06-Automatic Transaxle System

CHAPTER 6:
Automatic Transaxle System
General Information
2004 > 1.6L DOHC >
Special service tools

Tool (Number and Name) 0K201 170 AA0 Support, engine Illustration Use Used to support engine.
0K130 990 007 Engine stand
Used to disassemble and assemble transaxle.
0K201 323 021 Holder, Primary shaft
Used to hold primary shaft.
0K201 170 AA1 Installer, oil seal
Used to install oil sear.
0K 670 990 AA0 Puller set, bearing
Used to romeve bearing.
0K201 172 008 Removing plate
Used to remove gears.
0K130 171 013 Puller, bearing
Used to remove bearing.
0K130 283 021 Puller, ball joint
Used to remove tie-rod end.
0K130 175 011 AHanger, transaxle
0K130 170 012 Remover, bearing
0K130 175 008 Puller, fan pulley boss
0K900 175 AA1 Installer set, bearing
Used to install bearing.
0K130 175 A13
Used to install gear and bearing inner race.
0K130 175 A13 Body (Part of 0K900 175 AA1)
Used to install gear and bearing inner race.
0K201 171 A01 Attachment A (Part of 0K900 175 AA1)
Used to install bearing inner race and gear.
0K130 175 A11 Attachment B (Part of 0K900 175 AA1)
0K011 270 A02 Attachment E (Part of 0K900 175 AA1)
Used to install ear.
0K900 175 AA0 Shim selector set
Used to adjust bearing preload.
0K900 175 A01 Selector (Part of 0K900 175 AA0)
0K900 175 A02
0K130 175 A02 Collar (Part of 0K900 175 AA0)
0K130 175 A03 Bar (Part of 0K900 175 AA0)
0K130 191 A07 Bolt set (Part of 0K900 175 AA0)
0K130 191 A05 Adapter, preload
0K130 322 020
Used to measure preload.
0K130 322 020 Attachment
0K201 270 014 Holder, differential side gear
Used to hold differential side gears.
SPECIAL SERVICE TOOLS

Tool (Number and Name) 09431-39000 Oil seal installer Illustration Use Installation of differential oil seal
09432-22000 Bearing installer
Installation of output shaft's gear and sleeve
09432-22100 Bearing outer race installer
Installation of input and output shaft bearing outer race (Use with 09500-11000)
09432-33200 Bearing removing plate
Removal of input shaft's gear and ball bearing
09495-33100
Installation of input shaft bearing
Installation of input shaft bearing
09432-33400 Bearing race installer
Installation of input shaft bearing outer race (use with 09500-21000)
Installation of differential ball bearing
09455-32200/0K011 190 008 Oil seal puller
Removal of differential bearing spacer
09495-33000 Bearing and gear puller
Removal of ball bearing and gear
09517-21400 Drift
Separation of T/M housing from T/M assembly
09532-11000
Removal and installation of differential bearing
09532-11000 Differential bearing installer
Removal and installation of differential bearing
09532-11500 Pinion bearing outer race installer
Installation of output shaft and differential shaft bearing outer race (Use with 09500-11000)
09200-38001(J28467-B) Engine support fixture
Removal and installation of transaxle assembly

Tool (Number and Name) 09453-24000 Spring compressor Illustration Use Removal and installation of underdrive clutch snap ring
09452-21401/0K011 171 002 Guide pin
Installation of oil pump (use with 09452-21301)
09453-33100 Dial gauge extension
Measurement of the low and reverse brake and the second brake end play
09431-39000
Installation of differential oil seal
09431-39000 Oil seal installer
Installation of differential oil seal
09432-33200 Removing plate
Removal of transfer shaft bearing
a. Removal of transfer driven gear taper bearing (use with 09433-21000) b. Installation or transfer shaft bearing
09433-21000 Removing plate
a. Removal of transafer driven gear taper bearing (use with 09432-33800) b. Removal of differential ball bearing
09500-11000 Bar
Installation of differential bearing outer race (use with 09532-11500)
Installation of differential ball bearing and output shaft taper roller bearing
09453-21100
Removal and installation of the low-reverse
09453-21100 Spring compressor
Removal and installation of the low-reverse brake snap ring (use with 09453-21000)
09455-21000/0K011 430 017 Bearing and gear puller
Removal of ball bearing and tansfer drive gear
09455-21100 Bering installer
a. Intallation of ball bearing and transfer drive gear b. Installation of the transfer driven gear taper bearing
Installation of differential bearing outer race(use with 09500-11000)
a. Removal and installation of low-reverse brake snap ring b. Removal and installation of overdrive clutch snap ring (use with 09456-39000)
Removal and installation of low-reverse brake and overdrive clutch snap ring
09432-21701
Installation of output shaft outer race
09432-21701 Bearing outer race installer
Installation of output shaft outer race
09452-33100 Oil pump remover
Removal of the oil pump
09452-21200 Oil pump oil seal installer
Installation of the oil pump oil seal
09200-38001 Engine support fixture
Removal and installation of transaxle
09456-39100 A/B Clearance dummy plate
Measurement of low-reverse brake and second brake end plays
09457-39000 Special socket (41)
Removal and installation of output shaft lock nut

Tool (Number and Name) 0K2CA 089 HSP Illustration Use
0K2CA 089 HSP Hi-Scan Pro
0K130 283 021 Puller, ball joint
Used to remove tie-rod end.
0K130 990 007 stand, engine
Used to disassemble transaxle.
0K670 990 AA0 Puller set, bearing
Used to remove bearing
0K201 190 AA0 Gauge set, oil pressure
Used to measure line pressure
0K201 270 014 Holder, diff.side gear
Used to hold differential side gear.
0K130 175 011A
0K130 175 011A Hanger, transaxle
Used to remove bearing outer race.
0K201 170 AA0 Support, engine
Used to remove transaxle.
0K201 190 016 Leak 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 AA1 Compressor set, return spring
Used disassemble/assemble clutch assembly.
0K130 191 034 Holder, idler gear shaft
0K201 190 017 Installer, oil seal
Used to remove oil seal
0K201 190 019 Holder, turbine shaft
Used to remove/install turbine shaft
0K201 175 AA0 Selector set, shim
Used to adjust preload.
Used to remove differential bearing.
0K130 322 020
0K130 322 020 Preload, adapter
0K2CA 190 AA2 Servo Piston Lifter
Used to press servo piston lifter
0K2CA 190 AA1 Spring retainer assembly
Used to remove/install spring retainer assembly.

Tool (Number and Name) 0K201 170 AA0A Support, engine Illustration Use Used to support engine.
0K130 990 007 Engine stand
0K201 323 021 Holder, Primary shaft
Used to hold primary shaft.
0K201 170 AA1
0K670 990 AA0 Puller set, bearing
0K201 172 008 Removing plate
0K670 321 019 Puller, socket
Used to remove tie rod end.
0K130 175 011A Hanger, transaxle
0K130 170 012
0K130 175 008 Puller, fan pulley boss
0K900 175 AA1 Install set, bearing
0K130 175 AA0 Shim selector set
0K201 270 014 Holder, differential side gear
Used to hold differential side gears.
0K930 175 AA0
0K930 175 AA0 Bearing remover set
2004 > 1.6L DOHC >
TROUBLESHOOTING
Symptom Vibration, noise Probable cause Loose or damaged transaxle and engine mounts Inadequate shaft end play Worn or damaged gears Use of inadequate grade of gear oil Low oil level Inadequate engine idle speed Oil leakage Hard shift Broken or damaged oil seal Faulty control cable Remedy Tighten or replace mounts Correct end play Replace gears Replace with specified gear oil Replenish Adjust idle speed Replace oil seal Replace control cable
Poor contact or wear of synchronizer ring and Correct or replace gear cone Weakened synchronizer spring Use of inadequate grade of oil Jumps out of gear Worn gear shift fork or broken poppet spring Excessive clearance of synchronizer hub to sleeve spline Worn or damaged gears and/or bearings Replace synchronizer spring Replace with specified gear oil Replace shift fork or poppet spring Replace synchronizer hub and sleeve Replace
SERVICE ADJUSTMENT PROCEDURES TRANSAXLE GEAR OIL LEVEL INSPECTION

Inspect each component for evidence of leakage. Check the gear oil level by removing the filler plug. If the oil is contaminted, 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 OIL

Use 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 REPLACEMENT

1. 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 PROCEDURES

DIAGNOSTIC CHART Problem Possible cause Replace Replace Replace Replace Replace Action
Seized shift lever ball seat Shift lever does not shift smoothly Seized control rod joint or is hard to shift Bent control rod Worn control rod bushing Too much play in shift lever Weak shift lever ball spring
Worn shift lever ball bushing Difficult to shift Bent control rod No grease in shifter Insufficient oil Deterioration of oil quality Wear or play of shift fork or shift rod Worn synchronizer ring Worn synchronizer cone area of gear Bad contact of synchronizer ring and cone area of gear Excessive gear side clearance Worn bearing Worn synchronizer key spring Excessive primary shaft bearing preload Improperly adjusted change guide plate Does not stay in gear Bent control rod Worn control rod bushing Weak shift lever ball spring Improperly installed extension bar Worn shift fork Worn clutch hub Worn clutch hub sleeve Worn sliding surface of shaft gears Worn sliding surface of gear Worn sliding groove of control rod end Weak detent spring Excessive thrust clearance Worn bearing Improperly installed or loose engine mount Abnormal noise Insufficient oil Deterioration of oil quality Worn bearing Worn sliding surfaces of gears or shafts Excessive gear backlash Damaged gear teeth Foreign material in gears Damaged differential gear or excessive backlash
Replace Replace Lubricate with grease Add oil Replace with oil of specified quality Replace Replace Replace Replace Replace Replace Replace Adjust Adjust Replace Replace Replace Tighten Replace Replace Replace Replace Replace Replace Replace Replace Replace Tighten Add oil Replace with oil of specified quality Replace Replace Replace Replace Replace Replace
2004 > 1.6L DOHC >
Specifications
SPECIFICATIONS
Model Type Gear ratio First Second Third Fourth Fifth Reverse Final gear ratio M5GF1 Forward 5 speed, reverse 1 speed DIESEL 2.0 C/R 3.636 2.056 1.296 0.943 0.698 3.455 3.611
SERVICE STANDARD
Standard value Differential side bearing end play Gear backlash in differential Input front bearing snap ring end play Input rear bearing snap ring end play Output front bearing snap ring end play Output rear bearing snap ring end play 5TH input gear snap ring end play 3RD output gear snap ring end play mm (in.) 0.05T-0.10T (0.0019T-0.0039T) 0.025L-0.150L (0.00095L-0.0057L) 0.01L-0.12L(0.00038L-0.0045L) 0.01L-0.12L(0.00038L-0.0045L) 0.01L-0.12L(0.00038L-0.0045L) 0.01L-0.09L(0.00038L-0.00342L) 0.01L-0.05L(0.00038L-0.0019L) 0.01L-0.05L(0.00038L-0.0019L)
TIGHTENING TORQUE
Standard value Release bearing sleeve bolt Release fork shaft level nut Select lever Oil drain plug Poppet ball Clutch housing to transmission case Speedometer driven gear Reverse idler bolt Side cover bolt Shift control cable bracket Cylinder and hose assembly Shift lever bracket Front roll stopper bracket to subframe bolts Front roll stopper insulator bolt and nut Front roll stopper bracket to transaxle bolts Rear roll stopper bracket to subframe bolts Rear roll stopper insulator bolt and nut Rear roll stopper bracket to transaxle bolts Transaxle mounting sub bracket nut Transaxle mounting bracket bolts Transaxle mounting insulator bolt Front bearing retainer detent body cover bolt 5-8 27-40 20-27 30-35 35-42 35-42 4-6 43-55 10-12 20-27 15-22 9-14 60-80 50-65 60-80 50-65 50-65 60-80 60-80 60-80
Nm
kgcm 50-80 270-400 200-270 300-350 350-420 350-420 40-60 430-550 100-120 200-270 150-220 90-140 600-800 500-650 600-800 500-650 500-650 600-800 600-800 600-800 900-1100 150-220 4-6 20-29 15-20 22-26 26-31 26-31 3-4 32-40 7-8 15-20 11-16 7-10 43-58 36-47 43-58 36-47 36-47 43-58 43-58 43-58 65-80 10-16
lbft
90-110 15-22
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or loosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICATIONS
Item Transaxle gear oil lit. (U.S. qts., Imp.qts) Transaxle input shaft spline Transaxle oil seal lip Transaxle case and clutch housing alignment surface Transaxle case and rear cover alignment surface Bearing retain bolt (flush bolt only) Recommended sealants and adhesives SAE 75W/90 TGO-6 CASMOLY L9508 RETINAX AM, MOLYTEX GREASE EP-2 THREE BOND 1216 THREE BOND 1216 THREE BOND 2471 Quantity 2.1 (2.2, 1.8) As required As required As required As required As required
SPECIFICATIONS
Item Torque converter type Transmission type F4A42-2 3-element, 1-stage, 2-phase type 4-speed forward, 1-speed reverse
Engine displacement Gear ratio 1st 2nd 3rd 4th Reverse Final gear ratio
Diesel 2.0 Common Rail 2.842 1.529 1.000 0.712 2.480 3.770
SERVICE SPECIFICATIONS
Items Output shaft preload Brake reaction plate end play Low-reverse brake end play Second brake end play Underdrive sun gear end play Input shaft end play Differential case preload Underdrive clutch end play Reverse and overdrive clutch return spring end play Overdrive clutch end play Reverse clutch end play Backlash between differential side gear and pinion 0.01-0.09 mm 0-0.16 mm 1.65-2.11mm 0.79-1.25 mm 0.25-0.45 mm 0.70-1.20mm 0.045-0.105 mm 1.6-1.8 mm 0-0.09 mm 1.6-1.8 mm 1.5-1.7 mm 0.025-0.150 mm Standard value
SNAP RING AND SPACER FOR ADJUSTMENT

