06-Automatic Transaxle System

CHAPTER 6:

Automatic Transaxle

System

General Information

2004 > 1.6L DOHC >

Special service tools

Tool(Number and Name)

Illustration Use

0K201 170 AA0Support, engine

Used to support engine.

0K130 990 007Engine stand

Used to disassemble and assemble transaxle.

0K201 323 021Holder, Primary shaft

Used to hold primary shaft.

0K201 170 AA1Installer, oil seal

Used to install oil sear.

0K 670 990 AA0Puller set, bearing

Used to romeve bearing.

0K201 172 008Removing plate

Used to remove gears.

0K130 171 013Puller, bearing

Used to remove bearing.

0K130 283 021Puller, ball joint

Used to remove tie-rod end.

0K130 175 011AHanger, transaxle


0K130 170 012Remover, bearing


0K130 175 008Puller, fan pulley boss


0K900 175 AA1Installer set, bearing

Used to install bearing.

0K130 175 A13 Used to install gear and bearing inner race.

0K130 175 A13Body(Part of 0K900 175 AA1)

Used to install gear and bearing inner race.

0K201 171 A01Attachment A(Part of 0K900 175 AA1)

Used to install bearing inner race and gear.

0K130 175 A11Attachment B(Part of 0K900 175 AA1)


0K011 270 A02Attachment E(Part of 0K900 175 AA1)

Used to install ear.

0K900 175 AA0Shim selector set

Used to adjust bearing preload.

0K900 175 A01Selector(Part of 0K900 175 AA0)


0K900 175 A02 Used to adjust bearing preload.





0K130 175 A02Collar(Part of 0K900 175 AA0)


0K130 175 A03Bar(Part of 0K900 175 AA0)


0K130 191 A07Bolt set(Part of 0K900 175 AA0)


0K130 191 A05Adapter, preload


0K130 322 020 Used to measure preload.

0K130 322 020Attachment

Used to measure preload.

0K201 270 014Holder, differential side gear

Used to hold differential side gears.

SPECIAL SERVICE TOOLS

Tool(Number and Name) Illustration Use

09431-39000Oil seal installer

Installation of differential oil seal

09432-22000Bearing installer

Installation of output shaft's gear and sleeve

09432-22100Bearing outer race installer

Installation of input and output shaft bearingouter race (Use with 09500-11000)

09432-33200Bearing removing plate

Removal of input shaft's gear and ball bearing

09495-33100 Installation of input shaft bearing


Installation of input shaft bearing

09432-33400Bearing race installer

Installation of input shaft bearing outer race(use with 09500-21000)


Installation of differential ball bearing

09455-32200/0K011 190008Oil seal puller

Removal of differential bearing spacer

09495-33000Bearing and gear puller

Removal of ball bearing and gear

09517-21400Drift

Separation of T/M housing from T/M assembly

09532-11000 Removal and installation of differential bearing

09532-11000Differential bearing installer

Removal and installation of differential bearing

09532-11500Pinion bearing outer raceinstaller

Installation of output shaft and differentialshaft bearing outer race(Use with 09500-11000)

09200-38001(J28467-B)Engine support fixture

Removal and installation of transaxleassembly



09453-24000Spring compressor

Removal and installation of underdrive clutchsnap ring

09452-21401/0K011 171002Guide pin

Installation of oil pump(use with 09452-21301)

09453-33100Dial gauge extension

Measurement of the low and reverse brakeand the second brake end play

09431-39000 Installation of differential oil seal

09431-39000Oil seal installer

Installation of differential oil seal

09432-33200Removing plate

Removal of transfer shaft bearing


a. Removal of transfer driven gear taperbearing (use with 09433-21000)

b. Installation or transfer shaft bearing

09433-21000Removing plate

a. Removal of transafer driven gear taperbearing (use with 09432-33800)

b. Removal of differential ball bearing

09500-11000Bar

Installation of differential bearing outer race(use with 09532-11500)


Installation of differential ball bearing andoutput shaft taper roller bearing

09453-21100 Removal and installation of the low-reverse


Removal and installation of the low-reversebrake snap ring (use with 09453-21000)

09455-21000/0K011 430017Bearing and gear puller

Removal of ball bearing and tansfer drivegear

09455-21100Bering installer

a. Intallation of ball bearing and transferdrive gear

b. Installation of the transfer driven geartaper bearing


Installation of differential bearing outerrace(use with 09500-11000)


a. Removal and installation of low-reversebrake snap ring

b. Removal and installation of overdriveclutch snap ring (use with 09456-39000)


Removal and installation of low-reverse brakeand overdrive clutch snap ring

09432-21701 Installation of output shaft outer race

09432-21701Bearing outer race installer

Installation of output shaft outer race

09452-33100Oil pump remover

Removal of the oil pump

09452-21200Oil pump oil seal installer

Installation of the oil pump oil seal

09200-38001Engine support fixture

Removal and installation of transaxle

09456-39100A/B Clearance dummy plate

Measurement of low-reverse brake andsecond brake end plays

09457-39000Special socket (41)

Removal and installation of output shaft locknut



0K2CA 089 HSP

0K2CA 089 HSPHi-Scan Pro

0K130 283 021Puller, ball joint

Used to remove tie-rod end.

0K130 990 007stand, engine

Used to disassemble transaxle.

0K670 990 AA0Puller set, bearing

Used to remove bearing

0K201 190 AA0Gauge set, oil pressure

Used to measure line pressure

0K201 270 014Holder, diff.side gear

Used to hold differential side gear.

0K130 175 011A Used to disassemble transaxle.


Used to disassemble transaxle.


Used to remove bearing outer race.

0K201 170 AA0Support, engine

Used to remove transaxle.

0K201 190 016Leak checker

Used to disassemble/assemble 3-4 clutch.


Used to measure bearing preload.


Used to install oil seal.

0K201 190 AA1 Used disassemble/assemble clutch assembly.

0K201 190 AA1Compressor set, returnspring

Used disassemble/assemble clutch assembly.

0K130 191 034Holder, idler gear shaft


0K201 190 017Installer, oil seal

Used to remove oil seal

0K201 190 019Holder, turbine shaft

Used to remove/install turbine shaft

0K201 175 AA0Selector set, shim

Used to adjust preload.


Used to remove differential bearing.

0K130 322 020 Used to measure preload.

0K130 322 020Preload, adapter


0K2CA 190 AA2Servo Piston Lifter

Used to press servo piston lifter

0K2CA 190 AA1Spring retainer assembly

Used to remove/install spring retainerassembly.



0K201 170 AA0ASupport, engine

Used to support engine.

0K130 990 007Engine stand


0K201 323 021Holder, Primary shaft

Used to hold primary shaft.

0K201 170 AA1 Used to install oil seal.


Used to install oil seal.

0K670 990 AA0Puller set, bearing


0K201 172 008Removing plate




0K670 321 019Puller, socket

Used to remove tie rod end.



0K130 170 012 Used to remove bearing.



0K130 175 008Puller, fan pulley boss


0K900 175 AA1Install set, bearing


0K130 175 AA0Shim selector set




0K201 270 014Holder, differential side gear

Used to hold differential side gears.

0K930 175 AA0 Used to remove bearing.

0K930 175 AA0Bearing remover set


2004 > 1.6L DOHC >

TROUBLESHOOTING

Symptom Probable cause Remedy

Vibration, noise Loose or damaged transaxle and enginemounts

Tighten or replace mounts

Inadequate shaft end play Correct end play

Worn or damaged gears Replace gears

Use of inadequate grade of gear oil Replace with specified gear oil

Low oil level Replenish

Inadequate engine idle speed Adjust idle speed

Oil leakage Broken or damaged oil seal Replace oil seal

Hard shift Faulty control cable Replace control cable

Poor contact or wear of synchronizer ring andgear cone

Correct or replace

Weakened synchronizer spring Replace synchronizer spring

Use of inadequate grade of oil Replace with specified gear oil

Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring

Excessive clearance of synchronizer hub tosleeve spline

Replace synchronizer hub and sleeve

Worn or damaged gears and/or bearings Replace

SERVICE ADJUSTMENT PROCEDURES

TRANSAXLE GEAR OIL LEVEL INSPECTIONInspect each component for evidence of leakage. Check the gear oil level by removing the filler plug. If the oil iscontaminted, it is necessary to replace it with new oil.1. Remove oil filler plug and check level with finger.

2. Oil level must be up to fill hole, add oil until it runs out. Then reinstall plug.

3. Replace the oil that the transaxle gear oil is noticeably dirty, and that it is not of a suitable viscosity.

REPLACEMENT OF TRANSAXLE GEAR OILUse SAE 75W/90 TGO-6.1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil.

2. Replace the gasket with a new one and install the drain plug.

3. Add new oil through the filler plug, filling to below the plug opening.

Standard value

Transaxle oil total capacity :2.1 lit (2.2 U.S.qts., 1.8 imp.qts.)

DRIVE SHAFT OIL SEAL REPLACEMENT1. Disconnect the drive shaft form the transaxle (Refer to "DS" group).

2. Using a flat-tip screwdriver, remove the oil seal.

3. Using the special tool (09431-39000), tap the drive shaft oil seal into the transaxle.

4. Apply a coating of gear oil to the oil seal.

Transaxle gear oil : SAE 75W/90 TGO-6.

SYMPTOM-RELATED DIAGNOSTIC PROCEDURESDIAGNOSTIC CHART

Problem Possible cause Action

Shift lever does not shift smoothlyor is hard to shift

Seized shift lever ball seat Replace

Seized control rod joint Replace

Bent control rod Replace

Too much play in shift lever

Worn control rod bushing Replace

Weak shift lever ball spring Replace

Worn shift lever ball bushing Replace

Difficult to shift Bent control rod Replace

No grease in shifter Lubricate with grease

Insufficient oil Add oil

Deterioration of oil quality Replace with oil of specifiedquality

Wear or play of shift fork or shift rod Replace

Worn synchronizer ring Replace

Worn synchronizer cone area of gear Replace

Bad contact of synchronizer ring and conearea of gear

Replace

Excessive gear side clearance Replace

Worn bearing Replace

Worn synchronizer key spring Replace

Excessive primary shaft bearing preload Adjust

Improperly adjusted change guide plate Adjust

Does not stay in gear Bent control rod Replace

Worn control rod bushing Replace

Weak shift lever ball spring Replace

Improperly installed extension bar Tighten

Worn shift fork Replace

Worn clutch hub Replace

Worn clutch hub sleeve Replace

Worn sliding surface of shaft gears Replace

Worn sliding surface of gear Replace

Worn sliding groove of control rod end Replace

Weak detent spring Replace

Excessive thrust clearance Replace


Improperly installed or loose engine mount Tighten

Abnormal noise Insufficient oil Add oil

Deterioration of oil quality Replace with oil of specifiedquality


Worn sliding surfaces of gears or shafts Replace

Excessive gear backlash Replace

Damaged gear teeth Replace

Foreign material in gears Replace

Damaged differential gear or excessivebacklash

Replace

2004 > 1.6L DOHC >

Specifications

SPECIFICATIONS

Model M5GF1

Type Forward 5 speed, reverse 1 speedDIESEL 2.0 C/R

Gear ratio First 3.636

Second 2.056

Third 1.296

Fourth 0.943

Fifth 0.698

Reverse 3.455

Final gear ratio 3.611

SERVICE STANDARD

Standard value mm (in.)

Differential side bearing end play 0.05T-0.10T (0.0019T-0.0039T)

Gear backlash in differential 0.025L-0.150L (0.00095L-0.0057L)

Input front bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)

Input rear bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)

Output front bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)

Output rear bearing snap ring end play 0.01L-0.09L(0.00038L-0.00342L)

5TH input gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)

3RD output gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)

TIGHTENING TORQUE

Standard value N·m kg·cm lb·ft

Release bearing sleeve bolt 5-8 50-80 4-6

Release fork shaft level nut 27-40 270-400 20-29

Select lever 20-27 200-270 15-20

Oil drain plug 30-35 300-350 22-26

Poppet ball 35-42 350-420 26-31

Clutch housing to transmission case 35-42 350-420 26-31

Speedometer driven gear 4-6 40-60 3-4

Reverse idler bolt 43-55 430-550 32-40

Side cover bolt 10-12 100-120 7-8

Shift control cable bracket 20-27 200-270 15-20

Cylinder and hose assembly 15-22 150-220 11-16

Shift lever bracket 9-14 90-140 7-10

Front roll stopper bracket to subframe bolts 60-80 600-800 43-58

Front roll stopper insulator bolt and nut 50-65 500-650 36-47

Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58

Rear roll stopper bracket to subframe bolts 50-65 500-650 36-47

Rear roll stopper insulator bolt and nut 50-65 500-650 36-47

Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58

Transaxle mounting sub bracket nut 60-80 600-800 43-58

Transaxle mounting bracket bolts 60-80 600-800 43-58

Transaxle mounting insulator bolt 90-110 900-1100 65-80

Front bearing retainer detent body cover bolt 15-22 150-220 10-16

Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened orloosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.

LUBRICATIONS

Item Recommended sealants and adhesives Quantity

Transaxle gear oil lit. (U.S. qts., Imp.qts) SAE 75W/90 TGO-6 2.1 (2.2, 1.8)

Transaxle input shaft spline CASMOLY L9508 As required

Transaxle oil seal lip RETINAX AM, MOLYTEX GREASE EP-2 As required

Transaxle case and clutch housing alignmentsurface

THREE BOND 1216 As required

Transaxle case and rear cover alignmentsurface

THREE BOND 1216 As required

Bearing retain bolt (flush bolt only) THREE BOND 2471 As required

SPECIFICATIONS

Item F4A42-2

Torque converter type 3-element, 1-stage, 2-phase type

Transmission type 4-speed forward, 1-speed reverse

Engine displacement Diesel 2.0 Common Rail

Gear ratio 1st 2.842

2nd 1.529

3rd 1.000

4th 0.712

Reverse 2.480

Final gear ratio 3.770

SERVICE SPECIFICATIONS

Items Standard value

Output shaft preload 0.01-0.09 mm

Brake reaction plate end play 0-0.16 mm

Low-reverse brake end play 1.65-2.11mm

Second brake end play 0.79-1.25 mm

Underdrive sun gear end play 0.25-0.45 mm

Input shaft end play 0.70-1.20mm

Differential case preload 0.045-0.105 mm

Underdrive clutch end play 1.6-1.8 mm

Reverse and overdrive clutch return spring end play 0-0.09 mm

Overdrive clutch end play 1.6-1.8 mm

Reverse clutch end play 1.5-1.7 mm

Backlash between differential side gear and pinion 0.025-0.150 mm

SNAP RING AND SPACER FOR ADJUSTMENT

Part name Thickness mm Identification symbol

Thrust washer(For adjustment of input shaft end play)

1.8 18

2.0 20

2.2 22

2.4 24

2.6 26

2.8 28

Snap ring(For adjustment of underdrive clutch and overdrive clutch end plays)

1.6 None

1.7 Blue

1.8 Brown

1.9 None

2.0 Blue

2.1 Brown

2.2 None

2.3 Blue

2.4 Brown

2.5 None

2.6 Blue

2.7 Brown

2.8 None

2.9 Blue

3.0 Brown

Snap ring(For adjustment of low-reverse brake and second brake reactionplates end plays)

2.2 Blue

2.3 Brown

2.4 None

2.5 Blue

Pressure plate(For adjustment of low-reverse brake and second brake end plays)

1.6 6

1.8 1

2.0 0

2.2 2

2.4 4

2.6 6

2.8 8

3.0 D

Snap ring(For adjustment of reverse clutch end play)

1.6 None

1.7 Blue

1.8 Brown

1.9 None

2.0 Blue

2.1 Brown

2.2 None

2.3 Blue

2.4 Brown

2.5 None

2.6 Blue

2.7 Brown

2.8 None

Snap ring(For adjustment of reverse clutch and overdrive clutch spring retainersend plays)

1.48 Brown

1.53 None

1.58 Blue

1.63 Brown

Thrust race(For adjustment of underdrive sun gear end play)

1.6 -

1.7 -

1.8 -

1.9 -

2.0 -

2.1 -

2.2 -

2.3 -

2.4 -

2.5 -

2.6 -

Spacer(For adjustment of output shaft preload)

1.88 88

1.92 92

1.96 96

2.00 00

2.04 04

2.08 08

2.12 12

2.16 16

2.20 20

2.24 24

2.28 28

2.32 32

2.36 36

2.40 40

2.44 44

2.48 48

2.52 52

2.56 56

2.60 60

2.64 64

2.68 68

2.72 72

2.76 76

Spacer(For adjustment of differential case preload)

0.71 71

0.74 74

0.77 77

0.80 80

0.83 83

0.86 86

0.89 89

0.92 92

0.95 95

0.98 98

1.01 01

1.04 04

1.07 07

1.10 J

1.13 D

1.16 K

1.19 L

1.22 G

1.25 M

1.28 N

1.31 E

1.34 O

1.37 P

Spacer(For adjustment of backlash between differential side gear and pinion)

0.75 - 0.82 -

0.83 - 0.92 -

0.93 - 1.00 -

1.01 - 1.08 -

1.09 - 1.16 -

TIGHTENING TORQUE

Items N·m kg·cm lb·ft

Wiring harness bracket 20-26 200-260 14-18

Control cable bracket 20-26 200-260 14-18

Eye bolt 27-33 270-330 19-23

Oil cooler feed tube 10-12 100-120 7-8

Input shaft speed sensor 10-12 100-120 7-8

Output shaft speed sensor 10-12 100-120 7-8

Manual control lever 18-25 180-250 13-18

Transaxle range switch 10-12 100-120 7-8

Vehicle speed sensor 4-6 40-60 3-4

Valve body cover 8-10 80-100 6-7

Valve body mounting bolt 10-12 100-120 7-8

Oil temperature sensor 10-12 100-120 7-8

Manual control shaft detent 5-7 50-70 4-5

Rear cover 20-26 200-260 14-18

Torque converter housing 42-54 420-540 29-38

Oil pump 20-26 200-260 14-18

Transfer drive gear 16-22 160-220 11-15

Output shaft lock nut 160-180 1600-1800 110-126

Output shaft bearing retainer 20-26 200-260 14-18

Oil filler plug 29-34 290-340 20-24

Oil drain plug 29-34 290-340 20-24

Transfer drive gear lock nut 180-210 1800-2100 126-147

Differential drive gear 130-140 1300-1400 91-98

Valve body 10-12 100-120 7-8

Solenoid valve support 5-7 50-70 4-5

Plate 5-7 50-70 4-5

Pressure check plug 8-10 80-100 6-7

Front roll stopper bracket to subframe bolts 60-80 600-800 43-58

Front roll stopper insulator bolt and nut 50-65 500-650 36-47

Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58

Rear roll stopper bracket to subframe bolts 50-65 500-650 36-47

Rear roll stopper insulator bolt and nut 50-65 500-650 36-47

Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58

Transaxle mounting sub bracket nut 60-80 600-800 43-58

Transaxle mounting bracket bolts 60-80 600-800 43-58

Transaxle mounting insulator bolt 90-110 900-1100 65-80

Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened orloosening if under-tightened. In either case, serious personal injury or death could result to the vehicle occupants.

LUBRICATIONS

Items Specified lubricant Quantity

Transaxle fluid lit. (U.S. qts., Imp,qts.) GENUINE DIAMOND 7.8 (8.2,6.9)

ATF SP-III

SEALANTS

Items Specified sealant

Rear cover Genuine sealant FMD546, TB1281B or equivalant

Torque converter housing Genuine sealant FMD546, TB1281B or equivalant

Valve body cover Genuine sealant FMD546, TB1281B or equivalant

SPECIFICATIONS

SPECIFICATIONS

Automatic Transaxle System

2004 > 1.6L DOHC >

AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT

PARKING NEUTRAL

FIRST

SECOND

FOURTH

REVERSE

HYDRAULIC CIRCUITP range

R range

N range

D range: 1st gear

D range: 2nd gear

D range: 3rd gear

D range: O/D gear converter OFF

D range: O/D gear torque converter clutch ON

2nd gear

1 range

POWER FLOW DIAGRAM

2004 > 1.6L DOHC >

ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER

Operating Element and Their Functions

Operating element Code Function

Underdrive clutch UD Connects input shaft and underdrive sun gear

Reverse clutch REV Connects input shaft and reverse sun gear

Overdrive clutch OD Connects input shaft and overdrive planetary carrier

Low-and-reverse brake LR Locks low-and-reverse annulus gear and overdriveplanetary carrier

Second brake 2ND Locks reverse sun gear

COMPONENT OPERATION TABLE: O/D OFF SYSTEM

SOLENOID VALVE OPERATION TABLE: O/D OFF SYSTEM

FLUID PASSAGE LOCATIONSTransaxle case

DESCRIPTION AND OPERATION

Cross-sectional view

COMPONENT OPERATION TABLE: O/D OFF SYSTEM

SOLENOID VALVE OPERATION TABLE: O/D OFF SYSTEM

FLUID PASSAGE LOCATIONSTransaxle case

Cross-sectional view

Automatic Transaxle

2004 > 1.6L DOHC >

COMPONENTS

1. Apply gear oil sparingly to the speedometer driven shaft and insert the shaft.

COMPONENTS

SECTION VIEW

COMPONENT

COMPONENTS

COMPONENTS(CONTINUED)

BEARING AND RACE LOCATIONS

Bearing and race at location 2, 3, 4, 6, and 7 are one-piece units.

COMPONENT

COMPONENT(CONTINUED)

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY

a. Because the automatic transmission is manufactured from high-precision parts, sufficient care must be takennot to scratch or damage these parts during disassembly and reassembly.

b. The working area should be convered with a rubber mat to keep it clean at all times.c. Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if

you need to use something.d. Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent

but they should be dried completely using compressed air.e. Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF)

so that they do not become dirty.f. If the transmission body has been damaged, disassemble and clean the cooler system also.

1. Remove the torque converter and set aside.

2. Measure the input shaft end play.

3. Remove the left and right roll stopper brackets.

4. Remove the wiring harness bracket.

5. Remove the control cable support bracket.

6. Remove the dipstick.

7. Remove the oil cooler feed tube, gasket, and eye bolt.

8. Remove the input shaft speed sensor and the output shaft speed sensor.

9. Remove the manual control lever, then remove the transaxle range switch.

10. Remove the vehicle speed sensor.

11. Remove the valve body cover.

12. Remove the manual control shaft detent.

13. Disconnect the harness connectors of the valve body.

To prevent damage to transaxle components make sure that the manual control lever and the park/neutralswitch have been removed before attempting to remove the valve body.

The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.

14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.

15. Remove the oil temperature sensor.

16. Remove the valve body, gasket, and the 2 steel balls.

Make sure not to lose the 2 steel balls.

17. Remove the solenoid valve wiring harness snap ring.

18. Remove the solenoid valve harness.

19. Remove the strainer.

20. Remove the second brake retainer oil seal.

The second brake retainer oil seal must be removed before removing the transaxle powertrain componentsfrom the case or damage to the seal will occur.

21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.

Number Functional Name

1 Low-Reverse Brake

2 Underdrive Clutch

3 Second Brake

4 Overdrive Clutch

22. Remove the manual control lever shaft pin (roller).

23. Remove the manual control lever shaft.

24. Remove the parking pawl rod.

25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.

