Page 706 of 1395
Torque Converter Housing/Valve Body
Removal
NOTE:
. The illustration shows the 4WD automatic transmission; the 2WD is similar.' cleanall parts thoroughry in sorvent or carburetor creaner, and drythem with compressed air.. Blow out all passages.
. When removing the valve bodies, replace the following:- Lock washer- O-ringATF FEED PIPESERVO DETENTBASE137 - 98 models only)
DOWEL PIN
LOCK.UP VALVEBOOY
6x1.0mm'97 - 98 models:2 Bolts'99 - 00 modeb: 1 Bolt
LOCK.UP SEPARAPLATE
REGULAIOR VALVEBOOY
ATFSTRAINER
DOWEL PIN
COOLER RELIEF VALVE
6x1.0mm37 - 98 models:7 Bolts'gg - 0O models:8 Bolts
SERVO BODY137 - 98 modelsl
SERVOSEPARATORPLATE
TOROUE CONVERTERCHECK VALVE
STATOR SHAFT
O.RING
5x1.0mfi3 Bolts
SECONDARYVALVE BODY
MAIN VALVE BODY
6x 1.05 Bolts
ATF PUMP ORIVENGEAR SHAFT
DOWEL PIN
ATF PUMP DRIVENGEAR
\
CONTROL LEVERMOUNTING BOLT{awD)
SECONDARYSEPARATORPLATE
14-190
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Page 707 of 1395
1.Remove the control lever mounting bolt trom the
torque converter side of the torque converter hous-
ing. (4WD)
Remove the ATF feed pipes from the servo body,
secondary valve body, lock-up valve body, and main
valve body.
For '97 - 98 models:
Remove the two bolts securing the ATF strainer and
servo detent base, then remove the strainer and the
base.
For'99 - 00 models;
Remove the ATF strainer {one bolt).
4. For'97 - 98 models:
Remove the seven bolts securing the servo body,
then remove the servo body and separator plate'
For'99 - 00 models:
Remove the eight bolts securing the servo body,
then remove the servo body and separator plate'
5. Bemove the three bolts securing the secondary
valve body, then remove the secondary valve body'
stop shaft bracket, and separator plate.
6. Remove the eight bolts securing the ATF lubrication
plate and lock-up valve body, then remove the ATF
lubrication plate, lock-up valve body' and separator
plate.
7. Remove the one bolt securing the regulator valve
body, then remove the regulator valve body'
8. Remove the stator shaft and stop shaft.
9. Remove the detent spring from the detent arm, then
remove the control shaft from the torque converter
houslng.
10. Remove the detent arm and detent arm shaft from
the main valve body.
11. Remove the five bolts securing the main valve
body, then remove the main valve body.
When removing the main valve body, do not let the
eight check balls fall out.
12. Remove the ATF pump driven gear shaft, then
remove the ATF PumP gears.
13. Remove the main separator plate with two dowel
prns.
14, Clean the inlet opening of the ATF strainer thor-
oughly with compressed air, then check that it is in
good condition, and the inlet opening is not clogged
or damaged.
15.
INLET OPENING
Test the ATF strainer by pouring clean ATF through
the inlet opening, and replace it if it is clogged or
damaged.
14-191
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Page 714 of 1395
Secondary Valve Body
Disassembly/lnspection/Reassembly
NOTE:
' clean all parts thoroughly in solvent or carburetor cleaner. and dry them with compressed air. Blow out aU passages,. Replace the valve body as an assembly if any parts are worn or damaged.t check all valves for free movement. rf anyfair to sride freery. see varve Body Repair on page 14-192.. Coat all parts with ATF during reassembly.. The CPC valve is installed in the secondary valve body, held in place by the lock bolt.
@,.-.t'tr.,
,rr'^'//u
"/ ./
3-' SHIFT VALVE
VALVE CAP
SPRING SPEC!FICATIONS
2.3 SHIFT VALVE
VALVE SLEEVE
ROLLER
ilTH EXHAUST VALVE
N"*,"o"*,
Unit: mm (in)
t*-1
SECONOARY VALVE BODYInspect for wear, scratches, andscorang.
3.4 ORIFICE CONTROL VAL
No.SpringsStandald {Nswl
Wire Dia.o.D.Free LengthNo. of Coils
o
@
o
@
3 4 shift valve spring
2-3 shift valve spring
4th exhaust valve spring
3-4 orifice control valve spring
0.9 (0.035)
0.9 (0.035)
0.9 {0.035)
0.6 {0.024}
7.6 (0.299)
7.6 (0.299)
6.1 (0.240t
6.6 (0.2601
57 .O i.2.2441
57 .O 12.244J
36.4 (1.433)
37.9 (1.492)
26.A
26.8
19.5
31.6
14-198
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Page 715 of 1395
Regulator Valve Body
Disassembly/lnspection/Reassembly
NOTE:
o Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with com-
pressed air. Blow out all passages.
. Replace the valve body as an assembly if any parts are worn or damaged.
. Checkall valvesforfree movement. lf anyfail toslidefreely, see Valve Body Repair on page l4-192.
'1. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded Once
the stop bolt is removed, release the spring cap slowly so it does not pop out.
2. Reassembly is the reverse order of disassembly.
NOTE:
. Coat all parts with ATF during reassembly.
. Align the hole in the regulator spring cap with the hole in the valve body, thenpress the spring cap into the valve
REGULATOR SPSING CAPbody, and tighten the stop bolt.