Part name Thrust washer (For adjustment of input shaft end play) Thickness mm 1.8 2.0 2.2 2.4 2.6 2.8 Snap ring (For adjustment of underdrive clutch and overdrive clutch end plays) 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 Identification symbol 18 20 22 24 26 28 None Blue Brown None Blue Brown None Blue Brown None Blue
2.7 2.8 2.9 3.0 Snap ring (For adjustment of low-reverse brake and second brake reaction plates end plays) 2.2 2.3 2.4 2.5 Pressure plate (For adjustment of low-reverse brake and second brake end plays) 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Snap ring (For adjustment of reverse clutch end play) 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Snap ring (For adjustment of reverse clutch and overdrive clutch spring retainers end plays) 1.48 1.53 1.58 1.63 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
Brown None Blue Brown Blue Brown None Blue 6 1 0 2 4 6 8 D None Blue Brown None Blue Brown None Blue Brown None Blue Brown None Brown None Blue Brown -
2.6 Spacer (For adjustment of output shaft preload) 1.88 1.92 1.96 2.00 2.04 2.08 2.12 2.16 2.20 2.24 2.28 2.32 2.36 2.40 2.44 2.48 2.52 2.56 2.60 2.64 2.68 2.72 2.76 Spacer (For adjustment of differential case preload) 0.71 0.74 0.77 0.80 0.83 0.86 0.89 0.92 0.95 0.98 1.01 1.04 1.07 1.10 1.13 1.16 1.19 1.22 1.25
88 92 96 00 04 08 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 71 74 77 80 83 86 89 92 95 98 01 04 07 J D K L G M
1.28 1.31 1.34 1.37 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
N E O P -
TIGHTENING TORQUE
Items Wiring harness bracket Control cable bracket Eye bolt Oil cooler feed tube Input shaft speed sensor Output shaft speed sensor Manual control lever Transaxle range switch Vehicle speed sensor Valve body cover Valve body mounting bolt Oil temperature sensor Manual control shaft detent Rear cover Torque converter housing Oil pump Transfer drive gear Output shaft lock nut Output shaft bearing retainer Oil filler plug Oil drain plug Transfer drive gear lock nut Differential drive gear Valve body Solenoid valve support Plate Pressure check plug Front roll stopper bracket to subframe bolts Front roll stopper insulator bolt and nut Front roll stopper bracket to transaxle bolts 20-26 20-26 27-33 10-12 10-12 10-12 18-25 10-12 4-6 8-10 10-12 10-12 5-7 20-26 42-54 20-26 16-22 160-180 20-26 29-34 29-34 180-210 130-140 10-12 5-7 5-7 8-10 60-80 50-65 60-80 Nm kgcm 200-260 200-260 270-330 100-120 100-120 100-120 180-250 100-120 40-60 80-100 100-120 100-120 50-70 200-260 420-540 200-260 160-220 1600-1800 200-260 290-340 290-340 1800-2100 1300-1400 100-120 50-70 50-70 80-100 600-800 500-650 600-800 14-18 14-18 19-23 7-8 7-8 7-8 13-18 7-8 3-4 6-7 7-8 7-8 4-5 14-18 29-38 14-18 11-15 110-126 14-18 20-24 20-24 126-147 91-98 7-8 4-5 4-5 6-7 43-58 36-47 43-58 lbft
Rear roll stopper bracket to subframe bolts Rear roll stopper insulator bolt and nut Rear roll stopper bracket to transaxle bolts Transaxle mounting sub bracket nut Transaxle mounting bracket bolts Transaxle mounting insulator bolt
50-65 50-65 60-80 60-80 60-80 90-110
500-650 500-650 600-800 600-800 600-800 900-1100
36-47 36-47 43-58 43-58 43-58 65-80
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or loosening if under-tightened. In either case, serious personal injury or death could result to the vehicle occupants.
LUBRICATIONS
Items Specified lubricant 7.8 (8.2,6.9) Quantity Transaxle fluid lit. (U.S. qts., Imp,qts.) GENUINE DIAMOND ATF SP-III
SEALANTS
Items Rear cover Torque converter housing Valve body cover Specified sealant Genuine sealant FMD546, TB1281B or equivalant Genuine sealant FMD546, TB1281B or equivalant Genuine sealant FMD546, TB1281B or equivalant
SPECIFICATIONS
SPECIFICATIONS
Automatic Transaxle System
2004 > 1.6L DOHC >
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT

PARKING NEUTRAL
FIRST
SECOND
THIRD
FOURTH
REVERSE
HYDRAULIC CIRCUIT P 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 Underdrive clutch Reverse clutch Overdrive clutch Low-and-reverse brake Second brake UD REV OD LR 2ND Code Function Connects input shaft and underdrive sun gear Connects input shaft and reverse sun gear Connects input shaft and overdrive planetary carrier Locks low-and-reverse annulus gear and overdrive planetary carrier Locks reverse sun gear
COMPONENT OPERATION TABLE: O/D OFF SYSTEM
SOLENOID VALVE OPERATION TABLE: O/D OFF SYSTEM
FLUID PASSAGE LOCATIONS

Transaxle case

Transaxle case
DESCRIPTION AND OPERATION

Cross-sectional view
COMPONENT OPERATION TABLE: O/D OFF SYSTEM
SOLENOID VALVE OPERATION TABLE: O/D OFF SYSTEM

Transaxle case

Transaxle 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
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 taken not 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/neutral switch 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 components from 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 1 2 3 4 Functional Name Low-Reverse Brake Underdrive Clutch Second Brake 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 as improper 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.
35. Remove thrust bearing #2.
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. 43. Remove thrust bearing #6.
44. Remove the overdrive clutch hub. 45. Remove thrust bearing #5.
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. 54. Remove thrust bearing #3.
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 0953211500).
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, measure the 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 plates when 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 snap ring.
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 the service 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 plates when 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 service manual and recheck the clearance.
In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and plates 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. Standard value: 1.65-2.11 mm (0.0650-0.0830 in.) 22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service manual 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 lbsft) 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 lbft). Loosen the nut 1 full turn, then re-tighten to 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. Standard value: 0.01-0.09 mm (0.0004-0.0035 in.) 30. If the standard value is incorrect, use this formula to select the correct spacer from the chart in the service manual. 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 lbsft).
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 gear end 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 size from the chart in the service manual. 56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbsft).
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 the underdrive 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. Standard value: 0.70-1.45 mm (0.0276-0.0371 in.)
63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size from the chart in the service manual.
64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbsft).
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 converter housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbsft) 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 lbsft) 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 are identified in the illustration and in the chart below. Number 1 2 3 4 Function Name Low-Reverse Brake Underdrive Clutch Second Brake Overdrive Clutch
79. Install the accumulators with the springs according to the illustration and the chart below. The accumulators should be flush with the transaxle case. Number 1 2 3 4 Function Name Low-Reverse Brake Underdrive Clutch Second Brake Overdrive Clutch Color None Yellow White 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. 1 Part to be connected Underdrive solenoid valve Wire color White, Red, Red Connector housing color Black
2 3 4 5 6
Overdrive solenoid valve Low-Reverse solenoid valve Second solenoid valve Damper clutch control solenoid valve Oil temp. sensor
Orange, Red Brown, Yellow Green, Red,Red Blue,Yellow,Yellow Black,Red
Black Milky White Milky White Black Black
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 lbft) 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 lbsft) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 lbsft) 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 lock similar, 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 lbsft) of torque.
93. Install the dipstick. 94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 lbsft). 95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 lbsft). 96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 lbsft). 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 oil pump seal.
pump seal.
DISASSEMBLY
General note 1. 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 ATF has degenerated.
Cleaning note
1. 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 with compressed 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 note
1. 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 Clutch facing material Steel (magnetic) Aluminum(Nonmagnetic) Possible source Drive plate or brake band Bearings, gears, or driven plate wear 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 by tapping 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).
PRECAUTION
1. 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 assembly before 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).
REASSEMBLY
1. Align bush cover with guide bolts as shown, and press it in. Tightening torque: 96 -120 Ibin (10.8-13.7 Nm, 110-140 kgcm)
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 Ibin (19-25 Nm, 1.9-2.6 kgm) 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. Tightening torque: 11-13 Ibin (15-17 Nm, 1.5-1.8 kgm)
6. Install detent lever and return spring.
7. Install parking assist lever.
8. Install lever holder and bolt. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
9. Install manual shaft and manual plate. a. Install manual plate, washer, and nut. b. Tighten nut to specified torque. Tightening torque: 31-40 Ibin (42-54 Nm, 4.2-5.6 kgcm)
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. Tightening torque: 28-38 Ibin (38-51 Nm, 3.8-5.3 kgm)
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 carrier counterclockwise. 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 Ibin (19-25 Nm,190-260 kgcm) 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 piston stem stroke. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum Stroke: 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. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm) 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 Ibin (8.4-10. 7 Nm, 80-110 kgcm)
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 Ibin (7.9-10.7 Nm ,80-110 kgcm) 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. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm) 45. Install input/turbine speed sensor. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm) 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 converter and mounting surface of converter housing. Distance (A): 0.535 in (13.6 mm)
RE-ASSEMBLY
1. 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 Ibft (128-176 Nm,13-18 kgm)
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 Ibft (128-176 Nm, 13-18 kgm) Preload: 0.27-7.8 Ibin (0.03-0.8 Nm, 0.3-0.9 kgcm)
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 adjustment shims.
shims.
BEARING PRELOAD
1. 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 Ibin (10.8-13.7 Nm, 110-140 kgcm) 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 specified torque. Tightening torque: 14-18 Ibin (19-25 Nm, 1.9-2.6 kgm)
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. Preload: 0.27-7.8 Ibin (0.03-0.8 Nm, 0.3-9.0 kgcm)
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. Tightening torque: 14-18 Ibin (19-25 Nm, 1.9-2.6 kgm)
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. Preload: 0.27-7.8 Ibin (0.03-0.8 Nm, 0.3-9.0 kgcm)
23. Remove bearing housing and output gear assembly.
REMOVAL
1. 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, MAF sensor 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 mounting member.
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.
INSTALLATION
1. 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 Ibft (89-116 Nm 9.1-11.9 kgm)
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 Ibft (34-49 Nm, 3.5-5.0 kgm)
8. Install four engine oil pan-to-transaxle mounting bolts then install access cover. Tightening torque: 27.5-38.0 Ibft (37-52 Nm, 3.8-5.3 kgm)
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 Ibft (67-93.2 Nm, 6.8-9.5 kgm)
11. Install joint shaft and tighten the three bolts. (Refer to section DS) Tightening torque: 31-46 Ibft (42-62 Nm, 4.3-6.3 kgm)
12. Install new clip on left drive shaft. 13. Push drive shaft into transaxle with opening of clip pointing upward. Tightening torque: 32-46 Ibft (43-52 Nm, 4.4-5.3 kgm)
14. Install left lower ball joint into spindle then install pinch bolt. Tightening torque: 32-39 Ibft (43-54 Nm, 4.4-5.5 kgm)
15. Install left stabilizer control link to bracket attached to shock absorber assembly. Tightening torque: 32-45 Ibft (43-61 Nm, 4.4-6.2 kgm)
16. Install left tie rod end to steering knuckle then install tie rod end nut. Tightening torque: 22-33 Ibft (30-44 Nm, 3.0-4.5 kgm) 17. Insert cotter pin and bend over.
18. Install engine mounting member-to-chassis bolts (two front) and nuts. (two rear) Tightening torque: 48-65 Ibft (64-89 Nm, 6.5-9.1 kgm) 19. Install two nuts to No.2 engine mount-to-mounting member. Tightening torque: 28-38 Ibft (38-51 Nm, 3.8-5.3 kgm)
20. Install catalytic converter. (five nuts) Tightening torque: 27.4-38.3 Ibft (37.2-51.9 Nm, 3.8-5.3 kgm) 21. Install two catalytic converter bracket nuts to engine. Tightening torque: 27.4-38.3 Ibft (37.2-51.9 Nm, 3.8-5.3 kgm)
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 Ibft (88-118 Nm, 9-12 kgm) 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. Tightening torque: 24-83 Ibft (32-46 Nm, 3.2-4.7 kgm)
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 Ibft (68-93 Nm, 6.8-9.5 kgm) Bolt: 47-66 Ibft (64-89 Nm, 6.5-9.1 kgm)
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 BAND
1. 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 band 1. Check 2-4 brake band for wear and burnt friction material.
Servo return spring

1. 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 Ibft (40-53 Nm, 4.0-5.0 kg/cm) 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.
10. Install snap ring.
Torque Converter
2004 > 1.6L DOHC >
WASHING INSIDE CONVERTER

1. 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. 5. Shake converter to clean inside. Pour out ATF.
Replace torque converter if it contains any metallic particles.
WASHING INSIDE CONVERTER

1. 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. 5. Shake converter to clean inside. Pour out ATF.
Replace torque converter if it contains any metallic particles.
The Other Automatic Transaxle System
2004 > 1.6L DOHC >
COMPONENTS
2004 > 1.6L DOHC >
DISASSEMBLY
1. Remove accumulator pistons and springs from clutch housing by applying compressed air through oil passage as shown in figure.
INSPECTION
Accumulator spring 1. Measure spring free length.
2. If not within specification, replace spring.
RE-ASSEMBLY
Installation order 2-3 accumulator: piston-spring-stopper 1-2 accumulator: piston-spring-stopper N-D accumulator: piston-spring-stopper N-R accumulator: spring-piston-stopper Apply even pressure to perimeter of accumulator pistons and stops to avoid damaging O-ring and seal rings while installing. 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 ADJUSTMENT

AUTOMATIC TRANSMISSION FLUID CHECK 1. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80C). 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, and then 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 the bushesand 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 more fluid 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 inside the hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping 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 occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, in which 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 under severe conditions. 8. The replacement procedures are given below.
AUTOMATIC TRANSMISSION FLUID

REPLACEMENT If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluid by 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 lbft) 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 (70-80C), and then check the fluid level 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 TEST

This test measures the maximum engine speed when the selector lever is at the D or R position and the torque converter stalls to test the operation of the torque converter, starter motor and one-way clutch operation and the holding 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 gauge b. Fluid temperature : 80-100C c. Engine coolant temperature : 80-100C 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 maximum engine 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 value Stall speed : 2200-2600 r/min 6. Move the selector lever to the R position and carry out the same test again. Standard value Stall speed : 2200-2600 r/min
TORQUE CONVERTER STALL TEST JUDGEMENT RESULTS

a. a. b. b. a. c. a. d. a. b. Stall speed is too high in both D and R ranges Low line pressure Low reverse brake slippage Stall speed is too high in D range only Underdrive clutch slippage Stall speed is too high in R range only Reverse clutch slippage Stall speed too low in both D and R ranges Malfunction of torque converter Insufficient engine output
HYDRAULIC PRESSURE TEST