26. Remove the 2 O-rings from the case.

27. Remove the differential.

28. Remove the main oil filter.

29. Remove oil pump mounting bolts.

The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump asimproper alignment during assembly will cause pump failure and could cause damage to the transaxle.

30. Install the special tool (09452-33100), as shown in the illustration.

31. Remove the oil pump by turning special tool screws clockwise.

32. Remove the oil pump gasket.

33. Remove thrust bearing #1.

34. Grasp the input shaft, then pull out the underdrive clutch and input shaft as an assembly.


36. Remove the underdrive clutch hub.

37. Remove the rear cover and mounting bolts.

38. Remove the thrust race #8.

39. Remove the 4 seal rings.

Do not remove the input shaft rear bearing unless directed to do so by the instructor.Once this bearing has been removed, it MUST be replaced.

40. Remove the 3 O-rings.


42. Remove the reverse overdrive clutch.


44. Remove the overdrive clutch hub.


46. Remove the reverse sun gear.

47. Remove the second brake piston snap ring.

48. Remove the second brake piston and return spring.

49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.

50. Remove the overdrive planetary carrier.


52. Remove the output planetary carrier.

53. Remove the underdrive sun gear.


55. Remove the low/reverse reaction plate snap ring.

56. Remove the low/reverse reaction plate and brake disc.

57. Remove the low/reverse brake snap ring.

58. Remove the low/reverse 6 brake discs, 5 brake plates, and brake pressure plate.

59. Remove the wave spring.

60. Remove the parking pawl shaft.

61. Remove the spacer.

62. Remove the parking pawl spring. Note the orientation of the spring to aid in reassembly.

63. Remove the 2 parking roller support shafts.

64. Remove the parking pawl case.

65. Remove the parking roller support.

66. Remove the snap ring.

67. Remove the spring retainer.

68. Remove the return spring.

69. Remove the low/reverse brake piston. Use compressed air directed into the valve body passage.

70. Remove the 7 transfer gear mounting bolts.

71. Remove the transfer drive gear.

72. Remove the plastic cap, if present.

73. Straighten the locking tab of the output shaft lock nut, if bent.

The output shaft lock nut is left-hand thread.

74. Remove the output shaft lock nut.

75. Remove the output shaft bearing retainer mounting bolts.

76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.

77. Tap out the bearing outer race and spacer using a suitable driver.

78. Remove the snap ring.

79. Remove the differential bearing outer race and spacer from the torque converter housing.

80. Remove the differential bearing outer race from the transaxle case.

REASSEMBLY

a. Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.b. Never use grease other than blue petrolatum jelly and white Vaseline.c. Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch

disc or brake disc in ATF for at least two hours before assembling them.d. Never apply sealant or adhesive to gaskets.e. When replacing a bushing, replace the assembly which it belongs to.f. Never use any cloth gloves or any rags during reassembly.

Use nylon cloth or paper towels if you need to use something. Change the oil in the cooler system.

1. Tap the differential bearing outer race into the transaxle case using special tools tools (09500-11000 and 09532-11500).

2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).

3. Install the spacer and the snap ring.

4. Install the low-reverse brake piston, return spring, and spring retainer.

5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measurethe thickness and compare it to the chart in the service manual.

6. Install the wave spring.

In steps 7 through 9, you will determine the actual clearance between the low-reverse brake discs and plateswhen the clutch is released.

7. Replace the pressure plate of the low-reverse brake, then install the 6 brake discs, 5 brake plates and the snapring.

8. Install the low and reverse reaction plate and the old snap ring.

9. With a dial indicator installed, move the special tool up and down to measure the end play.

Standard Value:0-0.16 mm (0-0.0063 in.)

If the end play is incorrect, measure the old snap rig, then select the proper snap rig from the chart shown in theservice manual and recheck the clearance.

10. Remove the special tool.

In steps 11 through 16, you will determine the actual clearance between the second brake discs and plateswhen the clutch is released.

11. Install the 3 second brake discs and 2 plates.

12. Install the second brake return spring, second brake piston, and snap ring.

13. Install a dial indicator as shown in the illustration.

14. Move up and down, while observing the end play.

15. To determine the proper thickness of the second brake pressure plate.

Standard value:0.79-1.25 mm (0.0311-0.0492 in.)

16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the servicemanual and recheck the clearance.

In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs andplates when the clutch is released.

17. Install the special tool in place of the low/reverse brake pressure plate.

18. Install the 6 brake discs, 5 brake plates and snap ring.

19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.

20. Move the special tool up and down while observing the end play.

21. To determine the proper thickness of the low/reverse brake pressure plate.


22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the servicemanual and recheck the clearance.

23. Remove the special tool.

24. Install the output shaft.

25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 lbs·ft) of torque.

26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).

The output shaft lock nut is left-hand thread.

27. Apply ATF and install the old lock nut and tighten to 167 Nm (123 lb·ft). Loosen the nut 1 full turn, then re-tightento specifications. Do not stake the lock nut unless instructed to do so by the instructor.

28. Install a dial indicator as shown in the illustration.

29. Move the output shaft in and out to measure the end lay.


30. If the standard value is incorrect, use this formula to select the correct spacer from the chart in the servicemanual.

31. Install the output shaft protective cap.

32. Install the transfer drive gear using special tool (09500-11000).

33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm(14 lbs·ft).

34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.

35. Install the parking roller support, then the two parking roller support shafts.

Be sure to install the thrust bearing in the proper direction.

36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.


37. Install the output planetary carrier and thrust bearing #4.

38. Install the overdrive planetary carrier.

Rotating the output shaft will help align the clutch teeth and help the carrier seat.

39. Install the reverse sun gear.

40. Install the wave spring.

41. Install the pressure plate, 6 brake discs, and 5 brake plates.

42. Install the snap ring.

43. Install the reaction plate.


45. Install the pressure plate, 3 brake discs, and 2 brake plates.

46. Install the return spring and second brake piston.



48. Install thrust bearing #5.


49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.


50. Install the reverse overdrive clutch and thrust bearing #7.

51. Install the three O-rings.

52. Install the 3 seal rings into the rear cover.

The cover should be clean and dry for step 56. It is only being installed to measure the underdrive sun gearend play.

53. Install the used thrust race #8 and rear cover.

54. Using a dial indicator, measure the end play of the underdrive sun gear.

Standard Value:0.25-0.45 mm (0.0098-0.0177 in.)

55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper sizefrom the chart in the service manual.

56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs·ft).

57. Install the underdrive clutch hub.


58. Install thrust bearing #2.

59. Grasp the input shaft and lower the underdrive clutch into position.

Looking into the hole where the input speed sensor mounts to the case will help you ensure that theunderdrive clutch is fully seated.

underdrive clutch is fully seated.

60. Install the used thrust bearing #1.

Be sure to use a new oil pump gasket.

61. Install the oil pump, a new gasket, and the oil pump mounting bolts.

62. Using a dial indicator, measure the end play of the input shaft.


63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper sizefrom the chart in the service manual.

64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs·ft).

65. Install the oil internal filter.

66. Install the differential.

67. Place two strips of solder, approximately 10 mm (0.39 in) long and 3 mm (0.12 in) thick, on the torque converterhousing.

68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.

69. Remove the torque converter housing, the bolts and the solder.

70. Using a micrometer, measure the thickness of the pressed solder.

71. Select a spacer that will give the following clearance.

Standard value:0.045 mm (0.0018 in.)-0.105 mm (0.0041 in.)

72. Install the differential spacer selected in the previous step in the torque converter housing.

73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.

74. Install the two O-rings.

75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.

76. Install the manual control lever shaft and parking pawl.

77. Install the manual control shaft roller.

78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs areidentified in the illustration and in the chart below.

Number Function Name

1 Low-Reverse Brake

2 Underdrive Clutch

3 Second Brake

4 Overdrive Clutch

79. Install the accumulators with the springs according to the illustration and the chart below. The accumulatorsshould be flush with the transaxle case.

Number Function Name Color

1 Low-Reverse Brake None

2 Underdrive Clutch Yellow

3 Second Brake White

4 Overdrive Clutch None

80. Install the strainer and the second brake retainer oil seal.

Note the oil seal orientation in the illustration.

81. Install the solenoid wiring harness, then install the snap ring in its groove.

82. Install the valve body, gasket, and two steel balls.

83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm.

84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm.

85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart below.

No. Part to be connected Wire color Connector housing color

1 Underdrive solenoid valve White, Red, Red Black

2 Overdrive solenoid valve Orange, Red Black

3 Low-Reverse solenoidvalve

Brown, Yellow Milky White

4 Second solenoid valve Green, Red,Red Milky White

5 Damper clutch controlsolenoid valve

Blue,Yellow,Yellow Black

6 Oil temp. sensor Black,Red Black

86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 lb·ft) of torque.

87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm of torque.

88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm of torque.

89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (8 lbs·ft) of torque.

90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 lbs·ft) of torque.

91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm of torque.

Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter locksimilar, their filtering action is different. Installing the wrong oil filter could cause damage to the transaxle.Transaxle oil filters are identified as A/T ONLY.

92. Install the cooler feed tube with a new gasket and the eye bolt. Tighten the eye bolt to 30 Nm (22 lbs·ft) of torque.

93. Install the dipstick.

94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).

95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).

96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 lbs·ft).

97. Install the torque convertor and secure it so that dimension A.Meets the reference value.

Reference value :approx. 12.2 mm (0.480 in.)

Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oilpump seal.

pump seal.

DISASSEMBLY

General note1. Disassemble transaxle in a clean area (dustproof work space) to prevent entry of dust into mechanisms.

2. Inspect individual transaxle components.

3. Use only plastic hammers when applying force to separate light alloy case joints.

4. Never uses shop towels during disassembly; they may leave particles that can clog fluid passages.

5. Several parts resemble one another; organize them so that they do not get mixed up.

6. Disassemble control valve assembly and thoroughly clean it when a clutch or brake band has burned or when ATFhas degenerated.

Cleaning note1. Clean transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.

2. Clean removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages withcompressed air, and check that there are no obstructions.

Wear eye protection when using compressed air to clean components.

Do not allow ATF to spill when removing torque converter.

Disassemble note1. Remove torque converter from converter housing

2. Pull out oil pump shaft by hand.

3. Remove oil level gauge and oil filler tube.

4. Remove input/turbine speed sensor.

5. Remove transaxle range switch.

6. Remove selector cable bracket.

7. Remove bracket.

8. Remove crankshaft position sensor.

9. Remove vehicle speed sensor and driven gear.

10. Remove inlet pipe.

11. Remove outlet pipe.

12. Assemble SST(0K130 175 011A/0K130 990 007).

Do not lean transaxle to one side during disassembly. It may rotate suddenly and cause injury.

Remove oil pan before turning transaxle over. This will ensure that any foreign material remains in pan.

13. Remove oil pan and gasket (19 bolts).a. Examine any material found in pan or on magnet to determine condition of transaxle.

Material Possible source

Clutch facing material Drive plate or brake band

Steel (magnetic) Bearings, gears, or driven plate wear

Aluminum(Nonmagnetic) Bushings or cast aluminum parts wear

b. If large amounts of material are found, replace torque converter and carefully check transaxle for cause.

14. Remove clip (one bolt).

15. Disconnect solenoid connectors.

16. Remove strainer (three bolts).

17. Remove A, B and C bolts and brackets shown in figure.

Bolt length (Measured from below head):A: 1.18 in (30 mm)B: 1.97 in (50 mm)C: 0.55 in (14 mm)

18. Remove control valve body.

19. Remove manual shaft and manual plate.a. Loosen nut and pull out manual shaft.b. Remove nut, washer, and manual plate.

20. Remove bolt and parking pawl lever holder.

21. Remove parking pawl lever (two bolts).

22. Remove detent lever and return spring.

23. Remove actuator support.

24. Remove oil pump assembly (10 bolts).

25. Remove reverse/forward clutch assembly.a. Remove turbine shaft snap ring.

b. Pull reverse/forward drum and remove clutch assembly.

26. Remove small sun gear and one-way clutch No. 1.

Use a piece of wire to secure brake band so that it is not damaged by being stretched.

27. Remove 2-4 brake band.

28. Pull anchor shaft while holding strut.

29. Remove strut.

30. Remove servo with SST (0K2CA 190 AA2).a. Compress servo piston and remove snap ring.b. Remove servo retainer, servo piston, and spring.

31. Remove one-way clutch No. 2 and planetary carrier assembly.a. Remove snap ring.

b. Remove one-way clutch No. 2 together with planetary carrier assembly.c. Remove friction plate.

32. Remove internal gear.a. Remove snap ring.

b. Remove internal gear from output shell.

33. Remove 3-4 clutch assembly.a. Remove O-ring from turbine shaft at converter housing side.

b. Pull out turbine shaft to remove 3-4 clutch assembly.

c. Remove 3-4 clutch assembly from turbine shaft.

34. Remove bolts (converter housing side: eight bolts transaxle case side: seven bolts) and remove transaxle case bytapping lightly with a plastic hammer.

35. Remove output shell from output gear.

36. Remove differential assembly.

37. Remove bearing housing.a. Remove roll pin with a pin punch.b. Remove (11) bolts securing bearing housing.c. Remove bearing housing by tapping lightly with a plastic hammer.

38. Remove idler gear assembly and output gear assembly by tapping out from torque converter side.

39. Remove bearing cover.a. Remove bearing cover bolts.b. Remove converter housing from SST(0K130 175 011A).

c. Press bearing cover assembly out of converter housing.

Install bearing outer race during reassembly to adjust preload.

40. Press out bearing outer races by using SST(0K130 170 012).

PRECAUTION1. If drive plates or brake band are replaced with new ones, soak new part in ATF for at least two hours before

installation.

2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.

3. All O-rings, seals, and gaskets must be replaced with new ones.

4. Use petroleum jelly, not grease, during reassembly.

5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.

6. Assemble housing within 10 minutes after applying sealant and allow it to cure at least 30 minutes after assemblybefore filling transaxle with ATF.

DISASSEMBLY

Use protective plates in vise to prevent damage to SST(0K130 191 034).

1. Secure idler shaft in a vise with SST(0K130 191 034), and remove lock nut.

2. Remove bearing outer race from idler gear with SST(0K130 170 012).

REASSEMBLY1. Align bush cover with guide bolts as shown, and press it in.

Tightening torque:96 -120 Ib·in (10.8-13.7 N·m, 110-140 kg·cm)

2. Install idler gear and output gear as an assembly by tapping it with a plastic hammer.

3. Install bearing housing.

a. Install bearing housing on converter housing.

b. Align groove on idler shaft with mark on bearing housing.c. Tap a new roll pin in with a pin punch and hammer.d. Install 11 mounting bolts.

Tightening torque:14-18 Ib·in (19-25 N·m, 1.9-2.6 kg·m)

4. Install parking pawl.a. Install parking pawl and shaft.b. Install spring and snap ring.c. Move manual shaft and verify that parking pawl operates.

5. Install actuator support with new bolts.


6. Install detent lever and return spring.

7. Install parking assist lever.

8. Install lever holder and bolt.

Tightening torque:69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)

9. Install manual shaft and manual plate.a. Install manual plate, washer, and nut.b. Tighten nut to specified torque.

Tightening torque:31-40 Ib·in (42-54 N·m, 4.2-5.6 kg·cm)

10. Install differential assembly into converter housing.

11. Install SST(0K201 270 014) or equivalent.

12. Install a new oil control ring onto output gear assembly.

13. Install output shell to output gear and install bearing race onto output shell.

Thrust bearing outer diameter:2.84 in (72.1 mm)

14. Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.

15. Install new O-rings onto converter housing.

Insure that sealer will not be forced into oil passages when transaxle case is installed.

16. Mount transaxle case to converter housing.


17. Install SST(0K201 190 019) to hold turbine shaft.

18. Install turbine shaft and 3-4 clutch assembly.a. Assemble turbine shaft and 3-4 clutch assembly.

b. Verify that thrust bearing is properly installed.c. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly.

19. Install internal gear.a. Install internal gear to output shell.b. Install snap ring.

20. Install planetary carrier assembly.a. Verify that thrust bearing and bearing race are properly installed.

b. Hold turbine shaft with one hand to prevent it from rotating.c. Install planetary carrier assembly into 3-4 clutch drum by rotating it.

21. Install low and reverse brake drive and driven plates (four each).

Installation order:Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive

22. Install retaining plate.

23. Install snap ring.

24. Install friction plate.

25. Install one-way clutch No. 2.a. Hold one-way clutch No. 2 horizontally.

b. Install it by turning planetary carriercounterclockwise.

c. Install snap ring.

26. Install anchor strut and shaft.

Interlock 2-4 brake band and anchor strut as shown.

27. Install 2-4 brake band in transaxle case so that it is fully expanded.

28. Install small sun gear and one-way clutch No. 1.a. Verify that thrust bearing and bearing race are installed in correct position.

b. Install small sun gear and one-way clutch No. 1 while rotating it.

29. Install reverse/forward clutch assembly.a. Verify that thrust bearing is installed in correct position.

b. Install reverse/forward clutch assembly while rotating it.

Measure height difference between reverse/forward drum and transaxle case.

Maximum: 0.035 in (0.9 mm)

30. Install snap ring into bottom ring groove of turbine shaft.

31. Measure total end play select a suitable bearing race as follows:

a. Set thrust bearing onto reverse/forward clutch assembly.

b. Remove previously used race and gasket.c. Set thickest bearing race 0.087 in (2.2 mm) onto oil pump.d. Set oil pump onto clutch assembly.

Do not install oil pump gasket at this time.

e. Measure clearance (A) between transaxle case and oil pump.f. Select a suitable bearing race from chart below.

g. Remove oil pump.h. Place selected bearing race and a new gasket onto oil pump.i. Install oil pump onto transaxle assembly.

Tightening torque:14-18 Ib·in (19-25 N·m,190-260 kg·cm)

32. Verify 2-4 brake band adjustment as follows:a. Install servo piston to SST(0K2CA 190 AA2).b. Install servo retainer O-ring onto SST(0K2CA 190 AA2).c. Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.

Insure that 2-4 brake band is correctly positioned against band servo piston stem.

d. Set a dial indicator against piston stem.

e. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure pistonstem stroke.

Air pressure:57 psi (392 kPa, 4.0 kg/cm²) maximumStroke: 0.039-0.067 in (1.0-1.7 mm)

f. If not within specification, select proper piston stem from below.

g. Remove band servo assembly and remove SST.

Do not deform snap ring when removing it.

33. Install servo into transaxle case with SST (0K2CA 190 AA2)a. Install servo spring and servo assembly.b. Install snap ring.c. Position 2-4 brake band onto band servo piston stem.

34. Align manual valve with pin on manual plate and install control valve body.


Bolt length:(measured from below the head)A : 1.18 in (30 mm)B : 1.97 in (50 mm)C : 0.55 in (14 mm)

35. Connect solenoid valve and ATF temperature sensor connectors.

36. Connect solenoid connector.

Attach magnets inside oil pan in positions shown on illustration (in oil pan).

37. Install a new gasket and oil pan tighten 19 bolts.

Tightening torque:74.4-94.8 Ib·in (8.4-10. 7 N·m, 80-110 kg·cm)

38. Install inlet pipe and outlet pipe.

39. Install driven gear and vehicle speed sensor.

40. Install crankshaft position sensor.

41. Install bracket and select bracket.

42. Install transaxle range switch.a. Turn manual shaft to N position.b. Install transaxle range switch.c. Tighten transaxle range switch mounting bolts.

Tightening torque:70-95 Ib·in (7.9-10.7 N·m ,80-110 kg·cm)

d. Verify that the selector lever range position and transaxle range switch correspond.

43. Remove transaxle from SST(0K 130 990 007/0K130 175 011A).

44. Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.


45. Install input/turbine speed sensor.


46. Install oil pump shaft.

47. Install a new O-ring onto turbine shaft.

48. Fill torque converter with ATF.

ATF type: DIAMOND ATF SP-III or SK ATF SP-III

a. Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to overflow.b. If converter does not fit in easily, do not try to force it: install carefully.c. Do not damage O-ring onto turbine shaft.

49. Install torque converter in converter housing while rotating it to align splines.

50. To ensure that the torque converter is installed accurately, measure distance "A" between face of torque converterand mounting surface of converter housing.

Distance (A): 0.535 in (13.6 mm)

RE-ASSEMBLY1. Press bearing outer races.

2. Install idler gear bearing onto idler shaft, then install idler gear, adjustment shims, spacer, and bearing.

Use protective plates in vise to prevent damage to SST.

3. Secure idler shaft in a vise with SST(0K130 191 034) and tighten locknut to lower limit of tightening torque.

Tightening torque:95-130 Ib·ft (128-176 N·m,13-18 kg·m)

Use protective plates in vise to prevent damage to idler gear.

4. Check and adjust idler gear bearing preload.a. Turn idler gear assembly and SST(0K130 191 034) over and secure gear in vise.

b. Attach SST(0K130 191 034) and spring scale or torque wrench and measure preload while tightening locknut.

Read preload when idler shaft is rotating.

Tightening torque:95-130 Ib·ft (128-176 N·m, 13-18 kg·m)

Preload:0.27-7.8 Ib·in (0.03-0.8 N·m, 0.3-0.9 kg·cm)

a. The maximum allowable number of shims is 7.b. Preload is reduced by increasing thickness of shims, or increased by reducing thickness.

5. If specified preload cannot be obtained within specified tightening torque, adjust by selecting proper adjustmentshims.

shims.

BEARING PRELOAD1. Remove bearing outer race from bearing cover.

2. Install bearing cover with SST(0K201 190 017).

3. Align bearing cover with guide bolts as shown, and press it in. Torque bearing cover bolts.

Tightening torque:96-120 Ib·in (10.8-13.7 N·m, 110-140 kg·cm)

4. Remove bearing outer race and adjustment shims from bearing housing using a pin punch and hammer.

5. Install bearing outer race to bearing housing.

Do not install adjustment shims.Eliminate gap (arrow) by turning A or B of selector.

6. Set SST(0K201 175 A01) onto converter housing.

7. Install outer race removed in step 1 to SST(0K201 175 A01).

8. Set output gear assembly onto SST(0K130 191 A03).

9. Set four SST(0K130 191 A03) on converter housing in positions shown.

10. Set bearing housing on output gear assembly and install four SST(0K130 175 A04); then tighten them to specifiedtorque.


11. to increase clearance indicated by arrow with SST(0K130 175 A03) until SST(0K130 175 A03) no longer turns.

12. Turn selector in opposite direction until gap is reduced.

13. Mount SST(0K130 322 020) and torque meter on output gear.

14. Adjust clearance of SST(0K130 175 A03) to obtain specified preload.


Read preload when output gear is rotating.

a. Measure clearance around entire circumference and select shims equivalent to maximum clearance.b. The maximum allowable number of shims is 7.

15. Measure clearance. Select adjustment shim(s) equivalent to measured clearance.

16. Remove bearing housing and SST(0K201 175 AA0).

17. Remove bearing outer race from bearing housing, refer to Bearing and Race Locations.

18. Install required shim(s).

19. Press bearing race into bearing housing with SST(or equivalent).

20. Press bearing outer race into bearing cover.

21. Install output gear assembly and bearing housing.


Do not install idler gear at this time.

22. Using SST(0K130 191 A04) and a torque meter, verify that preload reading is within specification.


23. Remove bearing housing and output gear assembly.

REMOVAL1. Disconnect negative battery cable then positive battery cable.

