Beruflich Dokumente
Kultur Dokumente
T T T T T'
VALVE
BODY
85
CASE
COMP
ONENT
PITSG
94
INDEX
PAGE
TROUBLE SHOOTING
3
SERVICE ADJUSTMENT
23
COMPONENT SERVICE
27
TEARDOWN
34
ASSEMBLY
AUTO
MATI
C
TRAN
SMISS
ION
SERVI
CE
GROU
P
wo4
47
PUMP
64
CLUTCH ASSEMBLY
67
CARRIER
75
se;
;111
IV;
;IC
0'16?
7_,
Ps
1/4
4.
PI
mi.u.sig
1K
FITS 04,
E
A.
INTRODUCTION
MITSUBISHI KM-175 / 177
44TIC
TRANSMISSION
SERVICE
We
thank
Mitsub
ishi for
the
illustra
tions
and
inform
ation
that
made
this
booklet possible.
The
information
and part numbers
contained in this
booklet have been
carefully compiled
from
industry
sources known for
their reliability, but
ATSG
does
not
guarantee
its
accuracy.
ROBERT D. CHERRNAY
ENGLAND
TECHNICAL DIRECTOR
CONSULTANT
FRANK MIETUS
COLONNA
TECHNICAL CONSULTANT
CONSULTANT
WELDON BARNETT
KRUSE
TECHNICAL CONSULTANT
DALE
FIELD SERVICE
WAYNE
TECHNICAL
ED
LAY
OUT
AUTOMATIC TRANSMISSION SERVICE GROUP
9200 SOUTH DADELAND BLVD.
SUITE 720
M
I
A
M
I
,
F
L
O
R
I
D
A
3
3
1
5
6
(
3
0
5
)
6
6
1
4
1
6
1
PITS
G
TROUBLESHOOTING
TROUBLESHO
OTING
Functional malfunctions of the ELC4A/T can lead to other problems, such
as those described below:
(1) Improper maintenance and/or
adjustments
(2) Malfunctions of the electronic control
functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of the hydraulic control
functions
(5) Malfunctions
of
engine
performance etc.
In order to properly determine
("troubleshoot") the source of these
malfunctions, it is first essential to
methodically
question
the
user
concerning the details of the problem,
such as the condition of the problem,
the situation at the time the
problem occurred, and any other relevant
information, all in
as much detail as possible. The user
should also be asked whether or not
the problem has occurred more than
once, and under what conditions.
Subsequently, certain tests should be
conducted in a certain order, as
described at the right.
\7
Checks should be made of fluid
levels and the condition of the
ATF, as well as the condition of
the
manual
control cables;
adjustments should then be
made if found to be necessary.
\7
If a presumption has been made
that there is an abnormal
condition somewhere in the
electronic-control system, the
diagnosis tester should be used to
estimate the probable location by
checking
the
malfunctionindication pattern. If the ignition
key was already turned to OFF,
however, check by making a
road test.
\7
Presumed cause
.c
e'
4.
1
-0
g e.
ut
E
:.
IA
I
.8
.g 1e
7
,.1..
.
2.
o
e,
El-
O
a
7.
=
&
x
-2
"
E
,,
i
E
E
1,
,i;
>.'
TZg
te..;
7. a
i
la
.01 EE
if
e
-Z
-8
'LI
:2
X
X
1
,1
lc
&
i4
a
a..
we
1
a
a'
t
l
o
7,
st
ce
Ti
F6'
X
X
X
4 Malfunction of torque convertor (including damper
clutch)
5
Operation malfunction of oil pump
Malfunction of one-way clutch
E
-
.1.
IIf
1
,
0
X
X
X
8
E
_
T.
"..
Z.:
8
X
X
E
E
c4
8
a
E
T
IF.
<1
x
L.*
lot
0 1
'71
,5
.;
Dama
ged
or
worn gear
or other
rotating
part, or
improper
7
=w
adjustment of the preload
x
8 Incorrect tightening of center support
pE
9 Malfunction of parking mechanism
10 Cracked drive plate, or loose bolt
11 Worn inside diameter of front clutch retainer
12 Low fluid level
13 Line pressure too low (seal damaged, leakage,
looseness, etc.)
X
X
Li
E ..
E1
adjustment. etc.)
E 15
t ...7. 16
o
17
o
18
19
r
,
""
21
22
23
24
25
X
X
XX
0 ,
0
0
0
X
0
0
X
0
X
X
0
M
a
l
f
u
n
c
t
i
o
n
o
f
f
r
o
n
t
c
l
u
t
c
h
r,.
76.
.
ear clutch or
o piston
r Malfunction of
kickdown band or
p
i piston Improper
s adjustment of
t kickdown servo
o Malfunction of lown
reverse brake or
M piston
a 0-ring of low-reverse brake
l circuit between valve body
f and case not installed
u Malfunction of end clutch or piston (check ball
n hole, other)
c Malfunction
of
t inhibitors
switch,
or
i damaged
o disconnected wiring, or
improper
adjustment
n
Malfunction of TPS. or improper adjustment
o Pulse generator (A)
or
f damaged
disconnected wiring, or
short-circuit
r
Pulse generator (B) damaged or disconnected
wiring. or short-circuit
2 Malfunction of kickdown servo switch
6 SCSV-A or B damaged or
2 disconnected wiring. or
short-circuit or sticking
7 (valve open)
2
8
1
Li/ 2
9
3
1
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
Malfunction of
ignition signal
system
Incorrectly
grounded
ground strap
PCSV damaged or disconnected
wiring, or short-circuit PCSV
damaged or disconnected wiring
(valve open) DCCSV damaged or
disconnected wiring (valve dosed)
DCCSV short-circuit or sticking
(valve open)
X
X
X
X
X
X
X
X
X
X
Malfunction of OD switch
AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
4
SCSV = Shift
x
x
x
x
x
r
><
41
X
X
X
X
Si
J
Id
CI
:..
ti
7.
IS
z
SI
Id
W
J
x
x
X
7, to
I:
r.
r,
.:.
;.;
t., N -
x
x
x
d
x
I9
IS
is
It
x
x
x
x
x
x
x
x
x
x
x
x
x
x
t',9
x
>c
x
x
x
>c
0
x
x
x
x
x
x
x
x
x
X
x
x
x
x
5
X
x
x
X
X
431
x
x
x
x
x
x
x
x
x
x
>c
Exc
essi
ve
cre
epi
ng
or
idli
ng
vib
rati
on
Doesn't
shift
(shifting is possible)
E
x
c
e
s
s
i
v
e
v
i
b
r
a
t
i
o
n
s
h
o
c
k
vibration-
s
h
i
f
t
Excessive
shift
shock (other
described)
Abnormal
vibration in highload region in
low gear (approx.
I Hz)
vibration-
during
downshift
o
r
Sudden
3
.
