
AT-4
Diagnosis Procedure .............................................210
KEY INTERLOCK CABLE ...............................213
Removal and Installation .......................................213
ON-VEHICLE SERVICE ..................................216
Control Valve Assembly and Accumulators ...........216
Park/Neutral Position (PNP) Switch ......................219
Revolution Sensor .................................................221
Turbine Revolution Sensor (Power Train Revolu-
tion Sensor) ...........................................................
222
Differential Side Oil Seal ........................................223
AIR BREATHER HOSE ...................................225
Removal and Installation .......................................225
TRANSAXLE ASSEMBLY ..............................226
Removal and Installation .......................................226
OVERHAUL .....................................................230
Component ............................................................230
Oil Channel ............................................................237
Location of Adjusting Shims, Needle Bearings and
Thrust Washers .....................................................
238
Location of Snap Rings .........................................239
DISASSEMBLY ...............................................240
Disassembly ..........................................................240
REPAIR FOR COMPONENT PARTS ..............257
Manual Shaft .........................................................257
Oil Pump ................................................................260
Control Valve Assembly ........................................263
Control Valve Upper Body .....................................272
Control Valve Lower Body .....................................276
Reverse Clutch ......................................................279
High Clutch ............................................................284
Forward and Overrun Clutches .............................288
Low & Reverse Brake ............................................295
Rear Internal Gear and Forward Clutch Hub .........299
Output Shaft, Output Gear, Idler Gear, Reduction
Pinion Gear and Bearing Retainer .........................
302
Band Servo Piston Assembly ................................307
Final Drive .............................................................313
ASSEMBLY ......................................................318
Assembly (1) .........................................................318
Adjustment (1) .......................................................319
Assembly (2) .........................................................325
Adjustment (2) .......................................................330
Assembly (3) .........................................................333
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................
341
General Specification ............................................341
Vehicle Speed at Which Gear Shifting Occurs .....341
Vehicle Speed at When Lock-up Occurs/Releases
.
341
Stall Speed ............................................................341
Line Pressure ........................................................341
Adjusting shims, Needle Bearings, Thrust Wash-
ers and Snap Rings ..............................................
341
Control Valves .......................................................343
Accumulator ..........................................................343
Clutches and Brakes .............................................343
Final Drive .............................................................345
Planetary Carrier ...................................................345
Oil Pump ...............................................................345
Input Shaft .............................................................345
Reduction Pinion Gear ..........................................345
Band Servo ...........................................................345
Output Shaft ..........................................................346
Bearing Retainer ...................................................346
Total End Play .......................................................346
Reverse Clutch End Play ......................................346
Removal and Installation .......................................346
Shift Solenoid Valves ............................................346
Solenoid Valves ....................................................346
A/T Fluid Temperature Sensor ..............................347
Revolution Sensor .................................................347
Dropping Resistor .................................................347
Turbine Revolution Sensor (Power Train Revolu-
tion Sensor) ...........................................................
347

PRECAUTIONS
AT-9
< SERVICE INFORMATION >
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• Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and
seals, or hold bearings and washers in place during assembly. Do not use grease.
• Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
• Clean or replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Refer to
Refer to .
• After overhaul, refill the A/T with new ATF.
• When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque con-
verter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer to
MA-22, "
Changing A/T Fluid", MA-22, "Checking A/T Fluid".
Service Notice or PrecautionINFOID:0000000001703155
ATF COOLER SERVICE
If A/T fluid contains frictional material (clutches, bands, etc.), or if an A/T is repaired, overhauled, or replaced,
inspect and clean the A/T oil cooler mounted in the radiator or replace the radiator. Flush cooler lines using
cleaning solvent and compressed air after repair. Check Service Bulletins for latest A/T oil cooler cleaning pro-
cedure. For radiator replacement, refer to Refer to CO-11
.
TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:
• External leaks in the hub weld area.
• Converter hub is scored or damaged.
• Converter pilot is broken, damaged or fits poorly into crankshaft.
• Steel particles are found after flushing the cooler and cooler lines.
• Pump is damaged or steel particles are found in the converter.
• Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
• Converter is contaminated with engine coolant containing antifreeze.
• Internal malfunction of stator roller clutch.
• Heavy clutch debris due to overheating (blue converter).
• Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
• The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
• The threads in one or more of the converter bolt holes are damaged.
• A/T malfunction did not display evidence of damaged or worn internal parts, steel particles or clutch plate lin-
ing material in unit and inside the fluid filter.
• Vehicle has been exposed to high mileage (only). The exception may be where the torque converter clutch
dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic, such as
taxi, delivery or police use.
OBD-II SELF-DIAGNOSIS
• A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the OD OFF indicator lamp or the malfunction indicator lamp (MIL). Refer to the table
on AT-78, "
Diagnosis Procedure without CONSULT-III" for the indicator used to display each self-diagnostic
result.
• The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM memo-
ries.
Always perform the procedure “HOW TO ERASE DTC” on AT-36, "
OBD-II Diagnostic Trouble Code
(DTC)" to complete the repair and avoid unnecessary blinking of the MIL.
• The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when the
OD OFF indicator lamp does not indicate any malfunctions.
-PNP switch
- A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of OBD-II, refer to AT- 3 6
.
•Certain systems and components, especially those related to OBD, may use a new style slide-lock-
ing type harness connector.
For description and how to disconnect, refer to PG-65
.