2. Raise and properly support vehicle.

3. Place a drain pan under transaxle drain plug.

4. Remove auto transaxle drain plug and allow automatic transaxle fluid to fully drain.

5. Pull data link connector upward from mass air flow sensor.

6. To remove air cleaner assembly, disconnect hose from intake manifold, air temperature sensor connector, MAFsensor connector then remove two air cleaner assembly mounting bolts and one nut.

7. Remove three No.4 engine mounting nuts then loosen engine mounting bolt.

Disconnect input/turbine speed sensor connector.

8. Remove ground strap bolt from top of auto transaxle then disconnect ground strap.

9. Disconnect vehicle speed sensor connector from right side of auto transaxle.

10. Remove U-clip from selector cable to auto transaxle linkage.

11. Remove nut and washer from auto transaxle linkage.

12. Disconnect auto transaxle range switch (Inhibitor switch) connector.

13. Disconnect solenoid valve connector.

14. Disconnect crankshaft position sensor connector.

15. Disconnect oxygen sensor connector.

16. Disconnect two ATF cooler hoses.

17. Remove two upper converter housing bolts. (top two)

18. Remove two upper starter bolts.

19. Support engine by using SST(0K201 170 AA0).

20. Remove both front wheels. (four lug nuts each)

21. Remove splash shield from under engine. (three bolts and three fastners)

22. Remove left tie rod end from steering knuckle by removing one cotter pin and one nut.

23. Remove stabilizer control link from bracket attached to shock absorber assembly after loosening one nut.

24. Remove pinch bolt and nut from left ball joint.Separate ball joint from control arm.

25. Remove two nuts from No.2 engine mount-to-mounting member.

26. Remove engine mounting member-to-chassis bolts (two front) and nuts (two rear) then remove engine mountingmember.

27. Gently pry left drive shaft from auto transaxle.

28. Remove the joint shaft installed at the RH side.

29. Install SST(0K201 270 014) to prevent side gear from becoming misaligned.

30. Remove two nuts from U-bolt.

31. Remove five nuts (three front, two rear) then remove catalytic converter.

32. Remove converter housing access cover and remove four drive plate-to-torque converter mounting nuts.Rotate engine at crank pulley to gain access to all four nuts.

33. Remove one lower starter bolt.

34. Remove four engine oil pan-to-transaxle mounting bolts.

35. Remove three No.1 engine mounting-to-chassis bolts.

36. Remove three No.2 engine mounting bolts then remove No.2 engine mounting from auto transaxle.

37. Support (and secure if possible) auto transaxle with a transaxle jack or suitable floor jack.

38. Remove two remaining converter housing bolts on front and rear sides of transaxle.

39. Slowly lower drive train, allowing transaxle to tilt toward ground.

40. Gently separate transaxle from engine and pull unit out through wheel well.

INSTALLATION1. Set transaxle on transaxle jack or suitable floor jack and place under vehicle.

2. Raise transaxle and align with engine.

3. Connect transaxle to engine using four convert housing bolts to pull together; two on top and two on side.

Tightening torque:65-86 Ib·ft (89-116 N·m 9.1-11.9 kg·m)

4. Remove floor jack from auto transaxle.

5. Remove SST(0K201 270 014).

6. Install No.2 engine mounting to auto transaxle then install three bolts.

7. Install four drive plate -to-torque converter mounting nuts.Rotate engine at crank pulley to gain access to all four nuts.

Tightening torque:25-36 Ib·ft (34-49 N·m, 3.5-5.0 kg·m)

8. Install four engine oil pan-to-transaxle mounting bolts then install access cover.

Tightening torque:27.5-38.0 Ib·ft (37-52 N·m, 3.8-5.3 kg·m)

9. Install starter and ground strap. (Refer to starting system)

10. Install three No.1 engine mounting-to-chassis bolts.

Tightening torque:49.2-69 Ib·ft (67-93.2 N·m, 6.8-9.5 kg·m)

11. Install joint shaft and tighten the three bolts. (Refer to section DS)


12. Install new clip on left drive shaft.

13. Push drive shaft into transaxle with opening of clip pointing upward.


14. Install left lower ball joint into spindle then install pinch bolt.


15. Install left stabilizer control link to bracket attached to shock absorber assembly.


16. Install left tie rod end to steering knuckle then install tie rod end nut.


17. Insert cotter pin and bend over.

18. Install engine mounting member-to-chassis bolts (two front) and nuts. (two rear)


19. Install two nuts to No.2 engine mount-to-mounting member.


20. Install catalytic converter. (five nuts)

Tightening torque:27.4-38.3 Ib·ft (37.2-51.9 N·m, 3.8-5.3 kg·m)

21. Install two catalytic converter bracket nuts to engine.

Tightening torque:27.4-38.3 Ib·ft (37.2-51.9 N·m, 3.8-5.3 kg·m)

22. Install splash shield to under engine then tighten bolts. (three bolts and three fasteners)

23. Install both right and left wheels then tighten both right and left lug nuts. (four lug nuts each)

Tightening torque:65-87 Ib·ft (88-118 N·m, 9-12 kg·m)

24. Lower vehicle.

25. Remove SST(0K 201 170 AA0A).

26. Slide ATF inlet and outlet hose onto ATF cooler pipe until it is fully seated against the ridge.

27. Install hose clamp onto hose at center of mark and at angle shown.

28. Connect oxygen sensor connector.

29. Connect crankshaft position sensor connector.

30. Connect solenoid valve connector.

31. Connect auto transaxle range switch connector.

32. Install washer and nut to auto transaxle linkage and tighten nut then insert U-clip.


33. Connect vehicle speed sensor connector.

34. Connect input/turbine speed sensor connector.

35. Install No.4 engine mounting then tighten three nuts and bolt.

Tightening torque:Nuts: 49-68 Ib·ft (68-93 N·m, 6.8-9.5 kg·m)Bolt: 47-66 Ib·ft (64-89 N·m, 6.5-9.1 kg·m)

36. Install air cleaner assembly.

37. Connect air temperature sensor connector.

38. Connect MAF sensor connector

39. Insert diagnosis connector.

40. Connect negative and positive battery cable.

41. Fill transaxle with ATF. (Refer to automatic transaxle fluid)

42. Adjust auto transaxle control cable. (Refer to selector lever)

Kick Down Band

2004 > 1.6L DOHC >

BRAKE BAND1. Disassembly in order shown in figure.

Use a piece of wire to secure 2-4 brake band so that it is not damaged by being allowed to fully expand.

2004 > 1.6L DOHC >

INSPECTION

2-4 Brake band1. Check 2-4 brake band for wear and burnt friction material.

Servo return spring1. Measure servo return spring free length and check for deformation.

Free length: 1.703 in (43.25 mm)

2. If not within specification, replace servo return spring.

Orifice check spring

Do not compress spring when measuring it with vernier calipers.

1. Measure spring free length.

2. If not as specified, replace spring.

RE-ASSEMBLY

Install spring exactly in direction shown.

1. Install orifice valve, orifice check spring, and orifice holder as shown.

2. Install orifice assembly and washer to transaxle case.

3. Tighten orifice assembly using a hexagonal wrench.

Tightening torque:29-39 Ib·ft (40-53 N·m, 4.0-5.0 kg/cm²)

4. Install band strut.

5. Install 2-4 brake band.

6. Apply ATF to new O-rings and install them to servo piston.

D-ring inner diameter:Piston stem side: 2.303 in (58.5 mm)Servo retainer side: 1.157 in (29.4 mm)

7. Insert piston stem into servo piston and secure it with a new spring clip.

8. Apply ATF to new O-ring and install it to servo retainer.

O-ring inner diameter: 2.587 in (65.7 mm)

9. Assemble servo piston and servo retainer.

Do not install servo piston and retainer into transaxle case at this time.


Torque Converter

2004 > 1.6L DOHC >

WASHING INSIDE CONVERTER1. Drain any ATF remaining in converter.

2. Pour in ATF 0.5 US qt (0.5 liter, 0.44 lmp qt).

3. Shake converter to clean inside. Pour out ATF.

4. Pour in ATF.


Replace torque converter if it contains any metallic particles.

WASHING INSIDE CONVERTER1. Drain any ATF remaining in converter.

2. Pour in ATF 0.5 US qt (0.5 liter, 0.44 lmp qt).


4. Pour in ATF.


Replace torque converter if it contains any metallic particles.

The Other Automatic Transaxle System

2004 > 1.6L DOHC >

COMPONENTS

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove accumulator pistons and springs from clutch housing by applying compressed air through oil passage as

shown in figure.

INSPECTIONAccumulator spring1. Measure spring free length.

2. If not within specification, replace spring.

RE-ASSEMBLY

Installation order2-3 accumulator: piston-spring-stopper1-2 accumulator: piston-spring-stopperN-D accumulator: piston-spring-stopperN-R accumulator: spring-piston-stopperApply even pressure to perimeter of accumulator pistons and stops to avoid damaging O-ring and seal rings whileinstalling.

1. Apply ATF to new seal rings and install them onto accumulator pistons.

2. Install accumulator pistons and springs.

3. Install stopper and snap ring.

2004 > 1.6L DOHC >

TROUBLESHOOTING

BASIC INSPECTION ITEM ADJUSTMENTAUTOMATIC TRANSMISSION FLUID CHECK1. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C).

2. Park the vehicle on a level surface.

3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, andthen move the selector lever to the N position.

4. After wiping off any dirt around the oil level gauge, remove the oil level gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from thebushesand friction materials, a transmission overhaul may be necessary.

5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, pour in morefluid until the level reaches the HOT mark.Automatic transmission fluid : GENUINE DIAMOND ATF SP-III

If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form insidethe hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting andslipping of the clutches and brakes.If there is too much fluid, the gears can churn it up into foam and cause the same conditions that can occurwith low fluid levels.In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normalvalve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, inwhich case it may be mistaken for a leak.

6. Securely insert the oil level gauge.

7. The fluid should always be replaced when overhauling the transmission or after the vehicle has been driven undersevere conditions.

8. The replacement procedures are given below.

AUTOMATIC TRANSMISSION FLUIDREPLACEMENTIf you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluidby the following procedure.

1. Disconnect the hose which connects the transmission and the oil cooler (inside the radiator).

2. Start the engine and let the fluid drain out.

Running conditions : N range with engine idling.

The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,the engine should be stopped at that point.

3. Remove the drain plug from the bottom of the transmission case to drain the fluid.

4. Install the drain plug via the gasket, and tighten it the specified torque.

Tightening torque : 32 Nm (24 lb·ft)

5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.

6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (6) and (7).

7. Pour the new fluid in through the oil filler tube.

8. Reconnect the hose which was disconnected in step (1) above, and firmly replace the oil level gauge.

9. Start the engine and run it at idle for 1-2 minutes.

10. Move the select lever through all positions, and then move it to the N position.

11. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C), and then check the fluidlevel again. The fluid level must be at the HOT Mark.

12. Firmly insert the oil level gauge into the oil filler tube.

TORQUE CONVERTER STALL TESTThis test measures the maximum engine speed when the selector lever is at the D or R position and the torqueconverter stalls to test the operation of the torque converter, starter motor and one-way clutch operation and theholding performance of the clutches and brakes in the transmission.

Do not let anybody stand in front of or behind the vehicle while this test is being carried out.

1. Check the automatic transmission fluid level and temperature and the engine coolant temperature.a. Fluid level : At the HOT mark on the oil level gaugeb. Fluid temperature : 80-100°Cc. Engine coolant temperature : 80-100°C

2. Check both rear wheels (left and right).

3. Pull the parking brake lever on, with the brake pedal fully depressed.

4. Start the engine.

5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the maximumengine speed at this time.

a. The throttle should not be left fully open for any more than eight seconds.b. If carrying out the stall test two or more times, move the selector lever to the N position and run the engine

at 1,000r/min to let the automatic tranmission fluid cool down before carrying out subsequent tests.

Standard valueStall speed : 2200-2600 r/min

6. Move the selector lever to the R position and carry out the same test again.

Standard valueStall speed : 2200-2600 r/min

TORQUE CONVERTER STALL TEST JUDGEMENT RESULTSa. Stall speed is too high in both D and R rangesa. Low line pressureb. Low reverse brake slippageb. Stall speed is too high in D range onlya. Underdrive clutch slippagec. Stall speed is too high in R range onlya. Reverse clutch slippaged. Stall speed too low in both D and R rangesa. Malfunction of torque converterb. Insufficient engine output

HYDRAULIC PRESSURE TEST1. Warm up the engine until the automatic transmission fluid temperature is 80-100°C.

2. Jack up the vehicle so that the wheels are free to turn.

3. Connect the special tools oil pressure gauge to each pressure discharge port.

4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,and check that the measured values are with in the standard value ranges.

5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosistable.

STANDARD HYDRAULIC PRESSURE TEST

Measurement condition Standard hydraulic pressure kPa

Selectorleverposition

Shift position Enginespeed(rpm)

Under driveclutchpressure

Reverseclutchpressure

Overdriveclutchpressure

Low andreversebrakepressure

Secondbrakepressure

Torqueconverterpressure

P - 2,500 - - - 260-340 - 220-360

R Reverse 2,500 - 1.270-1,770

- 1,270-1,770

- 500-700

N Neutral - - - - 260-340 - 220-360

D 1st gear 2,500 1,010-1,050

- - 1,010-1,050

- 500-700

2nd gear 2,500 1,010-1,050

- - - 1,010-1,050

500-700

3rd gear 2,500 780-880 - 780-880 - - 450-650

4th gear 2,500 - - 780-880 - 780-880 450-650

HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause

All hydraulic pressures are high Incorrect transmission control cable adjustment

Malfunction of the regulator valve

All hydraulic presures are low Incorrect transmission control cable adjustment

Malfunction of the oil pump

Clogged internal oil filter

Clogged oil cooler


Malfunction of the relief valve

Incorrect valve body installation

Hydraulic pressure is abnormal in "R" rangeonly


Clogged orifice


Hydraulic pressure is abnormal in "3" or "4"range only


Clogged orifice


Malfunction of the overdrive solenoid valve

Malfuction of the overdrive pressure control valve


Malfunction of the switch valve

Clogged orifice


Only underdrive hydraulic pressure isabnormal

Malfunction of the oil seal K

Malfunction of the oil seal L

Malfunction of the oil seal M

Malfunction of the underdrive solenoid valve

Malfunction of the underdrive pressure control valve

Malfunction of check ball

Clogged orifice


Only reverse clutch hydraulic pressure isabnormal

Malfunction of the oil seal A

Malfunction of the oil seal B

Malfunction of the oil seal C

Clogged orifice


Only low and reverse hydraulic pressure isabnormal

Malfunction of the oil seal D

Malfunction of the oil seal E

Malfunction of the oil seal F

Malfunction of the overdrive solenoid valve

Malfunction of the overdrive pressure control valve

Malfunction check ball

Clogged orifice


Only second hydraulic pressure is abnormal Malfunction of the oil seal I

Malfunction of the oil seal J

Malfunction of the low and reverse solenoid valve

Malfunction of the low and reverse pressure control valve

Malfunction of the switch valve

Malfunction of the fail safe valve A


Clogged orifice


Only torque converter presure is abnormalPressure applied to non operating element

Malfunction of the oil seal G

Malfunction of the oil seal H

Malfunction of the oil seal O

Malfunction of the second solenoid valve

Malfunction of the second pressure control valve

Malfunction of the fail safe valve B

Clogged orifice


Only torque converter presure is abnormal Malfunction of the oil cooler

Malfunction of the oil seal N

Malfunction of the damper clutch control solenoid valve

Malfunction of the damper clutch control valve

Malfunction of the torque converter pressure control valve

Clogged orifice

Pressure applied to non operating element Incorrect valve body installation

Incorrect transmission control cable adjustment

Malfunction of the manual valve



DIAGNOSIS FUNCTION1. Connect HI-SCAN to the connector for diagnosis.

2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTICTRUBLE CODE DESCRIPTION" on the following page.

a. As many a maximum of 8 diagnostic trouble codes (in the sequence of occurrence) can be stored in theRandom Access Memory (RAM) incorporated within the control moduel.

b. The same diagnostic trouble code can be stored as many as one time.c. If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 8, already stored

diagnostic trouble codes will be erased, in sequence beginning with the oldest.d. Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been

read out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be canceled whenthe battery is disconnected.

3. If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the fail-safe code description will be stored in the RAM.Three of these diagnostic trouble codes can be stored.

4. The cancelation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position,but the diagnostic trouble code is stored in the RAM.

5. Memorizationa. Up to 8 diagnosis items and 3 fail-safe items can be memorized.b. If the memory capacity is exceeded, diagnosis and fail-safe items in the memory are overwritten, starting with

the oldest.c. No code can be memorized more than once.

6. Diagnosis Code Deletion.a. Automatic Deletion

All diagnosis codes are deleted from memory the 40th time the ATF temperature reaches 50°C aftermemorization of the most recent diagnosis code.

b. Forced Deletion.Memorized diagnosis codes can be deleted using the SCAN-TOOL provided the following conditions aresatisfied :

a. The ignition switch is ON;b. There is no detection pulse from the crank angle sensorc. There is no detection pulse from the output shaft speed sensord. There is no detection pulse from the vehicle speed sensore. The fail-safe function is not operational

ROAD TEST

No. Condition Operation Judgement : Value Check item

1 Ignition switch : OFF Ignition switch(1) ON

Battery voltage (mV) Control relay

2 Ignition switch : ONEngine : StoppedSelect lever position : P

Selector lever position(1) P,(2) R,(2) N, (4) D(3) 3, (6) 2, (7) L

(1) P,(2) R,(3)N,(4) D,(5)3,(6) 2,(7) L

Transaxle range switch

Accelerator pedal(1) Released(2) Half depressed(3) Depressed

(1) 400-1,000 mV(2) Gradually rises from(1)(3) 4,500-5,000 mV

Throttle position sensor

Brake pedal(1) Depressed(2) Released

(1) ON(2) OFF

Stop lamp switch

3 Ignition switch STEngine Stopped

Starting test with lever P orN range

Starting should bepossible

Starting possible orimpossible

4 Warming up Drive for 15 minutes ormore so that the automaticfluid temperature becomes70-90°C

Gradually rises to 70-90°C

Oil temperature sensor

5 Engine : IdlingSelector lever position N

A/C switch(1) ON(2) OFF

(1) ON(2) OFF

Triple pressure switch

Accelerator pedal(1) Released(2) Half depressed

(1) ON(2) OFF

Idle position switch

(1) 600-925rpm(2) Gradually rises from(1)

(1) Data changes Communication withengine-ECU

Selector lever position(1) N→D(2) N→R

Should be no abnormalshifting shocks Time lagshould be within 2seconds

Malfunction whenstarting

6 Selector lever position : N(Carry out on a flat andstraight road)

Selector lever position andvehicle speed1. Idling in 1st gear(Vehiclestopped)2. Driving at constant speedof 20km/h in 1st gear3. Driving at constant speedof 30 km/h in 2nd gear4. Driving at 50 km/h in 3rdgear with accelerator fullyclosed5. Driving at constant speedof 50 km/h in 4th gear(Each condition should bemaintained for 10 secondsor more)

(2) 1st, (4) 3rd, (3) 2nd,(5) 4th

Shift condition

(2)0%, (4) 100%, (3)100%, (5) 100 %

Low and reversesolenoid valve

(2) 0%,(4) 0%,(3) 0%,(5)100%

Underdrive solenoidvalve

(2)100%, (4)100%,(3) 0%,(5) 0% Second solenoid valve

(2) 100%, (4) 0%, (3) 100%, (5) 0 % Overdrive solenoid valve

(1) 0 km/h(4) 50 km/h Vehicle speed sensor

(4) 1,800-2,100 rpm

(4) 1,800-2,100 rpm Input shaft speed sensor

(3) 0%(5) Approx. 70-90%

Output shaft speedsensor

(5) Approx. 70-90% sensorDamper clutch controlsolenoid valve

(3) Approx. 100-300rpm(5) Approx. 0-10rpm

7 Selector lever position : D(Carry out on a flat andstraight road)

1. Accelerate to 4th gear ata throttle position sensoroutput of 1.5V (acceleratoropening angle of 30 %).2. Gently decelerate to astandstill3. Accelerate to 4th gear ata throttle position sensoroutput of 2.5 V (acceleratoropening angle of 50%).4. While driving at 60 km/hin 4th gear, shift down to3rd gear.5. While driving at 40 km/hin 3rd gear, shift down to2nd gear.6. While driving at 20 km/hin 2nd gear, shift down to1st gear.

For (1),(2) and (3), thereading should be thesame as the specifiedoutput shaft torque, andno abnormal shocksshould occur.For (4),(5) and (6),downshifting should occurimmediately after theshifting operation ismade.

Malfunction whenshifting

Displaced shift points

Does not shift

Does not shift from 1 to2 or 2 to 1



8 Selector lever position : N(Carry out on a flat andstraight road).

Move selector lever to Rrange drive at constantspeed of 10 km/h

The ratio between inputand output speed senordata should be the sameas the gear ratio whenreversing.

Does not shift

MIL REQUEST ITEM AND DIAGNOSIS CODE

No. FAIL CAUSEOBD-II

DTC *2 FAILSAFE REMARK

DTC *1 MIL

1OILTEMPERATURESENSOR

OPEN OR +B SHORT0710

O 0713 -

GND SHORT O 0712 -

2 INPUT SPEED (PG A) OPEN OR SHORT (GND, +B) 0715 O 0715 O

3 OUTPUT SPEED (PG B) OPEN OR SHORT (GND, +B) 0720 O 0720 O

4 BRAKE SW OPEN OR +B SHORT - - 0703 -

5 LR (DIR) SOLENOID OPEN OR GND SHORT 0750 O 0750 O

6 UD SOLENOID OPEN OR GND SHORT 0755 O 0755 O

7 2ND SOLENOID OPEN OR GND SHORT 0760 O 0760 O

8 OD SOLENOID OPEN OR GND SHORT 0765 O 0765 O

9 DCC SOLENOID OPEN OR GND SHORT 0743 O 0743 O

10 INHIBITOR SWOPEN OR GND SHORT

0705O 0707 -

+B SHORT OR SHORT OFSWITCHS

O 0708 -

11 1st Control System Abnormal 1st 0731 O 0731 O

12 2nd Control System Abnormal 2nd 0732 O 0732 O

13 3rd Control System Abnormal 3rd 0733 O 0733 O

14 4th Control System Abnormal 4th 0734 O 0734 O

15 Reverse Control System Abnormal Reverse 0736 O 0736 O

16 DAMPER CLUTCH

Abnormal System or STUCKOFF

0741 O 0741 -

Abnormal System or STUCKON

0742 O 0742 -

17 A/T CONTROL RELAY OPEN OR GND SHORT 1723 O 1723 O

18 CAN-BUS OFF TCU FAIL OR TCU SIDEOPEN/SHORT

- *3- 1630 -

19 CAN-TIME OUT ECU ECU FAIL OR ECU SIDEOPEN/SHORT

- O 1613 -

20 TCU CAN MI-COMMALFUNCTION

CAN MI-COMMALFUNCTION - *3- 1764 -

21 Vehicle Speed Sensor OPEN OR SHORT (GND, +B) - O 1500 -

*1) : TCU transfers only the DTCs related OBD-II to GST through TEST MODE 03.*2) : TCU transfers all stored DTCs through TEST MODE 13.*3) : When the CAN communication line is error, CAN ECU illuminates CHECK ENG LAMP.