1. Warm up the engine until the automatic transmission fluid temperature is 80-100C. 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 diagnosis table.
STANDARD HYDRAULIC PRESSURE TEST Measurement condition Selector lever position P R N D Shift position Engine speed (rpm) Reverse Neutral 1st gear 2nd gear 3rd gear 4th gear 2,500 2,500 2,500 2,500 2,500 2,500 Standard hydraulic pressure kPa Under drive Reverse clutch clutch pressure pressure 1,0101,050 1,0101,050 780-880 1.2701,770 Overdrive clutch pressure 780-880 780-880 Low and reverse brake pressure 260-340 1,2701,770 260-340 1,0101,050 Second brake pressure 1,0101,050 780-880 Torque converter pressure 220-360 500-700 220-360 500-700 500-700 450-650 450-650
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom All hydraulic pressures are high Probable cause 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 regulator valve Malfunction of the relief valve Incorrect valve body installation Hydraulic pressure is abnormal in "R" range only Malfunction of the regulator valve Clogged orifice Incorrect valve body installation Hydraulic pressure is abnormal in "3" or "4" range only Malfunction of the regulator valve Clogged orifice Incorrect valve body installation Malfunction of the overdrive solenoid valve Malfuction of the overdrive pressure control valve
Malfunction of the regulator valve Malfunction of the switch valve Clogged orifice Incorrect valve body installation Only underdrive hydraulic pressure is abnormal 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 Incorrect valve body installation Only reverse clutch hydraulic pressure is abnormal Malfunction of the oil seal A Malfunction of the oil seal B Malfunction of the oil seal C Clogged orifice Incorrect valve body installation Only low and reverse hydraulic pressure is abnormal 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 Incorrect valve body installation 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 Malfunction of check ball Clogged orifice Incorrect valve body installation Only torque converter presure is abnormal Pressure 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 Incorrect valve body installation
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 Malfunction of check ball Incorrect valve body installation
DIAGNOSIS FUNCTION
1. Connect HI-SCAN to the connector for diagnosis. 2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC TRUBLE 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 the Random 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 when the 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 failsafe 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. Memorization a. 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 50C after memorization of the most recent diagnosis code. b. Forced Deletion. Memorized diagnosis codes can be deleted using the SCAN-TOOL provided the following conditions are satisfied : a. The ignition switch is ON; b. There is no detection pulse from the crank angle sensor c. There is no detection pulse from the output shaft speed sensor d. There is no detection pulse from the vehicle speed sensor e. The fail-safe function is not operational
ROAD TEST
No. 1 2 Condition Ignition switch : OFF Ignition switch : ON Engine : Stopped Select lever position : P Operation Ignition switch (1) ON Selector lever position (1) P,(2) R, (2) N, (4) D (3) 3, (6) 2, (7) L Accelerator pedal (1) Released (2) Half depressed (3) Depressed Brake pedal (1) Depressed (2) Released 3 4 Ignition switch ST Engine Stopped Warming up Starting test with lever P or N range Drive for 15 minutes or more so that the automatic fluid temperature becomes 70-90C A/C switch (1) ON (2) OFF Accelerator pedal (1) Released (2) Half depressed Judgement : Value Battery voltage (mV) (1) P,(2) R,(3)N, (4) D,(5)3,(6) 2, (7) L (1) 400-1,000 mV (2) Gradually rises from (1) (3) 4,500-5,000 mV (1) ON (2) OFF Starting should be possible Gradually rises to 7090C Check item Control relay Transaxle range switch
Throttle position sensor
Stop lamp switch
Starting possible or impossible Oil temperature sensor
Engine : Idling Selector lever position N
(1) ON (2) OFF (1) ON (2) OFF (1) 600-925rpm (2) Gradually rises from (1) (1) Data changes
Triple pressure switch
Idle position switch
Communication with engine-ECU Malfunction when starting
Selector lever position (1) ND (2) NR 6 Selector lever position : N Selector lever position and (Carry out on a flat and vehicle speed straight road) 1. Idling in 1st gear(Vehicle stopped) 2. Driving at constant speed of 20km/h in 1st gear 3. Driving at constant speed of 30 km/h in 2nd gear 4. Driving at 50 km/h in 3rd gear with accelerator fully closed 5. Driving at constant speed of 50 km/h in 4th gear (Each condition should be maintained for 10 seconds or more)
Should be no abnormal shifting shocks Time lag should be within 2 seconds (2) 1st, (4) 3rd, (3) 2nd, (5) 4th (2)0%, (4) 100%, (3) 100%, (5) 100 % (2) 0%,(4) 0%,(3) 0%, (5)100%
Shift condition Low and reverse solenoid valve Underdrive solenoid valve
(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 (4) 1,800-2,100 rpm (4) 1,800-2,100 rpm (3) 0% (5) Approx. 70-90% Input shaft speed sensor Output shaft speed sensor Vehicle speed sensor
(5) Approx. 70-90% (3) Approx. 100-300rpm (5) Approx. 0-10rpm 7 Selector lever position : D 1. Accelerate to 4th gear at (Carry out on a flat and a throttle position sensor straight road) output of 1.5V (accelerator opening angle of 30 %). 2. Gently decelerate to a standstill 3. Accelerate to 4th gear at a throttle position sensor output of 2.5 V (accelerator opening angle of 50%). 4. While driving at 60 km/h in 4th gear, shift down to 3rd gear. 5. While driving at 40 km/h in 3rd gear, shift down to 2nd gear. 6. While driving at 20 km/h in 2nd gear, shift down to 1st gear. Selector lever position : N Move selector lever to R (Carry out on a flat and range drive at constant straight road). speed of 10 km/h For (1),(2) and (3), the reading should be the same as the specified output shaft torque, and no abnormal shocks should occur. For (4),(5) and (6), downshifting should occur immediately after the shifting operation is made.
sensor Damper clutch control solenoid valve Malfunction when shifting Displaced shift points Does not shift Does not shift from 1 to 2 or 2 to 1 Does not shift from 2 to 3 or 3 to 2 Does not shift from 3 to 4 or 4 to 3
The ratio between input and output speed senor data should be the same as the gear ratio when reversing.
Does not shift
MIL REQUEST ITEM AND DIAGNOSIS CODE

No. FAIL CAUSE OBD-II DTC *1 0710 0715 0720 0750 0755 0760 0765 0743 0705 0731 0732 0733 0734 0736 MIL O O O O O O O O O O O O O O O O DTC *2 0713 0712 0715 0720 0703 0750 0755 0760 0765 0743 0707 0708 0731 0732 0733 0734 0736 FAIL SAFE O O O O O O O O O O O O REMARK
1 2 3 4 5 6 7 8 9
OPEN OR +B SHORT OIL TEMPERATURESENSOR GND SHORT INPUT SPEED (PG A) OPEN OR SHORT (GND, +B)
OUTPUT SPEED (PG B) OPEN OR SHORT (GND, +B) BRAKE SW LR (DIR) SOLENOID UD SOLENOID 2ND SOLENOID OD SOLENOID DCC SOLENOID OPEN OR +B SHORT OPEN OR GND SHORT OPEN OR GND SHORT OPEN OR GND SHORT OPEN OR GND SHORT OPEN OR GND SHORT OPEN OR GND SHORT
10 INHIBITOR SW 11 1st Control System 12 2nd Control System 13 3rd Control System 14 4th Control System 15 Reverse Control System
+B SHORT OR SHORT OF SWITCHS Abnormal 1st Abnormal 2nd Abnormal 3rd Abnormal 4th Abnormal Reverse
16 DAMPER CLUTCH
Abnormal System or STUCK OFF Abnormal System or STUCK ON OPEN OR GND SHORT TCU FAIL OR TCU SIDE OPEN/SHORT ECU FAIL OR ECU SIDE OPEN/SHORT CAN MI-COMMALFUNCTION OPEN OR SHORT (GND, +B)
0741 0742 1723 -
O O O *3O *3O
0741 0742 1723 1630 1613 1764 1500
O -
17 A/T CONTROL RELAY 18 CAN-BUS OFF 19 CAN-TIME OUT ECU 20 TCU CAN MICOMMALFUNCTION
21 Vehicle Speed Sensor
*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

DTC No. P0713 Oil temperature sensor Diagnosis item Open circuit Probable cause Oil temperature sensor output > 4.57 V for 1 second or longer (oil temperature does not increase) Output < 0.49V for 1 second No input speed sensor output pulse detected for > 1 second at vehicle speed of > 30 km/h At vehicle speed of > 30 km/h, output speed sensor output < 50 of vehicle speed sensor output for > 1 second At vehicle speed of 6 km/h, stop lamp switch is ON continuously for 5 minutes With relay voltage > 10V, open or short circuit is continuously for 0.3 second.
P0712 P0715 Input speed sensor
Short circuit Short circuit/open circuit
P0720 Output speed sensor
Short circuit/open circuit
P0703 Stop lamp switch
Short circuit/open circuit
P0750 LR solenoid valve P0755 UD solenoid valve P0760 2nd solenoid valve P0765 OD solenoid valve P0743 DCC solenoid valve P0731 Gear shift incomplete P0732 P0733 P0734 P0736 P0741 DCC P0742
Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit 1st 2nd 3rd 4th Reverse Stuck off
After gear shift, output shaft speed sensor output x gear ratio of new gear = input shaft speed sensor output
DCC solenoid valve drive duty ratio is 100% for 4 seconds continuously At output speed > 1000rpm, calculated slip (engine speed-input speed) < 5rpm or > 5rpm for 10 seconds continuously.
Stuck on
P1723 A/T control relay P0707 Transaxle range switch (Inhibitor switch) P0708 P1630 CAN-BUS OFF P1631 CAN-TIME OUT ECU P1764 CAN CONTROLLER CIRCUIT P1500 Vehicle speed sensor
Earth short circuit/open circuit Open circuit Short circuit TCM Fail/open/short ECM Fail/open/short TCU internal circuit mal-function Open/short
After ignition ON, A/T control relay voltage < 7V No signal is continuous for > 30 seconds Above 2 kinds signals are continuous for 30 seconds Receive BUS-OFF information from CAN CONTROLLER No output signal for 1.5 second Communication error output is continuously for > 1 second At vehicle speed of 30km/h, No output signal for 30 second
INSPECTION CHART FOR DIAGNOSIS CODES

Code Diagnosis item Probable cause Malfunction of the oil temperature sensor Malfunction of connector Malfunction of the TCM P0713 Oil temperature sensor system Open circuit P0712 If the oil temperature sensor output voltage is 4.57 V or more even after driving for 10 minutes or more (if the oil temperature does not increase), it is judged that there is an open circuit in the oil temperature sensor and diagnosis codeP0713 is output. P0715 Input shaft speed sensor system Short circuit / Open If no output pulse is detected from the input shaft circuit speed sensor for 1 second or more while driving in 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 and diagnosis code P0715 is output. If diagnosis code P0715 is output four times, the transmission is locked into 3rd gear(D range or 3-range) or 2nd gear (2-range or L-range) as a fail-safe measure. P0720 Output shaft speed sensor system Short circuit /Open If the output from the output shaft speed sensor circuit is continuously 50% lower than the vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of 30km/h or more, there is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnosis code P0720 is output. If diagnosis code P0720 is output four times, the transmission is locked into 3rd gear (D range or 3-range) or 2nd gear (2range or L-range) as a fail-safe measure. P1703 Stop lamp switch system Short circuit / Open If the stop lamp switch is on for 5 minutes or circuit more while driving, it is judged that there is a short circuit in the stop lamp switch and diagnosis code P0703 is output. P0750 Low and reverse solenoid valve system P0755 Underdrive solenoid valve system Short circuit /Open circuit Short circuit /Open circuit
Malfunction of speed sensor Malfunction of clutch retainer Malfunction of Malfunction of
the input shaft the underdrive connector the TCM
Malfunction of throttle switch Malfunction of Malfunction of Malfunction of Malfunction of Malfunction of
the wide open connector the TCM solenoid valve connector the TCM
Malfunction of the stop lamp switch Malfunction of connector Malfunction of the TCM Malfunction of solenoid valve Malfunction of connector Malfunction of the TCM
P0760 Second solenoid valve system
Short circuit /Open circuit
P0765 Overdrive solenoid valve system Short circuit /Open If the resistance value for a solenoid valve is tool circuit large or too small, it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure. P0743 Damper clutch solenoid valve system Short circuit/ Open circuit Malfunction of the damper clutch control solenoid valve Malfunction of connector Malfunction of the TCM
P0741 Damper clutch solenoid valve system Defective system P0742 If the resistance value for the damper clutch control solenoid valve is too small, it is judged that there is a short circuit or an open circuit in the damper clutch control solenoid valve and diagnosis code P0743 in output. If the drive duty ratio for the damper clutch control solenoid valve is 100% for a continuous period of 4 seconds or more, it is judged that there is an abnormal it in the damper clutch control valve is stuck off and diagnosis code P0741 is output. If the calculated slip(engine speed-input speed) is less than 5rpm, it is judged that damper clutch control solenoid valve is stuck on rationality-low and if the calculated slip(engine speed-input speed) is more than 5rpm, it is judged that damperclutch control solenoid valve is stuck on rationality-high and diagnosis code P0742 is output. When diagnosis code P0743 is output, the transmission is locked into 3rd gear as a fail-safe measure. P0731 2nd gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from theinput shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code P0732 is output. If diagnosis code P0732 is output four times, the transmission is locked into 3rd gear as a fail-safe measure.
Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the low ad reverse brake system Malfunction of the underdrive clutch system Noise generated Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the underdrive clutch system Malfunction of the overdrive clutch system Noise generated
P0732 2nd gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from theinput shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code P0732 is output. If diagnosis code P0732 is output four times, the transmission is locked into 3rd gear as a fail-safe measure.
P0733 3rd gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from theinput shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code P0733 is output. If diagnosis code P0733 is output four times, the transmission is locked into 3rd gear as a fail-safe measure.
Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the underdrive clutch system Malfunction of the overdrive clutch system Noise generated Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the second brake system Malfunction of the overdrive clutch system Noise generated Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the low and reverse brake system Malfunction of the reverse clutch system Noise generated Malfunction of the A/T control relay Malfunction of connector Malfunction of the TCM
P0734 4th gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from theinput shaft speed sensor after shifting to 4th gear has been completed, diagnosis code P0734 is output. If diagnosis code P0734 is output four times, the transmission is locked into 3rd gear as a fail-safe measure.
P0736 Reverse gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output fromthe input shaft speed sensor after shifting to reverse gear has been completed, diagnosis code P0736 is output. If diagnosis code P0736 is output four times, the transmission is locked into 3rd gear as a fail-safe measure.
P1723 A/T control relay system Short circuit to If the A/T control relay voltage is less than 7 V earth/Open circuit after the ignition switch has been turned ON, it is judged that there is an open circuit or a shortcircuit in the A/T control relay earth and iagnosis code P1723 is output. Then the transmission is locked into 3rd gar as a fail-safe measure. P0707 Transaxle range switch P0708 No signal is continuous for > 30 seconds Above 2 kinds signals are continuous for > 30 second P1630 CAN-BUS OFF a. NO 3 SPEED HOLD FAIL b. NO PGA, B FAIL c. BATTRY VOLTAGE > 10V CONTINUOUSLY FOR 0.5 SECOND d. NO ENGINE STOP e. RECEIVE BUS OFF INFORMATION FROM CAN CONTROLLER P1631 CAN-TIME OUT ECM
Malfunction of transaxle range switch a. TCM Fail b. TCM side open & short * PGA : Input shaft speed sensor PGB : Output shaft speed sensor a. ECM fail
a. b. c. d. e. f.
No 3 speed hold fail No PGA, B fail Battry voltage > 10V continuously for 0.5 second No engine stop No output signal for 1.5 second Receive BUS OFF information from CAN CONTROLLER
b. ECM side open & short
P1764 TCM CAN CONTROLLER MALFUNCTION a. No 3 speed hold fail b. No PGA, B fail c. Battry voltage > 10V continuously for 0.5 second d. No engine stop e. Communication error output is continuously for > 1 second
a. CAN CONTROLLER circuit malfunction
INSPECTION CHART FOR THROUBLE SYMPTOMS

