Page 481 of 1413

NOTES
A.See flushing procedure, page l4-168 and 169.
B.Set idle rpm in gear to specitied idle speed. lf still no good, adiust motor mounts as outlined in engine
section of service manual.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the clutch pack is seized or is excessively worn, inspect the other clutches Jor wear, and check the
orifice control valves and throttle valves for free movement.
E.It throttle valve B is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed, the transmission will not upshift. lI stuck open, the transmission
has no lst gear.
H.lf the 2-3 orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressure control valve is stuck closed, the transmission will not shilt out of 1st gear.
K.improper alignment or main valve body and torque converter housing may cause oil pump seizure. The
symptoms ale mostly an rpm-related ticking noise or a high-pitched squeak.
L.ll the ATF strainer is ctogged with panicles of steel or aluminum, inspect the oil pump and ditferential
pinion shaft. lt both are OK and no cause lor the contamination is found, replace the torque converter.
M.lf the 1st clutch feedpipe guide in the right side cover is scored by the mainshaft, inspect the ball bear-
ing for excessive movement in the transmission housing. lf OK. replace the right side cover as it is dent-
ed. The O-ring under the guide is probably worn.
N.ReDlace the mainshstt if the bushing for the 4th feedpipe is loose or damaged.
It the 4th feedpipe is damaged or out ot tound, replace the right side cover'
Replace the subjshaft it thtbushing for the 1st-hold Jeedpipe is loose or damaged.
lf the 1st-hold feedpipe is damaged or out of round, replace it.
Replace the mainshaft if the bushing lor the 1st feedpipe is loose or damaged.
lf the lst feedpipe is damaged or out ot round, replace it.
o.A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse, such as rocking the car in snow.
P.InsDect the frame for collision damage.
o.Inspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamters of countershaft 4th and reverse gear.
3. Shift fork for scutt marks in center.
4. Differential Dinion shaJt for wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replace items 1 , 2, 3 and 4 it worn or damaged. lf transmission makes clicking, grinding or.whirring
noise, atso replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to
1,2,3ot4.lf ditiersntial Dinion shaft is worn, overhaul differential assembly, and replace ATF strainel, and thoroughly
clean transmission, tlush torque convertet, cooler and lines.
lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and tinal
driven gear.
R.Be wry careful not to dsmage the torque converter housing when replacing the main ballbearing. You
may al;o damage the oil pump when you torque down the main valve body. This will result in oil pump
seizure it not detected. Use proper tools.
qInstall the main seal tlush with the torque converter housing, lf you push it into the torque converter
housing until it bottoms out. it will block the oil return passage and result in damage.
T,Harsh do\/vnshiJt"\./l,'hen coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustment may clear this problem.
ifuitle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cable adjusted too long will result in throttle pressure being too low for the amount of engine torque
input into ihe trsnsmission and may cause clutch slippage. A cable adjusted too short will result in too
hi;h throttle pressure which may cause harsh shitts, erratic shrfts and torque con
14-89
Page 493 of 1413
1 2. Pry the right driveshaft out of the differential and pry
the lett driveshatt out of the intermediate shaft.
'13. Pull on the inboard joint and remove the right and
left driveshafts (see section 16).
'14. Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with
clean engine oil.
PLASTIC BAG
Disconnect the heated oxygen sensor (HO2S) con-
necror.
Remove the exhaust pipe A.16.
SELF-LOCKINGNUTReplace.
Replace.
14-101
17. Remove the intermediate shaft.
Remove the shift cable cover, then remove the shift
cable by removing the control lever.
CAUTION: Take care not to bend the shift control
cabls whilo removing it.
18.
SHIFT CABLE
LOCKWASHER CONTROLLEVERReplace.
(cont'dl
Page 498 of 1413

O) COUNTERSHAFT REVERSE GEAR COLLAR
@ NEEDLE BEARING
G) COUNTERSHAFT REVERSE GEAR
@ LOcK WASHER Reptace.