DIAGNOSTIC TROUBLE CODE DESCRIPTION

DTCNo.

Diagnosis item Probable cause

P0713 Oil temperature sensor Open circuit Oil temperature sensor output > 4.57V for 1 second or longer (oiltemperature does not increase)

P0712 Short circuit Output < 0.49V for 1 second

P0715 Input speed sensor Short circuit/open circuit No input speed sensor output pulsedetected for > 1 second at vehiclespeed of > 30 km/h

P0720 Output speed sensor Short circuit/open circuit At vehicle speed of > 30 km/h, outputspeed sensor output < 50 of vehiclespeed sensor output for > 1 second

P0703 Stop lamp switch Short circuit/open circuit At vehicle speed of 6 km/h, stop lampswitch is ON continuously for 5minutes

P0750 LR solenoid valve Short circuit/open circuit With relay voltage > 10V, open orshort circuit is continuously for 0.3second.

P0755 UD solenoid valve Short circuit/open circuit

P0760 2nd solenoid valve Short circuit/open circuit

P0765 OD solenoid valve Short circuit/open circuit

P0743 DCC solenoid valve Short circuit/open circuit

P0731 Gear shift incomplete 1st After gear shift, output shaft speedsensor output x gear ratio of newgear = input shaft speed sensoroutput

P0732 2nd

P0733 3rd

P0734 4th

P0736 Reverse

P0741 DCC Stuck off DCC solenoid valve drive duty ratio is100% for 4 seconds continuously

P0742

Stuck on

At output speed > 1000rpm,calculated slip (engine speed-inputspeed) < 5rpm or > 5rpm for 10seconds continuously.

P1723 A/T control relay Earth short circuit/open circuit After ignition ON, A/T control relayvoltage < 7V

P0707 Transaxle range switch (Inhibitorswitch)

Open circuit No signal is continuous for > 30seconds

P0708 Short circuit Above 2 kinds signals are continuousfor 30 seconds

P1630 CAN-BUS OFF TCM Fail/open/short Receive BUS-OFF information fromCAN CONTROLLER

P1631 CAN-TIME OUT ECU ECM Fail/open/short No output signal for 1.5 second

P1764 CAN CONTROLLER CIRCUIT TCU internal circuit mal-function Communication error output iscontinuously for > 1 second

P1500 Vehicle speed sensor Open/short At vehicle speed of ≥ 30km/h, Nooutput signal for 30 second

INSPECTION CHART FOR DIAGNOSIS CODES

Code Diagnosis item Probable cause

P0713P0712

Oil temperature sensor systemIf the oil temperature sensor output voltage is4.57 V or more even after driving for 10 minutesor more (if the oil temperature does notincrease), it is judged that there is an open circuitin the oil temperature sensor and diagnosiscodeP0713 is output.

Open circuit Malfunction of the oil temperaturesensorMalfunction of connectorMalfunction of the TCM

P0715 Input shaft speed sensor systemIf no output pulse is detected from the input shaftspeed sensor for 1 second or more while drivingin 3rd or 4th gear at a speed of 30 km/h or more,there is judged to be an open circuit or short.Circuit in the input shaft speed sensor anddiagnosis code P0715 is output. If diagnosis codeP0715 is output four times, the transmission islocked into 3rd gear(D range or 3-range) or 2ndgear (2-range or L-range) as a fail-safe measure.

Short circuit / Opencircuit

Malfunction of the input shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of connectorMalfunction of the TCM

P0720 Output shaft speed sensor systemIf the output from the output shaft speed sensoris continuously 50% lower than the vehicle speedfor 1 second or more while driving in 3rd or 4thgear at a speed of 30km/h or more, there isjudged to be an open circuit or short-circuit in theoutput shaft speed sensor and diagnosis codeP0720 is output. If diagnosis code P0720 isoutput four times, the transmission is locked into3rd gear (D range or 3-range) or 2nd gear (2-range or L-range) as a fail-safe measure.

Short circuit /Opencircuit

Malfunction of the wide openthrottle switchMalfunction of connectorMalfunction of the TCMMalfunction of solenoid valveMalfunction of connectorMalfunction of the TCM

P1703 Stop lamp switch systemIf the stop lamp switch is on for 5 minutes ormore while driving, it is judged that there is ashort circuit in the stop lamp switch and diagnosiscode P0703 is output.

Short circuit / Opencircuit

Malfunction of the stop lampswitchMalfunction of connectorMalfunction of the TCM

P0750 Low and reverse solenoid valve system Short circuit /Opencircuit

Malfunction of solenoid valveMalfunction of connectorMalfunction of the TCM

P0755 Underdrive solenoid valve system Short circuit /Opencircuit

P0760 Second solenoid valve system Short circuit /Opencircuit

P0765 Overdrive solenoid valve systemIf the resistance value for a solenoid valve is toollarge or too small, it is judged that there is ashort-circuit or an open circuit in the solenoidvalve and the respective diagnosis code isoutput. The transmission is locked into 3rd gearas a fail-safe measure.

Short circuit /Opencircuit

P0743 Damper clutch solenoid valve system Short circuit/ Opencircuit

Malfunction of the damper clutchcontrol solenoid valveMalfunction of connectorMalfunction of the TCM

P0741P0742

Damper clutch solenoid valve systemIf the resistance value for the damper clutchcontrol solenoid valve is too small, it is judgedthat there is a short circuit or an open circuit inthe damper clutch control solenoid valve anddiagnosis code P0743 in output. If the drive dutyratio for the damper clutch control solenoid valveis 100% for a continuous period of 4 seconds ormore, it is judged that there is an abnormal it inthe damper clutch control valve is stuck off anddiagnosis code P0741 is output. If the calculatedslip(engine speed-input speed) is less than 5rpm,it is judged that damper clutch control solenoidvalve is stuck on rationality-low and if thecalculated slip(engine speed-input speed) is morethan 5rpm, it is judged that damperclutch controlsolenoid valve is stuck on rationality-high anddiagnosis code P0742 is output. When diagnosiscode P0743 is output, the transmission is lockedinto 3rd gear as a fail-safe measure.

Defective system

P0731 2nd gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 3rdgear ratio is not the same as the output from theinput shaft speedsensor after shifting to 3rd gear has been completed, diagnosis codeP0732 is output. If diagnosis code P0732 is output four times, thetransmission is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaftspeed sensorMalfunction of the output shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of the transfer drivegear or driven gearMalfunction of the low ad reversebrake systemMalfunction of the underdriveclutch systemNoise generated

P0732 2nd gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 3rdgear ratio is not the same as the output from theinput shaft speedsensor after shifting to 3rd gear has been completed, diagnosis codeP0732 is output. If diagnosis code P0732 is output four times, thetransmission is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaftspeed sensorMalfunction of the output shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of the transfer drivegear or driven gearMalfunction of the underdriveclutch systemMalfunction of the overdrive clutchsystemNoise generated

P0733 3rd gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 3rdgear ratio is not the same as the output from theinput shaft speedsensor after shifting to 3rd gear has been completed, diagnosis codeP0733 is output. If diagnosis code P0733 is output four times, thetransmission is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaftspeed sensorMalfunction of the output shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of the transfer drivegear or driven gearMalfunction of the underdriveclutch systemMalfunction of the overdrive clutchsystemNoise generated

P0734 4th gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 4thgear ratio is not the same as the output from theinput shaft speedsensor after shifting to 4th gear has been completed, diagnosis codeP0734 is output. If diagnosis code P0734 is output four times, thetransmission is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaftspeed sensorMalfunction of the output shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of the transfer drivegear or driven gearMalfunction of the second brakesystemMalfunction of the overdrive clutchsystemNoise generated

P0736 Reverse gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the reversegear ratio is not the same as the output fromthe input shaft speedsensor after shifting to reverse gear has been completed, diagnosis codeP0736 is output. If diagnosis code P0736 is output four times, thetransmission is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaftspeed sensorMalfunction of the output shaftspeed sensorMalfunction of the underdriveclutch retainerMalfunction of the transfer drivegear or driven gearMalfunction of the low andreverse brake systemMalfunction of the reverse clutchsystemNoise generated

P1723 A/T control relay systemIf the A/T control relay voltage is less than 7 Vafter the ignition switch has been turned ON, it isjudged that there is an open circuit or a short-circuit in the A/T control relay earth and iagnosiscode P1723 is output. Then the transmission islocked into 3rd gar as a fail-safe measure.

Short circuit toearth/Open circuit

Malfunction of the A/T controlrelayMalfunction of connectorMalfunction of the TCM

P0707P0708

Transaxle range switchNo signal is continuous for > 30 secondsAbove 2 kinds signals are continuous for > 30 second

Malfunction of transaxle rangeswitch

P1630 CAN-BUS OFFa. NO 3 SPEED HOLD FAILb. NO PGA, B FAILc. BATTRY VOLTAGE > 10V CONTINUOUSLY FOR 0.5 SECONDd. NO ENGINE STOPe. RECEIVE BUS OFF INFORMATION FROM CAN CONTROLLER

a. TCM Failb. TCM side open & short

* PGA : Input shaft speedsensorPGB : Output shaft speedsensor

P1631 CAN-TIME OUT ECM a. ECM fail

a. No 3 speed hold failb. No PGA, B failc. Battry voltage > 10V continuously for 0.5 secondd. No engine stope. No output signal for 1.5 secondf. Receive BUS OFF information from CAN CONTROLLER

b. ECM side open & short

P1764 TCM CAN CONTROLLER MALFUNCTIONa. No 3 speed hold failb. No PGA, B failc. Battry voltage > 10V continuously for 0.5 secondd. No engine stope. Communication error output is continuously for > 1 second

a. CAN CONTROLLER circuitmalfunction

INSPECTION CHART FOR THROUBLE SYMPTOMS

Trouble symptom Probable cause

Communication with HI-SCAN is not possibleIf communication with the HI-SCAN is not possible, the cause is probably adefective diagnosis line or the TCM is not functioning.

Malfunction diagnosis lineMalfunction of connectorMalfunction of the TCM

Driving impossible Starting impossibleStarting is not possible when the selector lever is in P orN range.In such cases, the cause is probably a defective enginesystem, torque converter or oil pump.

Malfunction of the engine systemMalfunction of the torqueconverterMalfunction of the oil pump

Does not move forwardIf the vehicle does not move forward when the selectorlever is shifted from N to D, 3, 2 or L range while theengine isidling, the cause is probably abnormal linepressure or a malfunction of the underdrive clutch orvalve body.

Abnormal line pressureMalfunction of the underdrivesolenoid valveMalfunction of the underdriveclutchMalfunction of the valve body

Does not reverseIf the vehicle does not reverse when the selector lever isshifted from N to R range while the engine is idling, thecause is probably abnormal pressure in the reverse clutchor low and reverse brake or a malfunction of the reverseclutch, low and reverse brake or valve body.

Abnormal reverse clutch pressureAbnormal low and reverse brakepressureMalfunction of the low andreverse brake solenoid valveMalfunction of the reverse clutchMalfunction of the low andreverse brakeMalfunction of the valve body

Does not move (forward or reverse)If the vehicle does not move forward or reverse when theselector lever is shifted to any position while the engine isidling, the cause is probably abnormal line pressure or amalfunction of the power train, oil pump or valve body.

Abnormal line pressureMalfunction of power trainMalfunction of the oil pumpMalfunction of the valve body

Malfunction whenstarting

Engine stalling when shiftingIf the engine stalls when the selector lever is shifted fromN to D or R range while the engine is idling, the cause isprobably a malfunction of the engine system, damperclutch solenoid valve, valve body or torque converter(damper clutchmalfunction).

Malfunction of the engine systemMalfunction of the damper clutchcontrol solenoid valveMalfunction of the valve bodyMalfunction of the torqueconverter (Malfunction of thedamper clutch)

Shocks when changing from N to D and large time lagIf abnormal shocks or a time lag of 2 seconds or moreoccur when the selector lever is shifted from N to Drange while the engine is idling, the cause is probably

Abnormal underdrive clutchpressureAbnormal low and reverse brakepressure

range while the engine is idling, the cause is probablyabnormal underdrive clutch pressure or a malfunction ofthe underdrive clutch, valve body or idle position switch.

pressureMalfunction of the underdrivesolenoid valveMalfunction of the valve bodyMalfunction of the idle positionswitch

Shocks when changing from N to R and large time lagIf abnormal shocks or a time lag of 2 seconds or moreoccur when the selector lever is shifted from N to Rrange while the engine is idling, the cause is probablyabnormal reverse clutch pressure or low and reversebrake pressure, or a malfunction of the reverse clutch,low and reverse brake, valve body or idle position switch.

Abnormal reverse clutch pressureAbnormal low and reverse brakepressureMalfunction of the low andreverse solenoid valveMalfunction of the reverse clutchMalfunction of the low andreverse brakeMalfunction of the valve bodyMalfunction of the idle positionswitch

Shocks when changing from N to D, N to R and largetime lagIf abnormal shocks or a time lag of 2 seconds or moreoccur when the selector lever is shifted from N to Drange and from N to R range while the engine is idling,the cause is probably abnormal line pressure or amalfunction of the oil pumpor valve body.

Abnormal line pressureMalfunction of the oil pumpMalfunction of the valve body

Malfunction whenshifting

Shocks and running upIf shocks occur when driving due to upshifting ordownshifting and the transmission speed becomes higherthan the enginespeed, the cause is probably abnormalline pressure or a malfunction of a solenoid valve, oilpump, valve body or of a brake or clutch.

Abnormal line pressureMalfunction of each solenoidvalveMalfunction of the oil pumpMalfunction of the valve body

Displaced shiftingpoints

All pointsIf all shift points are displaced while driving, the cause isprobably a malfunction of the output shaft speed sensor,TPS or of a solenoid valve.

Malfunction of the output shaftspeed sensorMalfunction of the throttle positionsensorMalfunction of each solenoidvalveAbnormal line pressureMalfunction of the valve body

Some pointsIf some of the shift points are displaced while driving, thecause is probably a malfunction of the valve body, or it isrelated to control and is not an abnormality.

Malfunction of the valve body

Does not shift No diagnosis codesIf shifting does not occur while driving and no diagnosiscodes are output, the cause is probably a malfunction ofthe transaxle range switch, or TCM

Malfunction of the transaxle rangeMalfunction of the TCM

Malfunction whiledriving

Poor a accelerationIf acceleration is poor even if downshifting occurs whiledriving, the cause is probably a malfunction of the enginesystem or of a brake or clutch.

Malfunction of the engine systemMalfunction of the brake of clutch

VibrationIf vibration occur when driving at constant speed or whenaccelerating and deceleration in top range, the cause isprobably abnormal damper clutch pressure or amalfunction of the engine system, damper clutch controlsolenoid valve, torque converter or valve body.

Abnormal damper clutch pressureMalfunction of the damper clutchcontrol solenoid valveMalfunction of the torqueconverterMalfunction of the valve body

Transaxle range switch systemThe cause is probably a malfunction of the inhibitor switch circuit, ignition switchcircuit or a defective TCM.

Malfunction of the transaxle rangeswitchMalfunction of the ignition switchMalfunction of the TCM

Vehicle speed sensor systemThe cause is probably a defective vehicle speed sensor circuit or a defectiveTCM.

Malfunction of the vehicle speedsensorMalfunction of connectorMalfunction of the TCM

INSPECTION PROCESS FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1

Communication with the scan tool Probable cause

If communication with the scan tool is not possible, the cause isprobably a defective diagnostic trouble line or the TCM is notfunctioning.

a. Malfunction of diagnostic trouble lineb. Malfunction of connectorc. Malfunction of the TCM

INSPECTION PROCEDURE 2

Starting impossible Probable cause

Starting is not possible when the selector lever is in P or N range. Insuch cases, the cause is probably a defective engine system, torqueconverter or oil pump.

a. Malfunction of the engine systemb. Malfunction of the torque converterc. Malfunction of the oil pump


Does not move Probable cause

If the vehicle does not move forward when the selector lever isshifted from N to D,3,2 or L range while the engine is idling, thecause is probably abnormal line pressure or a malfunction of theunderdrive clutch or valve body.

a. Abnormal line pressureb. Malfunction of the underdrive solenoid

valvec. Malfunction of the underdrive clutchd. Malfunction of the valve body


Does not reverse Probable cause

If the vehicle does not reverse when the selector lever is shifted fromN to R range while the engine is idling, the cause is probablyabnormal pressure in the reverse clutch or low and reverse brake ora malfunction of the reverse clutch, low and reverse brake or valvebody.

a. Abnormal reverse clutch pressureb. Abnormal low and reverse brake pressurec. Malfunction of the low and reverse

solenoid valved. Malfunction of the reverse clutche. Malfunction of the low and reverse brakef. Malfunction of the valve body


Does not move (forward or reverse) Probable cause

If the vehicle does not move forward or reverse when the selectorlever is shifted to any position while the engine is idling, the cause isprobably abnormal line pressure, or a malfunction of the power train,oil pump or valve body.


valvec. Malfunction of the underdrive clutchd. Malfunction of the valve body


Engine stalling when shifting Probable cause

If the engine stalls when the selector lever is shifted from N to D or Rrange while the engine is idling, the cause is probably a malfunctionof the engine system, damper clutch solenoid, valve body or torqueconverter (damper clutch malfunction)

a. Malfunction of the engine systemb. Malfunction of the damper clutch solenoidc. Malfunction of the valve bodyd. Malfunction of the torque converter

(Malfunction of the damper clutch)


Shocks when changing from N to D and range time lag Probable cause

If abnormal shocks or a time lag of 2 second or more occur when theselector lever is shifted from N to D range while the engine is idling,the cause is probably abnormal underdrive clutch pressure or amalfunction of the underdrive clutch,valve body or closed throttleposition switch.


valvec. Malfunction of the underdrive clutchd. Malfunction of the valve bodye. Malfunction of the closed throttle position

switch


Shock when changing from N to R and large time lag Probable cause

If abnormal shocks or a time lag of 2 seconds or more occurs whenthe selector lever is shifted from N to R range while the engine isidling, the cause is probably abnormal reverse clutch pressure or lowand reverse brake pressure, or a malfunction or the reverse clutch,low and reverse brake, valve body or closed throttle position switch.


solenoid valved. Malfunction of the reverse clutche. Malfunction of the low and reverse brakef. Malfunction of the valve bodyg. Malfunction of the closed throttle position

switch


Shocks when changine from N to R and large time lag Probable cause

If abnormal shocks or a time lag of 2 seconds or more occurs whenthe selector lever is shifted from N to R range while the engine isidling, the cause is probably abnormal reverse clutch pressure or lowand reverse brake pressure, or a malfunction of the reverse clutch,low and reverse brake, valve body or closed throttle position switch.


solenoid valved. Malfunction of the reverse clutche. Malfunction of the low and reverse brakef. Malfunction of the valve bodyg. Malfunction of the closed throttle position

switch


Shocks and running up Probable cause

If shocks occur when driving due to upshifting or downshifting and thetransaxle speed becomes higher than the engine speed, the cause isprobably abnormal line pressure or a malfunction of a solenoid valve,oil pump, valve body or of a brake or clutch.

a. Abnormal line pressureb. Malfunction of each solenoid valvec. Malfunction of the oil pumpd. Malfunction of the valve bodye. Malfunction of each brake or each clutch


All points (Displaced shifting points) Probable cause

If all shift points are displaced while driving, the cause is probably amalfunction of the output shaft speed sensor, TPS or of a solenoidvalve.

a. Malfunction of the output shaft speedsensor

b. Malfunction of the throttle position sensorc. Malfunction of each solenoid valved. Abnormal line pressuree. Malfunction of the valve bodyf. Malfunction of the TCM


Some points (Displaced shifting points) Probable cause

If some of the shift points are displaced while driving, the cause isprobably a malfunction of the valve body, or it is related to control andis not an abnormality.

a. Malfunction of the valve body


No diagnostic trouble codes (Does not shift) Probable cause

If shifting does not occur while driving and no diagnostic troublecodes are output, the cause is probably a malfunction of thePark/Neutral position switch, or TCM.

a. Malfunction of the Park/Neutral positionswitch

b. Malfunction of the TCM


Poor acceleration Probable cause

If acceleration is poor even if downshifting occurs while driving, thecause is probably a malfunction of the engine system or of a brake orclutch.

a. Malfunction of the engine systemb. Malfunction of the brake or clutch


Vibration Probable cause

If vibration occurs when driving at constant speed or whenaccelerating in top range, the cause is probably abnormal damperclutch pressure or a malfunction of the engine system, damper clutchsolenoid, torque converter or valve body.

a. Abnormal damper clutch pressureb. Malfunction of the engine systemc. Malfunction of the damper clutch solenoidd. Malfunction of the torque convertere. Malfunction of the valve body

BRAKE REACTIONPLATE END PLAY ADJUSTMENTReplace the pressure plate of the low-reverse brake with the special tool, and then install the brake disc, brake plateand snap ring as shown in the figure. Install the reaction plate and the used snap ring. Move the special tool tomeasure the end play, and then replace the snap ring to adjust the end play to standard value.

Standard value : 0 - 0.16 mm

SECOND BRAKE END PLAY ADJUSTMENTReplace the pressure plate of the second brake with the special tool, and then install the brake disc and brake plateasshown in the figure. Install the return spring, second brake piston and snap ring.

Standard value : 0.79 - 1.25 mm

LOW-REVERSE BRAKE END PLAY ADJUSTMENTReverse the transmission. Measure the axial play.


IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

O.D. I.D. Thickness Symbol O.D. I.D. Thickness Symbol

59 47 1.8 # 1 48.9 37 1.6 # 8

59 47 2.0 # 1 48.9 37 1.7 # 8

59 47 2.2 # 1 48.9 37 1.8 # 8

59 47 2.4 # 1 48.9 37 1.9 # 8

59 47 2.6 # 1 48.9 37 2.0 # 8

59 47 2.8 # 1 48.9 37 2.1 # 8

49 34 3.6 # 2 48.9 37 2.2 # 8

49 34 3.6 # 3 48.9 37 2.3 # 8

46 31 3.3 # 4 48.9 37 2.4 # 8

49 34 3.6 # 5 48.9 37 2.5 # 8

49 34 3.6 # 6 48.9 37 2.6 # 8

59 37 2.8 # 7 - - - -

UNDERDRIVE SUN GEAR END PLAY ADJUSTMENTInstall the used thrust race #8, and then the rear cover. Measure end play of the underdrive sun gear. Replace thrustrace #8 to adjust the play to the standard value.


Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.

DIFFERENTIAL CASE PRELOAD ADJUSTMENTPlace a solder (approx. 10 mm in length, 3 mm in diameter) on the torque converter housing as shown in the figure.

Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to thespecified torque. Loosen the bolts, and remove the solder. use a micrometer to measure the thickness (T) of thepressed solder. Select a-spare which thickness is within the following value.

Standard value : (T+0.045 mm) to (T+0.105 mm)

SYMPTOM RELATED DIAGNOSTIC PROCEDURE

IntroductionMost of the automatic transaxle control system is electrically controlled. This often makes it difficult to diagnoseintermittent problems a in system. Before undertaking actual checks, take a few minutes to talk with customers whoapproachyou with a driveability a complaint. The customer is often good source of information regarding intermittentproblems. Through talks with customer, one can find out what the symptoms are and under what conditions theyoccur.

