06-Automatic Transaxle System PDF

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

Tool
Illustration Use
(Number and Name)
0K201 170 AA0 Used to support engine.
Support, engine
0K130 990 007 Used to disassemble and assemble transaxle.

Engine stand
0K201 323 021 Used to hold primary shaft.

Holder, Primary shaft
0K201 170 AA1 Used to install oil sear.

Installer, oil seal
0K 670 990 AA0 Used to romeve bearing.

Puller set, bearing
0K201 172 008 Used to remove gears.

Removing plate
0K130 171 013 Used to remove bearing.
Puller, bearing
0K130 283 021 Used to remove tie-rod end.

Puller, ball joint

AHanger, transaxle

Remover, bearing

Puller, fan pulley boss
0K900 175 AA1 Used to install bearing.

Installer set, bearing
0K130 175 A13 Used to install gear and bearing inner race.
0K130 175 A13 Used to install gear and bearing inner race.
Body
(Part of 0K900 175 AA1)
0K201 171 A01 Used to install bearing inner race and gear.
Attachment A
(Part of 0K900 175 AA1)
0K130 175 A11 Used to install bearing.

Attachment B
(Part of 0K900 175 AA1)
0K011 270 A02 Used to install ear.

Attachment E
(Part of 0K900 175 AA1)
0K900 175 AA0 Used to adjust bearing preload.

Shim selector set
0K900 175 A01 Used to adjust bearing preload.

Selector
(Part of 0K900 175 AA0)

Selector
(Part of 0K900 175 AA0)

Selector
(Part of 0K900 175 AA0)

Collar
(Part of 0K900 175 AA0)

Bar
(Part of 0K900 175 AA0)

Bolt set
(Part of 0K900 175 AA0)

Adapter, preload
0K130 322 020 Used to measure preload.

Attachment
0K201 270 014 Used to hold differential side gears.

Holder, differential side gear
SPECIAL SERVICE TOOLS

Tool
Illustration Use
(Number and Name)
09431-39000 Installation of differential oil seal
Oil seal installer
09432-22000 Installation of output shaft's gear and sleeve

Bearing installer
09432-22100 Installation of input and output shaft bearing

Bearing outer race installer outer race (Use with 09500-11000)
09432-33200 Removal of input shaft's gear and ball bearing

Bearing removing plate
09495-33100 Installation of input shaft bearing

09495-33100 Installation of input shaft bearing
Bearing installer
09432-33400 Installation of input shaft bearing outer race

Bearing race installer (use with 09500-21000)
09455-21100 Installation of differential ball bearing

Bearing installer
09455-32200/0K011 190 Removal of differential bearing spacer

008
Oil seal puller
09495-33000 Removal of ball bearing and gear

Bearing and gear puller
09517-21400 Separation of T/M housing from T/M assembly

Drift
09532-11000 Removal and installation of differential bearing

09532-11000 Removal and installation of differential bearing
Differential bearing installer
09532-11500 Installation of output shaft and differential

Pinion bearing outer race shaft bearing outer race
installer (Use with 09500-11000)
09200-38001(J28467-B) Removal and installation of transaxle

Engine support fixture assembly

Tool
Illustration Use
(Number and Name)
09453-24000 Removal and installation of underdrive clutch
Spring compressor snap ring
09452-21401/0K011 171 Installation of oil pump

002 (use with 09452-21301)
Guide pin
09453-33100 Measurement of the low and reverse brake

Dial gauge extension and the second brake end play

Oil seal installer
09432-33200 Removal of transfer shaft bearing

Removing plate
09432-33800 a. Removal of transfer driven gear taper

Bearing installer bearing (use with 09433-21000)
b. Installation or transfer shaft bearing
09433-21000 a. Removal of transafer driven gear taper

Removing plate bearing (use with 09432-33800)
b. Removal of differential ball bearing
09500-11000 Installation of differential bearing outer race

Bar (use with 09532-11500)
09455-33200 Installation of differential ball bearing and

Bearing installer output shaft taper roller bearing
09453-21100 Removal and installation of the low-reverse

09453-21100 Removal and installation of the low-reverse
Spring compressor brake snap ring (use with 09453-21000)
09455-21000/0K011 430 Removal of ball bearing and tansfer drive

