Part 1
TRANSMISSION HOUSING/LOWER VALVE BODY ASSEMBLYRemoval
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the lower valve body, replace the following:
- O-rings
- Automatic Transmission Fluid (ATF) pan gasket
CAUTION: Do not turn over the transmission before removing the ATF pan.
1. Remove the shift control solenoid valve connector from the connector holder, then separate it.
2. Remove the AFT gear position switch cover, then remove the ATF pan.
3. Remove the ATF strainer (four bolts).
4. Move the detent lever to the [P] position.
NOTE: If the detent lever is not in the [P] position, the lower valve body assembly cannot be removed.
5. Move the shift fork toward the torque converter side as shown.
6. Remove the main valve body plate (four bolts).
7. Remove the harness cover (four bolts).
8. Remove the one bolt securing the shift control solenoid valve harness connector, then remove the connector and pull the harness out.
9. Remove the lower valve body assembly (six bolts).
NOTE: Refer to Lower Valve Body Assembly Disassembly, when disassembling the lower valve body.
10. Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged.
11. Replace the ATF strainer if it is clogged or damaged.
NOTE: The ATF strainer can be reused if it is not clogged.
REAR COVER
Removal
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the rear cover, replace the following:
- O-rings
- Mainshaft and countershaft locknuts
- Conical spring washers
1. Remove the one bolt securing the A/T gear position switch harness clamp.
2. Remove the eight bolts securing the rear cover, then remove the rear cover.
3. Remove the four ATF feed pipes from the transmission housing.
4. Slip the special tool onto the mainshaft.
5. Engage the parking brake pawl with the parking gear.
6. Cut the lock tabs of each shaft locknut using a chisel as shown. Then remove the locknuts and conical spring washers from each shaft.
CAUTION: Keep all of the chiseled particles out of the transmission.
NOTE:
- Mainshaft locknut has left-hand threads.
- Always wear the safety glasses.
7. Remove the special tool from the mainshaft after removing the locknuts.
8. Remove the 1st-hold clutch assembly, thrust washer, thrust needle bearing and 1st-hold clutch hub from the countershaft.
9. Remove the 1st clutch assembly, thrust washer, thrust needle bearing and 1st gear from the mainshaft.
10. Remove the 1st gear, one-way clutch, needle bearings, 1st gear collar and parking gear from the countershaft,
11. Remove the thrust washer and 1st gear collar from the mainshaft.
12. Remove the parking brake pawl, shaft, spring, and stopper from the transmission housing.
TRANSMISSION HOUSING
Removal
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the transmission housing, replace the following:
- O-rings
- Transmission housing gasket
1. Disconnect the mainshaft and countershaft speed sensor connectors.
2. Remove the connector holder and connector brackets.
3. Remove the countershaft speed sensor and main shaft speed sensor from the transmission housing.
4. Remove the ten bolts securing the transmission housing, then remove the 10 mm bolt and three 8 mm bolts securing the transmission housing to the torque converter housing side.
5. Install the special tool on the transmission housing, then remove the transmission housing as shown.
CAUTION: Make sure that the mainshaft and countershaft speed sensors have been removed from the transmission housing before removing the transmission housing from the torque converter housing.
6. Remove the mainshaft sub-assembly and counter shaft sub-assembly together.
NOTE: When removing the shafts, take care to prevent damage to the regulator valve body.
7. Remove the secondary driven gear shaft from the torque converter housing.
TORQUE CONVERTER HOUSING/VALVE BODY
Removal
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the valve bodies, replace the following:
- O-rings
- Filters
1. Remove the Automatic Transmission Fluid (ATF) feed pipe from the ATF pump body and two ATF feed pipes from the torque converter housing.
2. Remove the two flange nuts securing the linear solenoid harness, then disconnect the harness from the linear solenoid and harness clamp.
3. Remove the regulator valve body (nine bolts).
4. Remove the stopper shaft and stator shaft.
5. Remove the regulator separator plate with two dowel pins.
6. Remove the six bolts securing the 2nd accumulator body, then remove the 2nd accumulator body and throttle valve body/linear solenoid as an assembly.
7. Remove the ATF pump body (five bolts).
8. Remove the ATF pump gears and ATF pump driven gearshaft.
9. Remove the torque converter check valve and spring.
10. Remove the ATF pump body separator plate with three dowel pins.
11. Remove the one bolt securing the linear solenoid harness connector, then remove the linear solenoid harness from the torque converter housing.
12. Disconnect the lock-up control solenoid valve connector, then remove the transmission sub-harness.
VALVE BODY
Repair
NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. You may use this procedure to free the valves in the valve bodies.
1. Soak a sheet of #600 abrasive paper in ATF for about 30 minutes.
2. Carefully tap the valve body so the sticking valve drops out of its bore.
CAUTION: It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.
3. Inspect the valve for any scuff marks. Use the ATF soaked #600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air.
4. Roll up half a sheet of ATF-soaked #600 paper and insert it in the valve bore of the sticking valve.
Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out.
CAUTION: The valve body is aluminum and doesn't require much polishing to remove any burrs.
5. Remove the #600 paper. Thoroughly wash the entire valve body in solvent, then dry with compressed air.
6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If not, repeat step 4, then retest.
7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.
VALVE
Assembly
NOTE: Coat all parts with Automatic Transmission Fluid (ATF) before assembly.
- Install the valve, valve spring and cap in the valve body, and secure with the roller.
- Set the spring in the valve, then install them in the valve body. Push the spring in with a screwdriver, then install the spring seat.
- Install the valve, spring and cap in the valve body. Push the cap, then install the valve cap stopper.
VALVE CAPS
Description
- Caps with one projected tip and one flat end are installed with the flat end toward the inside of the valve body.