Work flow

Troubleshooting item#: Each troubleshooting item is assigned a number. There are 28 troubleshooting items. Choose item that most closelycorresponds toactual symptom.

TROUBLESHOOTING CHART

1 Will start in other than P and N ranges

Description Engine starts in P, N and other ranges.

(TROUBLESHOOTING HINTS)1. Selector lever installation or adjustment incorrect.2. Transaxle range switch worn or not adjusted properly.

Step Inspection Action

1 Is selector lever operation OK? Yes Go to next step.

No Adjust selector lever.

2 Operate selector lever. Are selector lever andrange indicator positions aligned?

Yes Go to next step.

No Adjust transaxle range switch.

DescriptionFurther describes symptom. Confirm that chart addresses actual symptom before beginning troubleshooting.Troubleshooting hintsThis describes possible point of malfunction.StepThis shows order of troubleshooting. Proceed with troubleshooting as indicated.Inspection

This describes an inspection to quickly determine malfunction of parts. If a detailed procedure is necessary to performINSPECTION, refer to page shown.ActionThis recommends appropriate action to take as a result (Yes/No) of INSPECTION. How to perform action is describedon reference page shown.

SYMPTOM TROUBLESHOOTING

1 Will start in other than P and N ranges

Description Engine starts in P, N and other ranges.

(TROUBLESHOOTING HINTS)a. Selector lever installation or adjustment incorrect.b. Transaxle range switch worn or misadjusted.




2 Operate selector lever. Are selector lever andrange indicator positions aligned?



3 Operate selector lever. Does transaxle operatenormally and are selector lever and transaxlepositions aligned?


No Repair or replace parts as necessary.

4 Are measurements at TCM OK?

a. H-01/18, H-01/8, H-01/36, H-01/37Terminal: Transaxle range switch

Yes Temporarily install known good TCM.Go to step 5. If problem is corrected, replaceTCM.

No Check transaxle range switch and wiring.

5 Retrun vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan toolconnected and monitor for pending codes.


2 Engine stalls when shifted from N or P to other ranges

Description Engine stops unexpectedly when shifted from N or P to other ranges at idle

(TROUBLESHOOTING HINTS)a. Idle air control (IAC) valve malfunctionb. Torque converter clutch solenoid malfunctionc. Transaxle range signal malfunctiond. Oil pump worne. Control valve stuckf. Idle speed and ignition timing misadjust


1 Check that no diagnostic trouble codes exist byretrieving DTC's with a scan tool.


No Diagnostic trouble code(s) displayed on scantool.a. Check for cause of diagnostic trouble

code(s)If problem remains, go to next step.

2 Are measurements at TCM terminal OK? Yes Go to next step.

No Check for malfunctioning partsa. Throttle position (TP) sensor.b. Wiring

3 Are measurements at TCM OK?

a. H-01/18, H-01/8, H-01/36, H-01/37terminals: Transaxle range switch



4 Is continuity of transaxle range switch OK? Yes Go to next step.

No Adjust and/or replace transaxle range switch.

5 Are resistance of torque converter clutch solenoidvalve and output voltage of TCM terminal OK?


No If resistance is not OK, check formalfunctioning parts and wiring.a. Torque converter clutch solenoid valve.

If resistance is OK but voltage is not, checkwiring and TCM.

6 Is engine stall speed OK?

Stall speed: 2000~2500 rpm

Yes Check ECM parts & Engine.

No Repair or replace as necessary.


3 Engine stalls on deceleration

Description Engine stalls when brake pedal depressed while driving at low speed or stopping

(TROUBLESHOOTING HINTS)a. Idle air control (IAC) valve malfunction.b. Torque converter clutch solenoid malfunction.c. Idle speed and ignition timing misadjust.






2 Are resistance of torque converter clutch solenoidvalve and output voltage of TCM terminal H-01/4OK?


No If resistance is not OK, check formalfunctioning parts and wiringa. Torque converter clutch solenoid

If resistance is OK but voltage is not, checkwiring and / or replace TCM.



Yes Check TCM and / or engine parts.



4 Engine rough on deceleration

Description Engine shakes at beginning of deceleration, during deceleration, or recovery from decelerationExhaust afterburn

(TROUBLESHOOTING HINTS)a. Idle speed and ignition timing misadjust



Stall speed : 2000 ~ 2500 rpm

Yes Check TCM and / or Engine parts component.

No Repair or replace transaxle as necessary.


5 Poor acceleration at drive-away

Description Engine speed increases normally but vehicle speed slowly increases during acceleration

(TROUBLESHOOTING HINTS)a. ATF level low or highb. Throttle position sensor malfunction or improperly adjustedc. Line pressure incorrectd. Torque converter clutch solenoid malfunctione. Engine stall speed incorrect






2 Are ATF level and condition OK?Do transaxle seals, sealant, and gaskets preventleakage?

Clear pink: Normal condition Dark or black (with friction material): Worn

powertrain components Milky pink: Water contamination Light to dark brown (oxidation): Overheated or

old fluid


No If ATF level is not OK, add fluid as necessary.If ATF condition is not OK, repair as follows:a. condition - Overhaul transaxle and repair

or replace parts as necessary; then go tonext step.

b. or conditions - Replace ATF; then goto next step.

If there is leakage, repair or replace parts asnecessary, then go to next step.



4 Is line pressure OK? Yes Go to next step.

No Check linear solenoid valve.If line pressure is not within specifications afterlinear solenoid inspection, replace control valvebody assembly.



No If resistance is not OK, check for malfunctioningparts and wiring.a. Torque converter clutch solenoid.

If resistance is OK but voltage is not, checkwiring and /or TCM.



Yes Check EMS parts, Engine and TCM.



6 Poor acceleration on acceleration


(TROUBLESHOOTING HINTS)a. ATF level low or highb. Line pressure lowc. Engine stall speed incorrect correctlyd. Throttle position (TP) sensor malfunction or not adjustede. Torque converter clutch solenoid malfunction









old fluid


No If ATF level is not OK, add fluid as necessaryIf ATF condition is not OK, repair as follows:a. condition - Overhaul transaxle and repair

or replace parts as necessary; then go tonext step

b. or conditions - Replace ATF; then goto next step




4 Is line pressure OK? Yes Check TCM.




Yes Check Engine parts.


Stall speed: 2000~2500 rpmNo Repair or replace parts as necessary.

Check torque converter.

6 Drive vehicle if D & 1 range.Is vehicle starting from stop in 1st gear?

Yes Check Engine parts.

No Check torque converter.


7 Surges while cruising

Description Momentary minor irregularity in engine output at steady vehicle speed


8 Poor acceleration on acceleration


(TROUBLESHOOTING HINTS)a. ATF level low or highb. Throttle position (TP) sensor malfunction or not adjustedc. Torque converter clutch solenoid malfunction




No Diagnostic trouble code(s) displayed on scantool.a. Check for cause of diagnostic trouble code(s)

If problem remains, go to next step.




old fluid




b. or conditions - Replace ATF; then go tonext step




4 Are resistance of torque converter clutchsolenoid valve and output voltage of TCMterminal H-01/4 OK?


No If resistance is not OK, check for malfunctioningparts and wiring.

parts and wiring.a. Torque converter clutch solenoid.

If resistance is OK but Voltage is not, checkwiring and TCM.


9 Poor fuel economy

Description Fuel economy unsatisfactory

(TROUBLESHOOTING HINTS)a. ATF level lowb. Throttle position (TP) sensor malfunction or not adjusted correctlyc. Torque converter clutch solenoid not workingd. Line pressure lowe. Engine stall speed incorrect









old fluid






3 Is input voltage of throttle position (TP) sensor atTCM terminal OK?


No Check throttle position (TP) sensor and wiring.

4 Are resistance of torque converter clutch solenoidand output voltage of TCM terminals H-01/4 OK?

Yes Repair or replace parts as necessary.

No If resistance is not OK, check for malfunctioning

No If resistance is not OK, check for malfunctioningparts and wiring.a. Torque converter clutch solenoid

If resistance is OK but voltage is not, checkwiring and TCM.








10 Vehicle does not move in D, 2, and/or R range

Description a. No creep at allb. Vehicle does not move when accelerator pedal depressed after shifting to D, 2, 1 and/or R range

(TROUBLESHOOTING HINTS)a. ATF level lowb. Selector lever installation or adjustment incorrectc. Line pressure lowd. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2)e. Engine stall speed incorrectf. Control valve stuckg. Torque converter worn





old fluid








3 Operate selector lever; are selector lever andrange indicator positions aligned?



4 Operate selector lever; does transaxle operatenormally and are selector lever and transaxleposition aligned?





No If resistance is not OK, check for malfunctioningparts and wiring.a. Torque converter clutch solenoid.

If resistance is OK but Voltage is not, checkwiring and TCM.







8 Stop vehicle on flat paved surface with engineOFF.Does vehicle move when pushed(except P range, parking brake released)?


No Shift mechanism malfunction.Repair or replace as necessary.


11 Vehicle moves in N range

Description a. Vehicle creeps in N rangeb. Vehicle moves when accelerator pedal not depressed

(TROUBLESHOOTING HINTS)a. Selector lever installation or adjustment incorrectb. Powertrain damaged (forward clutch, coasting clutch, 3-4 clutch)











12 Vehicle moves in P range

Description a. Vehicle rolls in P range

(TROUBLESHOOTING HINTS)a. Selector lever installation or adjustment incorrectb. Parking mechanism wornc. Powertrain damaged (forward clutch, coasting, 3-4 clutch)










4 Stop vehicle on flat paved surface with engineOFF. Does vehicle move when pushed(except P range, parking brake released)?


No Shift mechanism malfunction.Repair or replace parts as necessary.


13 Excessive creep

Description a. Vehicle moves quickly in D, 2, 1 and R ranges (accelerator pedal depressed)

Excessive N to R range and N to D range shift shock felt

(TROUBLESHOOTING HINTS)Engine idle speed not adjusted correctly.


15 Abnormal shift

Description a. Shifts incorrectly (incorrect shift pattern(e.g.: Vehicle shifts from 1st to O/D directly when accelerating with accelerator pedal depressedslightly)

(TROUBLESHOOTING HINTS)a. Throttle position (TP) sensor malfunction or not adjusted correctlyb. Shift solenoid valves (A, B, C) wornc. Control valve stuckd. Differential assembly malfunctione. TCM malfunction




No Diagnostic trouble code(s) displayed on O/Dindicator or scan tool.a. Check for cause of diagnostic trouble code(s)


2 Are resistance and output voltage of shiftsolenoids (A, B, C) at TCM terminals OK?

a. H-01/30 terminal: Shift solenoid Ab. H-01/33 terminal: Shift solenoid Bc. H-01/32 terminal: Shift solenoid C


No If resistance is not OK, check for malfunctioningparts and wiring.a. Shift solenoid Ab. Shift solenoid Bc. Shift solenoid C

If resistance is OK but voltage is not, checkTCM.Go to step 4.

3 Are resistance and output voltage of throttleposition (TP) sensor at TCM terminals OK?



a. H-01/38 terminal: Throttle position (TP)sensor

No If resistance is not OK, check for malfunctioningparts and wiring.a. Throttle positionsensor

If resistance is OK but voltage is not, checkTCM.Go to next step.

4 Replace with known operational TCM.Is problem corrected?

Yes Replace TCM.

No Replace control valve body assembly.If problem remains, repair or replace parts asnecessary.


16 Frequent shifting

Description Downshift occurs when accelerator depressed slightly in D, 2 and 1 ranges (except O/D OFF mode)

(TROUBLESHOOTING HINTS)a. Throttle position (TP) sensor malfunction or not adjusted correctlyb. TCM malfunctionc. Control valve stuck






2 Are measurements at TCM terminals OK?

a. H-01/38 terminal: Throttle position (TP)sensor (from ECM)


No Check for malfunctioning parts and wiring.a. Throttle position (TP) sensor

3 Replace with known operational TCM.Is problem corrected?

Yes Replace TCM.

No Replace control valve body assembly.If problem remains, repair or replace parts asnecessary.


17 Shift point high or low

Description a. Shift points do not match shift diagramb. Shift delayed when acceleratingc. Shift occurs too fast when accelerating and engine speed does not increase

(TROUBLESHOOTING HINTS)a. Throttle position (TP) sensor malfunction or not adjusted correctlyb. Input/turbine speed sensor malfunctionc. Transaxle fluid temperature sensor malfunctiond. Selector lever installation or adjustment incorrecte. Shift solenoids valves (A, B, C) worn not adjusted correctlyf. PCM malfunctiong. Control valve stuckh. Transaxle range switch malfunction or not adjusted







a. H-01/38 terminal: Throttle position (TP)sensor ground

b. H-01/44 terminal: Input/turbine speedsensor ground

c. H-01/16 terminal: Input/turbine speedsensor signal


No Check for malfunctioning parts and wiring.a. Throttle position (TP) sensorb. Input/turbine speed sensor

3 Are measurements at TCM terminals OK? Yes Go to next step.

a. H-01/21 terminal: Transaxle fluidtemperature sensor ground

b. H-01/22 terminal: Transaxle fluidtemperature sensor signal

No Check transaxle fluid temperature sensor.












No Adjust and/or replace transaxle range switch.






If resistance is OK but voltage is not, replaceTCM.






18 No lock-up

Description No lock-up when vehicle speed reaches lock-up range

(TROUBLESHOOTING HINTS)a. Throttle position (TP) sensor malfunction or not adjusted correctlyb. Input / turbine speed sensor malfunctionc. Selector lever installation or adjustment incorrectd. Line pressure lowe. Transaxle range switch worn or maladjustedf. Torque converter clutch solenoid malfunctiong. TCM malfunctionh. Control valve stuck






2 Are resistance of torque converter clutch solenoidand output voltage of TCM terminal OK?

Yes Replace control valve body assembly.

No If resistance is not OK, check for malfunctioningparts and wiring.a. Torque converter clutch solenoid

If resistance is OK but voltage is not, checkwiring and / or replace TCM.




c. H-01/16 terminal: Input / turbine speedsensor signal

d. H-01/42 terminal: Vehicle speed sensore. HH-01/47, H-01/36, H-01/37

terminal: Transaxle range switch


No If resistance is not OK, check for malfunctioningparts and wiring.a. Throttle position sensorb. Input/turbine speed sensorc. Vehicle speed sensord. Transaxle range switch






No Adjust transaxle range switch





No Check linear solenoid valve.If line pressure is not within specifications afterlinear solenoid valve inspection, replace controlvalve body assembly.

8 Is input voltage of engine coolant tempera turesensor signal at TCM terminals OK?




18 No kickdown

Description Does not downshift when accelerator pedal depressed more than 7/8 while within kickdown range

(TROUBLESHOOTING HINTS)a. Throttle position sensor malfunction or not adjusted correctlyb. Line pressure lowc. TCM malfunctiond. Control valve stuck









3 Is accelerator cable installed correctly and does itoperate smoothly?


No Adjust or replace accelerator cable.



5 Replace with known good TCM.Is problem corrected?

Yes Replace TCM.

No Replace control valve body assembly.If problem remains, overhaul transaxle andrepair or replace parts as necessary.


19 No kickdown

Description Does not downshift when accelerator pedal depressed more than 7/8 while within kickdown range?

(TROUBLESHOOTING HINTS)a. Throttle position sensor malfunction or not adjusted correctlyb. Line pressure lowc. TCM malfunctiond. Control valve stuck









3 Is accelerator cable installed correctly and does itoperate smoothly?


No Adjust or replace accelerator cable.



5 Replace with known good TCM.Is problem corrected?

Yes Replace TCM.

No Replace control valve body assembly.If problem remains, overhaul transaxle andrepair or replace parts as necessary.


20 Engine speed flares up on acceleration

Description Engine speed flares up on acceleration

(TROUBLESHOOTING HINTS)a. ATF level lowb. Line pressure lowc. Control valve stuckd. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2, 3-4 clutch)e. Torque converter worn





old fluid













21 Engine speed flares up when upshifting and/or downshifting

Description a. Engine flares up when accelerator pedal depressed for upshiftingb. Engine flares up suddenly when accelerator pedal depressed for downshifting

(TROUBLESHOOTING HINTS)

a. ATF level lowb. Line pressure incorrectc. Throttle (TP) sensor malfunction or misadjustedd. Input/turbine speed sensor malfunctione. TCM malfunctionf. Servo piston malfunctiong. Orifice valve malfunctionh. 1-2, 2-3 accumulator malfunctioni. Control valve stuckj. Powertrain damaged (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch No. 1)

k. Oil pump malfunction









old fluid







No Check that linear solenoid valve.If line pressure is not within specifications afterlinear solenoid valve inspection, replace controlvalve body assembly.


a. H-01/38 terminal: Throttle position sensor

Yes Temporarily install known good TCM.Go to next step.If problem is corrected, replace TCM.

No If resistance is not OK, check for malfunctioningparts and wiring.a. Throttle position sensorb. Input/turbine speed sensor




5 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan toolconnected and monitor for pending codes.


22 Excessive shift shock at P, N to R and/or N to D

Description Strong shift shock felt at idle when shifting from P or N to D or R range

(TROUBLESHOOTING HINTS)a. AFT level lowb. Idle speed highc. Line pressure highd. Transaxle control module malfunctione. Throttle position (TP) sensor malfunction or misadjustedf. Input / Turbine speed sensor malfunctiong. Transaxle range switch worn or maladjustedh. TCM malfunctioni. Vehicle speed sensor malfunctionj. Selector installation or adjustment incorrect

k. N-D, N-R accumulator malfunction reverse clutch, low and reverse brake one-way clutch No. 1 or No. 2l. Shift solenoids valves (A, B, C) worn




No Diagnostic trouble code(s) displayed on O/Dindicator or scan tool.a. Check for cause of diagnostic trouble





old fluid














6 Drive vehicle in D and 1 range; does vehicle startfrom stop in 1st gear?






c. H-01/16 terminal: Input / turbine speedsensor signal

d. H-01/42 terminal: Vehicle speed sensore. H-01/47, H-01/8, H-01/36, H-01/37

terminal: Transaxle range switch


No If resistance is not OK, check for malfunctioningparts and wiring.a. Throttle position sensorb. Input/turbine speed sensorc. Vehicle speed sensord. Transaxle range switch




9 Is line pressure OK? Yes Temporarily install known good TCM.Go to next step.

Go to next step.If problem is corrected, replace TCM.




23 Excessive shift shock when upshifting and/or downshifting

Description a. Excessive shift shock felt when accelerating and upshiftingb. During cruising, excessive shift shock felt when accelerator pedal is depressed and downshifting

(TROUBLESHOOTING HINTS)a. ATF level lowb. Line pressure highc. Throttle position sensor malfunction or misadjustedd. Input/turbine speed sensor malfunctione. Transaxle fluid temperature sensor malfunctionf. TCM malfunctiong. Shift solenoids valves (A, B, C) wornh. Orifice valve malfunctioni. 1-2, 2-3 accumulator malfunctionj. Control valve stuck

k. Powertrain damaged (3-4 clutch, 2-4 brake band, one-way clutch No. 1)









old fluid












d. H-01/22 terminal: Transaxle fluidtemperature sensor

e. H-01/21 terminal: Ground










a. H-01/18, H-01/8, H-01/36, H-01/37terminals: Transaxle range switch


7 Check control valve body assembly.


24 No engine braking

Description a. Engine speed drops to idle but vehicle does not slow when accelerator pedal released while cruisingat medium to high speed

b. Engine speed drops to idle but vehicle does not slow when accelerator pedal released when in 1range at low vehicle speed

(TROUBLESHOOTING HINTS)a. Shift solenoids (B, C) malfunctionb. Transaxle range switch worn or not adjusted correctlyc. TCM malfunctiond. Line pressure lowe. Control valve stuckf. Powertrain slippage (3-4 clutch, coasting clutch, low and reverse brake)






2 Are resistance and output voltage of solenoidvalves (1-2, 2-3, 3-4 shift) at TCM terminals OK?



a. H-01/33 terminal: Shift solenoid Bb. H-01/32 terminal: Shift solenoid C

No If resistance is not OK, check for malfunctioningparts and wiring.a. Shift solenoid Bb. Shift solenoid C









No Overhaul transaxle and repair or replace partsas necessary.



7 Are measurements at TCM terminals OK? Yes Replace TCM.

a. H-01/47, H-01/8, H-01/36, H-01/37terminals:Transaxle range switch



25 No mode change

Description O/D OFF mode not selected or not canceled

(TROUBLESHOOTING HINTS)Inspect parts and wiring and repair, or replace malfunctioning parts as necessarya. O/D switch malfunctionb. Transaxle control module malfunction


26 Transaxle noise in all ranges

Description Transaxle noisy in all ranges when vehicle is idling

(TROUBLESHOOTING HINTS)Inspect parts and repair, adjust or replace malfunctioning parts as necessarya. ATF level lowb. Differential worn or damagedc. Parking mechanism malfunction


27 Transaxle noise in D, 2, 1 and R ranges

Description Abnormal noise from transaxle in D, 2, 1, and R ranges

(TROUBLESHOOTING HINTS)Inspect parts and repair, adjust or replace malfunctioning parts as necessarya. ATF level lowb. Differential worn and / or damaged


28 Transaxle overheats

Description ATF smells burnt and/or is discolored

(TROUBLESHOOTING HINTS)a. ATF level lowb. TCM malfunction


1 Are ATF level and condition OK?Do transaxle seals, sealant, and gasketsprevent leakage?


powertrain components Milky pink: Water contamination Light to dark brown (oxidation): Overheated

or old fluid


No If ATF level is not OK, add fluid as necessaryIf ATF condition is not OK, repair as follows:a. condition - Overhaul transaxle and repair or

replace parts as necessary; then go to nextstep

b. or conditions - Replace ATF; then go tonext step


2 Check that no diagnostic trouble codes existby retrieving DTC's with a scan tool.


No Diagnostic trouble code(s) displayed on scan tool.a. Check for cause of diagnostic trouble code(s)



SELF DIAGNOSTIC FUNCTIONInspection procedure1. Connect SST(0K2CA 089 HSP) to data link connector.

2. Turn ignition switch to ON.

3. Check diagnostic trouble code(s), referring to Hi-scan Pro operating manual.

4. If a diagnostic trouble code(s) is displayed, check for cause by using number on diagnostic trouble code table.Repair as necessary.

5. After repairs, perform After-Repair procedure to verify that there are no remaining diagnostic trouble codes.

After-repair procedure1. Cancel diagnostic trouble code memory by using SST(0K2CA 089 HSP).