017 gear
Bearing and gear puller
09455-21100 a. Intallation of ball bearing and transfer

Bering installer drive gear
b. Installation of the transfer driven gear
taper bearing
09532-11500 Installation of differential bearing outer

Bearing installer race(use with 09500-11000)
09453-21000 a. Removal and installation of low-reverse

Spring compressor brake snap ring
b. Removal and installation of overdrive
clutch snap ring (use with 09456-39000)
09456-39000 Removal and installation of low-reverse brake

Spring compressor and overdrive clutch snap ring
09432-21701 Installation of output shaft outer race

09432-21701 Installation of output shaft outer race
Bearing outer race installer
09452-33100 Removal of the oil pump

Oil pump remover
09452-21200 Installation of the oil pump oil seal

Oil pump oil seal installer
09200-38001 Removal and installation of transaxle

Engine support fixture
09456-39100 Measurement of low-reverse brake and

A/B Clearance dummy plate second brake end plays
09457-39000 Removal and installation of output shaft lock

Special socket (41) nut

Tool
Illustration Use
(Number and Name)
0K2CA 089 HSP
0K2CA 089 HSP
Hi-Scan Pro
0K130 283 021 Used to remove tie-rod end.

Puller, ball joint
0K130 990 007 Used to disassemble transaxle.

stand, engine
0K670 990 AA0 Used to remove bearing

Puller set, bearing
0K201 190 AA0 Used to measure line pressure

Gauge set, oil pressure
0K201 270 014 Used to hold differential side gear.

Holder, diff.side gear
0K130 175 011A Used to disassemble transaxle.

0K130 175 011A Used to disassemble transaxle.
Hanger, transaxle
0K130 170 012 Used to remove bearing outer race.

Remover, bearing
0K201 170 AA0 Used to remove transaxle.

Support, engine
0K201 190 016 Used to disassemble/assemble 3-4 clutch.

Leak checker
0K130 322 020 Used to measure bearing preload.

Attachment
0K201 170 AA1 Used to install oil seal.

Installer, oil seal
0K201 190 AA1 Used disassemble/assemble clutch assembly.

0K201 190 AA1 Used disassemble/assemble clutch assembly.
Compressor set, return
spring
0K130 191 034 Used to adjust bearing preload.

Holder, idler gear shaft
0K201 190 017 Used to remove oil seal

Installer, oil seal
0K201 190 019 Used to remove/install turbine shaft

Holder, turbine shaft
0K201 175 AA0 Used to adjust preload.

Selector set, shim
0K130 171 013 Used to remove differential bearing.

Puller, bearing

Preload, adapter
0K2CA 190 AA2 Used to press servo piston lifter

Servo Piston Lifter
0K2CA 190 AA1 Used to remove/install spring retainer

Spring retainer assembly assembly.

Tool
Illustration Use
(Number and Name)
0K201 170 AA0A Used to support engine.
Support, engine

Engine stand
0K201 323 021 Used to hold primary shaft.

Holder, Primary shaft

Installer, oil seal
0K670 990 AA0 Used to remove bearing.

Puller set, bearing

Removing plate

Puller, bearing
0K670 321 019 Used to remove tie rod end.

Puller, socket
0K130 175 011A Used to disassemble and assemble transaxle.

Hanger, transaxle

Remover, bearing

Puller, fan pulley boss
0K900 175 AA1 Used to install bearing.

Install set, bearing
0K130 175 AA0 Used to adjust bearing preload.

Shim selector set

Attachment
0K201 270 014 Used to hold differential side gears.

