Page 1 of 1701

AUTOMATICTRANSAXLE
SECTION
AT
CONTENTS
PREPARATION ANDPRECAUTIONS
3
Special Service Tools 3
Commercial ServiceTools 6
Service Notice 7
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 7
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 7
DESCRIPTION
8
Cross-sectional View 8
Hydraulic ControlCircuit 10
Shift Mechanism 14
Control System 15
TROUBLE DIAGNOSES 17
Preliminary Check(PriortoRoad Testing) 17
Road Testing 17
Stall Tasting 24
Pressure Testing 26
Wiring Diagram -AT - 28
Electrical Components Inspection 30
ON-VEHICLE SERVICE 31
Control ValveAssembly andAccumulator 31
Throttle WireAdjustment.. 33
Control CableInstallation andAdjustment 35
Governor Valve 36
Inhibitor SwitchAdjustment 37
Differential SideOilSeal Replacement.. 37
REMOVAL ANDINSTALLATION
39
Removal 39
Installation .40MAJOR
OVERHAUL.. 42
All Models 42
Except Model34X81 .44
Model 34X81 45•
Shift Control Components 46
i
Oil Channel 47
Locations ofAdjusting Shims,Needle
Bearings, ThrustWashers andSnap Rings -
Except Model34X81 .48
Locations ofAdjusting Shims,Needle
Bearings, ThrustWashers andSnap Rings -
Model 34X81 .49
DiSASSEMBLy 50
REPAIR FORCOMPONENT PARTS 66
Manual ShaftandThrottle Lever 66
Oil Pump 70
Control ValveAssembly 74
Control ValveUpper Body 86
Control ValveLower Body 90
Reverse Clutch 93
High Clutch 97
Forward ClutchandOverrun Clutch 102
Low &Reverse Brake 108
Rear Internal Gear,Forward ClutchHuband
Overrun ClutchHub 112
Output Shaft,Output Gear,IdlerGear,
Reduction PinionGearandBearing Retainer
- Except Model34X81 116
Output Shaft,IdlerGear, Reduction Pinion
Gear andBearing Retainer -Model 34X81 121
Band Servo Piston Assembly 126
Final Drive -Except Model34X81 131
Final Drive -Model 34X81 135
Page 19 of 1701

TROUBLEDIAGNOSES
Road Testing (Cont'd)
SHIFT SCHEDULE
Drive thevehicle forapprox. 10minutes. Measuretheoiltem-
perature. Whentheoiltemperature becomesbetween50and
80°C (122and176°F), carryoutthis check.
VEHICLE SPEEDWHENSHIFTING GEARS
Model 34X68
Throttle posi- Vehicle
speedkm/h(MPH)
tion
0,~O
2
O
2
->
0
3
0
3
->
0
4
0
4
~
0
3
0
3
->
O
2
O
2
->
0,
1
2
~
1,
Full throttle
48
-56 88
-96 133
-141
80-88 37-45 45-53
(30 -35) (55-60)
-
(83-88)
(50-55) (23-28) (28
-33)
Half throttle
31
-39 54
-62 102-110
75-83 44
-52
7-15 45
-53
(19 -24) (34
-39)
(63-68) (47
-52)
(27-32) (4
-9)
(28-33)
Model 34X69and34X70
Throttle pas
i-
Vehicle
speedkm/h(MPH)
tion
0,~O
2
O
2~
0
3
0
3
->
0
4
0
4~
0
3
0
3
->
O
2
O
2~
0,
1
2~
1,
Full throttle
51
-60 94
-102 136-144
85-93 40
-48
48-56
(32 -37) (58-63)
-
(85-89)
(53-58) (25
-30) (30-35)
Half throttle
30
-38 52
-60 97-105 67-75 42-50 8-16
48-56
(19 -24) (32-37) (60-65) (42-47) (26-31) (5-10) (30-35)
Model 34X80
Throttle posi- Vehicle
speedkm/h(MPH)
tion
0,~O
2
O
2
->
0
3
0
3~
0
4
0
4
->
0
3
0
3
~
O
2
O
2
->
0,
1"
->
1,
Full throttle
52
-60 100-108 145
-153
90-98 40
-48 49-57
(32 -37) (62-67)
-
(90-95) (56-61) (25-30) (30
-35)
Half throttle
