A/T - Harsh Shift Going into 2nd and 4th Gear

Group:
TRANSAXLE


Number:
92-40-007


Date:
NOVEMBER, 1992


Model:
ALL MODELS



SUBJECT:

AUTO TRANSAXLE AIR EXHAUST PLUG REPLACEMENT (FIELD FIX)



This bulletin provides the replacement procedures for the air exhaust plug in automatic transaxle equipped vehicles.

AIR EXHAUST PLUG

The air exhaust plug vents air trapped in automatic transaxle fluid during kickdown servo piston operation. If a harsh shift is experienced going into 2nd and 4th gear, inspect the air exhaust plug. The procedures for inspection and replacement of the air exhaust plug are below.

HOW TO INSPECT THE AIR EXHAUST PLUG





The air exhaust plug is composed of 3 parts: Housing, Filter & Steel Retainer.





If the steel retainer is not in place in the air exhaust plug, a harsh shift will occur going into 3rd gear. To check whether the steel retainer is in the proper position, feel for the air exhaust plug with a steel wire as shown. If the wire penetrates the housing more than 3/16", the steel retainer may be dislodged or missing.

If the steel retainer is not in place, check to see if it is sitting in the servo bore. Inspect the kickdown servo piston and O-ring for damage. Inspect the bore for damage. Light scoring in the bore may be polished out. Deep scoring will require case replacement.

AIR EXHAUST PLUG REPLACEMENT PROCEDURES

If the steel retainer is out of position the Air Exhaust Plug will need to be replaced.

1. Remove the transaxle from the vehicle following the procedures outlined in the appropriate shop manual.





2. Drill a 5/16" hole in the air exhaust plug.

NOTE:
Be sure to remove all of the metal chips from the bore.






3. Install a self tapping screw into the 5/16" hole.





4. Remove the air exhaust plug by pulling on the self tapping screw. (A tool like a dent puller with a slide hammer will work best.)

CAUTION:
Be very careful not to scratch or score the walls of the kickdown servo cylinder during air exhaust plug removal. Any scoring or damage will cause a loss of pressure or premature O-ring wear.





5. Install the new air exhaust plug carefully by using a brass drift and hammer.





6. Re-assemble the kickdown servo piston as shown in the appropriate shop manual.

7. Re-install the transaxle following the procedures in the appropriate shop manual.






PARTS INFORMATION






AFFECTED TRANSAXLES






WARRANTY INFORMATION