@ REVERSE sHIFT FoRK
@ BEVERSE SELECToR
O REVERSE SELECToR HUB
@ couNTERSHAFT 4TH GEAR
@ NEEDLE BEARING
@ DTSTANCE COLLAR, 29 mm Setecrive part.
@ coUNTERSHAFT 2ND GEAR
@ THRUST NEEDLE BEARING
@ GoUNTERSHAFT 3RD GEAR
@ NEEDLE BEARING
@ THRUST NEEDLE EEARING
G) COUNTERSHAFT 3RD GEAR COLI-AR
O 3RD cLuTcH ASSEMBLY
(!) O-RINGS Replace.
@ coUNTERSHAFT
@ REVERSE IDLER GEAR
@ SNAP RING
@ THRUST WASHER
@ THRUST NEEDLE BEARING
@ MAINSHAFT 4TH GEAR
@) NEEDLE BEARINGS
@ THRUST NEEDLE BEARING
@ MAINSHAFT 4TH GEAR coLLAR
@ 2ND/4TH cLUTcH ASSEMBLY
et O-RINGS Replace.
@ THRUST waSHER, 36.5 x 55 mm Setective pan.
@ THRUST NEEDLE EEARING
@ MA|NSHAFT 2ND GEAR
€, NEEDI.E BEARING
@ THRUST NEEDLE EEARING
.O MAINSHAFT
@ SEAL|NG RtNGs, 3s mm
@ SEAL|NG R|NG, 29 mm
@ NEEDLE BEARING
@ sET RING
@ 1ST-HOLD CLUTCH
@ O-RING Replace.
@ THRUST WASHER
@ THRUST NEEDLE BEARING
@ NEEDLE BEARING
@ SUB.SHAFT 4TH GEAR
@ THRUST NEEDLE BEARING
@ SUB.SHAFT 4TH GEAR COLLAR
@ SUB-SHAFT
@ SUB.SHAFT NEEDLE BEARING
@ NEEDLE BEARING SToPPER
@ otL GUTDE cAP Reptace.
@ REVERSE IDLER G€AR SIIAFT/HOLDER
@ NEEDLE BEARII{G
@ sHIFT GONTROL SOLENOID vAI.vE ASSEMBLY
PROTECTOR
@ sHrFT CONTROL SOLENOTD VALVE A/B
@ SHIFT CONTROL SOLENOID VALVE A/B FILTER/GASKET
Replace.
@ TRANSMISSION HANG€R
@ TRANSMtsstoN MouI{T BRAGKET
@ oll SEAL Replace.
@ sET RING Replace.
@ TRANSMISSION HOUSING GASKET Replace.
@ DOWEL PrN
@ SNAP RI G
@ SUB-SHAFT IRANSMtSStON HOUSNG AEARTNG
@ MAINSHAFT TRANSMISSION HOUSING BEARING
@ coUNTERSHAFT TRANSMISSION HOUSING BEARING
@ DIFFERENTIAL ASSEMELY
@ OtL SEAL Replace.
@ CoNNECTOR STAY
TOROUE SPECIFICATIONS
Rel No.Torque ValueBolt SizeRemarks
B
E
H
12 N.m (1.2 kgf.m,8.7 lbt.tt)
14 N.m (1 .4 kgf .m. 10 lbf .ft)
44 N.m (4.5 kgt.m, 33 lbf .ft)
64 N.m (6.5 kgf .m, 47 lbf .ft)
6 x 1.O mm
6 x 1.O mm'lO x 1.25 mm
12 x 1.25 mm
Special bolt
14-107
Page 548 of 1413
Transmission
12 x '1.25 fifi64 N.m {6.5 kgt'm,47 tbt'tr)
CONNECTOR STAY
Reassembly (cont'dl
TRANSMISSIONHANGER
TRANSMISSIONMOUNT BBACKET
MAINSHAFTSUB-ASSEMBLY
TRANSMISSION HOUSINGMOUNTING BOLTS, 18l0 x 1.25 mm
fl
44 N.m (4.5 kgl.m. 33 lbf.trl
TRANSMISSION HOUSING
T=
TRANSMISSION HOUSINGGASKETReplace.