2. Remove SST(0K2CA 089 HSP) from data link connector.

3. Drive vehicle at 31 mph (50 km/h), and depress accelerator pedal fully to activate kickdown. Stop vehicle gradually.

4. Connect SST(0K2CA 089 HSP) to data link connector.

5. Turn ignition switch to ON.

6. Verify that no diagnostic trouble codes are displayed.

7. Remove SST(0K2CA 089 HSP) from data link connector.

DIAGNOSTIC TROUBLE CODE

Code No. Diagnosed circuit MIL

P0601 TCM ROM malfunction (Only Europe) ON

P0604 TCM RAM malfunction (Only Europe) ON

P0707 Transaxle range signal (P, R, N, D, 2, 1) malfunction no signal (Only Europe) ON

P0708 Transaxle range signal (P, R, N, D, 2, 1) malfunction many signal (Only Europe) ON

P0712 ATF temperature sensor low ON

P0713 ATF temperature sensor high ON

P0716 Input/turbine speed sensor signal malfunction (Only Europe) ON

P0717 Input/turbine speed sensor circuit malfunction ON

P0726 Engine speed input signal malfunction (Only Europe) ON

P0727 Engine speed input malfunction ON

P0731 Incorrect first gear ratio(Only Europe) ON

P0732 Incorrect second gear ratio (Only Europe) ON

P0733 Incorrect third gear ratio (Only Europe) ON

P0734 Incorrect fourth gear ratio (Only Europe) ON

P0741 Torque converter clutch system malfunction stuck off (Only Europe) ON

P0742 Torque converter clutch system malfunction stuck on (Only Europe) ON

P0743 Torque converter clutch system circuit malfunction ON

P0748 Linear solenoid electrical ON

P0753 Shift solenoid A electrical ON

P0758 Shift solenoid B electrical ON

P0763 Shift solenoid C electrical ON

P1121 TPS signal circuit from ECM to TCM ON

P1500 Vehicle speed signal malfunction ON

P1700 O/D lamp circuit malfunction (Only Europe) OFF

P1780 Torgue reduction signal malfunction OFF

According to TCM logic, transaxle range (P0705) trouble code accompanies vehicle speed sensor (P1500) troublecode.Therefore, P0705 should be repaired first. Check P0705 is cleared and then inspect P1500.

TRANSAXLE CONTROL MODULE(TCM)

TCM terminal voltage chart

STALL TESTThis test is performed to determine if there is slippage of friction elements or a malfunction of hydraulic components.

a. Never unscrew radiator cap while engine is hot.b. Wrap a thick cloth around cap when loosening.

1. Engage parking brake and put wheel chocks at front and rear of each wheel.

2. Warm engine thoroughly to raise ATF temperature to an operating level of 140-158°F (60-70°C).

3. Check, and correct as necessary, engine coolant, engine oil, and ATF levels before testing.

4. Connect a tachometer to engine.

procedure

1. Start engine.

2. Check idle speed in P range. (Refer to emission control system)

Idle speed: 750-850 rpm (with parking brake applied)

3. Shift selector lever to R range.

Perform steps 4 and 5 within 5 seconds to prevent possible transaxle damage.

4. Firmly depress foot brake with left foot and gradually depress accelerator pedal fully with right foot.

5. When engine speed no longer increases, quickly read engine to speed and release accelerator.

6. Move selector lever to N range and allow engine to idle for at leastone minute.

a. Idling for at least one minute cools ATF and prevents its deterioration.b. Allow sufficient cooling time between each stall test.

7. Perform stall tests for remaining ranges in same manner.a. D rangeb. 2 rangec. 1 range

Stall speeds: 2000-2500 rpm

Condition Possible cause

Above specification In R position and all ranges Insufficient line pressure Worn oil pump

Oil leakage from oil pump,control valve and/ortransaxle case

Stuck pressure regulatorvalve

In D range Forward clutch slippingOne-way clutch 1 slippingOne-way clutch 2 slipping

In 2 range 2-4 brake band slipping

In R range Low and reverse brake slippingReverse clutch slippingPerform road test to determine whether problem is lowand reverse brake or reverse clutcha. Engine brake felt in 1 range, 1st gear reverse clutchb. Engine brake not felt in 1 range

Low and reverse brake

Below specification in R position and all ranges Engine out of tune

One-way clutch slipping within torque converter

LINE PRESSURE TESTThis test measures line pressure as a means of checking hydraulic components and inspecting for oil leakage.

Preparation1. Perform preparation procedure outlined in Stall Test.

2. Remove splash shield under front left bumper.

3. Connect SST(0K201 190 AA0) to line pressure inspection port (square-head "L" plug). It may be necessary to raisecar to get at inspection port.

Procedure

1. Start engine.

2. Check idle speed in P range, refer to emission control.

Idle speed: 750-850 rpm (with parking brake applied)

3. Shift selector lever to D range and read line pressure at idle.

Perform steps 4 and 5 within 5 seconds to prevent possible transaxle damage.

4. Depress brake pedal firmly with left foot and gradually depress accelerator pedal fully with the right foot.

5. Read line pressure as soon as engine speed becomes constant and release accelerator pedal.

Idling for at least one minute cools ATF and prevents deterioration.

6. Shift selector lever to N range and run engine at idle for at leastone minute.

7. Read line pressure at idle and at engine stall speed for each range in same manner.

Range Idle Stall

D, 2, 1 56.98-127.98 (392.4-882.9, 4.0-9.0) 113.76-184.86 (784.8-1275.3, 8.0-13.0)

R 71.1-142.2 (490.5-981.0, 5.0-10.0) 199.08-270.18 (1373.4-1863.9, 14.0-19.0)

8. Install a new square-head "L" plug in inspection port, refer to line pressure test.

Tightening torque:

44-86 Ib·in (5.0-9.8 N·m, 51-100 kg·cm)

Line pressure Possible location of problem

Low pressure in every position Worn oil pumpFluid leaking from oil pump, control valve, or transaxlecasePressure regulator valve stickingLinear solenoid valve sticking

Low pressure in D and 2 only Fluid leaking from hydraulic circuit of forward clutch

Low pressure in R only Fluid leaking from hydraulic circuit of low and reversebrake or reverse clutch

Higher than specification Pressure regulator valve stick or Linear solenoid valvesticking

2004 > 1.6L DOHC >

OIL SEAL1. Remove driveshaft. (Refer to driveshaft)

2. Remove oil seal with a screwdriver.

3. Tap new oil seal into transaxle case with SST(0K201 170 AA1).

a. Tap in until SST(0K201 170 AA1) contacts case.b. Coat oil seal lip with ATF.

INPUT/TURBINE SPEED SENSOR1. Disconnect negative battery cable.

2. Pull data link connector upward from MAF sensor.

3. Remove air cleaner assembly.

4. Disconnect input/turbine speed sensor connector.

5. Measure resistance between terminals 1 and 2 of turbine sensor connector H-04.

Resistance: 300-400Ω (@68°F/20°C)

6. If not as specified, replace input/turbine speed sensor.

Tightening torque:69.6-94.8 Ib·in (8-11 N·m, 80-110 kg·cm)

7. Install air cleaner assembly.

8. Install data link connector to MAF sensor.

9. Connect negative battery cable.

VEHICLE SPEED SENSOR1. Turn ignition to ON and use a voltmeter to back probe pin 1.

2. Have an assistant rotate one drive wheel, checking other drive wheel, if necessary. This will rotate vehicle speedsensor.

3. Voltmeter reading should alternate between approximately 1 and 10 volts.

4. If this requirement is not met, replace vehicle speed sensor.

AUTOMATIC TRANSAXLE FLUID (ATF)

Place vehicle on a flat surface.

Inspection1. Apply parking brake and position wheel chocks securely to prevent vehicle from rolling after roller test.

2. Warm-up engine until ATF reaches 140-158°F (60-70°C).

3. Firmly depress the foot brake, and shift the selector lever P→R→N→D→1→2→1→D→N→R→P.(stay at each range for over 3 second)

Use COOL 68°F (20°C) range only as a rough reference.

4. Ensure that the ATF level is in HOT 149°F (65°C) range. Add ATF to specification, if necessary.

ATF type:DIAMOND ATF SP-III or SK ATF SP-III

Fluid condition

a. Carefully check condition of ATF and determine whether or not automatic transaxle should be disassembled.b. If ATF is muddy and varnished, it could indicate burned drive plates or brake band.

1. Check ATF for discoloration.

2. Check ATF for any unusual smell.

Replacement1. Place a drain pan under transaxle drain plug.

2. Remove auto transaxle drain plug and allow automatic transaxle fluid to fully drain.

3. Install drain plug with specified torque.


4. Remove ATF level gauge, then pour specified ATF.

ATF type:DIAMOND ATF SP-III or SK ATF SP-III

Capacity:5.7 US qt (5.4 liter, 4.7 lmp qt)

Do not over fill above Hot range.

5. Check ATF level. (Refer to auto transaxle fluid)

ATF changer using process1. Fill ATF changer with specified ATF.

2. Disconnect ATF inlet and outlet hose from radiator.

3. Connect ATF inlet and outlet hose to ATF changer.

4. Start engine.

5. While engine is idling, replace ATF. (Refer to ATF changer instruction manual)

6. Check ATF level. (Refer to ATF)

Fluid leaksCheck for transaxle fluid leaks at points shown below and repair or replace as necessary. Additionally, check all offollowing:1. Gaskets, O-rings, and plugs.

2. Oil hoses, oil pipes, and connections.

3. Oil cooler.

Hydraulic System

Oil Cooler

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

REMOVAL1. Raise vehicle and support it with safety stands.

2. Remove RH side gravel shield (seven bolts) from under engine.

3. Place a drain pan under radiator.

4. Disconnect ATF inlet hose and outlet hose.

5. Remove ATF inlet pipe and outlet pipe.

6. Remove radiator. (Refer to section EM, cooling system)

RE-INSTALLATION1. Install radiator. (Refer to section EM, cooling system)

2. Install ATF inlet pipe and outlet pipe.


3. Slide ATF inlet and outlet hose onto ATF cooler pipe until it is fully seated against the ridge.

4. Install hose clamp onto hose at center of mark and at angle shown.

5. Verify that the hose clamp does not interfere with any other parts.

6. Install RH side gravel shield under engine.

7. Lower vehicle.

8. Check ATF level. (Refer to Automatic transaxle fluid)

Oil Pump

2004 > 1.6L DOHC >

COMPONENTS

COMPONENT

2004 > 1.6L DOHC >

REASSEMBLY

Oil seal replacement1. Using the special tool (09452-21200), install the oil seal to the pump housing.

2. Apply a thin coat of automatic transaxle fluid to the lip of the oil seal before installation.

DISASSEMBLY1. Remove bearing race.

2. Remove four seal rings.

3. Loosen six mounting bolts evenly in pattern shown and remove oil pump cover from oil pump housing.

Do not use a punch to mark outer and inner rotors.

4. Mark outer and inner rotors as shown, and separate them from oil pump housing.

5. Remove plug then remove washer, spring and fluid pressure by pass valve.

INSPECTIONOil pump housing, outer rotor, inner rotor1. Install outer rotor and inner rotor.

2. Measure clearance between end of oil pump housing and outer rotor and inner rotor at no less than four placesalong their circumferences.

along their circumferences.

ClearanceStandard: 0.00079-0.0157 in (0.02-0.04 mm)Maximum: 0.0020 in (0.05 mm)

3. If not as specified, replace oil pump assembly.

4. Measure clearance between oil pump boss and inner rotor in at least four places and calculate average value.

Inner diameterStandard:0.00157-0.00453 in (0.04-0.115 mm)Maximum:0.0049 in (0.125 mm)

5. If not within specification, replace oil pump as an assembly.

Spring1. Measure spring free length.

2. If not as specified, replace oil pump as an assembly.

Fluid pressure by pass valve1. Measure fluid pressure by pass valve and check for wear.

Outer diameterStandard: 0.551 in (14.00 mm)Minimum: 0.550 in (13.98 mm)

2. If not as specified, replace oil pump as an assembly.

RE-ASSEMBLY1. Install fluid pressure by pass valve spring into oil pump housing, and verity that fluid pressure by pass valve moves

smoothly.

2. Install a new washer and plug.

Tightening torque:24-33.6 lb·in (32-47 N·m, 3.2-4.8 kg·m)

3. Align marks and install outer and inner rotors.

4. Install oil pump flange.

5. Mount oil pump cover onto oil pump housing.

6. Tighten six bolts evenly and gradually in order shown.

Tightening torque:72-97.2 lb·in (8.1-10.9 N·m, 82-112 kg·m)

7. Install oil pump shaft and rotate pump rotors to verity smooth oil pump operation.

8. Install four seal rings.

9. Apply petroleum jelly to bearing race and secure it on oil pump cover.

Bearing race outer diameter: 3.46 in (88.0mm)

Valve Body System

Valve Body

2004 > 1.6L DOHC >

INSIDE VALVE BODY

OUTSIDE VALVE BODY

COMPONENTS

UNDERDRIVE CLUTCH AND INPUT SHAFT

CONTROL VALVE BODY

a. Be especially careful when handling control valve because it consists of most precise and delicate parts oftransaxle.

b. Neatly arrange removed parts to avoid confusing similar parts.c. Clean removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes and

passages with compressed air.

COMPONENT

COMPONENT(CONTINUED)

COMPONENT

a. Before assembly, make sure all parts are perfectly clean.b. Apply ATF to all parts.c. Do not reuse gaskets or O-rings.

MAIN CONTROL VALVE BODY

a. Each valve should slide in/out under its own weight.b. When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace

valve body open-side down and lightly tap it with a soft hammer.c. If a valve surface or bore is scratched or damaged, replace control valve body.

d. Do not drop or lose valves or internal parts.e. Before assembly, make sure all parts are thoroughly clean.f. Apply ATF to all parts and bores.g. Note proper direction of valves and internal parts.h. Do not reuse any part that has been dropped.i. Wrap a screwdriver or rod with tape before using it to insert a valve.

1. Disassemble in order shown in figure.

OIL STRAINER INSTALLATION POSITIONS

Low control valve body

Premain control valve body

Lower control valve body side

Main control valve body side

MAIN CONTROL VALVE BODY

Premain control valve body side

Upper control valve body side

Upper control valve body

BOLT INSTALLATION POSITIONS AND EXTERNAL PARTS LOCATIONS

Identificationmark

Lengthin (mm)

Tightening torqueIb·in (N·m, kg·cm)

0.551 (14)

70~95(7.9~10.7, 80~110)

A 1.181 (30)

B 1.575 (40)

C 1.969 (50)

D 3.228 (82)

E 3.543 (90)

01 3.740 (95)

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove the input shaft snap ring.

2. Remove the input shaft.

3. Remove the 2 seal rings.

4. Remove the clutch reaction plate snap ring.

5. Remove the clutch reaction plate.

6. Remove the 4 clutch discs and 4 clutch plates.

7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutchspring retainer snap ring.

8. Remove the clutch spring retainer.

9. Remove the D-ring seal.

10. Remove the clutch return spring.

11. Remove the underdrive clutch piston using compressed air.

12. Remove the 2 D-ring seals.

REASSEMBLY1. Install the 2 D-ring seals.

2. Install the underdrive clutch piston.

3. Install the clutch return spring.

4. Install the D-ring seal.

5. Install the clutch spring retainer.

6. Compress the clutch return springs using special tools, 09453-21100 and 09453-21000, then install the clutchspring retainer snap ring.

Dip each clutch disc in ATF before assembling.

7. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outercircumference hole (B) in the underdrive clutch retainer.

8. Install the 4 clutch discs and the 4 clutch plates.

9. Install the clutch reaction plate with the shear droop toward the clutch disc.

10. Install the clutch reaction plate snap ring.

11. Install special tools, MD998924 and 09456-21000 then check the clearance between the snap ring and thereaction plate using a feeler gauge.

Standard value : 1.6-1.8 mm

12. If the clearance is correct, measure the old snap ring, then select the correct size from the chart in the servicemanual.

13. Install the seal rings.

14. Install the input shaft.

15. Install the input shaft snap ring.

RE-ASSEMBLY1. Insert 3-4 shift spring, 3-4 shift valve, and stop plug. Secure them with stop pin.

2. Insert low reducing spring, low reducing valve, and stop plug. Secure them with stop pin.

3. Insert 1-2 shift spring, 1-2 shift valve, and stop plug. Secure them with stop pin.

4. Insert pressure regulator valve, pressure regulator spring, pressure regulator spring seat, regulator plug sleeve,pressure regulator plug, and stop plug. Secure them with roll pin.

5. Insert 2-3 timing valve and 2-3 timing spring. Secure them with spring retainer.

6. Proceed to insert manual valve.

REASSEMBLY

1. Install oil strainer into lower control valve body, refer to oil strainer installation Positions.

2. Set oil filter into lower separator plate.

Gasket F and gasket E are not interchangeable.They are identified by their shape in area designated in illustration.

3. Set new gasket F, lower separator plate, and new gasket E onto lower valve body.

4. Set premain control valve body onto lower valve body and install seven bolts.


5. Install two rubber balls and oil strainers into their proper positions in premain control valve body.(Refer to Rubber Ball and Oil Strainer Installation Positions)

6. Install rubber balls into their proper positions in main control valve body. (Refer to main control valve body)

Gasket C and gasket D are not interchangeable.They are identified by their shape in area designated in illustration.

7. Set the new gasket C, main separator plate, and gasket D onto main control valve body.

8. Secure gasket C, main separator plate and gasket D to main control valve body with two screws in locationsshown.


9. Set main control valve body onto premain control valve body.

Match bolt head letters as shown.

10. Loosely tighten bolts, refer to bolt installation positions and external parts locations.

11. Set the oil filter in upper separator plate.

Gasket A and gasket B are not interchangeable.They are identified by their shape in area designated in illustration.

12. Set new gasket A, upper separator plate, and new gasket B onto upper control valve body.

13. Secure gasket A, upper separator plate and gasket B to upper control valve body with two screws in locationsshown.

14. Set upper control valve body onto main control valve body and install nine bolts.


Match bolt head letters as shown.

15. Loosely tighten lower control valve body bolts.(Refer to bolt installation positions and external parts locations)

16. Install linear solenoid valve.


17. Install shift solenoids B and C, oil strainers, and bracket.

18. Tighten mounting bolts.


19. Install torque converter clutch solenoid and oil strainer.


20. Install shift solenoid A and oil strainer onto upper valve body.


21. Apply ATF to new O-rings and install them onto oil pipe assembly.

22. Install oil pipe assembly.


23. Apply ATF to new O-ring and install it onto oil strainer assembly.

24. Install oil strainer onto control valve body and then tighten three bolts.


DISASSEMBLY1. Remove oil pipe assembly.

2. Remove O-rings from oil pipe assembly.

3. Remove shift solenoid A.

4. Remove torque converter clutch solenoid valve and oil strainer.

5. Remove shift solenoids B and C.

6. Remove linear solenoid valve.

7. Remove nine upper control valve body bolts.

8. Remove two screws from upper control valve body.

9. Remove gasket B, upper separator plate, oil filter, oil strainer and gasket A.

10. Remove seven main control valve body bolts then remove main control valve.

11. Remove gasket D, main separator plate, and gasket C.

12. Remove four rubber balls from main control valve body.

13. Remove oil strainer, steel ball and two rubber balls from premain control valve body.

14. Remove six bolts then remove premain control valve body.

15. Remove gasket E, lower separator plate, oil filter, and gasket F.

16. Remove oil strainer from lower control valve body.

INSPECTION1. Measure spring free lengths.

2. If not within specification, replace spring(s).

REMOVAL

Clean transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.

1. Support engine with SST(0K201 170 AA0).

2. Raise vehicle and support it with safety stands.

3. Drain ATF into a suitable container.

4. Remove both gravel shield from under engine.

5. Remove nuts from No.2 engine mount-to-mounting member.

6. Remove engine mounting member-to-chassis bolts and nuts then remove engine mounting member.

7. Remove oil pan (19 bolts) and gasket.

8. Disconnect all electrical connectors, remove eight bolts, and remove control valve body.

REPLACEMENT1. Install control valve body, (8) bolts, and wiring clips as shown.

Bolt length (measured from below the head)A : 1.18 in (30 mm)B : 1.97 in (50 mm)


2. Install oil strainer, and (3) bolts.


3. Connect connectors.

4. Install oil pan (19 bolts) and a new gasket.


5. Loosely install nuts A and bolts B of engine mounting member.

6. Install engine mounting member.

Tightening torque:A: 28-38 Ib·ft (38-51 N·m, 3.8-5.3 kg·m)B: 48-65 Ib·ft (64-89 N·m, 6.5-9.1 kg·m)

7. Install both gravel shield to under engine.

8. Pour in ATF. Check ATF level with engine idling and check for leaks, refer to Automatic Transmission Fluid.

9. Drive vehicle and check shift points, shift schedule, and shift quality.

Upper Control Valve Body

2004 > 1.6L DOHC >

COMPONENT

a. Each valve should slide in/out under its own weight.b. When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace

valve body open-side down and lightly tap it with a soft hammer.c. If a valve surface or bore is scratched or damaged, replace control valve body.d. Do not drop or lose valves or internal parts.e. Before assembly, make sure all parts are thoroughly clean.f. Apply ATF to all parts and bores.g. Note proper direction of valves and internal parts.h. Do not reuse any part that has been dropped.i. Wrap a screwdriver or rod with tape before using it to insert a valve.

1. Disassemble in order shown in the figure.

2004 > 1.6L DOHC >



RE-ASSEMBLY1. Insert solenoid reducing valve and solenoid reducing spring then secure them with spring retainer.

2. Insert P.E accumulator valve and P.E accumulator spring then secure them with spring retainer.

a. Each valve should slide in/out under its own weight.b. When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or

replace valve body open - side down and lightly tap it with a soft hammer.c. If a valve surface or bore is scratched or damaged, replace control valve body.d. Do not drop or lose valves or internal parts.e. Before assembly, make sure all parts are thoroughly clean.f. Apply ATF to all parts and bores.g. Note proper direction of valves and internal parts.h. Do not reuse any part that has been dropped.i. Wrap a screwdriver or rod with tape before using it to insert a valve.

Pre Main Control Valve Body

2004 > 1.6L DOHC >

COMPONENT1. Disassemble in order shown in figure.

2004 > 1.6L DOHC >



RE-ASSEMBLY1. Insert bypass spring, by pass valve, and stop plug. Secure them with stop pin.

2. Insert 2-3 shift spring, 2-3 shift valve, and plug. Secure them with stop pin.

3. Insert converter relief valve and converter relief spring. Secure them with spring retainer.

4. Insert lock-up control spring, lock-up control valve, and stop plug. Secure them with stop pin.

a. Each valve should slide in/out under its own weight.b. When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or

replace valve body open-side down and lightly tap it with a soft hammer.c. If a valve surface or bore is scratched or damaged, replace control valve body.d. Do not drop or lose valves or internal parts.e. Before assembly, make sure all parts are thoroughly clean.f. Apply ATF to all parts and bores.g. Note proper direction of valves and internal parts.h. Do not reuse any part that has been dropped.i. Wrap a screwdriver or rod with tape before using it to insert a valve.

Shift Control Solenoid Valve (nodeSV)

2004 > 1.6L DOHC >

RESISTANCE INSPECTION1. Disconnect negative battery cable.


3. Measure resistance between each terminal and a ground.

Resistance: 14-18 Ω

a. 2: Torque converter clutch solenoidb. 1: Shift solenoid valve Ac. 4: Shift solenoid valve Bd. 7: Shift solenoid valve C

4. If not correct, check wiring for an open or short-circuit. Replace solenoid valve.

CONTINUITY INSPECTION1. Disconnect 55-pin connector from transaxle control module.

2. Check continuity between terminals H-03-1, H-03-2, H-03-3 and H-03-4 and H-03-7 ground.

3. If not correct, check wiring for an open or short circuit.

LINEAR SOLENOID VALVEResistance inspection1. Disconnect negative battery cable.