4
D-2
engine
increase
during upshift
c
e
rpm
increase
during
shift,
s
s
i
v
3-2
excessive
vibration
Excessive
vibration
-shock
&
1
ii
if
n
rpm
Sudden eingine
E
B
5'
Excessive
Abnormal noise
from convertor
housing together
with engine rpm
A'
6
3
Mechanical
noise
(clatter noise)
from
convenor housing
Abnormal
noise
inside transmission
Case
-i
3rd gear is held
>P
than already
Excessive
vibrationshock
during
upshift
shock
a
e.
vibration-
2-3 or 4-3
when
1.
shock
when
w
h
e
n
only
cold
11T5G
Road Test
m
in the "Presumed abnormal terminal
acaw
*4,149 2
56
of TCU" column.
3
sci
r
41131
.7.
0 F
F
*AC
;MODS
IAT5G1
Q
TO
MAK
E
YOUR
OWN
L.E.D.
TEST
ER
REFE
R TO
PAGE
96.
CIT5G
O
r
d
e
r
14
15
Operation
Connect the diagnosis
tester to the output
connector in the glove
compartment. Then set
the diagnosis tester switch
to the "ELC 4-speed
automatic with overdrive"
position.
With
the
engine
idling, shift from "R"
to "N".
Engine idling
(selector lever still in "D")
10
Accelerate
to
70
km/h (43 mph) with
the accelerator fully
open.
11
12
13
Same as above
C
h
e Same as above
c
k
"Creeping" should be small.
i (4,500 mm (177 in.) or less in 5
t seconds)
e
m Shift from "1" to "2" at
A-7, A-13
A-5, A-7, A-15
When the LED
flashes, determine
the
location of the
mal-function by
following the
indication pattern (*I).
There
should
be
no
abnormal feeling of shifting
impact.
Diagno
sis
tester
LED
illumin
ates
interm
ittently
.
LED
stops
illuminating
within
16
seconds
after
the engine is
started.
There
should
not
be
any
abnorma
l feeling
of
shifting
impact.
be no abnormal feeling of
shifting impact.
Also check damper clutch
control. After stopping, use
the diagnosis tester to check
whether there is an abnormal
condition.
A-10, B-12
A-17
A-3, A-14
B-2,
B-8,
B-10, A-7,
A-15
A-
A-2, A-15
ATSG
Malfunction
indication code
Lo .0 Ln
4 sec. O -: ci
2 sec.
l`
v,
,
re
ON
OFF
r, , ,
Repeat
s
,,,
r
Diagnosis
Assumed location
Microprocessor (computer)
(recharging system)
Computer
Pulse generator B
,g1 WI
41
- ci
4 sec .o -
477-'r--"
rr-
3
V
0
0
jo
Computer
Vehicle
speed
detected by pulse
generator B is much
lower than actual
vehicle speed.
P
u
ls
e
g
e
n
e
r
a
t
o
r
B
C
o
m
p
u
te
r
I
r
e
Shift-control
solenoid valve
A Computer
r
o/,
w 0;
,
Shift-control
solenoid valve
B Computer
computer
command.
Kickdown
servo switch
signal
differ
s
from
actua
l gear
engaged.
6
WV ; i
Computer
Shifting
doesn't finish.
r
r--
Pulse generator
A Pressurecontrol solenoid
valve
0
I
Computer
Pressure-control
solenoid valve
drive differs from
computer
command.
;
o w
o r
Engine
speed
is
judged to
be
6,500
rpm
or
more.
10
11
I V
Winailall
Kickdown
drum
rotation
speed
is
judged to be 6,500
rpm
or more.
Damper clutch control
solenoid
valve is directly
1
2
connected.
FAiLutkll
Pressure-control
solenoid
valve
Computer
Pu
lse
ge
ne
rat
or
B
Ig
nit
ion
coi
l
(ignition
signal
system)
Compute
r
Pulse
generat
ors A
B
Compu
ter
Damper clutch
control system
Computer
No ignition signal.
Ignition coil
Ignitio
n
signal
system
Compu
ter
A
T
S
G
Technical Service
Information
1989 FAULT
CODES
Output code
Description
Fail-safe
Co
de
5V-
Malfunction of the
code No.31 is
1
2
microprocessor
_-
Damaged or discon-nected
wiring of the pulse generator
B system
_-
Damaged or discon-nected
wiring, or
sshortho
circuit, of shift
control solenoid valve A
- -1
4
Damaged or discon-nected
wiring, or
ss hh ootr circuit, of shift control
solenoid valve B
_
lit.
17
When
-_
1
3
16
fault code)
OV
1
5
N
o
t
e
(
r
e
l
a
t
i
o
n
t
o
Damaged or discon-nected
wiring, or
short circuit, of the pressure
control sole-noid valve
1jiff
-
11.
g
e
n
e
r
a
t
e
d
Locked in
3rd (D) or Locked in 3rd gear
When
code
When code No.43 or
No.33 is
2nd
(2,
L)
4
t gear
h generated
4th time.
t
i
m
e
.
Locked in
3rd gear
When
code
No.41 or
42
is
generated 4th
time.
t
h
ti
m
e
.
4
4
ATSG
Fa
Fault code (for
ult
voltmeter)
co
de
Cause
Abnormal increase of TPS
output
21 5V OV
----
11__
Abnormal decrease of TPS
output
22
23
Incorrect
adjustment of the
throttle-position
sensor system
_if
Remedy
Check the throttle
position
sen-sor
connector.
Check the throttle position sensor itself.
Adjust the throttle position sensor.
Check
the
accelerator
switch
(No.
28: output or
not).
Check
the
throttle position
sen-sor
output
circuit harness.
24
_Milli ____
25
26
_FIL111111111_
1111a
_
27
28
Damaged
or
disconnected wiring
of the oil temperature
sensor sys-tern
Ell
_
Damaged
or
disconnected wiring
of the kickdown servo
switch sys-tern, or
improper contact
Short circuit of the
kickdown servo switch
system
Damaged
or
disconnected wiring
of the ignition pulse
pick-up cable system
Short circuit of the
accelerator switch
system or improper
adjust-ment
Check
the
ignition
pulse
signal line.
Check
the
accele
rator
switch
o
u
t
p
u
t circuit
harness
.
_111
1:11.
1111.
_
Adjust
Malfunction of the
microprocessor
33
the
accelerator
switch.
Replace
31
32
Check
the
accelerator
switch
connector.
Check the accelerator switch itself.
Damaged
or
disconnected wiring of
the pulse generator B
system
1111L
_
AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
11
Check
the
pulse generator
B output circuit
harness.
Check
pulse
generator B itself.
Check the vehicle
speed reed switch
(for chattering).
ATSG
F
Fault code (for
a
voltmeter)
ul
t
c
o
d
e
Cause
41
._
42
Damaged
or
disconnected wiring of
the shift control solenoid
valve A system
Remedy
Check
the
solenoid valve
con-nector.
Check
shift
control
solenoid valve
A itself.
Check the shift
control solenoid
valve
A drive
circuit harness
_
_IL_
Damaged
or
disconnected wiring of
the shift control solenoid
valve B system
43
-17.44
_Tin
iraL
Damaged
or
disconnected wiring of
the pressure control
solenoid valve system
45
'.
46
IT
M
I
M
I_
51
52
___
53
Fourth gear nonsynchronous
54
__
FUTTF
LIEJL
Check
the
solenoid
valve
con-nector.
Check
shift
control
solenoid valve
B itself.
