Page 1027 of 1865
INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring
Spring
Spring name Outer dia.
mm
(in) Free length
mm (in)
Wire dia.
mm
(in) Spring color
1-2 accumulator small spring F8 engine 9.9 (0.400) 84.7 (3.335) 1.2 (0.047) Red
1-2 accumulator large spring
FE engine 13.0 (0.512) 73.2 (2.881) 1.8 (0.071) Pink 1-2 accumulator large spring F8 engine 16.0 (0.630) 84.7 (3.335) 2.0 (0.079) White
Bypass spring 5.0 (0.197) 25.1 (0.988) 0.7 (0.028) Yellow
Servo control spring 4.9 (0.193) 27.1 (1.067) 0.5 (0.020) Light blue
2-3 timing spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—
N-R accumulator rear spring 11.1 (0.437) 68.2 (2.685) 1.0 (0.039) Blue
N-D accumulator front spring 9.8 (0.386) 60.9 (2.398) 1.1 (0.043) Yellow
Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
OD release spring 6.0 (0.236) 32.6 (1.283) 0.6 (0.024) Orange
Coasting bypass spring 5.8 (0.228) 31.3 (1.232) 0.6 (0.024) Yellow
3-2 timing spring 8.2 (0.323) 28.55 (1.124) 0.8 (0.031) Maroon
3-2 capacity spring 5.55 (0.219) 30.5 (1.201) 0.55 (0.022) Light green
Throttle relief ball spring 6.6 (0.260) 20.3 (0.799) 0.8 (0.031) Light green
76G07B-165
Assembly
1. Install the 3-2 capacity valve, 3-2 capacity spring,
stopper plug, and stopper pin.
2. Install the 3-2 timing valve, 3-2 timing spring, and
retainer.
83U07B-287
3. Install the coasting bypass plug, coasting bypass
valve, and coasting bypass spring.
4. Apply ATF to the O-rings, and install them onto the
piston; then insert the N-R accumulator rear spring,
and N-R accumulator piston.
5. Apply ATF to the O-rings, and install them onto the
piston; then insert the N-D accumulator piston, and
N-D accumulator front spring.
83U07B-288
7B—161
Page 1031 of 1865
INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring
Spring
Spring name Outer dia.
mm
(in) Free length
mm
(in) Wire dia.
mm (in)
Spring color
1-2 shift control spring 5.5 (0.217) 46.0 (1.811) 0.5 (0.020) Light green
1-2 shift spring 5.0 (0.197) 24.9 (0.980) 0.5 (0.020) Gray
2-3 shift spring 6.1 (0.240) 39.7 (1.563) 0.65 (0.026) Pink
3-4 shift spring 6.4 (0.252) 37.0 (1.457) 0.6 (0.024)
—
Throttle backup spring 6.4 (0.252) 33.5 (1.319) 0.6 (0.024) Pink
Throttle modulator front spring 5.0 (0.197) 27.8 (1.094) 0.6 (0.024) Red
Throttle modulator rear spring 7.15 (0.281) 30.8 (1.213) 0.85 (0.033) Red
1 rang control spring 6.15 (0.242) 39.2 (1.543) 0.65 (0.026) White
2 rang control spring 3.95 (0.156) 32.1 (1.264) 0.45 (0.018)
—
Kick-down spring 5.4 (0.213) 38.1 (1.500) 0.8 (0.031)
—
Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0,55 (0.022) Dark green
Throttle spring 5.4 (0.213) 48.3 (1.902) 0.8 (0.031)
—
Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0.9 (0.035) Maroon
Orifice check valve spring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
-
76G07B-220
Assembly
1. Install the throttle adjust plug, throttle assist spring,
throttle valve, throttle spring, and throttle plug as-
sembly.
83U07B-296
Caution
Install the throttle plug assembly with the
groove aligned with the bolt hole.
83U07B-297
7B—165
Page 1137 of 1865
ELECTRIC COMPONENTS 7C
76G07C-036
76G07C-037
76G07C-038
ELECTRIC COMPONENTS
INHIBITOR SWITCH
Inspection
1. Check that engine starts only at P and N range.
2. Check that the backup lights illuminate in R range
with the ignition switch ON.