Trouble symptom Communication with HI-SCAN is not possible If communication with the HI-SCAN is not possible, the cause is probably a defective diagnosis line or the TCM is not functioning. Driving impossible Starting impossible Starting is not possible when the selector lever is in P or N range. In such cases, the cause is probably a defective engine system, torque converter or oil pump. Does not move forward If the vehicle does not move forward when the selector lever is shifted from N to D, 3, 2 or L range while the engine isidling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body. Does not reverse If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse brake or valve body. Probable cause Malfunction diagnosis line Malfunction of connector Malfunction of the TCM Malfunction of the engine system Malfunction of the torque converter Malfunction of the oil pump Abnormal line pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse brake solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body Abnormal line pressure Malfunction of power train Malfunction of the oil pump Malfunction of the valve body Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the valve body Malfunction of the torque converter (Malfunction of the damper clutch) Abnormal underdrive clutch pressure Abnormal low and reverse brake pressure
Does not move (forward or reverse) If the vehicle does not move forward or reverse when the selector lever is shifted to any position while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the power train, oil pump or valve body. Malfunction when starting Engine stalling when shifting If the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine system, damper clutch solenoid valve, valve body or torque converter (damper clutchmalfunction). Shocks when changing from N to D and large time lag If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range while the engine is idling, the cause is probably
range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve body or idle position switch.
pressure Malfunction of the underdrive solenoid valve Malfunction of the valve body Malfunction of the idle position switch Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body Malfunction of the idle position switch Abnormal line pressure Malfunction of the oil pump Malfunction of the valve body
Shocks when changing from N to R and large time lag If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction of the reverse clutch, low and reverse brake, valve body or idle position switch.
Shocks when changing from N to D, N to R and large time lag If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range and from N to R range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the oil pumpor valve body. Malfunction when shifting Shocks and running up If shocks occur when driving due to upshifting or downshifting and the transmission speed becomes higher than the enginespeed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch. All points If all shift points are displaced while driving, the cause is probably a malfunction of the output shaft speed sensor, TPS or of a solenoid valve.
Abnormal line pressure Malfunction of each solenoid valve Malfunction of the oil pump Malfunction of the valve body Malfunction of the output shaft speed sensor Malfunction of the throttle position sensor Malfunction of each solenoid valve Abnormal line pressure Malfunction of the valve body
Displaced shifting points
Some points Malfunction of the valve body If some of the shift points are displaced while driving, the cause is probably a malfunction of the valve body, or it is related to control and is not an abnormality. Does not shift No diagnosis codes If shifting does not occur while driving and no diagnosis codes are output, the cause is probably a malfunction of the transaxle range switch, or TCM Malfunction of the transaxle range Malfunction of the TCM
Malfunction while driving
Poor a acceleration Malfunction of the engine system If acceleration is poor even if downshifting occurs while Malfunction of the brake of clutch driving, the cause is probably a malfunction of the engine system or of a brake or clutch. Vibration If vibration occur when driving at constant speed or when accelerating and deceleration in top range, the cause is probably abnormal damper clutch pressure or a malfunction of the engine system, damper clutch control solenoid valve, torque converter or valve body. Abnormal damper clutch pressure Malfunction of the damper clutch control solenoid valve Malfunction of the torque converter Malfunction of the valve body
Transaxle range switch system The cause is probably a malfunction of the inhibitor switch circuit, ignition switch circuit or a defective TCM. Vehicle speed sensor system The cause is probably a defective vehicle speed sensor circuit or a defective TCM.
Malfunction of the transaxle range switch Malfunction of the ignition switch Malfunction of the TCM Malfunction of the vehicle speed sensor Malfunction of connector Malfunction of the TCM
INSPECTION PROCESS FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1 Communication with the scan tool If communication with the scan tool is not possible, the cause is probably a defective diagnostic trouble line or the TCM is not functioning. Probable cause a. Malfunction of diagnostic trouble line b. Malfunction of connector c. Malfunction of the TCM
INSPECTION PROCEDURE 2
Starting impossible Starting is not possible when the selector lever is in P or N range. In such cases, the cause is probably a defective engine system, torque converter or oil pump. Probable cause a. Malfunction of the engine system b. Malfunction of the torque converter c. Malfunction of the oil pump
Does not move If the vehicle does not move forward when the selector lever is shifted from N to D,3,2 or L range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body. Probable cause a. Abnormal line pressure b. Malfunction of the underdrive solenoid valve c. Malfunction of the underdrive clutch d. Malfunction of the valve body
Does not reverse If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse brake or valve body. Probable cause a. Abnormal reverse clutch pressure b. Abnormal low and reverse brake pressure c. Malfunction of the low and reverse solenoid valve d. Malfunction of the reverse clutch e. Malfunction of the low and reverse brake f. Malfunction of the valve body
Does not move (forward or reverse) If the vehicle does not move forward or reverse when the selector lever is shifted to any position while the engine is idling, the cause is probably abnormal line pressure, or a malfunction of the power train, oil pump or valve body. Probable cause a. Abnormal line pressure b. Malfunction of the underdrive solenoid valve c. Malfunction of the underdrive clutch d. Malfunction of the valve body
Engine stalling when shifting If the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine system, damper clutch solenoid, valve body or torque converter (damper clutch malfunction) a. b. c. d. Malfunction Malfunction Malfunction Malfunction Probable cause of of of of the the the the engine system damper clutch solenoid valve body torque converter
(Malfunction of the damper clutch)
Shocks when changing from N to D and range time lag If abnormal shocks or a time lag of 2 second or more occur when the selector lever is shifted from N to D range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch,valve body or closed throttle position switch. Probable cause a. Abnormal line pressure b. Malfunction of the underdrive solenoid valve c. Malfunction of the underdrive clutch d. Malfunction of the valve body e. Malfunction of the closed throttle position switch
Shock when changing from N to R and large time lag If abnormal shocks or a time lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction or the reverse clutch, low and reverse brake, valve body or closed throttle position switch. Probable cause a. Abnormal reverse clutch pressure b. Abnormal low and reverse brake pressure c. Malfunction of the low and reverse solenoid valve d. Malfunction of the reverse clutch e. Malfunction of the low and reverse brake f. Malfunction of the valve body g. Malfunction of the closed throttle position switch
Shocks when changine from N to R and large time lag If abnormal shocks or a time lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction of the reverse clutch, low and reverse brake, valve body or closed throttle position switch. Probable cause a. Abnormal reverse clutch pressure b. Abnormal low and reverse brake pressure c. Malfunction of the low and reverse solenoid valve d. Malfunction of the reverse clutch e. Malfunction of the low and reverse brake f. Malfunction of the valve body g. Malfunction of the closed throttle position switch
Shocks and running up Probable cause
If shocks occur when driving due to upshifting or downshifting and the transaxle speed becomes higher than the engine speed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch.
a. b. c. d. e.
Abnormal line pressure Malfunction of each solenoid valve Malfunction of the oil pump Malfunction of the valve body Malfunction of each brake or each clutch
All points (Displaced shifting points) If all shift points are displaced while driving, the cause is probably a malfunction of the output shaft speed sensor, TPS or of a solenoid valve. Probable cause a. Malfunction of the output shaft speed sensor b. Malfunction of the throttle position sensor c. Malfunction of each solenoid valve d. Abnormal line pressure e. Malfunction of the valve body f. Malfunction of the TCM
Some points (Displaced shifting points) Probable cause If some of the shift points are displaced while driving, the cause is a. Malfunction of the valve body probably a malfunction of the valve body, or it is related to control and is not an abnormality.
No diagnostic trouble codes (Does not shift) If shifting does not occur while driving and no diagnostic trouble codes are output, the cause is probably a malfunction of the Park/Neutral position switch, or TCM. Probable cause a. Malfunction of the Park/Neutral position switch b. Malfunction of the TCM
Poor acceleration If acceleration is poor even if downshifting occurs while driving, the cause is probably a malfunction of the engine system or of a brake or clutch. Probable cause a. Malfunction of the engine system b. Malfunction of the brake or clutch
Vibration If vibration occurs when driving at constant speed or when accelerating in top range, the cause is probably abnormal damper clutch pressure or a malfunction of the engine system, damper clutch solenoid, torque converter or valve body. a. b. c. d. e.
Probable cause Abnormal damper Malfunction of the Malfunction of the Malfunction of the Malfunction of the clutch pressure engine system damper clutch solenoid torque converter valve body
BRAKE REACTIONPLATE END PLAY ADJUSTMENT

Replace the pressure plate of the low-reverse brake with the special tool, and then install the brake disc, brake plate and snap ring as shown in the figure. Install the reaction plate and the used snap ring. Move the special tool to measure 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 ADJUSTMENT

Replace the pressure plate of the second brake with the special tool, and then install the brake disc and brake plate asshown 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 ADJUSTMENT

Reverse the transmission. Measure the axial play. Standard value : 1.65 - 2.11 mm
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

O.D. 59 59 59 59 59 59 49 49 46 49 49 59 I.D. 47 47 47 47 47 47 34 34 31 34 34 37 Thickness 1.8 2.0 2.2 2.4 2.6 2.8 3.6 3.6 3.3 3.6 3.6 2.8 Symbol #1 #1 #1 #1 #1 #1 #2 #3 #4 #5 #6 #7 O.D. 48.9 48.9 48.9 48.9 48.9 48.9 48.9 48.9 48.9 48.9 48.9 I.D. 37 37 37 37 37 37 37 37 37 37 37 Thickness 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 Symbol #8 #8 #8 #8 #8 #8 #8 #8 #8 #8 #8 -
UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT

Install the used thrust race #8, and then the rear cover. Measure end play of the underdrive sun gear. Replace thrust race #8 to adjust the play to the standard value. Standard value : 0.25 - 0.45 mm
Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.
DIFFERENTIAL CASE PRELOAD ADJUSTMENT

Place 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 the specified torque. Loosen the bolts, and remove the solder. use a micrometer to measure the thickness (T) of the pressed 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