Check the shift
control
solenoid
valve
B
drive
circuit harness.
Check
the
solenoid
valve
con-nector.
Check the pressure
control
sole-noid
valve itself.
Check the pressure
control
sole-noid
valve drive circuit
harness.
Check
the
pulse
generator
A output
circuit harness.
Check
the
pulse
generator A connector.
Check
pulse
generator
A itself.
Kickdown
slippage.
brake
PTSG
FLUID LEAKAGE
TRANSAXLE
CONVERTER HOUSING AREA
1.
CLUTCH
TORQUE
CONVERTER
DIAGNOSIS Test-1
Inspection of damper
clutch
torque
converter operation
with engine idling.
E
n
g
a
g
e
t
h
e
p
a
r
k
i
n
g
b
r
a
k
e
s
e
c
u
r
e
l
y
Solenoid valve
is
not
completely
dosed
Shift
the
selector lever
to the "D" or
"R" position.
Does
the
engine stall?
the
Yes
Cor
rect
ope
rati
on
(Th
e
da
mp
er
clut
ch
did
not
ope
rat
e)
Replace
torque
converter
assembly
GITSG
Test-2
Inspection procedures
and
malfunction
classification for each
element
Check for continuity in the harness,
follo
wing
the
wiri
ng
diag
ram
01K015
Is
ther
ea
brok
en
wire
in
the
harn
ess?
Are
ther
e
any
impr
oper
conn
ectio
ns?
No
(1) Wiring
(3) Throttle position
sensor
NOTE Check while set
to the MPI
(2) Coolant
temperature sensor
1710
89
Throttle position
sensor terminals
T
e
Go to (2)
T
e
r
m
i
n
a
l
Go to (3)
--1K
Yes
Is
ther
e
cont
inui
ty
bet
wee
n
ter
min
al B
and
the
case
whe
n
the
cool
ant
tem
pera
ture
exce
eds
60
C
(140
F)?
Yes
Gene
rally
disen
gage
s in
all
rang
es
Resistance
Resistance too high
No
Replace the coolant temperature sensor
Broken
wire
/Check
the
resistance
between
terminals 2
and 1 while
idling
Is
the
resistan
ce just
8% of
resistan
ce
between
termina
ls 1 and
3?
No
Adjust
the
resistance value
by
using
the
adjusting screw
Yes
Disengages at 20 km/h (13 mph) in 2nd
Adjust
the
resistance value
by
using
the
adjusting screw
R
e
s
i
s
t
a
n
c
Check
the e
resistance
between
)
terminals 2
and 1 at full t
open
o
Is
the
o
resistance
just 96%
h
of
i
resistance
g
between
h
terminals
1 and 3?
No
Disengages in all
range
MIITSG
midway
through stroke
Does the resistance value between
rpm
C
h
a
n
g
e
s
c
o
n
t
i
n
u
o
u
s
l
y
G
o
t
o
(
4
)
:
b
r
o
k
e
n
w
i
r
e
O
r
0 : short
Check the resistance between terminals 1
Operation is OK
and 2.
in 2nd. but when
Is the resistance approx.
subsequently
driven in 3rd for
52051 at 20C?
Yes
longer
than 5 seconds, disengages in all ranges
...(
w
i
r
e
o
r
0 : short
Aand
= 1 and 2
Puls
e
gene
rato
rs A
- B
ter
min
als
(Use
an
oscil
losc
ope
to
chec
k.)
4.
No
171090
Disengages in all ranges Is the resistance approx. 52011 at
20C?
Yes
(5) Pulse generators A B
Go to (5)
Replace the pulse
generator
) No
Yes
No
ise
Adjust
the
gap
between
pulse
generator A and the
kickdown
drum
because
it is excessive,
or replace the
pulse
generator
AA
01K
015
Poor grounding of
shielded wire of pulse
generator circuit
Operation is OK in 2nd
ATSG
No
Insufficient
Noise
Noise in the wave form
A
d
j
u
s
t
9.
0.
Disengages in all
ranges, or vibration
occurs
t
h
e
Go to (6)
01K015
Poor
grounding
of
shielded wire of pulse
generator circuit
:
b
r
o
k
e
n
w
i
r
e
o
r
(6) Solenoid
NOTES
(1) If resistance is
()
side
lead
wire
may
minus
Chec
k the
resist
ance
betw
een
the
solen
oid
termi
nals
and
the
trans
axle
case.
Is the
resist
ance
appro
x.
3r1 at
20C
(68F
)?
n
o
t
0 : short
No
be
connected
(2) If there is a
short in the
solenoid,
the control
unit
may be damaged
Yes
V
Is there any foreign matter
on the valve seat?
) Yes _
trans
missi
on
fluid
V
Go to (7)
(7)
Brand
s of
auto
matic
Excessive vibration
Run the engine at 2,500
rpm or more and check
the steering wheel for
vibration
_.
<
Check the
brand of the
automatic
transmission
fluid
ATS
G
(8) Computer
Replace the
Yes
Normal
(
d
a
m
a
g
e
o
r
d
i
s
c
o
n
n
e
c
t
i
o
n
)
o
r
0
(
s
h
o
r
t
c
i
r
c
u
i
t
)
Check the resistance between solenoid
valve
terminal
1
and
the
(9)
Pressu
re
contro
l (PC)
transmission
solenoi
d
valve
V
Check
whethe
r there
is dirt
in the
valve
seat
Solenoid
valve
connector
1: PC
solenoid
valve 2:
Damper
clutch
solenoid
v
alve
3:
SC
solen
oid
valve
A
4: SC solenoid
valve B
171095
(
dirty valve seat) Solenoid valve
sound can be heard when
1Yes
Normal
)
No
the
I.(
C
h
e
c
k
w
h
e
t
h
e
r
t
h
e
r
e
i
s
d
i
r
t
i
n
t
h
e
v
a
l
v
e
s
e
a
t
.
(dirty valve seat)
No
Normal
17109
6
(11) Accelerator
switch
on
on
ATS
G
(12) Inhibitor
switch
na<
Continuity
Continuity
between 8 and 9.
No continuity
Continuit
y
Replac
e
the
inhibit
or
switch
Continuit
y
Continuit
y
V
Nor
mal
No
continuity
w(
Continuity
Start the engine and, with the engine idling and the transmission in the "D" range (be sure the brake is applied
securely), check for continuity between the kickdown servo switch terminal and the transmission case.
No continuity
V
Normal
Replace the kickdown servo switch
Continuity
AT5Gi
,!
`Reducing
pressure
F
ro
nt
cl
ut
c
h
pr
es
su
re
Kickd
own
brake
pressu
re
175103
5
Lowrevers
e
(4:\
End
clut
ch
brake
pressu
re
pre
ssu
re
175102
4
5
6
7 Select
lever
8
positio
n
N
N
D
D
(SW-ON)
D
(SW -OFF)
L
R
35 (0)
(Referen
ce)
vehicle
speed
km/h 0
0
0
110
Engine
speed
rpm
Idling
A pprox.
2500
Idling
Approx.
2500
Approx
75
25 00
50
Approx.
