Page 672 of 1395

Symptom-to-Com ponent Chart
Hydraulic System (cont'd)
NOTES
See flushing procedure, page l4-264 and 265,
BSet idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
clf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
Dlf the clutch pack is seized or is excessively worn. inspect the other clutches fot wear, and check the orificecontrol valves, CPC valve, and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed. the transmission will not upshift. lf stuck open, the transmission hasno lst gear.
Hlf the 2nd orifice control valve is stuck, inspect the 2nd and 3rd clutch Dacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
Jlf the clutch pressure control valve is stuck closed. the transmission will not shift out of lst gear.
Klmproper alignment of main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
Llf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Mlf the lst clutch feed pipe guide in the end cover is scored by the mainshaft. inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
N' Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged, lf the 4th feed pipe is darrFaged or out of round. replace the end cover.' Replace the mainshaft if the bushing for the l st feed pipe is loose or damaged. lf the 1st feed pipe is dam-aged or out of round, replace it.
oA worn or damaged sprag clutch is mostly a result of shifting the transmission in E!. E, or E positionwhile the wheels rotate in reverse. such as rocking the vehicle in snow.
PInspect the frame for collision damage.
lnspect for damage and wear:
l. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3. and 4 if worn or damaged. lf transmission makes a clicking, grinding, or whirring noise,also replace mainshaft 4th gear, reverse idler gear, and countershaft 4th gear in addition to 1,2, 3, or 4.lf differential pinion shaft is worn, overhaul differential assembly, replace ATF strainer, and thoroughly cjeantransmission, flush torque converter. cooler, and lines,lf bottom of 3rd clutch is swirled and transmission makes gear noise. replace the countershaft and final drivenoear,
Be very careful not to damage the torque converter housing when replacing the main ball bearing. you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the Drooer tools.
SInstall the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
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Page 675 of 1395

Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not te3t stall speed for mors than 10 s€€onds at a time'
. Do not shift the lever while raising th€ engine spsed.
. Be sure to remove tho pressuro gauge bofore testing stall speed,
1. Before testing, check the transmission fluid level, s€e page 14-160.
2. Engage the parking brake and block all four wheels
3. Connect the tachometer, and start the engane.
4. Make sure the Ay'C switch is OFF
5. After the engine haswarmed upto normal operating temperature (the radiator fan comes on),shiftinto@ position.
6. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine speed '
j. A|ow 2 minutes for cooling, then repeat the test in E, E ('97 - 98). E {'99 - 00}, and E positions. Stall speed should
be the same in E, E, E, tr. and E positions
Stall Speed rpm:
Specitication: 2,550 rpm
S€rvice Limit: ?,400 - 2.700 rpm
TROUBLEPROBAELE CAUSE
Stall rpm high in El, E, E, E and E
positions
ATF pump output is low
Clogged ATF strainer
Pressure regulator valve stuck closed
Slipping clutch
Stall rpm high in E positionSlippage of 1st clutch, 1st-hold clutch, or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 2nd clutch
stall rpm high in E! or E positionSlippage of 1st clutch or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 4th clutch
Stall rpm low in [dd, E. E, E, ana E
positions
. Engine output low
. Torque converter one-way clutch slipping
14-159
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Page 687 of 1395
13.Pry the right driveshaft out of the differential. and
orv the left driveshaft out of the intermediate shaft
{see section 16).
Pull out the inboard joint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshaft ends. Coat all
Drecision finished surfaces with clean engine oil.
Disconnect the primary heated oxygen sensor
(Primary HO2S) connector.
Remove exhaust pipe A.
GASKETReplace.
14.
16.
't7 .
ORIVESHAFT
Replace.
EXHAUST
14-171
18.
19.
Remove the shift cable cover.
Remove the shift cable.
ilWD:
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
2WD:
Remove the control lever, then separate the shift
cable from the control shaft. Do not bend the shift
cable excessivelv.
Replace.
SHIFT CAELE
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Page 703 of 1395

1. Remove the A/T gear position switch harness
cramp.
Remove the y'VT gear position switch cover.
Remove the bolt securing the ly'T gear position switch
harness clamp on the end cover, then remove the A/T
gear position switch.
Remove the 12 bolts securing the end cover. then
remove the cover.
Slip the special tool onto the mainshaft as shown.
6. Engage the park pawl with the park gear.
7. Cut the locktabs of each shaft locknut using a chisel as
shown. Keep all chiseled particles out of the transmis-
ston.
M=tt"
Align the hole of the sub-shaft 1st gear with the hole
of the transmission housing. then insert a pin to lock
the sub-shaft while removing the sub-shaft locknut.
Remove the locknuts and conical spring washers from
each shaft.
NOTE:
Mainshaft and countershaft locknuts have left-
hand threads.
Clean the old countershaft locknut. lt is used to
install the press fit park gear on the countershaft.
MAINSHAFT
PIN8 mm pin,
commercially
SUB-SHAFTLOCKNUTReplace.COUNTERSHAFTLOCKNUTReplace.
CONICAL SPNING WASHERSReplace.
9. Remove the lock pin that was installed to hold the
sub-shaft.
10. Remove the special tool from the mainshaft.
11. Remove the 1st clutch, mainshaft 1st gear assembly,
and mainshaft 1st gear collar.'12. Remove the sub-shaft 1st gear.
13. Remove the park pawl, pawl spring, pawl shaft. and
pawl stoP.
14. Remove the park lever from the control shaft.
15. Using a universal two jaw puller, remove the park
gear, one-way clutch, and countershaft 1st geal
assemblv.
{Commercially available)
1SY GEAR
Remove the needle bearing and countershaft 1st gear
co ar.
Remove the ATF cooler lines,
LOCKNUTReplace.
2\
Irot)
PULLER
11.
14-187
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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 734 of 1395
Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetorcleaner, and dry them with compressed air.. Blow out all passages.
o Lubricate all parts with ATF before reassembly.
1. Inspect the check valve; if it's loose, replace the pis_ton.
CHECK VALVE
2. Install new O-rings on the clutch piston.
PtsTot{
14-218
3. Install th€ piston in the clutch drum. Apply pressure
and rotate it to ensure proper seating, Lubricate thepiston O-ring with ATF betore insta ing the piston.
NOTE: Oo not pinch the O-ring by installing the pis_ton with too much force.
CLUTCH DRUM
Install the return spring, and spring retainer, thenposition the snap ring on the retainer.
4.
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
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Page 739 of 1395
Backlash Inspection
Place the differential assembly on V-blocks.
lnstall the driveshaft and intermediate shaft on the
differential assemblY.
Check the backlash of both pinion gears.
STANDARD: 0.05 - 0.15 mm (0.002 - 0.006 in)
OIFFEBENNAL ASSEMBLY
It the backlash is out of standard, replace the difter-
ential carrier.
1.
DIAL INDICATOR
Bearing Replacement
NOTE: Check bearings for wear and rough movement.
lf bearings are OK, removal is not required.
1. Remove the bearings using a bearing puller.
BEARING PULLER(Commercially available)
lnstall new
snown.
bearings using the sPecial tool
PRESS
14-223
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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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