This signals the ECM when the brake pedal is depressed
Inspeclion ot Brake Switch Signal.
Are the brake lights on withoutdepressing the brake pedal?
lnspect the HoRN STOP (20 Aifuse in the under-hood fuse/ relaybox,Do the brake lights come on?
Repair shori in the wire b€-
tween the brake switch and
the HoRN STOP {20 Al fuse.Replace tha HORN STOP (20 AlIus€.
Repair open in the wire be-tween the brtke switch andtho HORN STOP {20 Al tuse.
Inspect the brake switch {seesection 23).Check tor an open in the wire
{BKSW line):1- Depress the brake pedal.
2. Measure voltage between ECMconnector terminals D5 and Agwith the brake pedal depressed.
Repair open io th6 wiae batweonthe EcM lDs) rnd the brakeswitch.
Brake switch signal is OK.
ldle ControlSystem
Brake SwitchSignal
L
L
A {32P}LGl{BRN/BLX}
D {16P)
Wrre side of female terminals
I
ldle Speed Setting
IDLEADJUSTINGSCREW
7.
6.Turn the ignition switch OFF.
Reconnect the 2P connectors to the IAC valve and
the EVAP purge control solenoid valve, then do the
ECM reset procedures.
Restart and idle the engine with no-load conditions
for one minute, then check the idle speed.
NOTE: (Canada) Pullthe parking brake lever up.
Start the engine, then check that the headlights are off.
ldle speed should be;
Bl88l €ngine:
Mfi750 i 50 rpm
A/T750150 rpm (in Park or neutral)
818C1 engine:750 i 50 rpm
818C5 engine: 800 i 50 rpm
NOTE: 81881, Bl8Cl engines - It the idle speed
increases to *1rpm, this means the EVAP system ispurging the canister. To stop the purging termporarily.
raise the engine speed above 1,000 rpm with the
accelerator pedal, then slowly release the pedal.
*1: 81881 engine
M/T: 820 i 50 rpm
Ay'T: 840 t 50 rpm
818Cl engine
850 I 50 rpm
(cont'd)
Inspection/Adiustmont
NOTE:
. When setting the idle speed, checkthe following items:- The MIL has not been reported on.- lgnition timing
Spark plugs- Air cleaner- PCV system
. (Canada) Pull the parking brake lever up. Start the
engine, then check that the headlights are off.
1. Start the engine. Hold the engine at 3,000 rpm with
no load (in Park or neutral) until the radiator fan
comes on, then let it idle,
Connect a tachometer.
Disconnect the 2P connectors from the ldle Air
Control (lAC) valve and the EVAP purge control
solenoid valve.
2.
5.
if the engine stalls, restan the engine with the accel
erator pedal slightly depressed. Stabilize the rpm at
1,000, then slowly release the pedal until the engine
idles.
Check idling in no-load conditions: headlights, blower
fan, rear defogger, radiator fan, and air conditioner
are not ope€tlng.
ldlo speed should be;
B188l engine:
Mlf480 :l 50 rpm
A/T480 i 50 rpm (in Park or neutral)
B18C1 engine: /t80 t 50 rpm
818C5 sngine:550 t 50 rpm
lf necessary, adjust the idle speed, by turning theidle adjusting screw.
After adjusting the idle speed, recheck the ignition
timing {see section 23). lf it is out of spec, go back
to steo 4.
t"iI
Emission Gontrol System
System Description
Three Way Catalytic Converter (TWCI
\
t
The emission control system includes a Three Way
Catalytic Converter (TWC), Positive Crankcase Ventilation
(PCV) system and Evaporative Emission (EVAP) Control
system. The emission control system is designed to meet
tederal and state emission standards.
InsDeciion
!@@ Do not smoke during this procedure. Keep
any open llame away from your work area.
1. Start the engine. Hold the engine at 3,000 rpm with
no load {in Park or neutral) until the radiator fan
comes on, then let it idle.