3. Measure resistance between ground terminals and of connector terminal H-03-3.

Resistance: 4.1-5.1Ω

4. If not connect, check wiring for an open or short-circuit, replace pressure control valve.

5. Connect solenoid valve connector.


Clutch & Brake

Reverse and Overdrive Clutch

2004 > 1.6L DOHC >

COMPONENT

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove the overdrive clutch reaction plate snap ring.

2. Remove the overdrive clutch reaction plate.

3. Remove the 2 overdrive clutch discs and 2 plates.

4. Remove the reverse clutch reaction plate snap ring.

5. Remove the reverse clutch reaction plate.

6. Remove the 4 reverse clutch discs and 4 plates.

7. Compress the clutch return springs using special tools, 09453-21000 then remove the clutch spring retainer snapring.

8. Remove the clutch spring retainer.


10. Remove the clutch return spring.

11. Remove the overdrive clutch piston using compressed air.


13. Remove the Reverse clutch piston.

14. Remove the 3 D-ring seals.

REASSEMBLY1. Install the 3 D-ring seals.

2. Align the outer circumference holes (A and B) on the reverse piston and the reverse piston retainer beforeassembly.

3. Install the Reverse clutch piston.


5. Install the overdrive clutch piston.

6. Install the clutch return spring.


8. Install the clutch spring retainer.

9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snapring.

10. Check the clearance between the snap ring and the return spring retainer


11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the servicemanual.


12. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outercircumference hole (B) in the reverse clutch retainer.

13. Install the 4 reverse clutch discs and 4 plates.

14. Install the reverse clutch reaction plate.

15. Install the reverse clutch reaction plate snap ring.

16. Install special tools, 09453-21000 as shown, then check the clearance between the snap ring and the reactionplate using a feeler gauge.

Standard value :

1.6-1.8 mm (0.0630-0.0709 in.)



18. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outercircumference hole (B) in the overdrive clutch retainer.

19. Install the 2 overdrive clutch discs and 2 plates.

20. Install the overdrive clutch reaction plate.

21. Install the overdrive clutch reaction plate snap ring.

22. Check the clearance between the snap ring and the clutch reaction plate.

Standard value : 1.5-1.7 mm


DISASSEMBLY1. Remove thrust bearing.

2. Remove snap ring.

3. Remove retaining plate.

4. Remove forward clutch drive plates and driven plates. (each three)

5. Remove dished plate.

6. Install SST(0K201 190 AA1) in coasting clutch drum as shown.

7. Compress spring and retainer assembly.


9. Remove SST(0K201 190 AA1) then remove spring and retainer assembly.



12. Remove coasting clutch drive plates and driven plates. (each two)

13. Remove coasting clutch drum from reverse/forward drum by applying compressed air through fluid passage.

14. Remove coasting clutch piston from coasting clutch drum by applying compressed air through fluid passage.

15. Remove outer seal and inner seal from coasting piston.

16. Remove two seal rings and outer seal from coasting clutch drum.

17. Install SST(0K201 190 AA1) in reverse/forward drum as shown.

18. Compress piston return spring.

19. Remove snap ring from groove with snap ring pliers.

20. Remove SST(0K201 190 AA1) from reverse/forward drum.

21. Remove snap ring with a screwdriver.


23. Remove reverse clutch driven plates and driven plates. (each two)


25. Remove return spring stopper and piston.

26. Place reverse/forward drum on oil pump.

27. Remove reverse piston by applying compressed air through reverse clutch fluid passage.

28. Remove two seal rings from reverse piston.

RE-ASSEMBLY1. Install reverse clutch piston.

a. Apply ATF to inner and outer faces of seals, and install them to reverse clutch piston.

b. Insert reverse clutch piston by pushing evenly around circumference, bearing careful not to damage seal rings.

2. Install piston return spring with tabs facing away from reverse clutch piston.

3. Install return spring stop with step facing upward.

4. Install snap ring half-way down reverse/forward drum as shown.

5. Install SST(0K201 190 AA1) on reverse/forward drum.


7. Install snap ring with a screwdriver.

8. Remove SST(0K201 190 AA1).

9. Install dished plate with dished side facing downward into drum as shown.

10. Install drive and driven plates. (two each)

Installation order:Driven-Drive-Driven-Drive



13. Measure reverse clutch clearance.a. Measure clearance between snap ring and retaining plate of reverse clutch.b. If clearance is not within specification, adjust it by selecting correct thickness snap ring.

Reverse clutch clearance:0.035-0.047 in (0.9-1.2 mm)

14. Install coasting clutch drum.a. Apply ATF to inner and outer faces of seal, and install it onto coasting clutch drum.b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into

drum.

c. Install coasting clutch drum in correct position in reverse/forward drum as shown.d. Push evenly around circumference, being careful not to damage outer seal.

15. Install coasting clutch piston.a. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston.b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into

drum.

16. Install spring and retainer assembly.

17. Install SST(0K201 190 AA1) in coasting clutch as shown.




21. Install dished plate with dished side facing out of drum as shown.

22. Install drive and driven plate.

Installation order:Driven-Drive-Driven-Drive



25. Measure coasting clutch clearance.a. Measure clearance between snap ring and retaining plate of coasting clutch.b. If clearance is not within specification, adjust it by selecting correct thickness snap ring.

Coasting clutch clearance:0.039-0.048 in (1.0-1.2 mm)

26. Install dished plate with dished side facing downward into drum, as shown.

27. Install drive and driven plates.

Installation order:Driven-Drive-Driven-Drive-Driven-Drive



30. Measure forward clutch clearance.a. Measure clearance between snap ring and retaining plate of forward clutch.b. If clearance is not within specification, adjust it by selecting correct thickness snap ring.

Forward clutch clearance:0.039-0.048 in (1.0-1.2 mm)

31. Check clutch operation as follows:a. Set clutch assembly onto oil pump.b. Check clutch operation by applying compressed air though fluid passages shown.

Air pressure:57 psi (392 kPa, 4.0 kg/cm²) maximum

32. Apply petroleum jelly to thrust bearings, and secure them on each side of reverse/forward drum.

Thrust bearing outer diameter:Oil pump side: 3.39 in (86.0 mm)Small sun gear and one-way clutch side:2.21 in (56.1 mm)

INSPECTION

Drive plates1. Measure facing thickness in three places and determine average of three readings.

Standard: 0.063 in (1.6 mm)Minimum: 0.055 in (1.4 mm)

2. If not within specification, replace spring and retainer assembly.

Spring and retainer assembly1. Measure spring free length and check for deformation.



Reverse clutch piston1. Verity that there is no air leakage when applying compressed air through oil hole opposite return spring.

2. Verity that there is air flow when applying compressed air through oil hole on return spring side.


Coasting clutch piston1. Verity that there is no air leakage when applying compressed air through oil hole opposite return spring.



Reverse/forward drum1. Verity that there is air flow when applying compressed air through backside of drum.

2. Verity that there is no air leakage when applying compressed air through inside of drum.


INSPECTION

Drive plates1. Measure facing thickness in three places and determine average of three readings.






Reverse clutch piston1. Verity that there is no air leakage when applying compressed air through oil hole opposite return spring.



Coasting clutch piston1. Verity that there is no air leakage when applying compressed air through oil hole opposite return spring.



Reverse/forward drum1. Verity that there is air flow when applying compressed air through backside of drum.

2. Verity that there is no air leakage when applying compressed air through inside of drum.


One Way Clutch

2004 > 1.6L DOHC >

SMALL SUN GEAR ONE-WAY CLUTCH NO.1

ONE-WAY CLUTCH NO.2 AND PLANETARY CARRIER ASSEMBLY1. Disassembly in order shown in figure.

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove thrust bearing from small sun gear.

2. Remove snap ring with a snap ring pliers.

3. Remove one-way clutch inner race from sun gear drum.

4. Remove thrust bearing.

5. Remove snap ring with a snap ring pliers.

6. Remove small sun gear.

7. Remove one-way clutch No.1, one-way clutch outer race and thrust bearing from sun gear drum.

PRE-INSPECTION

One-way clutch No.1 operation1. While holding one-way clutch outer race, verify that one-way clutch inner race rotates smoothly when turned

counterclockwise and locks when turned clockwise. If not as specified, replace one-way clutch No.1.

RE-ASSEMBLY1. Install small sun gear into sun gear drum.

2. Install new snap ring.

3. Apply petroleum jelly to thrust bearing, and secure it to one-way clutch inner race.


Install one-way clutch into outer race with spring cage facing as shown.

4. Install one-way clutch No.1 into one-way clutch outer race.

Align splines of one-way clutch inner race and small sun gear clutch hub.

5. Install one-way clutch inner race into one-way clutch outer race by turning inner race counterclockwise.

6. Hold one-way clutch outer race. Verify that the inner race turns only counterclockwise.

7. Install new snap ring.

8. Verify that when small sun gear is held, one-way clutch outer race turns smoothly and only clockwise.

9. Apply petroleum jelly to thrust bearing, and secure it to sun gear drum.


RE-ASSEMBLY1. Assembly planetary carrier to inner race.


Install tangs of bearing race into alignment holes.

3. Apply petroleum jelly to bearing race and secure them to each side of one-way clutch No.2 and planetary carrierassembly.

assembly.

Bearing race outer diameter:Sun gear drum side:3.307 in (84.0 mm)

PRE-INSPECTION

One-way clutch No.1 operation1. While holding one-way clutch outer race, verify that one-way clutch inner race rotates smoothly when turned

counterclockwise and locks when turned clockwise. If not as specified, replace one-way clutch No.1.

Low and Reverse Brake

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove snap ring.


3. Remove drive plates and driven plates. (each four)

4. Install SST(0K2CA 190 AA1) in transaxle case as shown.



7. Remove SST(0K201 190 AA1), then remove spring and spring retainer assembly.

8. Remove low and reverse brake piston by applying compressed air through fluid passage.

Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)

9. Remove outer seal and inner seal from low and reverse brake piston.

INSPECTION

Drive plates1. Measure facing thickness in three places, and determine average of three readings.


2. If not within specification, replace drive plate(s).


Free length of spring: 0.563 in (14.3 mm)


RE-ASSEMBLY1. Install low and reverse brake piston.

a. Apply ATF to inner and outer seals, and install them onto low and reverse brake piston.

Seal Ring Inner Diameter:Inner Seal: 5.539 in (140.7 mm)Outer Seal: 6.713 in (170.5 mm)

b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into case.c. Install low and reverse brake piston by pushing evenly around circumference, being careful not to damage outer

seal.

2. Install spring and retainer assembly.

3. Install SST(0K2CA 190 AA1) in transaxle case.


5. Install snap ring with snap-ring pliers.

6. Remove SST(0K201 190AA1).

7. Check low and reverse brake piston operation.a. Pour in ATF until low and reverse brake piston is fully submerged.b. Check that no bubbles come from between piston and seals when applying compressed air through fluid

passage.

Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)

8. Install drive and driven plates.(each four)

Installation order:Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive



11. Measure low and reverse brake clearance.a. Measure clearance between snap ring and low and reverse brake retaining plate.b. If clearance is not within specification, adjust it by selecting a proper snap ring.

Low and reverse brake clearance:0.094- 0.083 in (2.1- 2.4 mm)

12. Check low and reverse brake operation by applying compressed air through fluid passage as shown in figure.


13. Remove snap ring, retaining plate, drive and driven plates and set aside for later assembly.

INSPECTION

Drive plates1. Measure facing thickness in three places, and determine average of three readings.




Free length of spring: 0.563 in (14.3 mm)


The Other Clutch & Brake Components

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove two trust bearings.

2. Install SST(0K201 190 AA1) to 3-4 clutch as shown.



5. Remove SST(0K201 190 AA1), then remove spring and retainer.



8. Remove drive and driven plates. (each three)

9. Install SST(0K201 190 016) onto 3-4 clutch drum and remove 3-4 clutch piston using compressed air.


10. Remove SST(0K201 190 016).

11. Remove outer seal and inner seal 3-4 clutch piston.

INSPECTION

Drive plate1. Measure facing thickness in three places, and determine average of three readings.



Return spring1. Measure spring free length.


3-4 clutch piston1. Verify that there is not air leakage when applying compressed air through oil hole opposite return spring.

2. Verify that there is air flow when applying compressed air through oil hole on return spring side.


RE-ASSEMBLY1. Install 3-4 clutch piston.

a. Apply ATF to inner and outer seals, and install them onto 3-4 clutch piston.b. Install piston by pushing evenly around circumference, being careful not to damage seal rings.

2. Install return spring and spring retainer.

3. Install SST(0K 201 190 AA1) to 3-4 clutch as shown.

4. Compress return spring and spring retainer.



7. Install drive and driven plates. (each three)

Installation order:Driven-Drive-Driven-Drive-Driven-Drive



10. Measure 3-4 clutch clearance.a. Measure clearance between snap ring and retaining plate of 3-4 clutch.b. If clearance is not within specification, adjust it by selecting correct thickness snap ring.

3-4 clutch clearance:0.051-0.063 in (1.3-1.6 mm)

11. Check clutch operation as follows:a. Install SST(0K201 190 016) as shown, and check clutch operation by applying compressed air.


12. Apply petroleum jelly to thrust bearings and secure them to each side of 3-4 clutch drum.

Thrust bearing outer diameterPlanetary carrier side: 2.21 in (56.1 mm)Output shell side: 2.84 in (72.1 mm)

INSPECTION

Drive plate1. Measure facing thickness in three places, and determine average of three readings.



Return spring1. Measure spring free length.


3-4 clutch piston1. Verify that there is not air leakage when applying compressed air through oil hole opposite return spring.

2. Verify that there is air flow when applying compressed air through oil hole on return spring side.

Air pressure:

57 psi (392 kPa, 4.0 kg/cm²) maximum

Gear System

Input Shaft

2004 > 1.6L DOHC >

Primary shaft assembly1. Measure thrust clearance of all gears before disassembly, refer to Preinspection.

2. Disassemble in order shown in figure, refer to Disassembly note.

Check thrust clearance of all gears before disassembly and after assembly.

COMPONENTS

2004 > 1.6L DOHC >

Preinspection

3rd gear thrust clearance1. Measure clearance between 3rd gear and 2nd gear.

Clearance: 0.002~0.008 in (0.05~0.20 mm)Maximum: 0.010 in (0.25 mm)

2. If clearance exceeds maximum, check contact surfaces of 3rd gear, 2nd gear and clutch hub (3rd/4th). Replaceworn and damaged parts.

4th gear thrust clearance1. Measure clearance between 4th gear and ball bearing.


2. If clearance exceeds maximum, check contact surfaces of 4th gear, ball bearing, and clutch hub (3rd/4th). Replaceworn and damaged parts.

Disassembly noteBearing (4th gear end)1. Remove bearing by using SST (0K130 171 013).

3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear

1. Remove retaining ring.

2. Remove 3rd/4th clutch hub assembly, 3rd synchronizer ring, and 3rd gear by usingSST (0K130 175 008).

Bearing (1st end)1. Remove bearing by using SST (0K670 990 AA0).

Primary shaft assemblyAssemble in order shown in figure, refer to Assembly note.

Assembly noteBearing (1st gear end)1. Install new bearing by using SST (0K130 175 A13/0K011 270 A02).

Primary 3rd gear, 3rd synchronizer ring and 3rd/4th clutch hub assembly1. Install 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub assembly

4th synchronizer ring, primary 4th gear and bearing (4th gear end)1. Install 4th synchronizer ring, 4th gear, and new bearing by using SST (0K130 175 008/0K011 270 A02).

2. Measure clearance between primary 3rd gear and 2nd gear.


3. Measure clearance between primary 4th gear and bearing (4th gear end).

Clearance: 0.007~0.015 in (0.17~0.37 mm)Maximum: 0.017 in. (42 mm)

4. If not as specified, disassemble and reassemble primary shaft assembly.

DISASSEMBLY1. Remove the snap ring and the ball bearing using the special tool (09432-21300).

2. Remove the stopper snap ring, snap ring, 5th and 4th speed gear, needle roller bearing, 4th speed gear sleeve,synchronizer ring (3rd 4th), synchronizer spring (1st, 2nd, 3rd, 4th), synchronizer sleeve (3rd 4th), 3rd speed gearand needle roller bearing.

INSPECTION

INPUT SHAFT1. Check the outer surface of the input shaft where the needle bearing is mounting for damage or abnormal wear.

2. Check the splines for damage or wear.

SYNCHRONIZER SLEEVE AND HUB1. Install the synchronizer sleeve on the hub and check that it slides smoothly.

2. Check that the sleeve is free from damage.

3. Check for wear of the hub end surfaces (in contact with each gear).

Replace the synchronizer hub and sleeve as a set.

REASSEMBLY1. Install the needle roller bearing, 3rd speed gear, synchronizer sleeve (3rd 4th), synchronizer spring (1st, 2nd, 3rd,

4th), synchronizer ring (3rd 4th), 4th speed gear sleeve, needle roller bearing, 5th and 4th speed gar, snap ringand the stopper snap ring using the special tool (09432-33200).

2. Install the snap ring and the ball bearing using special tool (09495-33100).

Transfer Drive Gear

2004 > 1.6L DOHC >

components

2004 > 1.6L DOHC >

DISASSEMBLY1. Loosen the lock nut caulking.

2. Remove the lock by using socket.

REASSEMBLY1. Apply ATF to the new lock nut and tighten to the specified torque. And loosen 1 turn and tighten to the specified

torque again.

2. Caulk the lock nut by using punch.

Output Gear

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove two seal rings.

2. Remove bearings from output gear with suitable tools.

RE-ASSEMBLY1. Press new bearings onto output gear with suitable tools.

2. Apply ATF to new seal rings and install them to each side of output gear.

Output Shaft

2004 > 1.6L DOHC >

COMPONENTS

2004 > 1.6L DOHC >

REASSEMBLY1. Install the needle roller bearing.

2. Install the 1st speed gear.

3. Install the triple cone assembly.

4. Install the synchronizer sleeve and hub.

5. Install the triple cone assembly.

6. Install the 2nd speed sleeve and the needle roller bearing.

7. Install the 2nd and 3rd speed gear with all together above mentioned using the special tool (09432-H1000).


9. Install the 4th speed gear, the 5th speed gear sleeve, the needle roller bearing, the 5th speed gear, thesynchronizer ring (5th), the synchronizer hub and the sleeve (5 & R).

10. Install the needle roller bearing, the reverse gear assembly and the reverse driven gear sleeve.

11. Install the rear taper roller bearing with all together above mentioned using the special tool (09432-22000).

DISASSEMBLY1. Remove the taper roller bearing and the reverse gear using the special tool (03495-33000).

2. Remove the synchronizer ring, synchronizer spring (5th & Rev), sleeve (5th & Rev).

3. Remove the synchronizer hub and the 5th gear using the special tool (03495-33000).

4. Remove the 4th, 3rd, 2nd, 1st gear all together the special tool (09432-33200).

INSPECTION

OUTPUT SHAFT1. Check the outer surface of where the needle bearing is mounted for damage or abnormal wear.

2. Check the splines for damage or wear.

NEEDLE BEARING1. Install the needle bearing on the shaft with the bearing sleeve and gear. Check that it rotates smoothly without

abnormal noise or play.

2. Check the needle bearing cage for distortion.

SYNCHRONIZER RING1. Check the clutch gear teeth for damage.

2. Check internal surface for damage, wear or broken grooves.

SYNCHRONIZER SLEEVE AND HUB1. Install the synchronizer sleeve on the hub and check that it slides smoothly.

2. Check that the sleeve is free from damage.

3. Check for wear of the hub end surfaces (in contact with each gear).

Replace the synchronizer hub and sleeve as a set.

GEARS1. Check the helical gear and clutch gear teeth for damage or wear.

2. Check the gear cone for rough surfaces, damage or wear.

3. Check the gear bore for damage or wear.

Bearing Cover Assembly

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

DISASSEMBLY1. Remove oil seal.

2. Remove bearing outer race with a pin punch and hammer as shown.

3. Remove O-ring.

RE-ASSEMBLY1. Apply ATF to new O-ring and install O-ring.

2. Press bearing outer race into the cover.

3. Press new oil seal into bearing cover with SST(0K201 190 017).

Automatic Transaxle Control System

Shift Lever

2004 > 1.6L DOHC >

COMPONENT

2004 > 1.6L DOHC >

OPERATION INSPECTION

Shift selector lever from P range to other ranges with ignition switch ON and brake pedal depressed.

1. Verify that selector lever can only be shifted as shown in figure.

2. Verify that there is a click at each range when shifted from P to 1 range.

3. Verify that positions of selector lever and indicator are aligned.

4. Verify that button returns smoothly when pushed.

Disassembly1. Disconnect negative battery cable.

2. Place vehicle in a straight forward position.

3. Loosen four air bag module bolts from steering wheel and remove driver's air bag module.

4. Disconnect horn switch and air bag module connector.

5. Mark an alignment mark on steering wheel and steering shaft for proper installation.

6. Remove retaining nut and snap ring from the end of steering shaft.

7. Remove steering wheel with a suitable puller.

Do not remove steering wheel by hitting end of shaft with a hammer. Damage to shaft threads and shaftsupport bearings could occur.

8. Remove three lower steering column panel screws and separate upper and lower steering column panels.

9. Remove two undercover bolts after loosening parking cable puller nut then disconnect two connectors.

10. Remove clock spring after loosening three clock spring screws.

11. Remove combination switch after disconnecting two combination switch connectors.

12. Rigidly support steering wheel lock portion of column, and use a chisel to make a groove (screwdriver slot) inhead of two steering lock bolts.

13. Remove the steering lock after loosening two bolts.

14. Remove change lever and return spring after loosening bolt, nut and two retainer rings.

15. Remove control cable from clamp assembly after loosening control cable nut then remove U - clip from columnshaft bracket.

16. Remove change lever bracket, change lever arm and bush after loosening three screws.

17. Remove clamp assembly from column shaft after loosening three bolts.

18. Separate clamp assembly after removing washer and E - ring.

19. Remove U - clip from selector cable to auto transaxle linkage.

20. Remove nut and washer from auto transaxle linkage.

21. Remove guide bracket after loosening two nuts.

Re-assembly1. Install guide bracket and tighten two nuts.

Tightening torque:69.4~95.9 Ib-in (7.8~10.8 N·m, 0.8~1.1 kg-m)

2. Install spacer and bolt into adjust slot and then tighten adjust nut after inserting U - clip.


3. Install washer and nut to auto transaxle linkage and tighten nut.

Tightening torque:24~83 Ib-in (32~46 N·m, 3.2~4.7 kg-m)

4. Assemble clamp assembly with washer and E - ring and then insert it into the column shaft and tighten three bolts.

5. Insert U - clip to fix control cable to column shaft bracket.

6. Install clamp assembly to control cable and tighten bolt and nut.


7. Insert shift lever arm, change lever bracket and bush in column shaft and tighten three screws.

8. Put return spring into the groove of shift lever arm and then install change lever with bolt and nut.


9. Install new steering lock mounting bolts, and tighten them until heads break OFF.

10. Install combination switch after connecting two combination switch connector.

11. Install clock spring (refer to section RT).

12. Tighten two undercover bolts after installing parking cable puller and connecting two harness connectors.

13. Tight three lower steering column panel screws after installing upper and lower steering column panels.

Tightening torque:12~17 Ib-in (16~23 N·m, 1.6~2.3 kg-m)

14. Align mark and install properly steering wheel to column shaft.

15. Insert snap ring and install retaining nut.

Tightening torque:29~36 Ib-in (39~493 N·m, 4~5 kg-m)

16. Connect horn switch and air bag module connector.

17. Install air bag module steering wheel and tighten four bolts.

18. Connect (-) terminal of battery.

Overdrive Switch

2004 > 1.6L DOHC >

Operation inspection1. Turn ignition switch ON.