2500
ADD
r"'
1000
Shift
Neutral
2nd gear
1.0 -2.1
2.5 - 3.9
Front clutch
pressure
End clutch
pressure
Low-reverse
brake
pressure
Torqueconvertor
pressure
2.5 -3.9
2.0 -2.4
Redu
cing
4th gear
Kick 6.2 --6.8
dow
n
positio 3rd gear
n
6.2
pressur
e
brake
2nd gear
pressure
6.2 - 6.8
Neutr
al
2.5
-3.9
-
2.5 - 3.9
^-6.8
2.5 - 3.9
1st gear
-
2.5 - 3.9
Reverse
-
2.5 - 3.9
Approx.
2500
6.2 - 6.8
6.2 - 6.8
6.2 - 6.8
3.0 - 4.2
11.6 - 17.6
11.6 -17.6
NOTE
- must he 0. I kg/cm or less.
SW-ON : Switch ON the OD switch.
SW-OFF : Switch OFF the OD switch.
E1,3 PTSG
"Line
pressures"
e. Improper oil pump dischange pressure
refers to oil
pressures
Cl, ,
T. ) and 31
in the
"Standar
d
oil
pressure
table" on
the
previous
page.
Imprope
r front
clut
ch
pres
sure
2.
Improper
reducing
pressur
e
5.
Imprope
r end
clut
ch
pres
sure
3.
Improper
kickd
o
w
n
b
a.
b.
4.
c.
d.
e.
a.
b.
c.
a.
b.
c.
d.
a.
Remedy
a.
Visually inspect the oil
filter; replace the oil
filter if it is clogged..
b. Measure line pressure CI)
(kickdown brake
pressure); if the
pressure is not
the standard
value, readjust
the line pressure,
or, if necessary,
replace the valve
body assembly.
c.
Check the operation of the
regulator valve;
repair
if
necessary, or
replace
the
valve
body
assembly.
d.
Tighten the valve body
tightening bolt and installation bolt.
e. Check the side clearance of
the oil pump gear;
replace the oil pump
assembly if necessary.
a.
Check the kickdown
brake pressure (line
pressure); if the
line pressure is
not the standard
value, check as
described in item
I above.
b.
Disassemble the valve body
assembly and check
the filter; replace the filter
if it is clogged.
c.
Measure the (D reducing
pressure; if it is not
the
standard
value, readjust,
or replace the
valve
body
assembly.
d.
Check the operation of the
reducing valve;
if
necessary,
repair
it,
or
ATSG
Technical
Service Information
End clutch
Seal ring
D-ring
1'D-ring
Rear clutch
Front clutch
j 0-ring
3
S
e
a
l
r
i
n
g
1
I
1
4
=
b
2
D-ring
Seal ring
JL
19'Seal r ing
Trouble symptom
Probable cause
6. Improper lowa.
valve body and transreverse
brake
0-ring between
c.
Loosene
ss of
valve
body
tightenin
g part
d.
Functio
nal
malfunc
tion of
the
valve
body assembly
e. Malfunction of
the D-ring of the
low-
e 0-ring
175143
Remedy
a.
b.
c.
d.
e.
reverse brake
piston or the
0-ring of
the
retainer
(Refer to the
figure above.)
7. Improper torque
a.
damper clutch control
a.
convertor pressure
(DCCSV) or the damper
Sticking of the
Repair
or
replace,
as
necessary, the cooler and/or
clutch control valve. piping.
b. Clogging or leaking Disassemble the transode
itself and check for damage
of the oil cooler
of the seal ring; replace the
b.
seal ring if there is damage.
and/or piping
Replace the torque convertor.
c. Damaged seal ring
@ of the input
c.
shaft (Refer to the
figure above.)
solenoid valve
d. Malfunction of the
torque convertor
d.
USG
LUBRICATION
Checking Fluid Level
interval:
Every 24,000 km (15,000 miles)
Inspect fluid level on dipstick with
engine idling, transaxle in neutral
position and vehicle on level ground.
A
proper fluid level should be
between upper and lower lines of
dipstick when fluid temperature is
50-80C (120-180 F).
Changing Fluid
Recommended fluid
DEXRON II
NOTES
When factory fill fluid is changed as
recommended above. If transaxle is
disassembled for any reason, fluid
and filter should be changed.
Flu
id
Ch
an
gin
g
Pr
oce
du
re
i
o
n
Wh
en
the
unit
is
dam
age
d
and
the
ATF
is
cha
nge
d,
be
sure
to
also
clea
n
the
cool
er
syst
em.
1.
Raise
vehicl
e on
hoi
st.
Pla
ce
dra
in
con
tai
ner
wit
h
lar
ge
openin
g,
under
drain
plug.
2.
Re
mo
ve
dra
in
plu
g
to
let
flui
d
dra
in.
3.
Pla
ce
a
dra
in
co
nta
ine
r
V-------
LL I
---
Fluid
level
must
be
within
this
range.
--;
o_
_
_
_.
..175124
ATSG
5. While holding
with special tool
MD998902 so that
the kickdown servo
piston won't turn,
use special tool
MD998901 to
"tighten", at 9.8 Nm
(7.2 ft.lbs.), and
"return" the
adjustment screw two
times each, and then
tighten at a
torque of 4.9 Nm
(3.6 ft.lbs.). Then
return the adjustment
screw 2 to 2-1/4
turns.
6. While holding
with special tool
MD998902 so that
the kickdown servo
piston won't turn,
tighten the lock nut to
the specified
torque.
Lock nut
7. After fitting
a
new D-ring in the
groove around the
cover, install the
cover to the case so
that the D-ring
won't
be twisted,
and
then
install
the
snap ring. 8.
Install
the
kickdown
servo
switch
to
the cover.
Kickdown servo switch screw
1.0-1.4 Nm (0.7-1.0 ft.lbs.)
AT5G
28 kPa (4 psi)
0-ring is installed on the
9.
ATSG
Install the oil filter and oil pan in the same way as for
adjustment of the line pressure.
Make the oil pressure test. Readjust if necessary.
ADJUSTMENT OF
THE THROTTLEPOSITION
SENSOR (TPS)
1. Measure
and
make a note of the
resistance between
terminals 1 and 3.
2. Measure and
make a note of the
resistance between
terminals 2 and
3. Measure the
resistance after the
engine has
warmed up, in the
AT5G
rt
Bushing
4
Pushbutton
knob
Selector
f
i
t
l
b
s
.
Slee
ve
Set screw
2.0 Nm
1.4 ft.lbs.
Bracket
Cover
REMOVAL
1.5
N
m
1.1
ft.t
bs.
Position
indicator
light
1
4
2
0
N
m
1
0
1
Selector lever
Slider
Indicator panel
Cable end
Control cable
09R
006
5
Indicator
3.
Remove
the
terminal from the
overdrive
switch
connector case.
(09R0054)
ATSG
6.
7.
8.
9.
m
ATSG
12.
Remove
the
control cable from
the transaxle and
the transaxle mount
bracket.
INSPECTION
Check detent place for wear.
Check pin at the end of selector lever for wear.
Check contact surface of the push button and the sleeve
for wear.