3. If the inhibitor switch is not operating properly, dis-
connect it and check the continuity between the
terminals.
Connection guide
Position
N
D, 1, 2
Connector terminal
-O
O -O
-O
O—O: Indicates continuity
4. If not correct, replace the inhibitor switch.
KICK-DOWN SWITCH
Inspection of Terminal Voltage
1. Turn the ignition switch ON.
2. Check the voltage at terminal (V) with a voltmeter.
Depressing stroke Terminal voltage
7/8-8/8 (Full) Approx. 12 V
0-7/8 Below 1,5V
3. If not correct, check the wiring harness or switch,
or adjust the switch position.
Inspection of Switch
1. Disconnect the kick-down switch connector.
2. Check for continuity of the switch with an
ohmmeter.
Switch Continuity
Pushed Yes
Released No
3. If not correct, replace the kick-down switch.
83U07B-060
7C—23
Page 1150 of 1865
7C DISASSEMBLY
Procedure
Precaution
(1) Clean the transaxle exterior thoroughly with steam and/or cleaning solvents prior to disassembly.
(2) Disassemble the transaxle in a clean area (dustproof workspace) to prevent dust entry into the
mechanisms.
(3) Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART
during disassembly.
(4) Use plastic hammers when applying force to separate the light alloy case joints.
(5) Do not use rags during disassembly to prevent contamination.
(6) Neatly arrange the removed parts in order during disassembly.
76G07C-073
1. Remove the torque converter from the converter
housing.
Note
Do not allow the ATF to spill when removing
the torque converter.
83U07B-119
2. Pull out the oil pump shaft by hand.
3. Remove the turbine shaft.
76G07C-074
h
ii ii = J
4. Remove the clip from the turbine shaft.
Note
Do not reuse the clip.
76G07C-075
7C-36
Page 1158 of 1865
7C DISASSEMBLY
76G07C-096
76G07C-097
76G07C-098
10. Remove the servo.
(1) Compress the servo retainer with the SST.
(2) Remove the snap ring.
(3) Remove the servo retainer and return spring
from the transaxle case while loosing the SST.
11. Remove the bolts, and remove the transaxle case
by tapping lightly with a plastic hammer.
12. Remove the governor assembly.
(1) Remove the governor cover and gasket.
(2) Remove the governor assembly and gasket.
76G07C-099
7C—44
Page 1166 of 1865
7C DISASSEMBLY
76G07C-122
76G07C-123
76G07C-124
Procedure
1. Remove the side bearing housing installation bolts
from the transaxle case.
2. Remove the side bearing housing from the trans-
axle case by tapping lightly with a plastic hammer.
3. Remove the differential assembly.
4. Remove the bearing housing.
(1) Remove the bolt indicated in the figure (arrow).
(2) Remove the roll pin with a pin punch.
(3) Remove the bearing housing by tapping light-
ly with a plastic hammer.
