Page 416 of 1680
Gearshift Mechanism
Overhaul
NOTE:
.Inspe(
.lnstall
a Turn t
. Make
Inspect rubber pans for wear and damage when disassembling; replace any worn or damaged pans.
Installthe spring pin and the clip on the change joint as shown.
Turn the shift rod boot so the hole is facing down as shown.
Make sure the shift rod boot is installed on the change rod.
\
tu
<:;s\-
-,-"Ye/
R€place.6x1.0mm9.8 N.m {1.0 kgl.m,7 lbt.ft)
liAru^
vll
o-FTNGS /Reptace. fREAR JOINT EUSHING
I x 1 .25 mm22 N.m {2.2 kgt m, 16 lbf.ft)
EXTENSIONMOUNTINGcusHtoN
6)\7\
EXTENSION ENDWASHER B
MOUNTINGCOLLAR
EXTENSIONMOUNTINGBRACKET
x 1.25 mm
SHIFT LEVERBALL SEAT
g sHrFr LEVERV-ousrssflg
@*3li.T'lib'l'
8x22mmSPBING PINRepl6ce.
I
t
SHIFT ROD
0 --..- "ttt
REAR JOINTCOLLARSHIFI ROD BOOT/
/rM
tllL#e
THRUST WASHER
@)*- sHtFr LEVER KNoB
(:// 7.8 N.m {0.8 ks{.m,6 lbf.ftl
SHIFT LEVEROUST SEAL A
EXTENSIONBOLT
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbtft)
/@
EXTENSION CNDBUSHING
ION ROD
-\
\
\EXTENS
ffi---4,
l'a13-51
Page 515 of 1680

Pressure Testing
a While testing, be careJulot the rotating front wheels.
a Make sule litts, iacks, and safety stands are placed
properly (see section 1).
CAUTION: Befoie testing, be sure the transmission fluid
is filled to the proper level.
'1. Raise the vehicle {see section 'll.
2. Warm up the engine (the radiator fan comes on),
then stop the engine and connect a tachometer.
3. Connect the special tool to each inspection hole(s).
TOROUE: 18 N.m l1-8 kgt.m, 13lbf.ftl
CAUTION: Connect the A/T pressure gauge secure-
ly, be sure not to allow dust and olher foreign pani-
cles to enter the inspection hole.
A/T PRESSURE GAUGESET W/PANEL07406 -0020400
A/T LOW PRESSUREGAUGE W/PANEI.07406-OO70300
A/T PRESSURE HOSE,2210 mmOTMAJ _PY4O1 1A{4 Required}
A/T PRESSURE HOSEADAPTER07MAJ -PY40120
l4 Requiredl
NOTE: Use the A/T Pressure Gauge Set (07406-
OO2O0O3) or A/T Low Pressure Gauge (07406-
OOTOOOO), and the A/T pressure gauge hoses and adap-
ters shown above.
4. Start the engine, and measure the respective pres
sures as follows.
a Line Pressure
a Clutch Pressure
a Clutch Low/High Pressure
a Throttle B Pressure
5. Install a new sealing washer and the sealing bolt in
the inspection hole and tighten to the specified
torque.
TOROUE:18 N.m (1.8 kgf.m, 13lbf.ft)
NOTE: Do not reuse old sealing washers; alwaysreplace washers.
Line Pressure Measurement
-1. Set the parking brake, and block both rear wheels
securely.
-2. Run the engine at 2,000 rpm
3. Shift to S or @ position.
4. lMeasure line pressure.
LINE PRESSUREINSPECTION HOLE
LOCK-UP CONTROLSOLENOID VALVEASSEMBLY
PRESSURESHIFT LEVER
POST ONSYMPTOMPROBABLE CAUSEFLUID PRESSURE
StandardService Limit
LineNo,BNo (or low)
Irne pressure
Torque converter,
ATF pump, pressure
regulator, torque
converter check
830 88o kPa
(8.5 9.O kgf/cm' ,
1 20 130 psi)
78O kPa(8.O kgf/cm' , 1 10 psi)
NOTE: Higher pressures may be indicated if measurements are made in shitt lever positions other than S or f, position.
{cont'd )
14-99
Page 516 of 1680