4. Check control cable for function and for damage.
5. Check busing for wear or damage.
6. Check overdrive switch for continuity. (09R0056)
1.
2.
3.
Terminal
Switch position
Overdrive activation (OFF)
1
(0.3-RW)
2
(0.3-BW)
3
(0.3-YW)
2.
0,11.11111, IN
ATSG
Technical Service
Information
3.
7.
Adjust
the
adjusti
ng nut
on the
transax
le side
so that
t
h
e
r
e
i
s
n
o
Inhibitor switch
Neutral position
aligning hole
5.
Caution
When connecting the control
cable to the transaxle mount
bracket, install the clip until it
contacts the control cable, in
the position shown in the figure.
(09R0058)
6.
l
o
o
s
e
n
e
s
s
i
n
t
h
e
c
o
n
t
r
o
l
c
a
Sleeve
Selector
lever
09R0070
AUTOMATIC TRANSMISSION
SERVICE GROUP
30
Tranza
xle
mount
bracke
t
09R0058
ATS
G
15-2'
35.42
TRANSAXLE
Removal
COMPONENTS
1.
Nm
A
43-55
B
43-55
C
22-32
D
30-35
E
10-12
Technical Service
Information
09 K069
ft. lbs.
31-40
10 x 40 (1.6)
Ax B
31-40
10 x 65 (2.6)
16-23
10 x 55 (2.2)
72-25
10 x 60 (2.4)
7-9
8 x 14 (0.6)
Y09512
11-16
8 x 20 (0.8) 25-30
ATSG
4.
7.
Remove the
upper
five
bolts
connecting
the
transaxle to
the
engine. (09K033)
8. Remove the starter motor.
AT5G
Installation
1.
Be sure to install the torque converter first to the transaxle and then to the engine.
Caution
HOT1
Recommended fluid
72R001
2
It2111T5
G
SECTIONAL
VIEW
3 45
10 11 12 13
14
49
48
15
16
17
47,
48-
e
l
.
I
f
it_
L
23
24
25
3
2
3
1
3
0
2
9
2
8
1 . Converter housing
Forward sun gear
20.
2.
21.
22. One-
24.
7. Front clutch
Transfer driven gear
8. Rear clutch
generator 8
9. Pulse generator A
Center support
26.
23.
25. Cover
27. Pulse
28.
29.
18
11. Planet gear set
30. Kickdown drum
12. Internal gear
31. Kickdown band
13. Output flange
32. Transaxle case
14.
33.
15.
34.
End clutch
Differential case
18.
37.
19.
38.
Bearing retainer
Side gear (2)
19
20
175001
-21
Impeller
43. Turbine
44. Stator
45.
Pump oil seal
46.
Input shaft
47.
One-way clutch
48.
Clutch plate
AT5G
D
I
S
A
S
S
E
M
B
L
Y
C
a
u
t
i
o
n
Because
the
automatic transaxle is
composed
of
component parts of
an especially high
degree of precision,
these parts should be
very
carefully
handled
during
disassembly
and
assembly so as not to
scar or scratch them.
A
rubber
mat
should be placed on
the workbench, and
it should always be
kept clean.
During disassembly,
cloth gloves or rags
should not be used. If
such items must be
used,
use
articles
made of nylon, or use
paper towels.
All
disassembled
parts
must
be
thoroughly cleaned.
Metal parts may be
cleaned
with
ordinary detergents,
but
must
be
thoroughly air dried.
Clean the clutch disc,
resin thrust plate and
rubber parts by using
ATF
(automatic
transmission
fluid),
being very careful
that dust, dirt, etc. do
not adhere.
If the transaxle main
unit is damaged, also
disassemble and clean
the cooler system.
1. Clean away any
sand,
mud,
etc.
adhered around the
transaxle.
2. Place the transaxle assembly on the workbench with the
oil pan down.
3. Remove the torque converter.
4.
ver.
In ATSG
6.
7.
8.
9.
ATSG
13.
Remove
the
thrust washer, and
pull out the end
clutch shaft.
Q ATSG
r
ATS
G
Te
ch
nic
al
Ser
vic
e
Inf
or
ma
tio
n
20.
Remove
the fiber
thrust
washer.
21. Remove
the front
clutch
assembly.
"NA AL_
v,ise
Law
(4
c
1112
2
ATSG
Thrust
bearing
175157
ATSG
29.
Remove
the
kickdow
n servo
cover
snap
ring.
Then
remove
the
kickdow
n servo
switch.
am
ATSG
33.
Remove
the
kickdown
servo
piston and
spring.
Caution
Do not place (turn)
transaxle
upside down as planetary gearset
thrust washers could fall out of place.
35. Turn
the
transaxle
over
so
that the
oil pan is
facing
34. Hold reverse sun gear with
Special Tool MD998345, so that
when transaxle is placed upside
down, forward sun
gear front and rear thrust
bearings will stay in position.
When no center support or further
disassembly is made, it is especially
important to hold reverse sun gear.
upward.
Be careful
not
to
scratch or
scar
the
end of the
manual control
shaft.
36. Remove the oil
pan and gasket.
37. Remove the oil
filter from the valve
body.
Spring
1751
59
IITSG
ATSG
46. Remove reverse sun gear and forward sun gear together.
\ Thrust race
'/
A
/ ,
i
Thrust bearing
r) (')
AUTOMATIC
TRANSMISSION SERVICE
GROUP
44
IITSG
49.
Remove
bearing
the
retainer,
ATSG
PTSG
Technical Service
Information
COMPONENT SERVICE-AUTOMATIC
TRANSAXLE ASSEMBLY
57. Remove snap ring
from transaxle case,
then remove taper
roller
bearing
inner and outer races.
REASSEMBLY
Caution
Do not reuse gaskets,
oil seals and rubber
parts. Replace them
with new ones at every
reassembly. 0-ring of
oil level dipstick need
not be replaced.
Do not use grease
other
than
petrolatum
or
industrial vase-line.
Apply automatic
transmission fluid
to friction element,
rotating parts, and
sliding parts before
installation. Use
"DEXRON II" type
automatic
transmission fluid.
New clutch disc
should be immersed
in automatic
transmission fluid for
more than two hours
before installation. Do
not apply sealer or
adhesive to gaskets.
8
.
AT5G
Technical
Service Information
I
n
s
e
r
t
S
p
e
c
i
a
l
Spacer
T
o
o
l
M
D
9
9
8
3
6
3
0
1
i
n
t
o
o
u
t
p
u
t
f
l
a
n
g
e
a
n
brit
Torque
wrench
MD998363.01
Groove for
id
e
nt
if
ic
at
io
n
o
f
in
st
al
li
n
g
di
re
ct
io
n
Inner races
Outer races
Transfer idler gear
170140
A040,)
forkSo
175169
ATSG
9.
Caution
The
clearance
between the idler
shaft and the lock
plate
should
be
closed
in
the
direction that will
prevent idler shaft
looseness, and then the
lock plate should be
tightened.
Lock
plate
175170
sealant
(THREEBOND
#1303) the top of
screws. Sealant
should not stick out
of screw head.
Install new 0-ring
for re- tainer edge.
Screw
13. Insert transfer shaft (with taper bearing inner race) into
Case.