2. Verify that the O/D OFF indicator light is not illuminated. Depress O/D OFF switch and verify that the O/D OFFindicator light illuminates.

3. If O/D OFF indicator light does not operate, continue with inspection of voltage test.

Operation inspection1. Turn ignition switch ON.

2. Verify that the O/D OFF indicator light is not illuminated. Depress O/D OFF switch and verify that the O/D OFFindicator light illuminates.

3. If O/D OFF indicator light does not operate, continue with inspection of voltage test.

Adjustment1. Disconnect negative battery cable.

2. Pull data link connector upward from MAF sensor.

3. Disconnect air temperature sensor connector and MAF sensor connector.

4. Remove fresh air duct and air cleaner assembly.

5. Remove nut. Disconnect selector cable.

6. Rotate manual shaft to N position.

7. Disconnect transaxle range switch connector.

8. Loosen transaxle range switch mounting bolts.

9. Connect ohmmeter between terminals 5 and 7.

10. Adjust switch to point where there is continuity between terminals.

11. Tighten two transaxle range switch mounting bolts.

Tightening torque:70~95 Ib-in (7.9~10.7 N·m, 80~110 kg-cm)

12. Verify that the selector lever range position and transaxle range switch correspond.

13. Connect transaxle range switch connector.

14. Connect selector cable and tighten nut.

Tightening torque:24~33 Ib-in (32~46 N·m,3.2~4.7 kg-cm)

15. Install air cleaner assembly, and fresh air duct.

16. Connect air temperature sensor connector and MAF sensor connector.

17. Install data link connector to MAF sensor.


Transaxle Oil Temperature Sensor

2004 > 1.6L DOHC >

RESISTANCE INSPECTION1. Remove air cleaner and freshair duct.

2. Connect ohmmeter between terminals H-03-5 and H-03-8.

3. Measure resistance while warming up ATF(driving vehicle).

4. Verify that the resistance drops as shown in following table and graph.

Inhibiter Switch

2004 > 1.6L DOHC >

CONTINUITY INSPECTION1. Disconnect negative battery cable.


3. Check for continuity at transaxle range switch.

4. If not as specified, replace or adjust transaxle range switch.



CONTINUITY INSPECTION1. Disconnect negative battery cable.


3. Check for continuity at transaxle range switch.

4. If not as specified, replace or adjust transaxle range switch.



Troubleshooting

2004 > 1.6L DOHC >

INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES

Diagnostic trouble codeP0707P0708

a. Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signal)b. Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signals)

Details a. Corroded or faulty Range Switch.b. Open between Meter Fuse and Range Switch.c. Open between Range Switch and TCM on one or more circuits.d. Short to Battery between Range Switch and TCM on one or more circuits.e. Short between two or more wires between Range Switch and TCM.

If a P1500 is stored along with a P0750, there is a problem with the MeterFuse circuit. Any shorts or opens in the Meter Fuse circuit should be repairedbefore continuing with this troubleshooting tree.

Possiblecause

1. Transaxle range switch malfunction.

2. Damaged wiring or connectors between transaxle range switch andtransaxlecontrol module.

3. Transaxle control module malfunction.


1 With ignition off, disconnect A-03 from RangeSwitch. Check for any signs of corrosion or water.Isany water or corrosion present?

Yes Spray inside of A-03 and Range Switch withsilicone lubricant and blow out connector andRange Switch with compressed air. Check A-03and Range Switch carefully for cracks or missingwater seals and replace as necessary. If corrosionhas penetrated terminals or wiring, replace FrontHarness and Range Switch.

No Go to step 2.

2 Verify Meter Fuse is okay. Turn ignition on and,measure voltage at A-03/I (B+).Is battery voltage available?

Yes Go to step 3.

No Locate source of open between Meter Fuse and A-03/I.Repair as necessary.

3 Turn ignition off and reconnect A-03 to RangeSwitch. Remove connector cover from H-01 (TCM)(leave H-01 connected to TCM to do tests). Turnignition on and measure voltages per chart "A".Are voltages correct per chart "A"?

Yes Go to step 4.

No If voltage is below specs in R, D, 2 or 1 (or morethan 0v in P or N), referring to chart "A", measureresistance acrossRange Switch with ignition off andA-03 disconnected. Replace Range Switch ifresistance between terminals is greater than 1 ohm.If Range Switch tests okay, check affected circuitper diagram "A" and repair as necessary.If voltageis available in R, D, 2 or 1 when Gear Selector is in"All other positions", disconnect A-03 from RangeSwitch and measure incorrect voltage(s) at TCMagain. Replace Range Switch if voltage drops to 0v.If voltage does not drop to 0v, refer to chart "A" andlocate source of short to voltage.If voltage is 0v in Park or Neutral when gearselector is "All other gear positions", disconnect A-03 from Range Switch and measure voltage at H-01/18 again. Replace Range Switch if voltage

01/18 again. Replace Range Switch if voltagereturns to specification. If voltage remains at 0v,locate short to ground between A-03/9 and H-01/18(refer to chart "A")

4 Clear codes and verify any repairs by starting vehicle with Hi-scan Pro connected to OBD-II connector andmonitoring forpending codes (refer to section 3 of the Hi-scan Pro Generic OBD-II Program Card referencemanual). Allow to idle in each gear position for a minimum of 2 1/2 minutes.

Chart A

2004 > 1.6L DOHC >


Code No.P0710 Oil temperature sensor system Probable cause

If the oil temperature sensor output voltage is 2.6 V or more evenafter driving for 10 minutes or more (If the oil temperature does notincrease), it is judged that there is an open circuit in the oiltemperature sensor and diagnostic trouble code No.P0710 is output.If the oil temperature sensor output detects the voltage whichcorresponds to 200°C(392°F) or more for more than one second, it isjudged that there is an open circuit in oil temperature sensor anddiagnostic trouble code No. P0710 is output.

a. Malfunction of the oil temperature sensorb. Malfunction of connectorc. Malfunction of the TCM

2004 > 1.6L DOHC >

ATF SENSOR


a. ATF sensor lowb. ATF sensor high

Details a. ATF sensor malfunction

Possiblecause

a. Short circuit in wiringb. ATF sensor malfunction


1 Are all connections at connector and connector pinsOK?


No Repair or replace connector(s).

2 Measure terminal voltage of transaxle controlmodule at terminal H-01/22.

Standard voltage:ATF 68°F (20°C): Approx. 4.0ATF 266°F (130°C): Approx. 1.5

Is terminal voltage as specified?

Yes Go to step 5.

No Go to next step.

3 Measure ATF sensor resistance of transaxle controlmodule at terminal H-01/21 and H-01/22.

Standard voltage:ATF 68°F (20°C): 24.461~29.205kΩATF 140°F (68°C): 4.29~5.61kΩATF 176°F (80°C): 3.05~3.6kΩ

Yes Go to step 5.

No Replace ATF sensor.

4 Are connectors and wiring between transaxlecontrol module and ATF sensor OK?


No Replace or repair connector and wiring.

5 After diagnostic trouble code has been cleared,does reinspection diagnostic trouble code appear?


No The problem is a temporarily poor connection ofwiring or connectors and should be investigatedfurther.

6 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connectedand monitor for pending codes.

2004 > 1.6L DOHC >


Code No.P0715 input shaft speed sensor system Probable cause

If no output pulse is detected from the input shaft speed sensor for 1second or more while driving in 3rd or 4th gear at a speed of 30 km/h(19 mph) or more, it is judged to be an open circuit or short-circuit inthe input shaft speed sensor and diagnostic trouble code No.P0715 isoutput. If diagnostic trouble code P0715 is output four times, thetransaxle is locked into 3rd gar or 2nd gear as a fail-safe measure.

a. Malfunction of the input shaft speedsensor

b. Malfunction of the underdrive clutchretainer

c. Malfunction of connectord. Malfunction of the TCM

2004 > 1.6L DOHC >



a. Input/turbine speed sensor signal malfunctionb. Input/turbine speed sensor circuit malfunction

Details Input/turbine speed sensor signal is not input to transaxle control module whenvehicle is above 25 mph (40 km/h); turbine is below 96 rpm and vehicle in D, 2or 1.

Possiblecause

a. Input/turbine speed sensor malfunction.b. Damaged wiring or connectors between input/turbine speed sensor transaxle

control module.


1 Are all connections at connectors and connectorpins OK?



2 Measure terminal voltage of transaxle controlmodule at terminal H-01/44 and H-01/16.

Standard voltage:Engine running (P, N position): Approx. 2.5 VIgnition switch ON: Approx. 2.3 V


Yes Go to step 6.

No Go to next step.

3 Measure input/turbine speed sensor resistanceterminals H-01/44 and H-01/16 of harnessconnector as follows:a. Disconnect negative battery cable.b. DisconnDisconnect transaxle control module

connector.c. Measure resistance.

Standard resistance: 300~400Ω(@68°F/20°C)

Is resistance within standard?

Yes Go to step 6.

No Go to next step.

4 Measure input/turbine speed sensor resistance atinput/turbine speed sensor itself as follows:a. Disconnect negative battery cable.b. Remove air cleaner assembly.c. Disconnect input/turbine speed sensor

connector.d. Measure resistance.

Standard resistance: 300~400Ω(@68°F/20°C)



No Replace input/turbine speed sensor.

5 Are connectors and wiring between transaxlecontrol module and input/turbine speed sensor OK?


No Repair or replace connectors and wiring.



If problem is corrected, replace TCM.



2004 > 1.6L DOHC >


Code No.P0720 Output shaft speed sensor system Probable cause

If the output from the output shaft speed sensor is continuously 50%lower than the vehicle speed for 1 second or more while driving in3rd or 4th gear at a speed of 30 km/h or more, it is judged to be anopen circuit or short-circuit in the output shaft speed sensor anddiagnostic trouble code No.P0720 is output. If diagnostic trouble codeNo.P0720 is output four times, the transmission is locked into 3rdgear or 2nd gear as a fail-safe measure.

a. Malfunction of the output shaft speedsensor

b. Malfunction of the transfer drive gear ordriven gear

c. Malfunction of connectord. Malfunction of the TCM

2004 > 1.6L DOHC >



a. Engine speed input signal malfunctionb. Engine speed input malfunction

Details a. (P0726): Loss of engine speed sensor signal to the transaxle control module.DTC is triggered if engine rpm is above 750 rpm

b. (P0727): Loss of engine speed sensor signal to the transaxle control module.DTC is triggered if turbine output is above600 rpm and engine output is below96 rpm and vehicle is not in P or N ranges.

Possiblecause

1. Damaged wiring or connectors between engine control module and transaxlecontrol module.


1 Is terminal voltage as specified? Yes Repair

No Go to next step.

2 Are all connections at connector and connector pinOK?



3 Measure terminal voltage of engine control module.

Is terminal as specified?

Yes Go to step 5.

No Go to next step.

4 Are connectors and wiring between engine controlmodule (B-01/59) and transaxle control module (H-01/40) OK?







2004 > 1.6L DOHC >


Code No.P0731 1st gear incorrect ratio Probable cause

If the output from the output shaft speed sensor multiplied by the 1stgear ratio is not the same as the output from the input shaft speedsensor after shifting to 1st gear has been completed, diagnostictrouble code NO.P0731 is output. If diagnostic trouble code No.P0731is output four times, the transaxle is locked into 3rd gear as a fail-safe measure.


b. Malfunction of the output shaft speedsensor

c. Malfunction of the underdrive clutchretainer

d. Malefaction of the transfer drive gear ordriven gear

e. Malfunction of the low and reverse brakesystem

f. Malfunction of the underdrive clutchsystem

g. Noise generated

2004 > 1.6L DOHC >


Code No.P0732 2nd gear incorrect ratio Probable cause

If the output from the output shaft speed sensor multiplied by the 2ndgear ratio is not the same as the output from the input shaft speedsensor after shifting to 2nd gear has been completed, diagnostictrouble code No.P0732 is output. If diagnostic trouble code No.P0732is output four times, the transaxle is locked into 3rd gear as a fail-safe measure.




d. Malfunction of the transfer drive gear ordriven gear

e. Malfunction of the second brake systemf. Malfunction of the underdrive clutch

systemg. Noise generated

2004 > 1.6L DOHC >


Code No.P0733 3rd gear incorrect ratio Probable cause

If the output from the output shaft speed sensor multiplied by the 3rdgear ratio is not the same as the output from the input shaft speedsensor after shifting to 3rd gear has been completed, diagnostictrouble code NO.P0733 is output. If diagnostic trouble code No.P0733is output four times, the transaxle is locked into 3rd gear as a fail-safe measure.







g. Noise generated

2004 > 1.6L DOHC >


Code No.P0734 4th gear incorrect ratio Probable cause

If the output from the output shaft speed sensor multiplied by the 4thgear ratio is not the same as the output from the input shaft speedsensor after shifting to 4th gear has been completed, diagnostictrouble code NO.P0734 is output. If diagnostic trouble code No.P0734is output four times, the transaxle is locked into 3rd gear as a fail-safe measure.







g. Noise generated

2004 > 1.6L DOHC >


Code No.P0736 reverse gear incorrect ratio Probable cause

If the output from the output shaft speed sensor multiplied by thereverse gear ratio is not the same as the output from the input shaftspeed sensor after shifting to reverse gear has been completed,diagnostic trouble code NO.P0736 is output. If diagnostic trouble codeNo.P0736 is output four times, the transaxle is locked into 3rd gear asa fail-safe measure.







g. Noise generated

2004 > 1.6L DOHC >



a. Torque converter clutch system malfunction (Stuck OFF)b. Torque converter clutch system malfunction (Stuck ON)

Details Shift solenoids A, B, C, vehicle speed sensor, input/turbine speed sensor andtransaxle fluid temperature sensor function normally. Vehicle speed is between44 mph (71 km/h) and 65 mph (105 km/h) and difference in the number ofengine revolutions and reverse and forward drum revolutions when in 4GR TCCoperation is above 100 rpm.

Possiblecause

1. Air leak between Throttle Position Sensor (TPS) and Mass Air Flow Sensor(MAFS).

2. ATF level low.

3. Line pressure low.

4. Torque converter clutch slipping.

5. Torque converter control valve or torque converter relief valve stuck.

6. Torque converter clutch (TCC) solenoid valve malfunction.

If any codes relating to TPS or MAFS are present, do ALL repairs associatedwith those codes before proceeding with troubleshooting for a P0741 andP0742 code. A faulty TPS or MAFS can set a P0741 and P0742.


1 Check for cracked intake tube, improperly installedintake tube or other source of air leak between TPSand MAFS.Were any air leaks found between TPS andMAFS?

Yes Repair as necessary.

No Go to step 2.

2 Check ATF level (transaxle at normal operatingtemperature).Is ATF level low?

Yes Check for any signs of leakage from transaxle.Repair as necessary and fill transaxle to full level.

No Go to step 3.

3 Check ATF condition and compare to following chart.1. Clear reddish pink: Normal condition.

2. Dark or black (with friction material): Internaltransaxle malfunction or excessive wear.

3. Milky pink: Water contamination.

4. Light to dark brown (oxidized): Overheated orworn out fluid.

Is fluid condition other than normal.

Yes For ATF condition #2, replace transaxle.For ATF condition #3, replace fluid, repair source ofcontamination and perform pressure tests. If watercontamination is severe, replace transaxle.For ATF condition #4, replace fluid and performpressure tests.

No Go to step 4.

4 Check line pressure and compare to the followingchart.

Yes Go to step 5.

No Replace transaxle.

Is line pressure within specification?

No Replace transaxle.

5 Check torque converter front chamber pressure asfollows:1. Remove front chamber access plug. NOTE:

Front chamber pressure access plug isaccessible through the front of the cut-out in theengine support cross member. It is the second 5mm allen headed plug (counting from the bottomof the transaxleforward).

2. Screw pressure port adapter into front chamberport and attach adapter to 100 psi gauge.

3. Disconnect coupler ass? from transaxle andattach a 10 amp fused jumper wire to the #2 pinat the transaxle (make the jumper wire longenough to reach the battery positive post).

4. Raise vehicle on the lift so the tires are at least5 inches off of the floor and apply hand brake.

5. Start engine and warm it up to operatingtemperature.

6. Shift transaxle into D and raise vehicle speed toapproximately 40 to 50 mph.

7. While maintaining vehicle speed, touch looseend of jumper wire to battery positive post andobserve front chamber pressure. Front chamberpressure will drop in 2 stages within 2 secondswith TCC energized.Front chamber pressureTCC solenoid off - approximately 88 to 92 psi.TCC solenoid on - approximately 30 to 38 psi.Is the front chamber pressure withinspecification and does it drop as describedwithin 2 seconds?

Yes Replace valve body.

No Remove transaxle drain pan and TCC solenoid fromvalve body. Attach a short piece of hose to TCCsolenoid nipple. Blow through hose and verify airdoes not escape from hole in body of solenoid.Jumper a wire from solenoid body to batterynegative and another wire from solenoid terminal tobattery positive. Blow through hose and verify airescapes from hole in body of the solenoid. If TCCsolenoid checks okay, replace valve body.Clear codes and verify any repairs by drivingvehicle with Hi scan pro connected to OBD-IIconnector

The torque converter can only be checked by theuse of special equipment. If replacing valve bodydoes not repair vehicle, replace transaxle.

2004 > 1.6L DOHC >


Code No.P0743/P0740 Damper clutch solenoid system Probable cause

If the resistance value for the torque converter clutch solenoid is toolarge or too small, it is judged that there is a short-circuit or an opencircuit in the damper clutch solenoid and diagnostic trouble codeNo.P0743 is output. If the drive duty rate for the damper clutchsolenoid is 100% for a continuous period of 4 seconds or more, it isjudged that there is an abnormality in the damper clutch system anddiagnostic trouble code NO.P0740 is output. When diagnostic troublecode No.P0743 is output, the transaxle is locked into 3rd gear as afail-safe measure. If the lock-up clutch remains engaged for acontinuous period of 10 seconds when the TCM is attempting todisengage the lock-up clutch, it is judged that the torque converterclutch is stuck on and diagnostic trouble code P0740.

a. Malfunction of the damper clutch solenoidb. Malfunction of connectorc. Malfunction of the TCM

2004 > 1.6L DOHC >


Diagnostic trouble codeP0748 Linear solenoid electrical

Details

Possiblecause

1. Short or open circuit in wiring.

2. Short or open circuit in transaxle control module internal transistors.

3. Short or open circuit in linear solenoid valve.







Yes Go to step 6.

No Go to next step.

3 Measure solenoid valve resistance betweenterminal H-01/5 of connector and a ground asfollows:a. Disconnect negative battery cable.b. Disconnect transaxle control module connector.c. Measure resistance.

Standard resistance: 4.1-5.1 Ω


Yes Go to step 6.

No Go to next step.

4 Measure solenoid valve resistance at torqueconverter clutch solenoid valve terminal of solenoidvalve connector as follows:a. Disconnect negative battery cable.b. Disconnect solenoid valve connector.c. Measure resistance.

Standard resistance: 4.1-5.1 Ω



No Replace linear solenoid valve.

5 Is the wiring between transaxle control module andsolenoid valve OK?







2004 > 1.6L DOHC >


Code No.P0750 Low and reverse solenoid valve system

Probable causeCode No.P0755 Underdrive solenoid valve system

Code No.P0760 Second solenoid valve system

Code No.P0765 Overdrive solenoid valve system

If the resistance value for a solenoid valve is too large or too small, itis judged that there is a short-circuit or an open circuit in the solenoidvalve and the respective diagnostic trouble code is output. Thetransaxle is locked into 3rd gear as a fail-safe measure.

a. Malfunction of solenoid valveb. Malfunction of connectorc. Malfunction of the TCM

2004 > 1.6L DOHC >


Diagnostic trouble codeP0753 Shift solenoid A electrica

Details

Possiblecause



3. Short or open circuit in shift solenoid A.





2 Measure terminal voltage of transaxle controlmodule at terminal H-01/30.Standard voltage:Solenoid valve ON: B+Solenoid valve OFF: 0 V


Yes Go to step 6.

No Go to next step.


Standard resistance: 14-18 Ω


Yes Go to step 6.

No Go to next step.

4 Measure solenoid valve resistance at terminal A ofsolenoid valve connector as follows:a. Disconnect negative battery cable.b. Disconnect solenoid valve connector.c. Measure resistance.




No Replace shift solenoid A.

5 Is wiring between transaxle control module andsolenoid valve OK?







2004 > 1.6L DOHC >


Diagnostic trouble codeP0758 Shift solenoid B electrical

Details

Possiblecause



3. Short or open circuit in shift solenoid B.





2 Measure terminal voltage of transaxle controlmodule at terminal H-01/33.Standard voltage:Solenoid valve ON: B+Solenoid valve OFF: 0 V


Yes Go to step 6.

No Go to next step.




Yes Go to step 6.

No Go to next step.

4 Measure solenoid valve resistance at terminal B ofsolenoid valve connector as follows:a. Disconnect negative battery cable.b. Disconnect solenoid valve connector.c. Measure resistance.




No Replace shift solenoid B.



No Replace or replace TCM concerning connectors andwiring.





2004 > 1.6L DOHC >


Diagnostic trouble codeP0763 Shift solenoid C electrical

Details

Possiblecause



3. Short or open circuit in shift solenoid C.






Standard voltage:Solenoid valve ON: B+Solenoid valve OFF: 0 V


Yes Go to step 6.

No Go to next step.




Yes Go to step 6.

No Go to next step.

4 Measure solenoid valve resistance at terminal C ofsolenoid valve connector as follows:a. Disconnect negative battery cable.b. Disconnect solenoid valve connector.c. Measure resistance.




No Replace shift solenoid C.








2004 > 1.6L DOHC >


Diagnostic trouble codeP1700 O/D OFF lamp circuit malfunction

Details 1. Short circuit to ground2. O/D off lamp switch malfunction

Possiblecause

1. Short circuit to ground.2. O/D OFF lamp switch malfunction


1 Are all connections at connectors and connectorpins OK?


No Repair or replace.



Yes Go to step 5.

No Go to next step.

3 Measure terminal voltage of O/D OFF switch.



No Replace or repair O/D OFF switch.

4 Are connectors and wiring between O/D off switchand transaxle control module (TCM) OK?







2004 > 1.6L DOHC >


Code No.P1723 A/T Control relay system Probable cause

If the relay voltage is less than 7 V after the ignition switch has beenturned to ON, it is judged that there is an open circuit or a short-circuit in the A/T control relay earth and diagnostic trouble codeP1723 is output. The transaxle is locked into 3rd gear as a fail-safemeasure.

a. Malfunction of the A／T control relayb. Malfunction of connectorc. Malfunction of the TCM

06-Automatic Transaxle System

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