Introduction Most of the automatic transaxle control system is electrically controlled. This often makes it difficult to diagnose intermittent problems a in system. Before undertaking actual checks, take a few minutes to talk with customers who approachyou with a driveability a complaint. The customer is often good source of information regarding intermittent problems. Through talks with customer, one can find out what the symptoms are and under what conditions they occur.
Work flow
Troubleshooting item #: Each troubleshooting item is assigned a number. There are 28 troubleshooting items. Choose item that most closely corresponds 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 1 Inspection Is selector lever operation OK? Yes Go to next step. No Adjust selector lever. 2 Operate selector lever. Are selector lever and range indicator positions aligned? Yes Go to next step. No Adjust transaxle range switch. Action
Description Further describes symptom. Confirm that chart addresses actual symptom before beginning troubleshooting. Troubleshooting hints This describes possible point of malfunction. Step This 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 perform INSPECTION, refer to page shown. Action This recommends appropriate action to take as a result (Yes/No) of INSPECTION. How to perform action is described on 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. Step 1 Inspection Is selector lever operation OK? Yes Go to next step. No Adjust selector lever. Action
Operate selector lever. Are selector lever and range indicator positions aligned? Operate selector lever. Does transaxle operate normally and are selector lever and transaxle positions aligned? Are measurements at TCM OK?
Yes Go to next step. No Adjust transaxle range switch.
Yes Go to next step. No Repair or replace parts as necessary.
Yes Temporarily install known good TCM. Go to step 5. If problem is corrected, replace TCM. No Check transaxle range switch and wiring.
a. H-01/18, H-01/8, H-01/36, H-01/37 Terminal: Transaxle range switch 5 Retrun vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected 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 malfunction b. Torque converter clutch solenoid malfunction c. Transaxle range signal malfunction d. Oil pump worn e. Control valve stuck f. Idle speed and ignition timing misadjust Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No Check for malfunctioning parts a. Throttle position (TP) sensor. b. Wiring Action
Are measurements at TCM terminal OK?
Are measurements at TCM OK?
Yes Go to next step. No Check transaxle range switch and wiring.
a. H-01/18, H-01/8, H-01/36, H-01/37 terminals: 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 solenoid valve and output voltage of TCM terminal OK? Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Torque converter clutch solenoid valve. If resistance is OK but voltage is not, check wiring and TCM.
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. Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring a. Torque converter clutch solenoid If resistance is OK but voltage is not, check wiring and / or replace TCM. Action
Are resistance of torque converter clutch solenoid valve and output voltage of TCM terminal H-01/4 OK?
Yes Check TCM and / or engine parts. No Repair or replace parts as necessary.
4 Engine rough on deceleration Description Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration Exhaust afterburn (TROUBLESHOOTING HINTS) a. Idle speed and ignition timing misadjust Step 1 Inspection Is engine stall speed OK? Stall speed : 2000 ~ 2500 rpm Action 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 high b. Throttle position sensor malfunction or improperly adjusted c. Line pressure incorrect d. Torque converter clutch solenoid malfunction e. Engine stall speed incorrect Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step. b. or conditions - Replace ATF; then go to next step. If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check for malfunctioning parts a. Throttle position (TP) sensor. b. Wiring Action
Are ATF level and condition OK? Do transaxle seals, sealant, and gaskets prevent leakage? 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
Is line pressure OK?
Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid inspection, replace control valve body assembly.
Are resistance of torque converter clutch solenoid Yes Go to next step. valve and output voltage of TCM terminal H-01/4 No If resistance is not OK, check for malfunctioning OK? parts and wiring. a. Torque converter clutch solenoid. If resistance is OK but voltage is not, check wiring and /or TCM.
Yes Check EMS parts, Engine and TCM. No Repair or replace as necessary.
6 Poor acceleration on acceleration Description Engine speed increases normally but vehicle speed slowly increases during acceleration (TROUBLESHOOTING HINTS) a. ATF level low or high b. Line pressure low c. Engine stall speed incorrect correctly d. Throttle position (TP) sensor malfunction or not adjusted e. Torque converter clutch solenoid malfunction Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check for malfunctioning parts a. Throttle position (TP) sensor. b. Wiring Action
Yes Check TCM. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid inspection, replace control valve body assembly.
Yes Check Engine parts. No Repair or replace parts as necessary.
Stall speed: 2000~2500 rpm 6 Drive vehicle if D & 1 range. Is vehicle starting from stop in 1st gear?
No Repair or replace parts as necessary. Check torque converter. Yes Check Engine parts. No Check torque converter.
7 Description Surges while cruising Momentary minor irregularity in engine output at steady vehicle speed
8 Poor acceleration on acceleration Description Engine speed increases normally but vehicle speed slowly increases during acceleration (TROUBLESHOOTING HINTS) a. ATF level low or high b. Throttle position (TP) sensor malfunction or not adjusted c. Torque converter clutch solenoid malfunction Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Action
Are ATF level and condition OK? Yes Go to next step. Do transaxle seals, sealant, and gaskets prevent No If ATF level is not OK, add fluid as necessary leakage? If ATF condition is not OK, repair as follows: Clear pink: Normal condition a. condition - Overhaul transaxle and repair Dark or black (with friction material): Worn or replace parts as necessary; then go to powertrain components next step Milky pink: Water contamination b. or conditions - Replace ATF; then go to Light to dark brown (oxidation): Overheated or next step old fluid If there is leakage, repair or replace parts as necessary, then go to next step. Are measurements at TCM terminal OK? Yes Go to next step. No Check for malfunctioning parts a. Throttle position (TP) sensor. b. Wiring
Are resistance of torque converter clutch solenoid valve and output voltage of TCM terminal H-01/4 OK?
Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring.
parts and wiring. a. Torque converter clutch solenoid. If resistance is OK but Voltage is not, check wiring and TCM.
9 Poor fuel economy Description Fuel economy unsatisfactory (TROUBLESHOOTING HINTS) a. ATF level low b. Throttle position (TP) sensor malfunction or not adjusted correctly c. Torque converter clutch solenoid not working d. Line pressure low e. Engine stall speed incorrect Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check throttle position (TP) sensor and wiring. Action
Is input voltage of throttle position (TP) sensor at TCM terminal OK?
Are resistance of torque converter clutch solenoid Yes Repair or replace parts as necessary. and output voltage of TCM terminals H-01/4 OK? No If resistance is not OK, check for malfunctioning
No If resistance is not OK, check for malfunctioning parts and wiring. a. Torque converter clutch solenoid If resistance is OK but voltage is not, check wiring and TCM.
Yes Check EMS parts, Engine and TCM. No Repair or replace as necessary.
10 Vehicle does not move in D, 2, and/or R range Description a. No creep at all b. Vehicle does not move when accelerator pedal depressed after shifting to D, 2, 1 and/or R range (TROUBLESHOOTING HINTS) a. ATF level low b. Selector lever installation or adjustment incorrect c. Line pressure low d. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2) e. Engine stall speed incorrect f. Control valve stuck g. Torque converter worn Step 1 Inspection Are ATF level and condition OK? Do transaxle seals, sealant, and gaskets prevent leakage? 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 Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. Action
Is selector lever operation OK?
No Adjust selector lever.
Operate selector lever; are selector lever and range indicator positions aligned? Operate selector lever; does transaxle operate normally and are selector lever and transaxle position aligned?
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Repair or replace as necessary.
Are resistance of torque converter clutch solenoid Yes Go to next step. valve and output voltage of TCM terminal H-01/4 No If resistance is not OK, check for malfunctioning OK? parts and wiring. a. Torque converter clutch solenoid. If resistance is OK but Voltage is not, check wiring and TCM.
Yes Check EMS parts, Engine and TCM. No Repair or replace parts as necessary. Yes Repair or replace parts as necessary. No Shift mechanism malfunction. Repair or replace as necessary.
Stop vehicle on flat paved surface with engine OFF. Does vehicle move when pushed (except P range, parking brake released)?
11 Vehicle moves in N range Description a. Vehicle creeps in N range b. Vehicle moves when accelerator pedal not depressed (TROUBLESHOOTING HINTS) a. Selector lever installation or adjustment incorrect b. Powertrain damaged (forward clutch, coasting clutch, 3-4 clutch) Step Inspection Action
Yes Go to next step. No Adjust selector lever.
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Repair or replace parts as necessary.
12 Vehicle moves in P range Description a. Vehicle rolls in P range (TROUBLESHOOTING HINTS) a. Selector lever installation or adjustment incorrect b. Parking mechanism worn c. Powertrain damaged (forward clutch, coasting, 3-4 clutch) Step 1 Inspection Is selector lever operation OK? Yes Go to next step. No Adjust selector lever. Action
Operate selector lever; are selector lever and range indicator positions aligned? Operate selector lever; does transaxle operate normally and are selector lever and transaxle position aligned? Stop vehicle on flat paved surface with engine OFF. Does vehicle move when pushed (except P range, parking brake released)?
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Repair or replace parts as necessary. Yes Repair or replace parts as necessary. No Shift mechanism malfunction. Repair or replace parts as necessary.
13 Description Excessive creep 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 depressed slightly) (TROUBLESHOOTING HINTS) a. Throttle position (TP) sensor malfunction or not adjusted correctly b. Shift solenoid valves (A, B, C) worn c. Control valve stuck d. Differential assembly malfunction e. TCM malfunction Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on O/D indicator or scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Shift solenoid A b. Shift solenoid B c. Shift solenoid C If resistance is OK but voltage is not, check TCM. Go to step 4. Action
Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK?
a. H-01/30 terminal: Shift solenoid A b. H-01/33 terminal: Shift solenoid B c. H-01/32 terminal: Shift solenoid C 3 Are resistance and output voltage of throttle position (TP) sensor at TCM terminals OK? Yes Go to next step. No If resistance is not OK, check for malfunctioning
No If resistance is not OK, check for malfunctioning parts and wiring. a. Throttle positionsensor If resistance is OK but voltage is not, check TCM. Go to next step.
a. H-01/38 terminal: Throttle position (TP) sensor 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 as necessary.
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 correctly b. TCM malfunction c. Control valve stuck Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on O/D indicator or scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No Check for malfunctioning parts and wiring. a. Throttle position (TP) sensor Action
Are measurements at TCM terminals OK?
a. H-01/38 terminal: Throttle position (TP) sensor (from ECM) 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 as necessary.
17 Shift point high or low Description a. Shift points do not match shift diagram b. Shift delayed when accelerating c. Shift occurs too fast when accelerating and engine speed does not increase (TROUBLESHOOTING HINTS) a. Throttle position (TP) sensor malfunction or not adjusted correctly b. Input/turbine speed sensor malfunction c. Transaxle fluid temperature sensor malfunction d. Selector lever installation or adjustment incorrect e. Shift solenoids valves (A, B, C) worn not adjusted correctly f. PCM malfunction g. Control valve stuck h. Transaxle range switch malfunction or not adjusted Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on O/D indicator or scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No Check for malfunctioning parts and wiring. a. Throttle position (TP) sensor b. Input/turbine speed sensor Action
a. H-01/38 terminal: Throttle position (TP) sensor ground b. H-01/44 terminal: Input/turbine speed sensor ground c. H-01/16 terminal: Input/turbine speed sensor signal 3 Are measurements at TCM terminals OK? Yes Go to next step.
No Check transaxle fluid temperature sensor.
a. H-01/21 terminal: Transaxle fluid temperature sensor ground b. H-01/22 terminal: Transaxle fluid temperature sensor signal 4 Is selector lever operation OK? Yes Go to next step. No Adjust selector lever.
Operate selector lever; does transaxle operate normally and are selector lever and transaxle position aligned? Operate selector lever; are selector lever and range indicator positions aligned? Are measurements at TCM terminals OK?
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Repair or replace parts as necessary. Yes Go to next step. No Check transaxle range switch and wiring.
Is continuity of transaxle range switch OK?
Yes Go to next step. No Adjust and/or replace transaxle range switch.
Yes Go to next step. No If resistance is not OK, check for malfunctioning
No If resistance is not OK, check for malfunctioning parts and wiring. a. Shift solenoid A b. Shift solenoid B c. Shift solenoid C If resistance is OK but voltage is not, replace TCM.
a. H-01/30 terminal: Shift solenoid A b. H-01/33 terminal: Shift solenoid B c. H-01/32 terminal: Shift solenoid C 10 Is engine stall speed OK? Stall speed: 2000~2500 rpm Yes Check EMS parts, Engine and TCM. No Repair or replace parts as necessary.
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 correctly b. Input / turbine speed sensor malfunction c. Selector lever installation or adjustment incorrect d. Line pressure low e. Transaxle range switch worn or maladjusted f. Torque converter clutch solenoid malfunction g. TCM malfunction h. Control valve stuck Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Action
Are resistance of torque converter clutch solenoid Yes Replace control valve body assembly. and output voltage of TCM terminal OK? No If resistance is not OK, check for malfunctioning parts and wiring. a. Torque converter clutch solenoid If resistance is OK but voltage is not, check wiring and / or replace TCM.
Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Throttle position sensor b. Input/turbine speed sensor c. Vehicle speed sensor d. Transaxle range switch If resistance is OK but voltage is not, replace TCM.
a. H-01/38 terminal: Throttle position (TP) sensor b. H-01/44 terminal: Input/turbine speed sensor ground c. H-01/16 terminal: Input / turbine speed sensor signal d. H-01/42 terminal: Vehicle speed sensor e. HH-01/47, H-01/36, H-01/37 terminal: Transaxle range switch 4 Is selector lever operation OK? Yes Go to next step. No Adjust selector lever.
Operate selector lever; are selector lever and range indicator positions aligned?
Yes Go to next step. No Adjust transaxle range switch
Operate selector lever; does transaxle operate normally and are selector lever and transaxle position aligned? Is line pressure OK?
Yes Go to next step. No Repair or replace parts as necessary. Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly.
Is input voltage of engine coolant tempera ture sensor signal at TCM terminals OK?
Yes Go to next step. No Check throttle position (TP) sensor and wiring.
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 correctly b. Line pressure low c. TCM malfunction d. Control valve stuck Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No Check throttle position (TP) sensor and wiring. Action
Is accelerator cable installed correctly and does it Yes Go to next step. operate smoothly? No Adjust or replace accelerator cable. Is line pressure OK? Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly.
Replace with known good TCM. Is problem corrected?
Yes Replace TCM. No Replace control valve body assembly. If problem remains, overhaul transaxle and repair 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 correctly b. Line pressure low c. TCM malfunction d. Control valve stuck Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. No Check throttle position (TP) sensor and wiring. Action
Is accelerator cable installed correctly and does it Yes Go to next step. operate smoothly? No Adjust or replace accelerator cable. Is line pressure OK? Yes Go to next step.
No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly.
Replace with known good TCM. Is problem corrected?
Yes Replace TCM. No Replace control valve body assembly. If problem remains, overhaul transaxle and repair or replace parts as necessary.
20 Engine speed flares up on acceleration Description Engine speed flares up on acceleration (TROUBLESHOOTING HINTS) a. ATF level low b. Line pressure low c. Control valve stuck d. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2, 3-4 clutch) e. Torque converter worn Step 1 Inspection Are ATF level and condition OK? Do transaxle seals, sealant, and gaskets prevent leakage? 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 Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly. Action
Yes Check EMS parts, Engine and TCM. No Repair or replace parts as necessary.
21 Engine speed flares up when upshifting and/or downshifting Description a. Engine flares up when accelerator pedal depressed for upshifting b. Engine flares up suddenly when accelerator pedal depressed for downshifting (TROUBLESHOOTING HINTS)
a. b. c. d. e. f. g. h. i. j. k.
ATF level low Line pressure incorrect Throttle (TP) sensor malfunction or misadjusted Input/turbine speed sensor malfunction TCM malfunction Servo piston malfunction Orifice valve malfunction 1-2, 2-3 accumulator malfunction Control valve stuck Powertrain damaged (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch No. 1) Oil pump malfunction Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check that linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly. Action
Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No If resistance is not OK, check for malfunctioning parts and wiring. a. Throttle position sensor b. Input/turbine speed sensor If resistance is OK but voltage is not, replace TCM.
a. H-01/38 terminal: Throttle position sensor
b. H-01/44 terminal: Input/turbine speed sensor ground c. H-01/16 terminal: Input/turbine speed sensor signal 5 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected 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 low b. Idle speed high c. Line pressure high d. Transaxle control module malfunction e. Throttle position (TP) sensor malfunction or misadjusted f. Input / Turbine speed sensor malfunction g. Transaxle range switch worn or maladjusted h. TCM malfunction i. Vehicle speed sensor malfunction j. 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. 2 l. Shift solenoids valves (A, B, C) worn Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on O/D indicator or scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Adjust selector lever. Action
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Repair or replace parts as necessary.
Drive vehicle in D and 1 range; does vehicle start Yes Go to next step. from stop in 1st gear? No Repair or replace parts as necessary. Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK? Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Throttle position sensor b. Input/turbine speed sensor c. Vehicle speed sensor d. Transaxle range switch If resistance is OK but voltage is not, replace TCM.
a. H-01/38 terminal: Throttle position (TP) sensor b. H-01/44 terminal: Input/turbine speed sensor ground c. H-01/16 terminal: Input / turbine speed sensor signal d. H-01/42 terminal: Vehicle speed sensor e. H-01/47, H-01/8, H-01/36, H-01/37 terminal: Transaxle range switch 8 Is continuity of transaxle range switch OK? Yes Go to next step. No Adjust 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. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly.
10
Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected and monitor for pending codes.
23 Excessive shift shock when upshifting and/or downshifting Description a. Excessive shift shock felt when accelerating and upshifting b. During cruising, excessive shift shock felt when accelerator pedal is depressed and downshifting (TROUBLESHOOTING HINTS) a. ATF level low b. Line pressure high c. Throttle position sensor malfunction or misadjusted d. Input/turbine speed sensor malfunction e. Transaxle fluid temperature sensor malfunction f. TCM malfunction g. Shift solenoids valves (A, B, C) worn h. Orifice valve malfunction i. 1-2, 2-3 accumulator malfunction j. Control valve stuck k. Powertrain damaged (3-4 clutch, 2-4 brake band, one-way clutch No. 1) Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly. Action
Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Shift solenoid A b. Shift solenoid B c. Shift solenoid C If resistance is OK but voltage is not, replace TCM.
a. H-01/38 terminal: Throttle position (TP) sensor b. H-01/44 terminal: Input/turbine speed sensor ground c. H-01/16 terminal: Input/turbine speed sensor signal d. H-01/22 terminal: Transaxle fluid temperature sensor e. H-01/21 terminal: Ground 5 Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK? Yes Go to next step. No If resistance is not OK, check for malfunctioning parts and wiring. a. Shift solenoid A b. Shift solenoid B c. Shift solenoid C If resistance is OK but voltage is not, replace TCM.
a. H-01/30 terminal: Shift solenoid A b. H-01/33 terminal: Shift solenoid B c. H-01/32 terminal: Shift solenoid C 6 Are measurements at TCM terminals OK? Yes Go to next step.
No Check transaxle range switch and wiring.
a. H-01/18, H-01/8, H-01/36, H-01/37 terminals: 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 cruising at medium to high speed b. Engine speed drops to idle but vehicle does not slow when accelerator pedal released when in 1 range at low vehicle speed (TROUBLESHOOTING HINTS) a. Shift solenoids (B, C) malfunction b. Transaxle range switch worn or not adjusted correctly c. TCM malfunction d. Line pressure low e. Control valve stuck f. Powertrain slippage (3-4 clutch, coasting clutch, low and reverse brake) Step 1 Inspection Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool. Yes Go to next step. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. Action
Are resistance and output voltage of solenoid Yes Go to next step. valves (1-2, 2-3, 3-4 shift) at TCM terminals OK? No If resistance is not OK, check for malfunctioning
No If resistance is not OK, check for malfunctioning parts and wiring. a. Shift solenoid B b. Shift solenoid C If resistance is OK but voltage is not, replace TCM.
a. H-01/33 terminal: Shift solenoid B b. H-01/32 terminal: Shift solenoid C 3 Is selector lever operation OK? Yes Go to next step. No Adjust selector lever.
Operate selector lever; are selector lever and range indicator positions aligned? Operate selector lever; does transaxle operate normally and are selector lever and transaxle position aligned? Is line pressure OK?
Yes Go to next step. No Adjust transaxle range switch. Yes Go to next step. No Overhaul transaxle and repair or replace parts as necessary. Yes Go to next step. No Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly.
Yes Replace TCM.
No Check transaxle range switch and wiring.
a. H-01/47, H-01/8, H-01/36, H-01/37 terminals: Transaxle range switch
25 Description No mode change O/D OFF mode not selected or not canceled
(TROUBLESHOOTING HINTS) Inspect parts and wiring and repair, or replace malfunctioning parts as necessary a. O/D switch malfunction b. Transaxle control module malfunction
26 Description Transaxle noise in all ranges Transaxle noisy in all ranges when vehicle is idling
(TROUBLESHOOTING HINTS) Inspect parts and repair, adjust or replace malfunctioning parts as necessary a. ATF level low b. Differential worn or damaged c. Parking mechanism malfunction
27 Description Transaxle noise in D, 2, 1 and R ranges Abnormal noise from transaxle in D, 2, 1, and R ranges
(TROUBLESHOOTING HINTS) Inspect parts and repair, adjust or replace malfunctioning parts as necessary a. ATF level low b. Differential worn and / or damaged
28 Transaxle overheats
Description ATF smells burnt and/or is discolored (TROUBLESHOOTING HINTS) a. ATF level low b. TCM malfunction Step 1 Inspection Are ATF level and condition OK? Do transaxle seals, sealant, and gaskets prevent leakage? 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 Yes Go to next step. 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 to next step b. or conditions - Replace ATF; then go to next step If there is leakage, repair or replace parts as necessary, then go to next step. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No Diagnostic trouble code(s) displayed on scan tool. a. Check for cause of diagnostic trouble code(s) If problem remains, go to next step. 3 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected and monitor for pending codes. Action
Check that no diagnostic trouble codes exist by retrieving DTC's with a scan tool.
SELF DIAGNOSTIC FUNCTION