AT5G
15. Using Special
Tool MD998350-01,
drive bearing inner
race onto transfer
shaft. (175198)
16.
Install
taper
roller bearing outer
race, then install
snap ring.
ATSG
Technical
Service Information
2
#1
#2
#12
#3
#7
#11
(selection)
(selection)
175100
Unit: mm
Part no.
1
Shape
t_
D
Shape
.11
.A
70
55.7
1.8
70
55.7
2.2
D
55.7
70
2.6
70
55.7
3.0 _t___
d
D
t
d
Part no.
MD707901
(incL
0 *11
55.7
MD7079
1.8
170232
02
(incL
48.1
"2)
34.4
#1
-
Code
MD707903 (incl. 3)
MD707904
(incL 4)
MD707290
#2
MD707271
#4
Code
V
t
48.9
37
1.2
2
HH
48.9
37
0.8
48.9
37
L6
48.9
37
2.0
40
19
#5
2.4
MD704980
1.6
MD704936
26
#10
1.2
MD955671
38.7
#13
0.B
MD704935
26
#9
MD704933
#3 54
D
42.6
26
38.0
22.2
#11
MD704930
#6
52
I
I
36.4
-.
MD707270
54
170229
d
D
41
38.7
#7
MD720010
#8
#1
2
41
d
D
17
02
47
170228
AT5G
1 , n ^ C A
1:1T5G
i
i
tighten
bolts
to
specified
torque.
Center
_,
0
ioo0c
Lente
r supP
/41,--lockin
g
bolts
O.ND"
support lock
bolts
20-26 Nm
(15-19 ft.
lbs.)
NOTE
For proper alignment of the reverse
and low apply port, be sure to tighten
bolt A first.
If
installed
before
inserting
shaft, the 0ring
will
interface with
shaft
set
screw hole.
28.
After
installing new
0-ring
on
manual
control shaft,
draw shaft
back
into
case,
then
install
set
screw
and
gasket.
Also
install
detent
steel ball
and
spring at
the same
time.
(170150)
.1 "if'
L:.,`i7\B :.1.
?.. 3 )Z1--.
,,
'-.. --.-.
., \ ....,) .
.;.)-)
17
01
48
8-9.5 Nm
(6-7 ft. lbs.)
Detent plate
Detent ball
shaft
Manual control
17
01
50
AT5G
oh
ATSG
39. Install new oil pan gasket and oil pan by tightening
bolts to 10-11.5 Nm (7.5-8.5 ft. lbs.). (170066)
12
PTSG
45.
Install
the
kickdown servo cover,
and then install the
kick- down
servo
switch.
46. Install the kickdown servo cover snap ring.
ATSG
Thrust
bearing
1:1T5G
54. Install thrust race #3. If the end play of the input shaft
(measured
and
noted
at
the
time
of
disassembly)
is
the
standard
value, make the
selection of thrust
race #3 so that the
end play will be
within
the
standard value.
If thrust race #3 was changed for one of a different
thickness, thrust washer #1 (between the oil pump and
the front clutch) must be replaced with one which will
correspond to the thickness of the thrust race.
Thrust
Example
0.8 (.031)
1.8 (.071)
1.2 (.047)
2.2 (.087)
1.6 (.063)
2.6 (.102)
2.0 (.079)
3.0 (.118)
MD707901
MD707902
Parts No. of
thrust washer set
M0707903
MD707904
ATSG
ATSG
60. Install new oil pump gasket and the oil pump assembly.
63. Prior to
installation of
converter housing,
make certain that
transfer shaft end
play measured and
recorded at
disassembly is
same. If measurement
is out of specification, pull off
taper roller bearing
outer race from converter housing and
replace spacer with
spacer of suitable
thickness.
Standard
end
play is between
0.025
mm
170127
ve'ATSG
flange.
66. Install new case gasket to transaxle case.
0
.
0
2
5
(
t
i
g
h
t
)
0
.
0
2
5
m
m
(
l
o
o
s
e
)
[
.
0
0
1
0
(
t
i
g
h
t
)
.
0
0
1
0
i
n
.
(
l
o
o
s
e
)
]
Differential end play
70. Using
Special
Tool
MD998325-01
and MB990938-01,
drive two drive
shaft oil seals into
transaxle case and
converter housing. (170155)
71. Install inhibitor
switch and manual
lever. Adjust inhibitor
switch. (See
ADJUSTMENT.)
Y*"iOrg
MIIPP11."-"1111
144'410
11re
M B990938-0
MD998325-01
X.-----c-170155
AUTOMATIC TRANSMISSION
SERVICE GROUP
61
ell
PTSG
73. Install the thrust washer with the grooved side outward.
CITSG
cylindrical portion of
torque converter,
install torque
converter carefully so
as not to damage the
oil seal lip. Make
certain that torque
con- verter is in mesh
with oil pump drive
gear.
Measure distance
between ring gear
end and converter
housing
end.
Torque converter
has been properly
in-stalled
when
measurement
is
about 12 mm (.47
in.).
1:1T5G
s
h
a
f
t
s
u
p
p
o
r
t
D
r
i
v
e
n
g
e
a
r
S
t
e
e
l
b
a
l
l
D
r
i
v
e
g
e
a
r
H
o
u
s
i
n
g
O
i
l
s
e
a
l
S
e
a
l
r
i
n
g
S
e
a
l
r
i
n
g
0-ring
170173
DISASSEMBLY
1. Removp 0-ring from oil pump housing.
2. Remove
five
bolts and remove
reaction
shaft
support from housing.
3. Remove oil pump
drive and
driven
gears from pump
housing.
4. Make reassethbly alignment marks on drive and driven
gears.
5. Remove steel ball from housing.
6.
PITSG
INSPECTION
1. Measure the side clearance of the oil pump gear; if the
measurement
exceeds
the
standard
value,
replace the gear or
the
oil
pump
assembly.
2. Replace if the gear contact part of the reaction shaft
support shows step-like wear.
Drive and driven gear side clearance
0.025 to 0.05 mm (.001 to .002 in.)
REASSEMBLY
1. After immersing
drive and driven
gears in automatic
transmission
fluid, install them to
pump housing. When
reusing gears,
install with mating
marks properly
aligned.
2. Fit a new 0-ring
into the groove at the
inner circumfer- ence
of the drive gear.
3. Install steel ball
in hole as shown in
the
illustration.
(170302)
4.
ATSG
1.
S
na
p
ri
ng
se
le
ct
C
l
u
t
c
h
r
e
a
c
t
i
o
n
p
l
a
t
e
(
4
)
t
h
i
c
k
n
e
s
s
3
.
8
m
m
(
.
1
5
0
i
n
.
)
Snap ring.
S
p
r
i
n
g
r
e
t
a
i
n
e
R
e
t
u
r
n
s
p
r
i
n
g
D
r
i
n
g
F
r
o
n
t
c
l
u
t
c
h
p
i
s
t
o
n
D
r
i
n
g
Front clutch retainer
EITSG
CLUTCH ASSEMBLY
DISASSEMBLY
1. Remove snap ring from clutch retainer.
2. Take out four clutch reaction plates and three clutch
discs.