76G07C-125
7C-52
Page 1289 of 1865
10
STEERING SYSTEM
OUTLINE 10— 2
STRUCTURAL VIEW 10— 2 SPECIFICATIONS 10— 6
TROUBLESHOOTING GUIDE 10— 7
MANUAL STEERING 10— 7
POWER STEERING 10— 8
4WS 10— 9
ON-VEHICLE MAINTENANCE 10— 10
STEERING WHEEL PLAY 10— 10
LOOSENESS OR PLAY OF THE
STEERING WHEEL 10— 10
STEERING WHEEL EFFORT 10— 10
POWER STEERING FLUID LEVEL 1 fl-11
LOOSE OR DAMAGED
OIL PUMP BELT IC— 12
REAR STEERING GEAR OIL 10— 12 LEAKAGE OF POWER STEERING
FLUID 10— 13
INSPECTION AND ADJUSTMENT. 10— 15
BLEEDING OF POWER STEERING
SYSTEM 10— 15
POWER STEERING PRESSURE ... 10— 16
TIE-ROD END BOOTS 10— 18
REMOVAL AND INSTALLATION .. 10— 18
STEERING WHEEL AND COLUMN 10— 21
STRUCTURAL VIEW 10— 21
REMOVAL 10— 22
DISASSEMBLY AND ASSEMBLY.. 10— 24
INSPECTION 10— 25
INSTALLATION 1 fl-27
STEERING GEAR AND LINKAGE .. IC— 28
STRUCTURAL VIEW 10— 28
REMOVAL 10— 29
INSTALLATION 10— 30
4-WHEEL STEERING GEAR AND
LINKAGE 10— 31
STRUCTURAL VIEW 10— 31 4WS PERFORMANCE INSPECTION 10— 32
ADJUSTMENT OF STEERING
ANGLE TRASFER SHAFT 10— 35
REMOVAL AND INSTALLATION .. 10— 37
INSPECTION 10— 44
MANUAL STEERING 10— 48
DISASSEMBLY 10— 48
INSPECTION 10— 51
ASSEMBLY 10— 52
ENGINE SPEED SENSING POWER
STEERING 10— 58
DISASSEMBLY 10— 58
INSPECTION 10— 62
ASSEMBLY 10— 64
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 75
DISASSEMBLY 10— 75
INSPECTION 10— 78
ASSEMBLY 10— 79
OIL PUMP 10— 83
REMOVAL AND INSTALLATION .. 10— 83
ELECTRICAL COMPONENTS OF
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 87
CIRCUIT DIAGRAM 10— 87
TROUBLESHOOTING GUIDE 10— 87
TROUBLESHOOTING 10— 87
ELECTRICAL COMPONENTS OF
4 WHEEL STEERING 10— 94
CIRCUIT DIAGRAM 10— 94
TROUBLESHOOTING GUIDE 10— 95
TROUBLESHOOTING 10— 95
4WS WARNING LIGHT 10—102
SPEED SENSOR (IN METER) 10—103
SPEED SENSOR (AT TRANSAXLE) 10—103
REAR-TO-FRONT STEERING
RATIO SENSOR 10—103
OIL LEVEL SWITCH
(IN P/S RESERVOIR) 10—103
RELAY AND TIMER 10—104 76G10X-001
Page 1296 of 1865
1 0 TROUBLESHOOTING GUIDE
POWER STEERING
Problem Possible cause Remedy Page
Hard steering
Loose
or
damaged belt Low fluid level,
or air in
fluid Leakage
of
fluid
Malfunctioning electrical system* Insufficient oil pump pressure Improperly adjusted wheel alignment Malfunctioning steering gear Linkage ball joint not operating smoothly
Adjust
or
replace Add fluid
or
bleed
air
Repair
or
replace Repair
or
replace Repair
or
replace Refer
to
Section
13
Repair
or
replace Replace
10—12 10-11 10-13 10-87 10-16
10—28,
37
10-18
Poor return
Insufficient tire pressure
Improperly adjusted wheel alignment
Ball-joint not operating smoothly
Steering shaft contacting something
Refer
to
Section
12
Refer
to
Section
13
Replace
Repair
10-20 10-21
Excessive play
Loose gear box housing mounting bolts Worn linkage
or
tie-rod ball joint Worn lower ball joint Worn
or
damaged steering joint Worn rack and pinion gear
Tighten Replace
Refer
to
Section
13
Replace
Replace
10—30
10—18
10—21
10-58,
75
Steering wheel
vibrates
Insufficient tire pressure Damaged
or
unbalanced wheel Improperly adjusted wheel alignment Loose gear box housing mounting bolts Incorrect pinion preload adjustment Worn ball joints
Loose shock absorber mounting Malfunctioning shock absorber
Refer
to
Section
12
Refer
to
Section
13
Refer
to
Section
13
Tighten Adjust
Replace Refer
to
Section
13
Refer
to
Section
13
10-30 10-72,
81
10—18
Steering wheel
pulls
Unevenly worn tires
Incorrect tire pressure
Dragging brake
Improperly adjusted wheel alignment
Refer
to
Section
12
Refer
to
Section
12
Refer
to
Section
11
Refer
to
Section
13 —
Excessively light
steering at high
speed*
Malfunctioning electrical system Repair
or
replace 10-87
*... Only
for
electronically
-
controlled type
76G10X-002
10—8