Inspection procedure 1. 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 procedure
1. 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. P0601 P0604 P0707 P0708 P0712 P0713 P0716 P0717 P0726 P0727 P0731 P0732 P0733 P0734 P0741 P0742 P0743 P0748 P0753 P0758 P0763 P1121 P1500 P1700 P1780 TCM ROM malfunction (Only Europe) TCM RAM malfunction (Only Europe) Transaxle range signal (P, R, N, D, 2, 1) malfunction no signal (Only Europe) Transaxle range signal (P, R, N, D, 2, 1) malfunction many signal (Only Europe) ATF temperature sensor low ATF temperature sensor high Input/turbine speed sensor signal malfunction (Only Europe) Input/turbine speed sensor circuit malfunction Engine speed input signal malfunction (Only Europe) Engine speed input malfunction Incorrect first gear ratio(Only Europe) Incorrect second gear ratio (Only Europe) Incorrect third gear ratio (Only Europe) Incorrect fourth gear ratio (Only Europe) Torque converter clutch system malfunction stuck off (Only Europe) Torque converter clutch system malfunction stuck on (Only Europe) Torque converter clutch system circuit malfunction Linear solenoid electrical Shift solenoid A electrical Shift solenoid B electrical Shift solenoid C electrical TPS signal circuit from ECM to TCM Vehicle speed signal malfunction O/D lamp circuit malfunction (Only Europe) Torgue reduction signal malfunction Diagnosed circuit MIL ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
According to TCM logic, transaxle range (P0705) trouble code accompanies vehicle speed sensor (P1500) trouble code. Therefore, P0705 should be repaired first. Check P0705 is cleared and then inspect P1500.
TRANSAXLE CONTROL MODULE(TCM)
TCM terminal voltage chart
STALL TEST
This 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 140-158F (60-70C). 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 range b. 2 range c. 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/or transaxle case Stuck pressure regulator valve
In D range
Forward clutch slipping One-way clutch 1 slipping One-way clutch 2 slipping 2-4 brake band slipping Low and reverse brake slipping Reverse clutch slipping Perform road test to determine whether problem is low and reverse brake or reverse clutch a. Engine brake felt in 1 range, 1st gear reverse clutch b. Engine brake not felt in 1 range Low and reverse brake Engine out of tune One-way clutch slipping within torque converter
In 2 range In R range
Below specification in R position and all ranges
LINE PRESSURE TEST

This test measures line pressure as a means of checking hydraulic components and inspecting for oil leakage.
Preparation
1. 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 raise car 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 D, 2, 1 R Idle 56.98-127.98 (392.4-882.9, 4.0-9.0) 71.1-142.2 (490.5-981.0, 5.0-10.0) Stall 113.76-184.86 (784.8-1275.3, 8.0-13.0) 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 Ibin (5.0-9.8 Nm, 51-100 kgcm) Line pressure Low pressure in every position Possible location of problem Worn oil pump Fluid leaking from oil pump, control valve, or transaxle case Pressure regulator valve sticking Linear solenoid valve sticking Fluid leaking from hydraulic circuit of forward clutch Fluid leaking from hydraulic circuit of low and reverse brake or reverse clutch Pressure regulator valve stick or Linear solenoid valve sticking
Low pressure in D and 2 only Low pressure in R only Higher than specification
2004 > 1.6L DOHC >
OIL SEAL
1. 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 SENSOR

1. 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: 300-400 (@68F/20C)
6. If not as specified, replace input/turbine speed sensor. Tightening torque: 69.6-94.8 Ibin (8-11 Nm, 80-110 kgcm) 7. Install air cleaner assembly. 8. Install data link connector to MAF sensor. 9. Connect negative battery cable.
VEHICLE SPEED SENSOR

1. 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 speed sensor.
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.
Inspection
1. Apply parking brake and position wheel chocks securely to prevent vehicle from rolling after roller test. 2. Warm-up engine until ATF reaches 140-158F (60-70C). 3. Firmly depress the foot brake, and shift the selector lever PRND121DNRP. (stay at each range for over 3 second)
Use COOL 68F (20C) range only as a rough reference.
4. Ensure that the ATF level is in HOT 149F (65C) 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.
Replacement
1. 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. Tightening torque: 29-40 Ibft (39-54 Nm, 4.0-5.5 kgm)
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 process

1. 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 leaks
Check for transaxle fluid leaks at points shown below and repair or replace as necessary. Additionally, check all of following: 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 >
REMOVAL
1. 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-INSTALLATION
1. Install radiator. (Refer to section EM, cooling system) 2. Install ATF inlet pipe and outlet pipe. Tightening torque: 24-84 Ibft (32-47 Nm, 3.3-4.8 kgm) 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 replacement 1. 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.
DISASSEMBLY
1. 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.
INSPECTION
Oil pump housing, outer rotor, inner rotor 1. 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 places along their circumferences.
along their circumferences. Clearance Standard: 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 diameter Standard: 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.
Spring
1. Measure spring free length.
2. If not as specified, replace oil pump as an assembly.
Fluid pressure by pass valve

1. Measure fluid pressure by pass valve and check for wear. Outer diameter Standard: 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-ASSEMBLY
1. 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 lbin (32-47 Nm, 3.2-4.8 kgm)
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 lbin (8.1-10.9 Nm, 82-112 kgm)
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 of transaxle. 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
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. e. f. g. h. i.
Do not drop or lose valves or internal parts. Before assembly, make sure all parts are thoroughly clean. Apply ATF to all parts and bores. Note proper direction of valves and internal parts. Do not reuse any part that has been dropped. 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
Identification mark
Length in (mm) 0.551 (14)
Tightening torque Ibin (Nm, kgcm)
1.181 (30)
1.575 (40)
1.969 (50)
70~95 (7.9~10.7, 80~110)
3.228 (82)
3.543 (90)
01
3.740 (95)
2004 > 1.6L DOHC >
DISASSEMBLY
1. 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 clutch spring 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.
REASSEMBLY
1. 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 clutch spring 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 outer circumference 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 the reaction 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 service manual. 13. Install the seal rings. 14. Install the input shaft.
15. Install the input shaft snap ring.
RE-ASSEMBLY
1. 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. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
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 locations shown. Tightening torque: 11.3-16.5 Ibin (1.27-1.86 Nm, 13-19 kgcm)
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 locations shown.
14. Set upper control valve body onto main control valve body and install nine bolts. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
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. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
17. Install shift solenoids B and C, oil strainers, and bracket.
18. Tighten mounting bolts. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
19. Install torque converter clutch solenoid and oil strainer. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm) 20. Install shift solenoid A and oil strainer onto upper valve body. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
21. Apply ATF to new O-rings and install them onto oil pipe assembly. 22. Install oil pipe assembly. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
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. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
DISASSEMBLY
1. 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.
INSPECTION
1. 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.
REPLACEMENT
1. 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) Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
2. Install oil strainer, and (3) bolts. Tightening torque: 69.6-94.8 Ibin (7.9-10.7 Nm, 80-110 kgcm)
3. Connect connectors. 4. Install oil pan (19 bolts) and a new gasket. Tightening torque: 74.4-94.8 Ibin (8.4-10.7 Nm, 85-110 kgcm) 5. Loosely install nuts A and bolts B of engine mounting member. 6. Install engine mounting member. Tightening torque: A: 28-38 Ibft (38-51 Nm, 3.8-5.3 kgm) B: 48-65 Ibft (64-89 Nm, 6.5-9.1 kgm)
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 >
INSPECTION
1. Measure spring free lengths. 2. If not within specification, replace spring(s).
RE-ASSEMBLY
1. 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 >
COMPONENT
1. Disassemble in order shown in figure.
2004 > 1.6L DOHC >
INSPECTION
1. Measure spring free lengths. 2. If not within specification, replace spring(s).
RE-ASSEMBLY
1. 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 INSPECTION
1. Disconnect negative battery cable. 2. Disconnect solenoid valve connector. 3. Measure resistance between each terminal and a ground. Resistance: 14-18
a. b. c. d.
2: 1: 4: 7:
Torque converter clutch solenoid Shift solenoid valve A Shift solenoid valve B Shift solenoid valve C
4. If not correct, check wiring for an open or short-circuit. Replace solenoid valve.
CONTINUITY INSPECTION
1. 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 VALVE

Resistance inspection 1. Disconnect negative battery cable. 2. Disconnect solenoid valve connector. 3. Measure resistance between ground terminals and of connector terminal H-03-3. Resistance: 4.1-5.1 4. If not connect, check wiring for an open or short-circuit, replace pressure control valve. 5. Connect solenoid valve connector. 6. Connect negative battery cable.
Clutch & Brake
Reverse and Overdrive Clutch
2004 > 1.6L DOHC >
COMPONENT
COMPONENT
2004 > 1.6L DOHC >
DISASSEMBLY
1. 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 snap ring.
8. Remove the clutch spring retainer. 9. Remove the D-ring seal. 10. Remove the clutch return spring. 11. Remove the overdrive clutch piston using compressed air. 12. Remove the D-ring seal. 13. Remove the Reverse clutch piston. 14. Remove the 3 D-ring seals.
REASSEMBLY
1. Install the 3 D-ring seals. 2. Align the outer circumference holes (A and B) on the reverse piston and the reverse piston retainer before assembly.
3. Install the Reverse clutch piston. 4. Install the D-ring seal. 5. Install the overdrive clutch piston. 6. Install the clutch return spring. 7. Install the D-ring seal.
8. Install the clutch spring retainer. 9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snap ring.
10. Check the clearance between the snap ring and the return spring retainer Standard value: 0.01-0.09 mm (0.0004-0.0035 in.)
11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service manual.
Dip each clutch disc in ATF before assembling. 12. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer circumference 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 reaction plate using a feeler gauge. Standard value :
1.6-1.8 mm (0.0630-0.0709 in.)
Dip each clutch disc in ATF before assembling. 18. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer circumference 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
DISASSEMBLY
1. 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. 8. Remove snap ring. 9. Remove SST(0K201 190 AA1) then remove spring and retainer assembly. 10. Remove snap ring. 11. Remove retaining plate. 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.
22. Remove retaining plate. 23. Remove reverse clutch driven plates and driven plates. (each two) 24. Remove snap ring. 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-ASSEMBLY
1. 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.
6. Compress spring and retainer assembly. 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 11. Install retaining plate. 12. Install snap ring. 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.
18. Compress spring and retainer assembly. 19. Install snap ring. 20. Remove SST(0K201 190 AA1). 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 23. Install retaining plate. 24. Install snap ring.
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 28. Install retaining plate. 29. Install snap ring.
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/cm) 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 plates 1. 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 assembly

1. Measure spring free length and check for deformation. Free length: 0.805 in (20.45 mm)
Reverse clutch piston

1. 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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
Coasting clutch piston

Reverse/forward drum
1. 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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
INSPECTION
Drive plates 1. 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)

1. Measure spring free length and check for deformation. Free length: 0.805 in (20.45 mm)
Reverse clutch piston

Coasting clutch piston

Reverse/forward drum
1. 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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
One Way Clutch
2004 > 1.6L DOHC >
SMALL SUN GEAR ONE-WAY CLUTCH NO.1
ONE-WAY CLUTCH NO.2 AND PLANETARY CARRIER ASSEMBLY

1. Disassembly in order shown in figure.
2004 > 1.6L DOHC >
DISASSEMBLY
1. 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 operation 1. 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-ASSEMBLY
1. 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. Thrust bearing outer diameter: 3.39 in (86.0 mm)
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. Thrust bearing outer diameter: 3.39 in (86.0 mm)
RE-ASSEMBLY
1. Assembly planetary carrier to inner race.
2. Install snap ring.
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 carrier assembly.
assembly. Bearing race outer diameter: Sun gear drum side: 3.307 in (84.0 mm)
PRE-INSPECTION
One-way clutch No.1 operation 1. 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 >
DISASSEMBLY
1. Remove snap ring. 2. Remove retaining plate. 3. Remove drive plates and driven plates. (each four) 4. Install SST(0K2CA 190 AA1) in transaxle case as shown.
5. Compress spring and retainer assembly. 6. Remove snap ring. 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/cm)
9. Remove outer seal and inner seal from low and reverse brake piston.
INSPECTION
Drive plates 1. 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 drive plate(s).