30
-38 53-61 103
-111
69-77 42
-50 8-16 49-57
(19 -24) (33-38) (64-69) (43-48) (26-31) (5-10) (30-35)
Model 34X81
Throttle posi- Vehicle
speedkm/h(MPH)
tion
0,~O
2
O
2
->
0
3
0
3
~
0
4
0
4
->
0
3
0
3
->
O
2
O
2
~
0,
1
2~
1,
Full throttle
58
-66 107
-115 160
-168
96-104 39
-47 48-56
(36 -41) (66
-71)
-
(99-104) (60-65) (24
-29) (30
-35)
33 -41 57-65 105
-113 69-77 45-53 8-16 48-56
Half throttle
(21-25) (35-40)
(65-70) (43
-48) (28-33) (5-10) (30
-35)
AT-19
•
Page 24 of 1701
TROUBLEDIAGNOSES
Stall Tasting
STALL TESTPROCEDURE
1. Check
AIT
and engine fluidlevels. Ifnecessary, addfluid.
2. Drive vehicle forabout 10minutes untilengine oiland ATF
reach operating temperature.
ATF operating temperature:
50 -80
0
e (122-176°F)
SAT6478
3.Set parking brakeandblock wheels.
4. Install atachometer whereitcan beseen bydriver during
test.
SAT513G 5.
~ ~ID
•
~c;>
SAT7678
Start
engine, applyfootbrake, andplace selector leverin
"0"
position.
6. Accelerate towide-open throttlegradually whileapplying
foot brake.
7. Quickly notetheengine stallrevolution andimmediately
release throttle.
• During test,never holdthrottle wide-open formore than5
seconds. Stall revolution .standard:
Refer toSDS, AT-166.
SAT514G
8.Move selector leverto"N" position.
9. Cool offATF.
• Run engine atidle foratleast oneminute.
10. Repeat steps5through 9with selector leverin"2", "1"and
"R
n
positions.
SAT7718 AT-24
Page 26 of 1701
TROUBLEDIAGNOSES
Pressure Testing
• Location ofpressure testport.
• Always replace pressure plugsasthey areself-sealing
bolts.
Test portfor
line pressure governor
pressure
SAT565D
LINEPRESSURE TESTPROCEDURE
1. Check AfTand engine fluidlevels. Ifnecessary, addfluid.
2. Drive vehicle forabout 10minutes untilengine oiland ATF
reach operating temperature.
ATF operating temperature:
50 -80°C (122-176°F)
SAT647B
3.Install pressure gaugetoline pressure port.
4. Set parking brakeandblock wheels.
Continue todepress brakepedalfullywhile performing line
pressure testatstall speed.
SAT513G
5.Start engine andmeasure linepressure atidle and stall
speed. Line pressure:
Refer toSOS, AT-166.
JUDGEMENT OFLINE PRESSURE TEST
• Ifline pressure doesnotrise, firstcheck tomake surethat
throttle wireisconnected properly.
1) When linepressure whileidling
is
low atall positions ("D",
"2", "1", "R"and"P"), theproblem maybedue to:
SAT494G •
Wear oninterior ofoil pump
AT-26
Page 27 of 1701

'-)
(
~)o
Front
SAT498GTROUBLE
DIAGNOSES
Pressure Testing(Cont'd)
• Oilleakage ator around oilpump, control valvebody, trans-
mission caseorgovernor
• Sticking pressure regulator valve
• Sticking pressure modifiervalve
2) When linepressure whileidling islow ataparticular
position, checkthefollowing.
• Ifoil leaks ator around low
&
reverse brakecircuit, line
pressure becomes lowin"R" position. Butline pressure is
normal in"P", "D", "2"or"1" position.
3) When linepressure ishigh while idling, pressure regulator
valve mayhave stuck.