Holder, differential side gear

Bearing remover set
2004 > 1.6L DOHC >
TROUBLESHOOTING
Symptom Probable cause Remedy
Vibration, noise Loose or damaged transaxle and engine Tighten or replace mounts
mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Use of inadequate grade of gear oil Replace with specified gear oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged oil seal Replace oil seal
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and Correct or replace
gear cone
Weakened synchronizer spring Replace synchronizer spring
Use of inadequate grade of oil Replace with specified gear oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
Excessive clearance of synchronizer hub to Replace synchronizer hub and sleeve
sleeve spline
Worn or damaged gears and/or bearings 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 Action

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

Part name Thickness mm Identification symbol
Thrust washer 1.8 18
(For adjustment of input shaft end play)
2.0 20
2.2 22
2.4 24
2.6 26
2.8 28
Snap ring 1.6 None
(For adjustment of underdrive clutch and overdrive clutch end plays)
1.7 Blue
1.8 Brown
1.9 None
2.0 Blue
2.1 Brown
2.2 None
2.3 Blue
2.4 Brown
2.5 None
2.6 Blue
2.7 Brown
2.8 None
2.9 Blue
3.0 Brown
Snap ring 2.2 Blue
(For adjustment of low-reverse brake and second brake reaction
2.3 Brown
plates end plays)
2.4 None
2.5 Blue
Pressure plate 1.6 6
(For adjustment of low-reverse brake and second brake end plays)
1.8 1
2.0 0
2.2 2
2.4 4
2.6 6
2.8 8
3.0 D
Snap ring 1.6 None
(For adjustment of reverse clutch end play)
1.7 Blue
1.8 Brown
1.9 None
2.0 Blue
2.1 Brown
2.2 None
2.3 Blue
2.4 Brown
2.5 None
2.6 Blue
2.7 Brown
2.8 None
Snap ring 1.48 Brown
(For adjustment of reverse clutch and overdrive clutch spring retainers
1.53 None
end plays)
1.58 Blue
1.63 Brown
Thrust race 1.6 -
(For adjustment of underdrive sun gear end play)
1.7 -
1.8 -
1.9 -
2.0 -
2.1 -
2.2 -
2.3 -
2.4 -
2.5 -
2.6 -
Spacer 1.88 88
(For adjustment of output shaft preload)
1.92 92
1.96 96
2.00 00
2.04 04
2.08 08
2.12 12
2.16 16
2.20 20
2.24 24
2.28 28
2.32 32
2.36 36
2.40 40
2.44 44
2.48 48
2.52 52
2.56 56
2.60 60
2.64 64
2.68 68
2.72 72
2.76 76
Spacer 0.71 71
(For adjustment of differential case preload)
0.74 74
0.77 77
0.80 80
0.83 83
0.86 86
0.89 89
0.92 92
0.95 95
0.98 98
1.01 01
1.04 04
1.07 07
1.10 J
1.13 D
1.16 K
1.19 L
1.22 G
1.25 M
1.28 N
1.31 E
1.34 O
1.37 P
Spacer 0.75 - 0.82 -
(For adjustment of backlash between differential side gear and pinion)
0.83 - 0.92 -
0.93 - 1.00 -
1.01 - 1.08 -
1.09 - 1.16 -
TIGHTENING TORQUE
Items N·m kg·cm lb·ft
Wiring harness bracket 20-26 200-260 14-18
Control cable bracket 20-26 200-260 14-18
Eye bolt 27-33 270-330 19-23
Oil cooler feed tube 10-12 100-120 7-8
Input shaft speed sensor 10-12 100-120 7-8
Output shaft speed sensor 10-12 100-120 7-8
Manual control lever 18-25 180-250 13-18
Transaxle range switch 10-12 100-120 7-8
Vehicle speed sensor 4-6 40-60 3-4
Valve body cover 8-10 80-100 6-7
Valve body mounting bolt 10-12 100-120 7-8
Oil temperature sensor 10-12 100-120 7-8
Manual control shaft detent 5-7 50-70 4-5
Rear cover 20-26 200-260 14-18
Torque converter housing 42-54 420-540 29-38
Oil pump 20-26 200-260 14-18
Transfer drive gear 16-22 160-220 11-15
Output shaft lock nut 160-180 1600-1800 110-126
Output shaft bearing retainer 20-26 200-260 14-18
Oil filler plug 29-34 290-340 20-24
Oil drain plug 29-34 290-340 20-24
Transfer drive gear lock nut 180-210 1800-2100 126-147
Differential drive gear 130-140 1300-1400 91-98
Valve body 10-12 100-120 7-8
Solenoid valve support 5-7 50-70 4-5
Plate 5-7 50-70 4-5
Pressure check plug 8-10 80-100 6-7
Front roll stopper bracket to subframe bolts 60-80 600-800 43-58
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Rear roll stopper bracket to subframe bolts 50-65 500-650 36-47
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting bracket bolts 60-80 600-800 43-58
Transaxle mounting insulator bolt 90-110 900-1100 65-80
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or
loosening if under-tightened. In either case, serious personal injury or death could result to the vehicle occupants.
LUBRICATIONS
Items Specified lubricant Quantity
Transaxle fluid lit. (U.S. qts., Imp,qts.) GENUINE DIAMOND 7.8 (8.2,6.9)
ATF SP-III
SEALANTS
Items Specified sealant
Rear cover Genuine sealant FMD546, TB1281B or equivalant
Torque converter housing Genuine sealant FMD546, TB1281B or equivalant
Valve body cover Genuine sealant FMD546, TB1281B or equivalant
SPECIFICATIONS
SPECIFICATIONS
Automatic Transaxle
System
2004 > 1.6L DOHC >
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT

PARKING NEUTRAL
FIRST
SECOND
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 Code Function

Underdrive clutch UD Connects input shaft and underdrive sun gear
Reverse clutch REV Connects input shaft and reverse sun gear
Overdrive clutch OD Connects input shaft and overdrive planetary carrier
Low-and-reverse brake LR Locks low-and-reverse annulus gear and overdrive
planetary carrier
Second brake 2ND Locks reverse sun gear
COMPONENT OPERATION TABLE: O/D OFF SYSTEM

SOLENOID VALVE OPERATION TABLE: O/D OFF SYSTEM
FLUID PASSAGE 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 Functional Name

1 Low-Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
22. Remove the manual control lever shaft pin (roller).

23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.
25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.
26. Remove the 2 O-rings from the case.
27. Remove the differential.
28. Remove the main oil filter.
29. Remove oil pump mounting bolts.
The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump 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.

36. Remove the underdrive clutch hub.
37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.

39. Remove the 4 seal rings.
Do not remove the input shaft rear bearing unless directed to do so by the instructor.
Once this bearing has been removed, it MUST be replaced.
40. Remove the 3 O-rings.

42. Remove the reverse overdrive clutch.
44. Remove the overdrive clutch hub.

46. Remove the reverse sun gear.
47. Remove the second brake piston snap ring.

48. Remove the second brake piston and return spring.
49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.
50. Remove the overdrive planetary carrier.

52. Remove the output planetary carrier.
53. Remove the underdrive sun gear.
55. Remove the low/reverse reaction plate snap ring.
56. Remove the low/reverse reaction plate and brake disc.
57. Remove the low/reverse brake snap ring.

58. Remove the low/reverse 6 brake discs, 5 brake plates, and brake pressure plate.
59. Remove the wave spring.
60. Remove the parking pawl shaft.

61. Remove the spacer.
62. Remove the parking pawl spring. Note the orientation of the spring to aid in reassembly.
63. Remove the 2 parking roller support shafts.
64. Remove the parking pawl case.
65. Remove the parking roller support.
66. Remove the snap ring.
67. Remove the spring retainer.

68. Remove the return spring.
69. Remove the low/reverse brake piston. Use compressed air directed into the valve body passage.
70. Remove the 7 transfer gear mounting bolts.
71. Remove the transfer drive gear.
72. Remove the plastic cap, if present.

73. Straighten the locking tab of the output shaft lock nut, if bent.
The output shaft lock nut is left-hand thread.
74. Remove the output shaft lock nut.
75. Remove the output shaft bearing retainer mounting bolts.
76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.
77. Tap out the bearing outer race and spacer using a suitable driver.
78. Remove the snap ring.