AT-10
< SERVICE INFORMATION >
PREPARATION
PREPARATION
Special Service ToolINFOID:0000000001703156
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
ST2505S001
(J-34301)
Oil pressure gauge set
1. ST25051001
(J-34301)
Oil pressure gauge
2. ST25052000
(J-34301)
Hose
3. ST25053000
(J-25695-3)
Joint pipe
4. ST25054000
(J-25695-4)
Adapter
5. ST25055000
(J-25695-5)
AdapterMeasuring line pressure
ST35325000
( — )
DriftInstalling LH differential side oil seal
(Use with KV31103000)
a: 215 mm (8.46 in)
b: 25 mm (0.98 in) dia.
c: M12 X 1.5P
KV31103000
(J-38982)
DriftInstalling LH differential side oil seal
(Use with ST35325000)
a: 59 mm (2.32 in) dia.
b: 49 mm (1.93 in) dia.
ST37830000
( — )
DriftInstalling idler gear bearing outer race
a: 61.9 mm (2.437 in) dia.
b: 39 mm (1.54 in) dia.
ST27180001
(J-25726-A)
PullerRemoving idler gear
a: 100 mm (3.94 in)
b: 110 mm (4.33 in)
c: M8 X 1.25P
NT097
SCIA7102E
SCIA7103E
NT084
NT424

PREPARATION
AT-11
< SERVICE INFORMATION >
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KV31103200
(J-39186)
Clutch spring compressor• Removing and installing clutch spring retainer as-
sembly
• Removing and installing cancel cover
a: 179 mm (7.05 in)
b: 76 mm (2.99 in) dia.
c: 174 mm (6.85 in)
ST23540000
(J-25689-A)
Pin punch• Removing and installing retaining pin of manual
plate
• Installing retaining pin of manual shaft
• Installing retaining pin of parking rod plate
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
KV32101000
(J-25689-A)
Pin punchRemoving and installing lock pin of pinion mate shaft
a: 4 mm (0.16 in) dia.
ST33400001
(J-26082)
DriftInstalling oil pump housing oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
KV381054S0
(J-34286)
Puller• Removing radial needle bearing
• Removing idler gear bearing outer race
• Removing differential side bearing outer races
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST30031000
(J-22912-01)
PullerRemoving reduction pinion gear bearing inner race
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST35272000
(J-26092)
Drift• Installing reduction pinion gear bearing inner race
• Installing idler gear bearing inner race
a: 72 mm (2.83 in) dia.
b: 40 mm (1.57 in) dia.
c: 35.5 mm (1.398 in) dia. Tool number
(Kent-Moore No.)
Tool nameDescription
SCIA7104E
NT442
NT410
NT086
NT414
NT411
NT107

PREPARATION
AT-13
< SERVICE INFORMATION >
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Commercial Service ToolINFOID:0000000001703157
ST30633000
( — )
DriftInstalling differential side bearing outer races
a: 67 mm (2.48 in) dia.
b: 49 mm (1.93 in) dia.
ST3306S001
(J-22888-D)
Differential side bearing pull-
er set
1. ST33051001
Puller
2. ST33061000
AdapterRemoving differential side bearing inner race
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in) Tool number
(Kent-Moore No.)
Tool nameDescription
NT073
AMT153
Tool name Description
Power tool Loosening bolts and nuts
DriftInstalling manual shaft oil seal
a: 22 mm (0.87 in) dia.
DriftInstalling RH differential side oil seal
a: 54 mm (2.13 in) dia.
b: 47 mm (1.85 in) dia.
Puller• Removing idler gear bearing inner race
• Removing and installing band servo piston snap
ring
PBIC0190E
SCIA7105E
NT115
NT077