If
the
clutch
reaction
plates
and the clutch
discs are to be reused, be sure not
to change the
installation order
or direction.
3. With return spring
compressed with
Special Tool, Spring
Compressor
(MD998337-01),
remove snap ring,
then spring retainer
and return spring.
(170094) 4. Remove
piston from retainer.
5. Remove the Dsection rings from the
inner and outer circumferences of the
piston.
REASSEMBLY
1. Install D-section ring in groove in outside
surface of
piston with its round side out. Install another
D-section ring to front clutch retainer. (170096)
D-section ring
4.
Compres
s return
spring
with
Special
Tool
MD9983
37-01
and
instal
l
snap
ring.
Piston
Front clutch
0-section ring
Snap ring
retainer
1700
96
Shear drop
AUTOMATIC
TRANSMISSION
SERVICE GROUP
6
7
C
l
u
tc
h
p
la
te
(
4
)
C
l
u
tc
h
d
is
c
s
1720
18
fiT5G
6. After installing
snap ring, check to
see if there is a 0.60.8 mm (.024-.031
in.) clearance
between snap ring
and clutch reaction
plate.
To
check
clearance,
hold
entire
circumference of
clutch
reaction
plate down with
50 N (11 lbs.)
force. If clearance is out of
specification,
select snap ring
for
correct
clearance.
Kinds of snap ring
Thickness mm (in.)
Ident. color
Parts No.
1.6 (.063)
None
MD955630
1.8 (.071)
Blue
MD955631
2.0 (.079)
Brown
REAR CLUTCH
ASSEMBLY
COMPONENTS
MD955632
2.2 (.087)
None
MD955633
2.4 (.094)
Blue
Wave pring D-ring
MD955634
2.6 (.102)
Brown
MD955635
2.8 (.110)
None
MD955636
3.0 (.118)
MD955637
Blue
Rear clutch
piston
Rear
clutc
h
retain
er
Thrust race
Clutch disc (3)
Snap ring
Clutc
h
reacti
on
plate
thick
ness
3.8
mm
(.150
in.)
Clutc
h
plate
(2)
thick
ness
1.8
mm
(.071
in.)
C
l
u
t
c
h
p
r
e
s
s
u
r
e
p
l
a
t
e
R
e
t
u
r
n
s
p
r
i
n
g
Dring
175135
voKAT56
DISASSEMBLY
1. Remove snap ring and then remove thrust race. (175060)
2. Remove the input shaft from the rear clutch retainer.
3. Remove snap ring from clutch retainer.
4. Remove the clutch reaction plate, two clutch plates,
three clutch discs and clutch pressure plate from retainer.
REASSEMBLY
1.
order of
disassembly.
Prior
to
installing,
apply
Snap ring
Caution
When new dutch discs are used,
immerse
them
in
automatic
transmission fluid for more than two
hours before installa-tion.
Shear drop
Snap ring
R
e
a
c
t
i
o
n
p
l
a
t
e
R
e
t
u
r
n
s
p
r
i
n
g
1
7
5
1
7
5
fiT5G
Technical Service
Information
6.
END CLUTCH
COMPONENTS
Seal ring
E
n
c
l
u
t
c
h
r
e
t
a
i
n
e
r
D
r
i
n
g
R
e
t
u
r
n
s
p
r
i
n
g
S
n
a
p
r
i
n
g
C
l
u
t
c
h
d
i
s
c
C
l
u
t
c
h
d
i
s
c
C
l
u
t
c
h
d
i
s
c
Snap ring
D-ring
Piston
Washer
C
l
u
t
c
h
p
l
a
t
e
C
l
u
t
c
h
p
l
a
t
e
C
l
u
t
c
h
l
a
t
e
Clutch reaction plate
175061
CITSG
DISASSEMBLY
1. Remove the snap
ring by using snapring pliers, and then
remove the washer
and return spring.
2. Remove the snap ring, and then remove the clutch
reaction plate, the
clutch disc, and
the clutch plate. If
the
disc
and
plate are reused,
be sure not to
change
the
installation order
and
direction
when they are
disassembl-ed.
175062
3.
REASSEMBLY
1. Install the Dsection rings and oil
seal in the piston
inner and
outer
grooves.
2. After applying a coating of automatic transmission fluid
to the D-section rings outer circumference, manually
press the piston into the end clutch retainer.
3. Install the return spring and washer.
4. After fitting a new snap ring into the guide of the special
tool snap-ring
installer
(MD998367),
install the
retainer. Fit the
snap ring as far
down on the guide
as possible. Attach
the installer and
press until the
snap ring enters
the groove. Do not
press more than
necessary. The
places indicated
by arrows in
the illustration
(center projections) are not
to be supported.
I.
1:1T5G
Technical Service
Information
6.
Ident. color
Part no.
1.05 (.04)
White
MD715800
L30 (.05)
Yellow
MD715801
1.55 (.06)
None
MD715802
1.80 (.07)
Green
MD715803
2.05 (.08)
Pink
MD720849
Center
support
0-ring
17202
1
ATSG
DISASSEMBLY
1. Remove snap ring from center support.
2. Take out reaction plate, brake discs, brake plates and
brake pressure plate.
If the discs and
plates are to be
re-used, be sure
not to change the
installation order
or direction.
3.
Compress
the
return spring by using
the spring compressor,
and then remove
the snap ring.
REASSEMBLY
1. Install new D-section rings to piston. (170108)
2. Apply automatic transmission fluid to circumference of
D-section rings,
and push piston
into
center
support by hand.
3.
ATSG
4.
5.
2.
6
(.
1
0
2)
Snap ring
When
a new disc is used,
immerse it in automatic transmission fluid for more than two
hours before installation.
Pressure
Snap ring
Return spring
6.
between
Ident. color
Parts No.
1.8 (.071)
Blue
MD707413
2.0 (.079)
Brown
MD707406
2.2 (.087)
None
MD707407
2.4 (.094)
Blue
MD707408
B
r
o
w
n
M
D
7
0
7
4
0
9
2.8 (.110)
None
MD707410
3.0 (.118)
Blue
MD707411
3.2 (.126)
Brown
MD707412
Bra
ke
plat
e (5)
Bra
ke
disc
(51
AUTOMATIC
TRANSMISSION
SERVICE GROUP
175176
7
4
1:1T5G
COMPONENTS
washer
(3)
Thrust bearing
Overrun
ning
clutch
Part A
(6)
B
(3)
2. Remove
overrunning clutch
outer race assembly.
Remove
overrunning clutch
end plate.
DISASSEMBLY
1. Unbend three lock plates and then remove
three bolts.
Roller (60)
175066
illininoulin II Lop
1702
54
ATSG
3.
4,
7.
REASSEMBLY
1.
Install
thrust
bearing to carrier.
Be sure that it fits
cor-rectly in carrier.
AUTOMATIC
TRANSMISSIO
N SERVICE
GROUP
76
IITSG
2.
3. Line up holes in
rear thrust washer
and front thrust
washer with shaft
hole of carrier.
4. Install short
pinion, spacer
bushing and two
front thrust washers
and align holes. Use
care not to allow
rollers to get out of
position.