2. Connect a tachometer.
Check and adjust the idle speed, if necessary (see
page '11-11 ! ).
Warm up and calibrate the CO meter according to the
meter manufacturer's instructions.
Check idle CO with rhe headlights, heater blower,
rear window defogger, cooling fan, and air condition-
er off.
NOTE: {Canada) Pull the parking brake lever up.
Start the engine, then check that the headlights are
olf.
CO meter should indicste 0.17o maximum.
DescriDtion
The Three Way Catalytic Converter {TWC) is used to convert hydrocarbons (HC), carbon monoxide (CO), and oxides of
nitrogen (NOx) in the exhaust gas, to carbon dioxide (COr), dinitrogen {Nr) and water vapor.
Bl8Cl engine l818Bl, 818C5 engines is similar):
FRONT OFVEHICLE
PRIMAEYHEATEDOXYGEN SENSORIPRIMARY HO2S}
HOUSING
WAYCATALYSTS
SECONOARYHEATEDOXYGEN SENSOR{SECONDARYH02St
\
Emission Control System
Check the vacuum when hot:1. Turn the ignition switch OFF.2. Block the rear wheels and setthe parking brake.3. Jack up the front of the vehi-cle and support it with safetystands.4- Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutral) untilthe radiator fan comes on, thenlet it idle.5. Check for vacuum at the vacuum hose with transmissionin gear (A/T in E position,M/T in 'l st gear) after startingrne engrne.6. Ouickly raise the engine speedto 3,000 rpm.
Evaporative Emission (EVAP) Controls (cont'd)
(From page 1'l 147)Check the EVAP purge controlsolenoid valve:1. Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve.2. Ouickly raise the engine speedto 3,000 rpm.
{To page 11 149)
tfl'I
Check lor a short in the wire{PCS line}l1. Turn the ignition switch OFF.2. Disconnect ECM connector A(32P).
3. Check for continuity betweenthe EVAP purge control solenoid valve 2P connector termi-nal No. 2 (818C5 engine: No. 1)and body ground.
Check for an open in the wire llclline):1. Turn the ignition switch OFF.2, Disconnect the 2P connectorfrom the EVAP purge controlsolenoid valve.3. Turn the ignition switch ON (ll).
4. At the harness side, measurevo ltage between the EVAPpurge controlsolenoid valve 2Pco n nector terminal No. 1( B 18C5 engine: No. 2) andbody ground.
EVAP PURGE CONTROI SOLENOIDVALVE 2P CONNECTOR IC114)B18C1, Cl8Bl engines: 818C5 engine:
PCSIRED/YEL}
femaleWire side offemaleterminals
YES
IGPl{YEL/BLKI
IGPlIYEL/BLKI
ECM CONNECTOR A {32PIPG1IBLKI
Insp€ct vacuum hose routing.lf OK, replace the EVAP purge
control solenoid valve.
neDair short in the wire betweenthe EVAP purge control solenoidvalve and the ECM lAl5).
Substitute a known-90od ECMand recheck. lI symptom/indica-tion goes away, replace the origi-nal ECM.
Repair open in the wirc betweenEVAP purge control solenoidvalve and PGM-FI main relav fuse.ls there battery voltage?
Check for an open in the wireIPCS linel:1. Turn the ignition switch OFF.2. Reconnect the 2P connector tothe EVAP purge control sole'noid valve.3. Turn the ignition switch ON (ll).
4. Measure voltage betweenECM connector terminals A15and A10.
Bopair open in the wiro betweenthe EVAP purgo control 3olanoidvalvo and the EcM {415).
11-144
(To page 11-149)
CAUTION:
a Do not 3pill brakefluid on the vehicle; it may damege
th€ paid; if brake fluid do63 contact th€ paint. wa3h
it otf immediately with water.
a Plug the end of the clutch pipe and reservoir hose with
a shop towel to prevent brake fluid from coming out.