79. Remove the differential bearing outer race and spacer from the torque converter housing.
80. Remove the differential bearing outer race from the transaxle case.
REASSEMBLY
a. Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
b. Never use grease other than blue petrolatum jelly and white Vaseline.
c. Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch
disc or brake disc in ATF for at least two hours before assembling them.
d. Never apply sealant or adhesive to gaskets.
e. When replacing a bushing, replace the assembly which it belongs to.
f. Never use any cloth gloves or any rags during reassembly.
Use nylon cloth or paper towels if you need to use something. Change the oil in the cooler system.
1. Tap the differential bearing outer race into the transaxle case using special tools tools (09500-11000 and 09532-
11500).
2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).
3. Install the spacer and the snap ring.
4. Install the low-reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, 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 lbs·ft) of torque.
26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).
The output shaft lock nut is left-hand thread.
27. Apply ATF and install the old lock nut and tighten to 167 Nm (123 lb·ft). Loosen the nut 1 full turn, then re-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 lbs·ft).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts.
Be sure to install the thrust bearing in the proper direction.
36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.
37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier.
Rotating the output shaft will help align the clutch teeth and help the carrier seat.
39. Install the reverse sun gear.
40. Install the wave spring.
41. Install the pressure plate, 6 brake discs, and 5 brake plates.
42. Install the snap ring.
43. Install the reaction plate.
45. Install the pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.
48. Install thrust bearing #5.
49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.

50. Install the reverse overdrive clutch and thrust bearing #7.
51. Install the three O-rings.
52. Install the 3 seal rings into the rear cover.
The cover should be clean and dry for step 56. It is only being installed to measure the underdrive sun 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 lbs·ft).
57. Install the underdrive clutch hub.
58. Install thrust bearing #2.
59. Grasp the input shaft and lower the underdrive clutch into position.
Looking into the hole where the input speed sensor mounts to the case will help you ensure that 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 lbs·ft).
65. Install the oil internal filter.
66. Install the differential.
67. Place two strips of solder, approximately 10 mm (0.39 in) long and 3 mm (0.12 in) thick, on the torque converter
housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.
69. Remove the torque converter housing, the bolts and the solder.
70. Using a micrometer, measure the thickness of the pressed solder.
71. Select a spacer that will give the following clearance.
Standard value:
0.045 mm (0.0018 in.)-0.105 mm (0.0041 in.)
72. Install the differential spacer selected in the previous step in the torque converter housing.
73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.
74. Install the two O-rings.
75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.
76. Install the manual control lever shaft and parking pawl.
77. Install the manual control shaft roller.

78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs are
identified in the illustration and in the chart below.
Number Function Name

1 Low-Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
79. Install the accumulators with the springs according to the illustration and the chart below. The accumulators
should be flush with the transaxle case.
Number Function Name Color

1 Low-Reverse Brake None
2 Underdrive Clutch Yellow
3 Second Brake White
4 Overdrive Clutch None
80. Install the strainer and the second brake retainer oil seal.
Note the oil seal orientation in the illustration.
81. Install the solenoid wiring harness, then install the snap ring in its groove.
82. Install the valve body, gasket, and two steel balls.
83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm.
84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm.
85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart below.
No. Part to be connected Wire color Connector housing color

1 Underdrive solenoid valve White, Red, Red Black
2 Overdrive solenoid valve Orange, Red Black
3 Low-Reverse solenoid Brown, Yellow Milky White
valve
4 Second solenoid valve Green, Red,Red Milky White
5 Damper clutch control Blue,Yellow,Yellow Black
solenoid valve
6 Oil temp. sensor Black,Red Black
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 lb·ft) of torque.
87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm of torque.
88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm of torque.
89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (8 lbs·ft) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 lbs·ft) of torque.
91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm of torque.
Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter 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 lbs·ft) of torque.
93. Install the dipstick.

94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).
95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).
96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 lbs·ft).
97. Install the torque convertor and secure it so that dimension A.
Meets the reference value.
Reference value :
approx. 12.2 mm (0.480 in.)
Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the 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 Possible source

Clutch facing material Drive plate or brake band
Steel (magnetic) Bearings, gears, or driven plate wear
Aluminum(Nonmagnetic) Bushings or cast aluminum parts wear
b. If large amounts of material are found, replace torque converter and carefully check transaxle for cause.
14. Remove clip (one bolt).
15. Disconnect solenoid connectors.
16. Remove strainer (three bolts).

17. Remove A, B and C bolts and brackets shown in figure.
Bolt length (Measured from below head):

A: 1.18 in (30 mm)
B: 1.97 in (50 mm)
C: 0.55 in (14 mm)
18. Remove control valve body.