STOP BOLT6x1.0mm12 N.m 11.28.? tbt.fil
REGULATOR VALVE BODYlnspect for wear, scratches,ano scoflng.
REGULATOR VALVE
No,SpringsStandard {New}
wire Dia.o.D.F ee LengthNo. ot Coils
o
@
@,6
a,
Regulator valve spring A
Regulator valve spring B
Stator reaction spring
Cooler relief valve spring
Torque converter check valve spring'97 Model'98 - 00 Models
Lock-up control valve spring
1.8 (0.071)
1.8 (0.071)
4.5 (0.177)
1.0 {0.039)
1.1 (0.043)
1.2lO.O47l
0.7 t0.028)
14.7 (0.579)
9.6 (0.378)
35.4 (1.394)
8.4 {0.331)
8.4 (0.331)
8.4 (0.331)
6.6 (0.260)
87.8 (3.457)
44.0 t1.7321
30.3 (1.193)
33.8 (1.331)
36.4 (1.433)
32.4 11.2761
38.0 (1.496)
'11.0
1.9
't2.0
12.7
14.'l
14-199
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Page 732 of 1395
Clutch
Disassembly
l. Remove the snap ring, then remove the clutch endplate, clutch discs and plates.
SCREWORIVER
SNAP RING
2. Remove the disc spring.
1ST, 2ND, 4TH lST-HOLD CLUTCH:
CLUTCH DBUM
3RD CLUTCH:
-'=*.=:--
'..p
Remove the disc spring.
DISC SPRING
DISC SPRING
14-216
3. Install the special tools as shown.
CLUTCHCOMPRESSORAOLT ASSEMBLY07GAE - FGao2OO orOTGAE . PG4O2OA
CLUTCH SPNINGCOMPRESSORATTACHMENT07LAE - PX40100
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX4010O or07HAE - PL50100
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40t00
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX4010O or07HAE - PL50100
CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLY07GAE - PG0200 orOTGAE - PG4O2OA
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Page 735 of 1395
5. Install the specialtools as shown
CLUTCH SPRINGCOMPRESSORBOLT ASSEMALY07GAE - PG{0200 orOTGAE - PG|(IMA
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100 orO?HAE - PL5O1OO
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PXaOI 0o
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX4010O ol07HAE - PL50100CLUTCH SPRINGCOMPBESSORAOL| ASSEMALY07GAE - PG/9t200 otOTGAE - PG/(,20A
CAUTION: It sither end of the spscial tool is sot
over an area of the spring retain€l which is unsup'
ported by the return spring, the retainer may be
damaged. Be sure the special tool is adiusted to
have full contaqt with th€ spring ratainel.
Set here.
SPECIAL TOOL
SPRING RETAINER
6. Compress the return spring.
(cont'd)
Do not set here.
14-219
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Page 740 of 1395
Differential
Differential Carrier Replacement
NOTE: The illustration shows the 4WD automatic trans-mission differential; the 2WD differential is similar.
1. Remove the snap ring from the differential carrier.
Remove the 5 x 15 mm roller (4WD) or 5 x 10 mmroller (2WDl and the speedometer drive gear.
SPEEDOMETER DRIVE GEAR RoI I FP
Remove the bolts securing the final driven gear andthe transfer shaft drive gear (4WD), then replace thedifferential carrier.
5 x 15 mm (/tWD)5 x 10 mm {2WDl
14-224
SPRING PINGROOVE
Install the final driven gear on a new differential car-rier with its chamfered side facing the carrier andthe transfer drive gear (4WD),
Tighten the bolts to the specified torque.
NOTE: The 2WD differentiat bolt has left-handthreads,
10 x 1.0 mm103 N.m 110.5 kd.m,7s.9 rbr.ft)
7.
FINAL DRIVEN GEAR
TRANSFER SHAFT
Install the speedometer drive gear with its cham-fered side facing the carrier. Align the cutout on thebore of the speedometer drive gear with the 5 x 15mm roller (4WD) or 5 x 10 mm roller (2WD).
Align the hooked end of the snap ring with thespring pin in the pinion shaft. then install the snaoring in the differential carrier groove
SNAP RINGInstall in this direction.Hooked end
PINION SHAFT
{4WDl
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Page 742 of 1395
Differential
Side Clearance Inspection
1. Instsll the 80 mm set ring in the transmission hous-Ing,
SET RING, 80 mrn
Install the differential assembly in the torque con-verter housing using the specialtool.
Install the transmission housing on the torque con-verter housing, and tighten the transmission hous-ing mounting bolts (see pages 14-252 and t4-253).
TOROUE: 4a N.m l/r.5 kgf.m, 33 tbt.ftl
14-226
4. Tap on the transmission housing side of the diffsrential assembly with the special tool to seat the dif-ferential assemblv.
DBIVER ilo m.n LO.0t746 - 0030100
Measure the clearancs between the 80 mm set ringand the bearing outer race with a feeler gauge,
STANDARD: 0 - 0.15 mm (0 - 0.006 inl
FEEI..ER GAUGE
lf the clearance is out of standard, remove rne setring and measurs its thickness.
Select and instsll a new 80 mm set ring.
SET RING, 80 mm
Recheck the clearance, and make sure it is withinstandard.
7.
Part NumborThicknoss
90414-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
2.50 mm (0.098 in)
2.60 mm (0.102 in)
2.70 mm (0.106 inl
2.80 mm (0.110 in)
2.90 mm (0.114 in)
3.00 mm (0. t'18 inl
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