1. Remove the brake fluid trom the clutch master
cylinder reservoir with a syringe,
2. Disconnect the clutch pipe and reservoir hose from
the clutch master cylinder.
Remove the clutch master cylinder.
NOTE: Do not spill braketluid ontheclutch master
cylinder damper.
CLUTCH PIPE15 N.m {1 .5 kgf'm,11 lbt.Ir)
5.
cLulcHMASTERCYLINDER
Install the clutch master cylinder in the reverse or-
der of removal.
NOTE: Bleed the clutch hydraulic system {see page
I z-ol.cturcHMASTERCYLINDER
Pry out the cotter pin, and pull the pedal pin out of
the yoke. Remove the nuts.
NUTS13 N.m {1.3 kgt.m,9 rbf.ftl
PEOAL PIN
-6rl(P/N 08798-90021
Clutch Master Cylinder
Removal/lnstallation
2-5
T
fi
;ill
Slave Cylinder
Removal/lnstallation
CAUTION:
a Do not spill brakelluid onthe vehicle; it may dameg€
the paint; if brake fluid does coniaqt the paint, wash
it otf immodiaioly wilh w8ter.
a Plug the end of the clutch pipe with a shop towel to
prevent brake fluid from coming out.
-6|1, Super High Temp Urea Grease (P/N
4==? 08798- 9OO2).-='aii^5Fi: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch pipe from the slave cylinder.
2. Remove the slave cylinder from the clutch housing.
12-6
-Gl
lP/N 08798
Install the slave cylinder in the reverse order of
removal.
NOTE: Make sure the boot is installed on the slave
.wlin.larCLUTCH PIPE15 N.m 11.5 kgt.m, 11 lbf.ttl
SLAVE CYLINDER
*9002t
I x 1.25 rnm22 N.m 12.2 kgl.m,16 lbl.lt)
.'....-..-:::-9!!!!!i
{Brake Assembly '
Lube)
Bleed the clutch hydraulic system.
a Attach a hose to the bleeder screw, and suspend
the hose in a container ot brake fluid.
a lvlake sure there is an adequate supply ot fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
a Refill the clutch master cylinder with fluid when
done.
a Use only DOT 3 or 4 brake tluid.
We recommend Genuine Honda Super Duty
DOT 3.
a Confirm clutch operation. and check for leaking
fluid.
Transmission Assembly
Removal
r@i Make surs iacks and safety stands sro placod propor-
ly (3ee s€ction 1).
. Apply parking brake and block resr whaeb 30 vohicle
will not roll off stands and hll on You whil6 working
under it.
CAUTION: Use fender covers to svoid damaging
paintod surtacos.
1. Disconnect the negative (-) cable from the battery,
then the positive {+) cable.
2. Remove the intake 8ir duct and the air cleaner hous-
ing assembly,
AIR CLEANERHOUSINGASSEMBL
Disconnect the back-up light switch connector and
the transmission ground wire.
BACK.UP LIGHTSWITCH CONNECTOR
TRANSMISSIONTRANSMISSIO
GROUND WIRE HANGEB B
4. Remove tne lowei radiator hose"clamp from the
transmission hsnger B.
INTAKE AIR DUCT
13-4
\-
5. Remove the wire hsrness clamps.
VSS CONNECTOR
Disconnect the starter motor cables and the vehicle
speed sensor (VSS) connector.
Remove the clutch pipe bracket and the slave cylin-
der.
NOT€: Do not operate the clutch pedsl once the
slave cvlinder has been removed.
7.