1. Measure spring free length and check for deformation. Free length of spring: 0.563 in (14.3 mm)
RE-ASSEMBLY
1. 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.
4. Compress spring and retainer assembly. 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/cm)
8. Install drive and driven plates.(each four)
Installation order: Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
9. Install retaining plate. 10. Install snap ring.
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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
13. Remove snap ring, retaining plate, drive and driven plates and set aside for later assembly.
INSPECTION
Drive plates 1. 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 drive plate(s).

1. Measure spring free length and check for deformation. Free length of spring: 0.563 in (14.3 mm)
The Other Clutch & Brake Components
2004 > 1.6L DOHC >
COMPONENT
2004 > 1.6L DOHC >
DISASSEMBLY
1. Remove two trust bearings. 2. Install SST(0K201 190 AA1) to 3-4 clutch as shown. 3. Compress spring and retainer assembly. 4. Remove snap ring. 5. Remove SST(0K201 190 AA1), then remove spring and retainer. 6. Remove snap ring. 7. Remove retaining plate. 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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
10. Remove SST(0K201 190 016). 11. Remove outer seal and inner seal 3-4 clutch piston.
INSPECTION
Drive plate 1. 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 drive plate(s).
Return spring
3-4 clutch piston

1. 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/cm) maximum
RE-ASSEMBLY
1. 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. 5. Install snap ring. 6. Remove SST(0K201 190 AA1). 7. Install drive and driven plates. (each three)
Installation order: Driven-Drive-Driven-Drive-Driven-Drive 8. Install retaining plate. 9. Install snap ring.
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. Air pressure: 57 psi (392 kPa, 4.0 kg/cm) maximum
12. Apply petroleum jelly to thrust bearings and secure them to each side of 3-4 clutch drum. Thrust bearing outer diameter Planetary carrier side: 2.21 in (56.1 mm) Output shell side: 2.84 in (72.1 mm)
INSPECTION
Drive plate 1. 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 drive plate(s).
Return spring
3-4 clutch piston

1. 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/cm) maximum
Gear System
Input Shaft
2004 > 1.6L DOHC >
Primary shaft assembly

1. 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 clearance 1. 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). Replace worn and damaged parts.
4th gear thrust clearance

1. Measure clearance between 4th gear and ball bearing. Clearance: 0.007~0.015 in (0.17~0.37 mm) Maximum: 0.017 in (0.42 mm) 2. If clearance exceeds maximum, check contact surfaces of 4th gear, ball bearing, and clutch hub (3rd/4th). Replace worn and damaged parts.
Disassembly note
Bearing (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 using SST (0K130 175 008).
Bearing (1st end)

1. Remove bearing by using SST (0K670 990 AA0).
Primary shaft assembly

Assemble in order shown in figure, refer to Assembly note.
Assembly note
Bearing (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 assembly
1. 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. Clearance: 0.002~0.008 in (0.05~0.20 mm) Maximum: 0.010 in (0.25 mm)
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.
DISASSEMBLY
1. 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 gear and needle roller bearing.
INSPECTION
INPUT SHAFT 1. 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 HUB

1. 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.
REASSEMBLY
1. 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 ring and 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 >
DISASSEMBLY
1. Loosen the lock nut caulking.
2. Remove the lock by using socket.
REASSEMBLY
1. 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 >
DISASSEMBLY
1. Remove two seal rings. 2. Remove bearings from output gear with suitable tools.
RE-ASSEMBLY
1. 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 >
REASSEMBLY
1. 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, the synchronizer 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).
DISASSEMBLY
1. 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 SHAFT 1. 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 BEARING
1. 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 RING
1. Check the clutch gear teeth for damage. 2. Check internal surface for damage, wear or broken grooves.
SYNCHRONIZER SLEEVE AND HUB

1. 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.
GEARS
1. 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 >
DISASSEMBLY
1. Remove oil seal. 2. Remove bearing outer race with a pin punch and hammer as shown.
3. Remove O-ring.
RE-ASSEMBLY
1. 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.
Disassembly
1. 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 shaft support 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) in head 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 column shaft 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-assembly
1. Install guide bracket and tighten two nuts. Tightening torque: 69.4~95.9 Ib-in (7.8~10.8 Nm, 0.8~1.1 kg-m) 2. Install spacer and bolt into adjust slot and then tighten adjust nut after inserting U - clip. Tightening torque: 69.4~95.9 Ib-in (7.8~10.8 Nm, 0.8~1.1 kg-m)
3. Install washer and nut to auto transaxle linkage and tighten nut. Tightening torque: 24~83 Ib-in (32~46 Nm, 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. Tightening torque: 69.4~95.9 Ib-in (7.8~10.8 Nm, 0.8~1.1 kg-m) 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. Tightening torque: 5.1~7.2 Ib-in (6.8~9.8 Nm, 0.7~1.0 kg-m)
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 Nm, 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 Nm, 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 inspection
1. 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 OFF indicator light illuminates. 3. If O/D OFF indicator light does not operate, continue with inspection of voltage test.
Operation inspection
1. 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 OFF indicator light illuminates. 3. If O/D OFF indicator light does not operate, continue with inspection of voltage test.
Adjustment
1. 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 Nm, 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 Nm,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. 18. Connect negative battery cable.
Transaxle Oil Temperature Sensor
2004 > 1.6L DOHC >
RESISTANCE INSPECTION
1. 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 >
1. Disconnect negative battery cable. 2. Disconnect transaxle range switch connector. 3. Check for continuity at transaxle range switch.
4. If not as specified, replace or adjust transaxle range switch. 5. Connect transaxle range switch connector. 6. Connect negative battery cable.
1. Disconnect negative battery cable. 2. Disconnect transaxle range switch connector. 3. Check for continuity at transaxle range switch.
4. If not as specified, replace or adjust transaxle range switch. 5. Connect transaxle range switch connector. 6. Connect negative battery cable.
Troubleshooting
2004 > 1.6L DOHC >
INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES

Diagnostic trouble code P0707 P0708 Details 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) a. b. c. d. e. Corroded or faulty Range Switch. Open between Meter Fuse and Range Switch. Open between Range Switch and TCM on one or more circuits. Short to Battery between Range Switch and TCM on one or more circuits. 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 Meter Fuse circuit. Any shorts or opens in the Meter Fuse circuit should be repaired before continuing with this troubleshooting tree. Possible cause 1. Transaxle range switch malfunction. 2. Damaged wiring or connectors between transaxle range switch and transaxlecontrol module. 3. Transaxle control module malfunction.
Step 1
Inspection With ignition off, disconnect A-03 from Range Switch. Check for any signs of corrosion or water.Is any water or corrosion present?
Action Yes Spray inside of A-03 and Range Switch with silicone lubricant and blow out connector and Range Switch with compressed air. Check A-03 and Range Switch carefully for cracks or missing water seals and replace as necessary. If corrosion has penetrated terminals or wiring, replace Front Harness and Range Switch. No Go to step 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 A03/I. Repair as necessary. Yes Go to step 4. No If voltage is below specs in R, D, 2 or 1 (or more than 0v in P or N), referring to chart "A", measure resistance acrossRange Switch with ignition off and A-03 disconnected. Replace Range Switch if resistance between terminals is greater than 1 ohm. If Range Switch tests okay, check affected circuit per diagram "A" and repair as necessary.If voltage is available in R, D, 2 or 1 when Gear Selector is in "All other positions", disconnect A-03 from Range Switch and measure incorrect voltage(s) at TCM again. Replace Range Switch if voltage drops to 0v. If voltage does not drop to 0v, refer to chart "A" and locate source of short to voltage. If voltage is 0v in Park or Neutral when gear selector is "All other gear positions", disconnect A03 from Range Switch and measure voltage at H01/18 again. Replace Range Switch if voltage
Turn ignition off and reconnect A-03 to Range Switch. Remove connector cover from H-01 (TCM) (leave H-01 connected to TCM to do tests). Turn ignition on and measure voltages per chart "A". Are voltages correct per chart "A"?
01/18 again. Replace Range Switch if voltage returns 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 and monitoring forpending codes (refer to section 3 of the Hi-scan Pro Generic OBD-II Program Card reference manual). 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 If the oil temperature sensor output voltage is 2.6 V or more even after driving for 10 minutes or more (If the oil temperature does not increase), it is judged that there is an open circuit in the oil temperature sensor and diagnostic trouble code No.P0710 is output. If the oil temperature sensor output detects the voltage which corresponds to 200C(392F) or more for more than one second, it is judged that there is an open circuit in oil temperature sensor and diagnostic trouble code No. P0710 is output. Probable cause a. Malfunction of the oil temperature sensor b. Malfunction of connector c. Malfunction of the TCM
2004 > 1.6L DOHC >
ATF SENSOR
Diagnostic trouble code P0712 P0713 Details Possible cause a. ATF sensor low b. ATF sensor high a. ATF sensor malfunction a. Short circuit in wiring b. ATF sensor malfunction
Step 1
Inspection
Action
Are all connections at connector and connector pins Yes Go to next step. OK? No Repair or replace connector(s). Measure terminal voltage of transaxle control module at terminal H-01/22. Standard voltage: ATF 68F (20C): Approx. 4.0 ATF 266F (130C): Approx. 1.5 Is terminal voltage as specified? Yes Go to step 5. No Go to next step.
Measure ATF sensor resistance of transaxle control Yes Go to step 5. module at terminal H-01/21 and H-01/22. No Replace ATF sensor. Standard voltage: ATF 68F (20C): 24.461~29.205k ATF 140F (68C): 4.29~5.61k ATF 176F (80C): 3.05~3.6k
Are connectors and wiring between transaxle control module and ATF sensor OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear?
Yes Go to next step. No Replace or repair connector and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further.
2004 > 1.6L DOHC >

Code No.P0715 input shaft speed sensor system If no output pulse is detected from the input shaft speed sensor for 1 second 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 in the input shaft speed sensor and diagnostic trouble code No.P0715 is output. If diagnostic trouble code P0715 is output four times, the transaxle is locked into 3rd gar or 2nd gear as a fail-safe measure. a. Malfunction sensor b. Malfunction retainer c. Malfunction d. Malfunction Probable cause of the input shaft speed of the underdrive clutch of connector of the TCM
2004 > 1.6L DOHC >

Diagnostic trouble code P0716 P0717 Details a. Input/turbine speed sensor signal malfunction b. Input/turbine speed sensor circuit malfunction Input/turbine speed sensor signal is not input to transaxle control module when vehicle is above 25 mph (40 km/h); turbine is below 96 rpm and vehicle in D, 2 or 1. a. Input/turbine speed sensor malfunction. b. Damaged wiring or connectors between input/turbine speed sensor transaxle control module.
Possible cause
Step 1
Inspection Are all connections at connectors and connector pins OK? Measure terminal voltage of transaxle control module at terminal H-01/44 and H-01/16. Standard voltage: Engine running (P, N position): Approx. 2.5 V Ignition switch ON: Approx. 2.3 V Is terminal voltage as specified? Yes Go to next step.
Action
No Repair or replace connector(s). Yes Go to step 6. No Go to next step.
Measure input/turbine speed sensor resistance terminals H-01/44 and H-01/16 of harness connector as follows: a. Disconnect negative battery cable. b. DisconnDisconnect transaxle control module connector. c. Measure resistance. Standard resistance: 300~400(@68F/20C) Is resistance within standard?
Yes Go to step 6. No Go to next step.
Measure input/turbine speed sensor resistance at input/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: 300~400(@68F/20C) Is resistance within standard?
Yes Go to next step. No Replace input/turbine speed sensor.
Are connectors and wiring between transaxle Yes Go to next step. control module and input/turbine speed sensor OK? No Repair or replace connectors and wiring. After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear? Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM.
If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further. 7 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected and monitor for pending codes.
2004 > 1.6L DOHC >

Code No.P0720 Output shaft speed sensor system If the output from the output shaft speed sensor is continuously 50% lower than the vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, it is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnostic trouble code No.P0720 is output. If diagnostic trouble code No.P0720 is output four times, the transmission is locked into 3rd gear or 2nd gear as a fail-safe measure. a. Malfunction sensor b. Malfunction driven gear c. Malfunction d. Malfunction Probable cause of the output shaft speed of the transfer drive gear or of connector of the TCM
2004 > 1.6L DOHC >

Diagnostic trouble code P0726 P0727 Details a. Engine speed input signal malfunction b. Engine speed input malfunction 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 below 96 rpm and vehicle is not in P or N ranges. 1. Damaged wiring or connectors between engine control module and transaxle control module.
Possible cause
Step 1
Inspection Is terminal voltage as specified? Yes Repair No Go to next step.
Action
Are all connections at connector and connector pin OK? Measure terminal voltage of engine control module.
Yes Go to next step. No Repair or replace connector(s). Yes Go to step 5. No Go to next step.
Is terminal as specified? 4 Are connectors and wiring between engine control module (B-01/59) and transaxle control module (H01/40) OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear? Yes Go to next step. No Repair or replace connectors and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further. 6 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected and monitor for pending codes.
2004 > 1.6L DOHC >

Code No.P0731 1st gear incorrect ratio If the output from the output shaft speed sensor multiplied by the 1st gear ratio is not the same as the output from the input shaft speed sensor after shifting to 1st gear has been completed, diagnostic trouble code NO.P0731 is output. If diagnostic trouble code No.P0731 is output four times, the transaxle is locked into 3rd gear as a failsafe measure. Probable cause a. Malfunction of the sensor b. Malfunction of the sensor c. Malfunction of the retainer d. Malefaction of the driven gear e. Malfunction of the system f. Malfunction of the system g. Noise generated input shaft speed output shaft speed underdrive clutch transfer drive gear or low and reverse brake underdrive clutch
2004 > 1.6L DOHC >

