3 kgf/cm2

4.2-5.0 kgf/cm2

N position → D position N position → R position

49-127 kPa147-226 kPa412-490 kPa

Less than 1.2 secondsLess than 1.5 seconds

49-127 kPa147-226 kPa412 -490kPa

9.2-10.7 kgf/cm2

14.4-16.8 kgf/cm2

AT stall (Throttle valve fully opened)

Engine idling D position R position

7-19 psi21 -33 psi60-71 psi

3.7 -4.3 kgf/cm2

5.4-7.2 kgf/cm2

902 -1,049 kPa1,412-1,648 kPa

7-19 psi21-33 psi60-71 psi

Line pressure (wheel locked)

131-152 psi205 - 239 psi

363-422 kPa530-706 kPa

Vehicle speed km/h (mph)

Vehicle speed km/h (mph)

Throttle valve fully opened

Throttle valve fully opened

53-61 psi77-102 psi

Engine stall revolution

D positionR position

0.0118 in.0.0079 in.

Puerto Rico

40-48 (25-30)

36-44 (22-27)

0.30 mm0.20 mm

2,400±200 rpm

Shifting point

Shifting point

Shift position

Shift position

LimitLimit

D position

D position

L position

L position

800 rpm

Time lag

2→1

2→1

-AUTOMATIC TRANSAXLE SERVICE SPECIFICATIONSAX-49

Page 50: Automatic transaxle

TORQUE SPECIFICATIONS

Park/Neutral position switch x Transaxle case (bolt)

Engine rear mounting bracket x Engine

Torque converter clutch x Drive plate

Engine rear mounting bracket x Body

Transaxle rear cover x Transaxle case

Park/Neutral position switch (nut)

Valve body x Transaxle case

Parking lock pawl bracket

12 mm bolt10 mm bolt

Cooler pipe union nut

LH engine mounting

Transaxle x Engine

Oil pan drain plug

Part tightened

Testing plug

Oil strainer

650350

48 in.-lbf

43 in.-lbf

65 in.-lbf

65 in.-lbf

61 in.-lbf

Oil pan

6434

kgf-cm

4725

ft-lbf

100

500

440

590

250

100

740

185

N-m

275

5.4

7.4

7.4

6.9

-AUTOMATIC TRANSAXLE SERVICE SPECIFICATIONSAX-50