. Insert pinion
shaft. Be sure that
flattened end of
pinion shaft fits
properly into the
hole in rear thrust
plate when pinion
shaft is inserted.
6.
ATSG
7.
8.
9.
Caution
Lock plates must not be reused.
AT5G
Snap ring
Bearing
Interial gear
Bearing
Transfer drive gear
Output flange
170178
DISASSEMBLY
1. Remove snap ring from rear end of output flange.
1
70113
1.70114
PTSG
3.
REASSEMBLY
1.
MD998349-01
Caution
Replace output flange and transfer drive gear as a set.
Groove
2. Install transfer
drive gear in proper
direction with attention paid to groove
provided
in
side
surface.
Install in
this
direction
170118
3.
170119
4.
170120
ATSG
COMPONENTS
Transfer shaft
170179
DISASSEMBLY
If
tapered
roller
bearing is damaged,
remove
it
using
Special
Tool
MD990339-01
(MIT45287
and
MTT304325).
Caution
Replace taper roller bearing inner and outer races as a set.
REASSEMBLY
Install taper roller
bearing inner race
assembly
using
Special
MD998318-01.
Tool
ATSG
COMPONENTS
Taper
roller
bearing
Washer
Pinion gear
Lock pin
Pinion shaft
Bolt
(8)
Side gear
Pinion gear
Spacer
(
;)--
Washer
Differential case
166012
DISASSEMBLY
1 Remove the drive gear retaining bolts and remove the
2.
3.
Lock pin
4.
5.
Distinguish
between
the
removed
gears
and spacers for
the left and right
sides.
ATSGJ
REASSEMBLY
1. With spacers
installed to back of
differential side
gears, install gears in
differential case. If
reusing removed
parts, install them in
original positions
noted during
disassem- bly. If using
new differential side
gears, install spacers
of
medium thickness 1.0
_0 .07 mm (.039
spacer
ID
Thickness mm
(in.)
_0.08(Q394_.003
MA180876
0-0.076 mm (0-.0030 in.)
MA180875
MA180860
Parts No.
MA180861
1.0
MA180862
4.
Install pinion
shaft lock pin in
direction
specified
in illustration.
After
installation,
check
to
ensure
that
projection is less than 3 mm (.118 in.).
(160029)
Caution
Lock pin must not be reused. Lock
pin not requiring more than 1,960 N
(44 lbs.) installation load must not be
used.
Lock
pin
Differential case
Pinion shaft
Projection of
3 mm
(.118
in.)
max.
I
n
s
t
a
l
l
i
n
g
d
i
r
e
c
t
i
o
n
160029
ATSG
5.
Press
Taper
roller
6.
1
60125
(8) indicate
sequence.
Tightening torque
1:1T5G
Regulator valve
Shift control plug,*
Upper valve
body
2-3 shift valve
R
e
a
r
c
l
u
t
c
h
e
x
h
a
u
s
t
a
l
v
e
R
e
a
r
c
l
u
t
c
h
e
x
h
a
u
s
t
v
a
l
v
e
F
r
o
n
t
e
n
d
c
o
v
e
r
175078
DISASSEMBLY
1. Remove the 4 solenoid valves.
2.
USG
3.
4.
-----
7.
8.
17C471,1
MI
ATSG
1.
2.
a
4.
1
7
5
0
7
8
ATSG
12. Pull out the pin, remove the stopper and then remove
the plug spring and end clutch valve.
i
13. Remove the end cover and then
o
remove the valve and spring shown in
the figure.
n
Note the following when
assembling the valve
body.
Thoroughly clean
each component in
clean automatic
transmission
fluid
before
installation. Do
not wipe them
with a rag.
When inserting
the valve into the
valve body, do not
apply excessive
force.
Tighten all bolts
to the specified
torque using a
torque
screwdriver or
similar tool. All
valve body bolts
are to be
tightened to 4.0-6.0
R
Nm (3.0-4.0 ft.lbs.).
E
A
S
S
E
M
B
L
Y
C
a
u
t
175091
ATSG
2.
Install the 1-2 shift valve, spring, shift control valve and
plug to the upper valve body, install the rear end cover,
and tighten the bolt to 4.0-6.0 Nm (3.0-4.0 ft.lbs.).
4.
89
ATS6
7.
1.End clutch
valve
2. End clutch
valve plug
3. Stopper
4. Pin
5. Damper
clutch control
valve
6. Damper
clutch valve
sleeve
7. End cover
8.N-R control
valve
9. Reducing
valve
10. Adjusting
screw
175091
9.
ATSG
ATSG
Technical Service
Information
15. Install the solenoid valves.
Use the shape and lead wiring colors to identify so that the
Solenoid valve
Red
Orange
Yellow
Blue
s
e
r
v
o
s
w
i
t
c
h
S
n
a
p
r
i
n
g
Kickdown servo cover
Snap ring
11:07c)
0-ring
Seel ring
D-ring
Nut
Kickdown
servo
sleeve
Coil spring
D-ring
(((ir,
172028-A
REASSEMBLY
1. Insert the adjust rod assembly into
kickdown servo piston, and then screw
the nut.
2. Install new D-rings and Seal ring to
piston.
3. Apply automatic transmission fluid to
D-rings and Seal ring.
Seal ring
D-ring
Adjust
rod
assembly
Seal ring
ATSG
COMPONENTS
0-ring
0-ring
Gear
172002
DISASSEMBLY
Drive spring pin out,
and gear and sleeve
can be disassembled.
Caution
Do not reuse 0-rings and spring pin.
REASSEMBLY
Spri
ng
pin
Speedom
eter
driven
gear
When tapping it
in, be sure that the slit is not at the gear
side.
0ring
0-ring Sleeve
rA
LA
Speedom
eter
driven
gear
u,
Spring
Sleeve
a
pin
Section A A
160038
AT5G
Technical Service
Information
COMPONE
NT
SERVICECASE
ASSEMBLY
(AUTOMAT
IC
TRANSAXL
E)
COMPONENTS
0.ring
Plug
pressu
re
170182
REASSEMBLY
Using Special Tool
MD998325-0 I and
MB990938-0I, drive
two drive shaft oil
seals into transaxle
case
AT5G
COMPONENTS
B
e
a
r
i
n
g
o
u
t
e
r
r
a
c
e
S
p
a
c
e
r
Dowel pin
Housing
Oil seal
170183
M099834701
M8990938-01
AUTOMATIC TRANSMISSION
SERVICE
95
1711128
ATSG
L.E.D. TESTER
(
probe lead -
20 milliampere L.E.D.
(Can be Red, White or Green),
41
Solder to test)
4
(Annode longest leg is +)
1
Encase in suitable
OHM
plastic tube
Solder 560
Resistor
{
[
C
o
v
e
r
b
a
r
e
w
i
r
e
w
i
t
h
i
n
s
u
l
a
t
i
n
g
s
l
e
e
v
e
o
r
t
a
p
e
)
N
(
S
o
l
d
e
r
t
o
t
e
s
t
p
r
o
b
e
l
e
a
d
/Solder to alligator
(
+
)
A
N
Y
L
E
N
G
T
H
D
E
S
I
R
E
D