- Caps with a projected tip on each end are installed with the smaller tip toward the inside of the valve body. The small tip is a spring guide.
- Caps with one projected tip and a hollow end are installed with the tip toward the inside of the valve body. The tip is a spring guide.
- Caps with hollow ends are installed with the hollow end away from the inside of the valve body.
- Caps with notched ends are installed with the notch toward the inside of the valve body.
- Caps with flat ends and a hole through the center are installed with the smaller hole toward the inside of the valve body.
SERVO BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the servo body as an assembly if any parts are worn or damaged.
- Replace the O-rings and filters.
- Install the filters in the direction shown.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
MAIN VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.
ATF PUMP BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly. & Install the filters in the direction shown.
ATF PUMP
Inspection
1. Install the Automatic Transmission Fluid (ATF) pump gears and ATF pump driven gear shaft in the ATF pump body.
NOTE:
- Lubricate all parts with ATF during inspecting.
- Install the ATF pump driven gear with its grooved and chamfered side facing up as shown.
2. Measure the side clearance of the ATF pump drive and driven gears.
ATF Pump Gears Side (Radial) Clearance:
Standard (new):
ATF Pump drive gear 0.210 - 0.265 mm (0.0083 - 0.0104 inch)
ATF pump Driven Gear 0.070 - 0.125 mm (0.0028 - 0.0049 inch)
3. Remove the ATF pump driven gear shaft. Measure the thrust clearance of the ATF pump driven gear-to-valve body, with a straight edge and a feeler gauge.
ATF Pump Drive/Driven Gear Thrust (Axial) Clearance:
Standard (New): 0.03 - 0.05 mm (0.001 - 0.002 inch)
Service Limit: 0.07 mm (0.003 inch)
REGULATOR VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
1. Hold the regulator spring cap in place while removing the stopper bolt. Once the stopper bolt is removed, release the spring cap slowly.
CAUTION: The regulator spring cap can pop out when the stopper bolt is removed.
2. Reassembly is the reverse of the disassembly procedure.
NOTE:
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
- Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve body, and tighten the stopper bolt.
1ST ACCUMULATOR/1ST-HOLD ACCUMULATOR
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
- Replace the O-rings and sealing washer.
2nd ACCUMULATOR BODY/THROTTLE VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace valve body as an assembly if any parts are worn or damaged.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
- Replace the O-rings and filter.
- Install the filter in the direction shown.
THROTTLE VALVE BODY/LINEAR SOLENOID
Test
1. Connect the linear solenoid harness to the linear solenoid terminals.
2. Connect the No. 2 (RED: +) terminal of the linear solenoid connector to the positive battery terminal and the No. 1 (WHT: -) terminal to the negative battery terminal. Check that the throttle valve moves.
3. Repeat the above steps 1 and 2.
NOTE: You can see the movement of the throttle valve through the fluid passage in the mounting surface of the throttle valve body.
4. If the throttle valve binds, or moves sluggishly, or the linear solenoid does not operate, replace the throttle valve body/linear solenoid as an assembly.
5. If the linear solenoid does not operate, disconnect the linear solenoid harness from the linear solenoid assembly. Connect the battery directly to the linear solenoid.
6. If the linear solenoid operates after connecting the battery, and the throttle valve movement is OK, replace the linear solenoid harness.
Replacement
NOTE: Throttle valve body/linear solenoid must be replaced as an assembly.
1. Check the throttle valve body passages for dust or dirt, and replace as an assembly, if necessary.
2. Clean the mounting surface and fluid passages of the throttle valve body.
3. Assemble the throttle valve body/linear solenoid to the 2nd accumulator body.
MAINSHAFT
Disassembly/Inspection/Reassembly
NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Locknut has left-hand threads.
Inspection
- Clearance Measurements
NOTE: Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
1. Remove the mainshaft bearing from the transmission housing.
2. Assemble the parts below on the mainshaft.
NOTE: Do not install the O-rings during inspection.
3. Torque the mainshaft locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).
NOTE: Mainshaft locknut has left-hand threads.
4. Move the 4th/2nd clutch assembly to check the axial clearances.
5. Attach the dial indicator to the mainshaft 2nd gear as shown.
6. Measure the 2nd gear axial clearance while pushing the 4th/2nd clutch toward the 1st clutch.
STANDARD: 0.07 - 0.15 mm (0.003 - 0.006 inch)
NOTE: Take measurements in at least three places, and use the average as the actual clearance.
7. If the clearance is out of tolerance, remove the 2nd gear thrust washer and measure its thickness.
8. Select and install a new 2nd gear thrust washer, then recheck.
9. After replacing the 2nd gear thrust washer, make sure that the clearance is within tolerance.
Sub-Assembly
NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Assemble the mainshaft sub-assembly when assembling the transmission.
1. Assemble the parts below on the mainshaft.
COUNTERSHAFT
Disassembly/Inspection/Reassembly
NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
Inspection
Clearance Measurement
NOTE: Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
1. Remove the countershaft bearing from the transmission housing.
2. Assemble the parts below on the countershaft.
NOTE: Do not install the O-rings during inspection.
3. Torque the countershaft locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).
4. Hold the 4th gear against the distance collar. Measure the clearance between the 4th gear and the reverse selector hub with a feeler gauge.
NOTE: Take measurements in at least three places, and use the average as the actual clearance.
5. If the clearance is out of tolerance, remove the distance collar and measure its length.
6. Select and install a new distance collar, then recheck.
7. After replacing the distance collar, make sure that the clearance is within tolerance.
Sub-Assembly
NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Assemble the countershaft sub-assembly when assembling the transmission.
1. Assemble the parts on the countershaft.