Code No.P0732 2nd gear incorrect ratio If the output from the output shaft speed sensor multiplied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd gear has been completed, diagnostic trouble code No.P0732 is output. If diagnostic trouble code No.P0732 is output four times, the transaxle is locked into 3rd gear as a failsafe measure. Probable cause a. Malfunction of the sensor b. Malfunction of the sensor c. Malfunction of the retainer d. Malfunction of the driven gear e. Malfunction of the f. Malfunction of the system g. Noise generated input shaft speed output shaft speed underdrive clutch transfer drive gear or second brake system underdrive clutch
2004 > 1.6L DOHC >

Code No.P0733 3rd gear incorrect ratio If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 3rd gear has been completed, diagnostic trouble code NO.P0733 is output. If diagnostic trouble code No.P0733 is output four times, the transaxle is locked into 3rd gear as a failsafe measure. Probable cause a. Malfunction of the sensor b. Malfunction of the sensor c. Malfunction of the retainer d. Malefaction of the driven gear e. Malfunction of the system f. Malfunction of the system g. Noise generated input shaft speed output shaft speed underdrive clutch transfer drive gear or low and reverse brake underdrive clutch
2004 > 1.6L DOHC >

Code No.P0734 4th gear incorrect ratio If the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from the input shaft speed sensor after shifting to 4th gear has been completed, diagnostic trouble code NO.P0734 is output. If diagnostic trouble code No.P0734 is output four times, the transaxle is locked into 3rd gear as a failsafe measure. Probable cause a. Malfunction of the sensor b. Malfunction of the sensor c. Malfunction of the retainer d. Malefaction of the driven gear e. Malfunction of the system f. Malfunction of the system g. Noise generated input shaft speed output shaft speed underdrive clutch transfer drive gear or low and reverse brake underdrive clutch
2004 > 1.6L DOHC >

Code No.P0736 reverse gear incorrect ratio Probable cause input shaft speed output shaft speed underdrive clutch transfer drive gear or low and reverse brake underdrive clutch If the output from the output shaft speed sensor multiplied by the a. Malfunction of the reverse gear ratio is not the same as the output from the input shaft sensor speed sensor after shifting to reverse gear has been completed, b. Malfunction of the diagnostic trouble code NO.P0736 is output. If diagnostic trouble code sensor No.P0736 is output four times, the transaxle is locked into 3rd gear as c. Malfunction of the a fail-safe measure. retainer d. Malefaction of the driven gear e. Malfunction of the system f. Malfunction of the system g. Noise generated
2004 > 1.6L DOHC >

Diagnostic trouble code P0741 P0742 Details a. Torque converter clutch system malfunction (Stuck OFF) b. Torque converter clutch system malfunction (Stuck ON) Shift solenoids A, B, C, vehicle speed sensor, input/turbine speed sensor and transaxle fluid temperature sensor function normally. Vehicle speed is between 44 mph (71 km/h) and 65 mph (105 km/h) and difference in the number of engine revolutions and reverse and forward drum revolutions when in 4GR TCC operation is above 100 rpm. 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.
Possible cause
If any codes relating to TPS or MAFS are present, do ALL repairs associated with those codes before proceeding with troubleshooting for a P0741 and P0742 code. A faulty TPS or MAFS can set a P0741 and P0742.
Step 1
Inspection Check for cracked intake tube, improperly installed Yes Repair as necessary. intake tube or other source of air leak between TPS No Go to step 2. and MAFS. Were any air leaks found between TPS and MAFS? Check ATF level (transaxle at normal operating temperature). Is ATF level low? Check ATF condition and com pare to following chart. 1. Clear reddish pink: Normal condition. 2. Dark or black (with friction material): Internal transaxle malfunction or excessive wear. 3. Milky pink: Water contamination. 4. Light to dark brown (oxidized): Overheated or worn out fluid. Is fluid condition other than normal.
Action
Yes Check for any signs of leakage from transaxle. Repair as necessary and fill transaxle to full level. No Go to step 3. Yes For ATF condition #2, replace transaxle. For ATF condition #3, replace fluid, repair source of contamination and perform pressure tests. If water contamination is severe, replace transaxle. For ATF condition #4, replace fluid and perform pressure tests. No Go to step 4.
Check line pressure and compare to the following chart.
Yes Go to step 5. No Replace transaxle.
No Replace transaxle.
Is line pressure within specification? 5 Check torque converter front chamber pressure as Yes Replace valve body. follows: No Remove transaxle drain pan and TCC solenoid from 1. Remove front chamber access plug. NOTE: valve body. Attach a short piece of hose to TCC Front chamber pressure access plug is solenoid nipple. Blow through hose and verify air accessible through the front of the cut-out in the does not escape from hole in body of solenoid. engine support cross member. It is the second 5 Jumper a wire from solenoid body to battery mm allen headed plug (counting from the bottom negative and another wire from solenoid terminal to of the transaxleforward). battery positive. Blow through hose and verify air 2. Screw pressure port adapter into front chamber escapes from hole in body of the solenoid. If TCC port and attach adapter to 100 psi gauge. solenoid checks okay, replace valve body. Clear codes and verify any repairs by driving 3. Disconnect coupler ass? from transaxle and vehicle with Hi scan pro connected to OBD-II attach a 10 amp fused jumper wire to the #2 pin connector at the transaxle (make the jumper wire long enough to reach the battery positive post). 4. Raise vehicle on the lift so the tires are at least 5 inches off of the floor and apply hand brake. 5. Start engine and warm it up to operating temperature. 6. Shift transaxle into D and raise vehicle speed to approximately 40 to 50 mph. 7. While maintaining vehicle speed, touch loose end of jumper wire to battery positive post and observe front chamber pressure. Front chamber pressure will drop in 2 stages within 2 seconds with TCC energized. Front chamber pressure TCC solenoid off - approximately 88 to 92 psi. TCC solenoid on - approximately 30 to 38 psi. Is the front chamber pressure within specification and does it drop as described within 2 seconds? The torque converter can only be checked by the use of special equipment. If replacing valve body does not repair vehicle, replace transaxle.
2004 > 1.6L DOHC >

Code No.P0743/P0740 Damper clutch solenoid system If the resistance value for the torque converter clutch solenoid is too large or too small, it is judged that there is a short-circuit or an open circuit in the damper clutch solenoid and diagnostic trouble code No.P0743 is output. If the drive duty rate for the damper clutch solenoid is 100% for a continuous period of 4 seconds or more, it is judged that there is an abnormality in the damper clutch system and diagnostic trouble code NO.P0740 is output. When diagnostic trouble code No.P0743 is output, the transaxle is locked into 3rd gear as a fail-safe measure. If the lock-up clutch remains engaged for a continuous period of 10 seconds when the TCM is attempting to disengage the lock-up clutch, it is judged that the torque converter clutch is stuck on and diagnostic trouble code P0740. Probable cause a. Malfunction of the damper clutch solenoid b. Malfunction of connector c. Malfunction of the TCM
2004 > 1.6L DOHC >

Diagnostic trouble code P0748 Details Possible cause 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. Linear solenoid electrical
Step 1
Inspection
Action
Are all connections at connector and connector pins Yes Go to next step. OK? No Repair or replace connector(s). Measure terminal voltage of transaxle control module at terminal H-01/5. Yes Go to step 6. No Go to next step.
Is terminal voltage as specified? 3 Measure solenoid valve resistance between terminal H-01/5 of connector and a ground as follows: a. Disconnect negative battery cable. b. Disconnect transaxle control module connector. c. Measure resistance. Standard resistance: 4.1-5.1 Is resistance within standard? 4 Measure solenoid valve resistance at torque converter clutch solenoid valve terminal of solenoid valve connector as follows: a. Disconnect negative battery cable. b. Disconnect solenoid valve connector. c. Measure resistance. Standard resistance: 4.1-5.1 Is resistance within standard? 5 Is the wiring between transaxle control module and solenoid valve OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear? Yes Go to next step. No Repair or replace connectors and wiring. Yes Go to next step. No Replace linear solenoid valve. Yes Go to step 6. No Go to next step.
Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further.
2004 > 1.6L DOHC >

Code No.P0750 Low and reverse solenoid valve system Code 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, it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnostic trouble code is output. The transaxle is locked into 3rd gear as a fail-safe measure. a. Malfunction of solenoid valve b. Malfunction of connector c. Malfunction of the TCM Probable cause
2004 > 1.6L DOHC >

Diagnostic trouble code P0753 Details Possible cause 1. Short or open circuit in wiring. 2. Short or open circuit in transaxle control module internal transistors. 3. Short or open circuit in shift solenoid A. Shift solenoid A electrica
Step 1
Inspection
Action
Are all connections at connector and connector pins Yes Go to next step. OK? No Repair or replace connector(s). Measure terminal voltage of transaxle control module at terminal H-01/30. Standard voltage: Solenoid valve ON: B+ Solenoid valve OFF: 0 V Is terminal voltage as specified? Yes Go to step 6. No Go to next step.
Measure solenoid valve resistance between terminal H-01/30 of connector and a ground as follows: a. Disconnect negative battery cable. b. Disconnect transaxle control module connector. c. Measure resistance. Standard resistance: 14-18 Is resistance within standard?
Measure solenoid valve resistance at terminal A of solenoid valve connector as follows: a. Disconnect negative battery cable. b. Disconnect solenoid valve connector. c. Measure resistance. Standard resistance: 14-18 Is resistance within standard?
Yes Go to next step. No Replace shift solenoid A.
Is wiring between transaxle control module and solenoid valve OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear?
Yes Go to next step. No Repair or replace connectors and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further.
2004 > 1.6L DOHC >

Diagnostic trouble code P0758 Details Possible cause 1. Short or open circuit in wiring. 2. Short or open circuit in transaxle control module internal transistors. 3. Short or open circuit in shift solenoid B. Shift solenoid B electrical
Step 1
Inspection
Action
Measure solenoid valve resistance at terminal B of solenoid valve connector as follows: a. Disconnect negative battery cable. b. Disconnect solenoid valve connector. c. Measure resistance. Standard resistance: 14-18 Is resistance within standard?
Yes Go to next step. No Replace shift solenoid B.
Is wiring between transaxle control module and solenoid valve OK?
Yes Go to next step. No Replace or replace TCM concerning connectors and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further.
After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear?
2004 > 1.6L DOHC >

Diagnostic trouble code P0763 Details Possible cause 1. Short or open circuit in wiring. 2. Short or open circuit in transaxle control module internal transistors. 3. Short or open circuit in shift solenoid C. Shift solenoid C electrical
Step 1
Inspection
Action
Measure solenoid valve resistance at terminal C of solenoid valve connector as follows: a. Disconnect negative battery cable. b. Disconnect solenoid valve connector. c. Measure resistance. Standard resistance: 14-18 Is resistance within standard?
Yes Go to next step. No Replace shift solenoid C.
Is wiring between transaxle control module and solenoid valve OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear?
Yes Go to next step. No Repair or replace connectors and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further.
2004 > 1.6L DOHC >

Diagnostic trouble code P1700 Details Possible cause O/D OFF lamp circuit malfunction 1. Short circuit to ground 2. O/D off lamp switch malfunction 1. Short circuit to ground. 2. O/D OFF lamp switch malfunction
Step 1
Inspection Are all connections at connectors and connector pins OK? Measure terminal voltage of transaxle control module at terminal H-01/45. Yes Go to next step. No Repair or replace. Yes Go to step 5. No Go to next step.
Action
Is terminal voltage as specified? 3 Measure terminal voltage of O/D OFF switch. Yes Go to next step. No Replace or repair O/D OFF switch.
Is terminal voltage as specified? 4 Are connectors and wiring between O/D off switch and transaxle control module (TCM) OK? After diagnostic trouble code has been cleared, does reinspection diagnostic trouble code appear? Yes Go to next step. No Repair or replace connectors and wiring. Yes Temporarily install known good TCM. Go to next step. If problem is corrected, replace TCM. No The problem is a temporarily poor connection of wiring or connectors and should be investigated further. 6 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool connected and monitor for pending codes.
2004 > 1.6L DOHC >

Code No.P1723 A/T Control relay system If the relay voltage is less than 7 V after the ignition switch has been turned to ON, it is judged that there is an open circuit or a shortcircuit in the A/T control relay earth and diagnostic trouble code P1723 is output. The transaxle is locked into 3rd gear as a fail-safe measure. Probable cause a. Malfunction of the AT control relay b. Malfunction of connector c. Malfunction of the TCM

06-Automatic Transaxle System

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06-Automatic Transaxle System

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CHAPTER 6:

Automatic Transaxle System

2004 > 1.6L DOHC >

Special service tools

0K130 990 007 Engine stand

Used to disassemble and assemble transaxle.

0K201 323 021 Holder, Primary shaft

Used to hold primary shaft.

0K201 170 AA1 Installer, oil seal

Used to install oil sear.

0K 670 990 AA0 Puller set, bearing

Used to romeve bearing.

0K201 172 008 Removing plate

Used to remove gears.

0K130 171 013 Puller, bearing

Used to remove bearing.

0K130 283 021 Puller, ball joint

Used to remove tie-rod end.

0K130 175 011 AHanger, transaxle

Used to disassemble and assemble transaxle.

0K130 170 012 Remover, bearing

Used to remove bearing.

0K130 175 008 Puller, fan pulley boss

Used to remove gears.

0K900 175 AA1 Installer set, bearing

Used to install bearing.

0K130 175 A13

Used to install gear and bearing inner race.

0K130 175 A13 Body (Part of 0K900 175 AA1)

Used to install gear and bearing inner race.

0K201 171 A01 Attachment A (Part of 0K900 175 AA1)

Used to install bearing inner race and gear.

0K130 175 A11 Attachment B (Part of 0K900 175 AA1)

Used to install bearing.

0K011 270 A02 Attachment E (Part of 0K900 175 AA1)

Used to install ear.

0K900 175 AA0 Shim selector set

Used to adjust bearing preload.

0K900 175 A01 Selector (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K900 175 A02

Used to adjust bearing preload.

0K900 175 A02 Selector (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K900 175 A03 Selector (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K130 175 A02 Collar (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K130 175 A03 Bar (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K130 191 A07 Bolt set (Part of 0K900 175 AA0)

Used to adjust bearing preload.

0K130 191 A05 Adapter, preload

Used to adjust bearing preload.

0K130 322 020

Used to measure preload.

0K130 322 020 Attachment

Used to measure preload.

0K201 270 014 Holder, differential side gear

Used to hold differential side gears.

SPECIAL SERVICE TOOLS

09432-22000 Bearing installer

Installation of output shaft's gear and sleeve