GOVERNOR PRESSURETESTING
1. Check
AIT
and engine fluidlevels. Ifnecessary, addfluid.
2 .. Drive vehicle forabout 10minutes untilengine oiland ATF
reach operating temperature.
ATF operating temperature:
50 -80°C (122-176°F)
3. Install pressure gaugetogovernor pressureport.
4. Set parking brakeandblock rearwheels.
5. Jack upfront wheels.
6. Set selector leverinDposition anddrive vehicle.
Be careful ofrotating wheels.
•
Governor pressure:
• Governor pressureisnot generated whenvehicle is
stopped. (frontwheels arenotrotating.)
• Governor pressurerisesgradually inresponse tovehicle
speed. (frontwheel rotating speed.)
If not, check governor valveassembly. RefertoAT-36.
AT-27
Page 37 of 1701
InhibitorSwitchAdjustment
1. Remove controlcableendfrom manual shaft.
2. Set manual shaftin"N" position.
3." Loosen inhibitor switchfixingbolts.
Use a4 mm (0.16 in)pin forthis adjustment. •
Insert thepinstraight intothemanual shaftadjustment hole.
Rotate inhibitor switchuntilthepincan also beinserted
straight intohole ininhibitor switch.
Tighten inhibitor switchfixingbolts.
Remove pinfrom adjustment holeafter adjusting inhibitor
switch.
Reinstall anypart removed.
Adjust control cable-Refer to"Control CableInstallation
and Adjustment", AT-35.
Check continuity ofinhibitor switch-Refer to"Electrical
Components Inspection",AT-30.
ON-VEHICLE
SERVICE
Governor Valve(Cont'd)
4. Remove governor valveassembly fromtransaxle.
5. Check governor valveassembly ifnecessary -Refer to
"DISASSEMBLY", AT-65.
4. a.b.
5.
6.
7.
8.
SAT580E 9.
Differential SideOilSeal Replacement
1. Remove driveshaftassemblies. -Refer toFA section
("Removal", "FRONTAXLE-Drive Shaft").
2. Remove oilseals.
AT-37
Page 50 of 1701
DISASSEMBLY
J!in plug
1.
Drain ATFthrough drainplug.
SAT007D
2.Remove torqueconverter.
3. Check torque converter one-wayclutchusingcheck toolas
shown atleft.
a. Insert checktoolintothegroove ofbearing supportbuiltinto
one-way clutchouterrace.
b. While fixingbearing supportwithcheck tool,rotate one-way
clutch spline usingflat-bladed screwdriver.
c. Check innerracerotates clockwise only.Ifnot, replace
torque converter assembly.
/
SAT009D
One-way
clutch
~:e2
/ I
;,cr~~ar~ /
-
~
/
Bend awire anduse
it as acheck tool.
.----:-
Approx. 3.0(0.118)
[Bend a1.5 (0.059) die..
wire Inhall.]
Outer race
g
....
Unit: mm(in)
..
2
:
Approx.
15 (0.59)
4.Remove oilcharging pipeandoilcooler tube.
SAT586H AT-50
Page 51 of 1701
SAT620EDISASSEMBL
Y
5. Set manual shaftto"P" position.
6. Remove inhibitorswitch.
Waste material
Oil
pan
SAT013D
7.
Remove oilpan andoilpan gasket.
• Donot reuse oilpan bolts.
8. Check foreign materials inoil pan tohelp determine cause•
of malfunction. Ifthe fluid isvery dark, smells burned, or
contains foreignparticles, thefrictional material(clutches,
band) mayneed replacement. Atacky filmthat willnotwipe
clean indicates varnishbuildup.Varnish cancause valves,
servo andclutches tostick andcaninhibit pumppressure.
• Iffrictional materialisdetected, replaceradiator afterrepair
of AlT. Refer toLC section ("Radiator", "ENGINECOOLING
SYSTEM").
SAT711D
9.
Remove controlvalveassembly according tothe following
procedures.
a. Remove controlvalveassembly mountingbolts@,
CID,
@
and @.
AT-51