Pressure Testing
.Y
Clutch P.6ssure Measuremgnt
@ wnirc testing. be caretul ot the rorating tront wheels.
- 1. Set the parking brake, and block both rear wheels securely.- 2. Raise the front of the vehicle, and support it with safety stands.- 3. Allow the front wheels to rotate freelv.- 4. Run the engine at 2.000 rpm.- 5. Measure each clutch oressure.
LOCK"UP CONTROL SOLENOIDVALVE ASSEMBLY
lST-HOLD CLUTCHPRESSURE IiISPECTIONHOLE
4TH CLUTCH PRESSUREINSPECTION HOLE
1ST CLUTCH PRESSURE
INSPECTION HOLE
t
DRAIN P
l,i
PfiESSURESTIIFT LEV€RPOStTtONSYMPTOMPROAAALE CAUSEFLUID PRESSURE
S€rvico Limit
lst Clutch11 o' D;llst Clurch830 - 880 kPa(8.5 - 9.0 kgflcm,120 - 130 psi)
780 kPa(8.0 kgflcm,, 1 10 psi)
Clutch
zno cruiltr
1No or low lsr hold C utch
lr,2nd C ltch
2nd Clutch420 - 440 kPa14.3 - 4.9 kg?cm,,61 - 70 psi)throttle controldrumtully-closed8:|0 - 880 kPa18.5 - 9.0 kgflcm' ,120 - 130 psi)throttle controldrummore than 1/4 ooened
400 kPa(4.1 kg?cm,,58 psi)throttle control drum
780 kPa(8.0 kgflcm,, 110 psi)throttle controldrummore than 1/4 opened
3rd Clulch No or ow
I , !,q !le"**4th Clutch No or Low4th pressufe
3rd Clurch
a,r il","r,
Clulch
440 - 480 kPa(4.5 - 4.9 kgtcm,,64 - 70 psi)throttle control drumfully-closed830 - 880 kPa{8.5 - 9.0 ksf/cm' ,120 - 130 psi)throttle control drumrn9l9!q l/4 olqg
830 - 880 kPa(8.5 - 9.0 kgtcm?,120 - 130 psi)
400 kPa14.1 kgvcm,,58 psi)throttle control drumfully-closed780 kPa(8.0 kgflcm' , 110 psi)throttle control drummore th6n 1/4 opened
zeo rpi(8.0 kgtcm' , 110 Psa,
14-100
I
Page 523 of 1680

u19.Remove the right front mount/bracket, then remove
the end of the throltle control cable from the throt-
tle control drum.
Remove the ATF cooler hoses at the ATF cooler
lines. Turn the ends of the cooler hoses up to pre-
vent ATF from flowing out, then plug the ATF cooler
lines.
NOTE: Check for any sign ol leakage at the hosejornrs.
THROTTLE CONTROL CABLE
20.
f
RIGHT FRONT MOUNT/BRACKET
21. Remove the engine stiftener and torque converter
cover,
22. Remove the eight drive plate bolts one at a time whilerotating the crankshaft pulley.
EOLTS ATF COOLERReplace. HOSES
ENGINESTIFFENERCOVERTRA
14-107
23. Place a jack under the transmission. raise the trans-mission just enough to take weight off of the
mounts, then remove the transmtssion mount.
TRANSMISSION MOUNT
24. Remove the transmission housing mounting bolts
and rear engine mounting bolts.
25. Pull the transmission away trom the engine until itclears the 14 mm dowel pins, then lower it on thetransmission jack.
REAR ENGINEMOUNTING BOLTSReplace.
WASHERS
MISSION JACK\NS
Page 583 of 1680

Transmission
lnstallation
Flush the ATF cooler as described on pages 14-172
thru 173.
lnstall the starter motor on the transmission hous-
ing, then install the two 14 mm dowel pins in the
torque convener housing. Install the torque conven-
er assembly securely with a new O-ring on the
mainshalt.45 N.m (4.5
33 lbJ.ft)STARTER
14 mm DOWEL PIN
mm DOWEL PIN
CONVERTERReplace.
3. Place the transmission on a transmission jack, and
raise it to the engine level.
4. Attach the transmission to the engine, then install
the transmission housing mounting bolts and two
rear engine mounting bolts with new washers.
TRANSMISSION HOUSINGMOUNNNG BOLTS12 x 1 ,25 mm64 N.m (6.5 kgf.m, 47 lbf.ftl
REAR ENGINEMOUNT BOLTS14 x 1.5 mm118 N.m 112.0 kgl.m86.8 rb{.tr)
WASHEFS
14-168
5. Install th€ transmission mount.
6. Instsll the transmission
12 x 1.26 mm64 N.m 16.5 kgt.m,47 lbf.ftl
74 t{'m {7.5 kgt'm,
54 rbl.ftl
housing mounting bolts.
MOUNNNG SOLTS12 r 1.25 mm6,t N.m 16.5 kgl.rn, 47 lbf"ftl
TRANSMISSON HOUSING
Page 619 of 1680