REVERSE GEAR COLLAR
NEEOLE BEARING
REVEBSE GEAR
LOCK WASHERReplace.
SHIFT FORK
REVERSE SELECTORDOWEL PINS, 3
COUNTERSHAFTSUB.ASSEMBLY
DIFFERENTIALASSEMBLY
TOROUE CONVERTERHOUSING
14-158
Page 549 of 1413

18. Install the sub-shaft assembly in the transmission
housing {see page 14-138).
19- Install the reverse idler gear and gear shatt holder
(see page 14-154).
20. Install the differential assembly in the torque con-
verter housing.
21. Install the mainshaft and countershaft sub-assembly
together in the torque converter housing.
MAINSHAFTSUB.ASSEMBLY
COUNTERSHAFTSUB.ASSEMBLY
22.Turn the shift fork so the large chamtered hole is fac-
ing the fork bolr hole. then installthe shift fork with
the reverse selector and torque the lock bolt. Bend
the lock tab against the bolt head.
SHIFT FORK
LOCI( WASHERReplace.
6 x 1.0 mm4 N.m(1.4 kgl.m, rO lbt.ft)
Large chamfered holefaces this way.
,,1
24.
lnstall the reverse gear with the collar and needle
bearing on the countershalt.
Align the spring pin of the control shaft with the
transmission housing groove by turning the control
shalt.
Place the transmission housing on the torque con-
verter housing with a new gasket and the dowel pins.
CONTROL
/K"\
//2"\TRANSMISSION HOUSING
Install the transmission housing bolts along with the
t.ansmission hanger and the connector stay, then
torque the bolts in two or more steps in the sequence
shown.
TOROUE: 44 N.m (4.5 kgf.m, 33 lbf'ft)
TRANSMISSIONHANGER
25.
CONNECTOR
14-159
Page 556 of 1413

Transmission
Installation {cont'd)
14.
15.
Install new set rings on the end of the intermediate
shaft and the driveshaft.
Install the intermediate shaft.
SET RINGBeplace.
16.
10 x 139 N.m14.O kgf.m, 29 lbf.ftl
Install exhaust pipe A. and connect the heated oxv-gen sensor {HO2S) connector.
SELF-LOCKING NUT10 x 1.25 mm54 N.m (5.5 kgl.m,40 rbt.trlReplace.
GASKETReplace.
SELF.LOCKING NUTSI x 1.25 mm22 N.m 12.2 kgl'n,16 lbt.trlRepl6ce.
SHAFT
14-166
DAMPER PINCH BOLT10 x 1.25 mm43 N.m 14.4 kgf.m,32 tbr.ftl
1 7. Install the right and left drivershafts (see section l6l.
NOTE: Turn the right and left steering knuckle fullyoutward, and slide the right driveshaft into the
differential until you feel its spring clip engages theside geaf. Slide the left driveshaft into the intermedi-
ate shaft until you teel the spring clip of the inter-mediate shaft engage the driveshaft.
18. Install right damper fork, then install the right andlett balljoints to each lower arm with the castle nuts
and new cotter Dins.
\
COTTERReplace.CASTLE NUT12 x 1.25 mm49-59 N.m{5.O-6.0 ksf.m, 36-43
SELF.LOCKING NUT12 x 1 .25 mm64 N.m (6.5 kgl.h, 47 lbt.ftlReplace.
rbt'ft1
19. Install the splash shield.
6 x 10 mm BOLT
cltPs, 5
Page 567 of 1413
Differential
Manual Transmission
81881 engine
818C1 engine .......
Automatic Transmission ..................
15-1
15-9
15-19
Page 568 of 1413
Differential (81881 enginel
Speciaf Tools ........ ........15-2
Differential
lllustrated Index ......... . 15-3
Backlash Inspection .... 15-4
Final Driven Gear Replacement ...... 15-4
Bearing Replacement .................... 1 5-5
Oil Seal Removal ........ 15-5
Side Clearance Adiustment ........... 15-6
Oil Seal lnstallation ..... 15-8