Automatic Transmission
Special Tools ................ '14-2
Descraption .................... 14-3
Clutches ............ ...... 14-6
Power Flow ..,........... 14-8
Electronic Control System ..................... 1 4-1 8
Hydraulic Control ...... 14-23
Hydraulic Flow .........- 14-28
Lock-up System ........ 14-38
Electrical System
Component Location -................................ 1 4-45
Circuit Diagram ............. 14-46
TCM Terminal Voltage/
Measuring Conditions ......,.................... 1 4-48
Troubleshooting Procedures .. . ... ........ ...... ... 14-50
Symptom-to-Component Chart
Electrical System ...... 14-54
Electrical Troubleshooting
Troubleshooting Flowcharts .......... ... ...,.. 14-56
Lock-up Control Solenoid Valve A/B Assembly
Test .................. ...... 14-A7
Replacement ............. 14-a7
Shilt Control Solenoid Valve A/B Assembly
Test .................. ...... '14-88
Replacement .,..,........ 14-88
lvlainshaf t/Countershaft Speed Sensors
Replacement ....-......,. 14-89
Transmission Control Module (TCM)
Replacement ............. 14-89
Hydraulic System
Symptom-to-Component Chart
Hydraulic System ...... 14-90
Road Test ,................... 14-94
Stall Speed
Test .................. ...... 14-97
Fluid Level
Checking/Changing .... 14-98
Pressure Testing ........... 14-99
Transmission
Transmission
Removal ............. ...... 14-10 4
lllustrated lndex
Transmission/Right Side Cover ............... 1 4-1 08
Transmission Housin9 ................,..,....... 1 4-1'1 O
Torque Converter Housing/ValveBody .................. .. 14-112
Right Side Cover
Removal ............. ...... 14-114
Transmission Housing
Removal ............. ...... 14-1 l6
Torque Converter Housing/Valve Body
Removal ............. ...... l4-1 18
Valve Caps
Description ...........-... 14-120
Valve Body
Repair ................ ...... 14-12'l
Valve
Assembly
ATF Pump
Inspeclton
Main Valve Body
Disassembly/lnspection/Reassembly
Regulator Valve Body
Disassembly/lnspection/Reassembly
Lock-up Valve Body
Disassembly/lnspection/Reassembly
Secondary Valve Body
Disassembly/lnspection/Reassembly
Servo Body
....... 14-124
....... 14-126
....... 14-127
....... 14 124
Disassembly/lnspection/Reassembly .......
1st-hold Accumulator/Right Side Cover
Disassembly/lnspection/Reassembly .......
Mainsha{t
14-130
14-132
Disassembly/lnspection/Reassembly ....... 14-133
Inspection ................. 14-134
Countershaft
Disassembly/lnspection/Reassembly,..,.., l4-136
Disassembly/Reassembly ..,...,..,.........,,.. 1 4-1 37
Inspection ......,...,..,... 14-138
One-way Clutch
Disassembly/lnspection/Reassembly ....,.. 14-141
Sub-shaft
Disassembly/lnspection/Reassembly ...,,..'14-142
Disassembly/Reassembly ....................... 1 4- l 43
Sub-shaft Bearings
Replacement ,..,,.,,..,.. 14-144
Clutch
lllustrated Index ................................... I 4-1 45
Disassembly ............. 14-144
Reassembly .............. 14-150
Torque Converter Housing Bearings
Mainshaft Bearing/Oil Seal
Replacement ......... 14-154
Countershaft Bearing Replacement ......... 1 4- 1 55
Transmission Housing Bearings
Mainshaft/Countershaft BearingReplacement ......,.. 14-'156
Sub-shaft Bearing Replacement .,............ 1 4-1 57
Reverse ldler Gear
Installation .........-..... 14-158
Parking Brake Stop
Inspection/Adjustment .......................... 1 4-1 58
Transmission
Reassembly .............. 14-160
Torque Converler/Drive Plate ..............,.,,.,, 1 4-1 67
Transmission
Installation ............... 14-168
Cooler Flushing ......... 14-172
ATF Cooler Hoses
Connection ,..,,,....,,.,, '14-'174
*shift cable
Removal/lnstallation . . .. .... ... .... ... .... .. . ... .. 14-'l75
Adjustment ,..,...,,,,.,, 14-'116*Shilt lever
Disassembly/Reassembly ....................... 1 4-'17 7'Shift Indicator Panel
Adjustment .............. 14-178
\l
)g