Operational Check
Set the parking brake and block the rear wheels.
Raise the front of the vehicle, and support it with
safety stands in the proper locations (see section 1).
With the engine off, shift the transmission into lstgear,
Rotate either front wheel bv hand and check that
the other wheel rotates in the opposite direction.
lf the opposite tront wheel does not rotste, or if voucannot spin the front wheels at all, the limited slip
differential is faulty and should be roplaced.
Rotating Torque Check
Setting parking brake and block the rear wheels.
Raise the front of the vehicle, and support it with
safety stands in proper locations (see section 1).
With the engine off, shift the transmission into
Neutral.
Measure the rotating torque with a beam-type
torquo wrench in the direction shown, Rotate the
torque wrench morg than two complete turns and
take the maximum reading.
Shift the transmission into 1st gear and measure
the rotating torque again.
Calculate the rotating torque:
Service Limit:
Measur€ment from steD 5
Measurementfrom step 4 =--
For example:
7.8 N.m (0.8 kgf.m)
zg N"ll (03 kgf'ntl = z'ot > z''
Repeat step 3 through 6 for the other wheel.
Replace the limited slip differential assembly if the
rotsting lorque is lower than the service limit.
!
15-23
Page 690 of 1680

Power Steering Gearbox
Removal (cont'd)
Remove the cotter pin from the ball joint pin and
remove the nut.
Install the 10 mm hex nut on the ball ioint.
Be sure that the 10 mm hex nut is flush with the ball
joint pin end, or the threaded section of the ball
joint pin might be damaged by the ball joint re-
mover.
NOTE: Remove the ball joint using the special tool.
Refer to section 18 for the ball joint remover usage
instructions.
Separate the tie-rod ball ioint and knuckle using the
special tool.
CAUTION: Avoid damaging th. ball ioint boot.
t{ePrace. BALL JOINT REMOVER,23 mm07MAC - SL0020o
10. Disconnect the shift linkage (M/T model: see section
13, A,/T model: see section 14).
11. Disconnect the secondary heated oxygen sensor
(H02Sl connector, and separate the three way cat-
alytic convener by removing the self-locking nuts.
NOTE: Always replace the gaskets with new ones.
SECONDARy HEATED OXycEN SENSOR SELF-LOCKING NUT
17 -42
Replace.CATAI.YTIC CONVERTER
12.
13.
Remove the return line clamp from the left side of
the rear beam, and move the return line above the
steering gearbox.
Remove the rear beam brace rod.
Remove the left tie-rod end. then slide the rack all
the way to the ri9ht.
14.
RETURN LINE CLAMP
LEFT NE-ROD END
Page 691 of 1680
15. Disconnect the two lines from the valve bodv unit
on the steering gearbox.
CAUTION: After disconnscting the hose and line,plug or seal the hose and lino whh I pi6ce ot tape
o. oquivalent to prevont foreign matarials from
6rioring the vslve body unit,
NOTE:
. Place the line disconnected in the previous steD
at the rear side of the gearbox so that they do
not hinder in the gearbox removal.
. Do not loosen the cylinder lines A and B between
the valve body unit 8nd cvlinoer.
ADJUSTABLE HOSE CLAMP
Remove the steering gearbox mounting bolts.16.
\
RETURN HOSE
GEARBOX MOUNTING BOTTS
17-43
't7.
19.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead, and remove thepinion shaft grommet.
Move the steering gearbox to the right so th€ left
rack end clears the rear beam.
Mov€ the steering gearbox to the loft, and tilt theleft side down to remove it from the vehicle.
PINION SHAFT GBOMMET
STEERING GEARBOX