A/T CONTROL SYSTEM
AT-19
< SERVICE INFORMATION >
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A/T CONTROL SYSTEM
Cross-Sectional ViewINFOID:0000000001703161
Shift MechanismINFOID:0000000001703162
CONSTRUCTION
1. Converter housing 2. Oil pump 3. Brake band
4. Reverse clutch 5. High clutch 6. Front planetary gear
7. Low one-way clutch 8. Rear planetary gear 9. Forward clutch
10. Overrun clutch 11. Low & reverse brake 12. Output gear
13. Band servo piston 14. Reverse clutch drum 15. Side cover
16. Idler gear 17. Forward one-way clutch 18. Transaxle case
19. Reduction pinion gear 20. Final gear 21. Differential case
22. Input shaft 23. Torque converter
SCIA7938E

AT-20
< SERVICE INFORMATION >
A/T CONTROL SYSTEM
FUNCTION OF CLUTCH AND BRAKE
CLUTCH AND BAND CHART
1. Torque converter 2. Oil pump 3. Input shaft
4. Brake band 5. Reverse clutch 6. High clutch
7. Front sun gear 8. Front pinion gear 9. Front internal gear
10. Front planetary carrier 11. Rear sun gear 12. Rear pinion gear
13. Rear internal gear 14. Rear planetary carrier 15. Forward clutch
16. Forward one-way clutch 17. Overrun clutch 18. Low one-way clutch
19. Low & reverse brake 20. Parking pawl 21. Parking gear
22. Output shaft 23. Idle gear 24. Output gear
SAT998I
Clutch and brake components Abbr. Function
5Reverse clutch R/C To transmit input power to front sun gear 7.
6High clutch H/C To transmit input power to front planetary carrier 10.
15Forward clutch F/C To connect front planetary carrier 10 with forward one-way clutch 16.
17Overrun clutch O/C To connect front planetary carrier 10 with rear internal gear 13.
4Brake band B/B To lock front sun gear 7.
16Forward one-way clutch F/O.CWhen forward clutch 15 is engaged, to stop rear internal gear 13 from rotating in
opposite direction against engine revolution.
18Low one-way clutch L/O.CTo stop front planetary carrier 10 from rotating in opposite direction against en-
gine revolution.
19Low & reverse brake L & R/B To lock front planetary carrier 10.
Shift posi-
tionR/C
5H/C
6F/C
15O/C
17Band servo
F/O.C
16L/O.C
18L&R/B
19Lock-
upRemarks
2nd
apply3rd re-
lease4th ap-
ply
PPA R K
POSITION
RREVERSE
POSITION
NNEUTRAL
POSITION
D*4 1st *1D B B

A/T CONTROL SYSTEM
AT-21
< SERVICE INFORMATION >
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• *1: Operates when OD OFF. (OD OFF indicator lamp is on.)
• *2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not contract
because oil pressure area on the “release” side is greater than that on the “apply” side.
• *3: Oil pressure is applied to 4th “apply” side on condition *2 above, and brake band contracts.
• *4: A/T will not shift to 4th when OD OFF. (OD OFF indicator lamp is on.)
• : Operates.
• A: Operates when throttle opening is less than specification**, activating engine brake.
• B: Operates during “progressive” acceleration.
• C: Operates but does not affect power transmission.
• D: Operates when throttle opening is less than specification**, but does not affect engine brake.
- **: Overrun clutch remains in engaged condition when throttle opening is less than 1/16.
POWER TRANSMISSION
“N” and “P” Positions
• “N” position
Power from the input shaft is not transmitted to the output shaft because the clutches do not operate.
• “P” position
Similar to the “N” position, the clutches do not operate. The parking pawl engages with the parking gear to
mechanically hold the output shaft so that the power train is locked.
“11” Position
2nd *1A BAutomatic
shift
3rd *1A *2C C B
*11 ⇔ 2 ⇔ 3
⇔ 4
4th C *3C C
21stBB
Automatic
shift
1 ⇔ 2 ⇐ 3 2ndB
3rd *2C C B
11stBB
Locks (held
stationary)
in 1st speed
1 ⇐ 2 ⇐ 3 2ndB
3rd *2C C B Shift posi-
tionR/C
5H/C
6F/C
15O/C
17Band servo
F/O.C
16L/O.C
18L&R/B
19Lock-
upRemarks
2nd
apply3rd re-
lease4th ap-
ply
SAT991I