19. Remove manual shaft and manual plate.
a. Loosen nut and pull out manual shaft.
b. Remove nut, washer, and manual plate.
20. Remove bolt and parking pawl lever holder.
21. Remove parking pawl lever (two bolts).
22. Remove detent lever and return spring.
23. Remove actuator support.

24. Remove oil pump assembly (10 bolts).
25. Remove reverse/forward clutch assembly.

a. Remove turbine shaft snap ring.
b. Pull reverse/forward drum and remove clutch assembly.
26. Remove small sun gear and one-way clutch No. 1.
Use a piece of wire to secure brake band so that it is not damaged by being stretched.
27. Remove 2-4 brake band.
28. Pull anchor shaft while holding strut.

29. Remove strut.
30. Remove servo with SST (0K2CA 190 AA2).
a. Compress servo piston and remove snap ring.
b. Remove servo retainer, servo piston, and spring.
31. Remove one-way clutch No. 2 and planetary carrier assembly.

a. Remove snap ring.
b. Remove one-way clutch No. 2 together with planetary carrier assembly.

c. Remove friction plate.
32. Remove internal gear.

a. Remove snap ring.
b. Remove internal gear from output shell.
33. Remove 3-4 clutch assembly.

a. Remove O-ring from turbine shaft at converter housing side.
b. Pull out turbine shaft to remove 3-4 clutch assembly.
c. Remove 3-4 clutch assembly from turbine shaft.

34. Remove bolts (converter housing side: eight bolts transaxle case side: seven bolts) and remove transaxle case 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 Ib·in (10.8-13.7 N·m, 110-140 kg·cm)
2. Install idler gear and output gear as an assembly by tapping it with a plastic hammer.
3. Install bearing housing.
a. Install bearing housing on converter housing.
b. Align groove on idler shaft with mark on bearing housing.

c. Tap a new roll pin in with a pin punch and hammer.
d. Install 11 mounting bolts.
Tightening torque:
14-18 Ib·in (19-25 N·m, 1.9-2.6 kg·m)
4. Install parking pawl.

a. Install parking pawl and shaft.
b. Install spring and snap ring.
c. Move manual shaft and verify that parking pawl operates.
5. Install actuator support with new bolts.
Tightening torque:
11-13 Ib·in (15-17 N·m, 1.5-1.8 kg·m)
6. Install detent lever and return spring.
7. Install parking assist lever.
8. Install lever holder and bolt.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
9. Install manual shaft and manual plate.

a. Install manual plate, washer, and nut.
b. Tighten nut to specified torque.
Tightening torque:
31-40 Ib·in (42-54 N·m, 4.2-5.6 kg·cm)
10. Install differential assembly into converter housing.
11. Install SST(0K201 270 014) or equivalent.
12. Install a new oil control ring onto output gear assembly.
13. Install output shell to output gear and install bearing race onto output shell.
Thrust bearing outer diameter:

2.84 in (72.1 mm)
14. Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.
15. Install new O-rings onto converter housing.
Insure that sealer will not be forced into oil passages when transaxle case is installed.
16. Mount transaxle case to converter housing.
Tightening torque:
28-38 Ib·in (38-51 N·m, 3.8-5.3 kg·m)
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 Ib·in (19-25 N·m,190-260 kg·cm)
32. Verify 2-4 brake band adjustment as follows:

a. Install servo piston to SST(0K2CA 190 AA2).
b. Install servo retainer O-ring onto SST(0K2CA 190 AA2).
c. Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.
Insure that 2-4 brake band is correctly positioned against band servo piston stem.
d. Set a dial indicator against piston stem.
e. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure piston
stem stroke.
Air pressure:
57 psi (392 kPa, 4.0 kg/cm²) 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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
Bolt length:
(measured from below the head)
A : 1.18 in (30 mm)
B : 1.97 in (50 mm)
C : 0.55 in (14 mm)
35. Connect solenoid valve and ATF temperature sensor connectors.
36. Connect solenoid connector.
Attach magnets inside oil pan in positions shown on illustration (in oil pan).
37. Install a new gasket and oil pan tighten 19 bolts.
Tightening torque:
74.4-94.8 Ib·in (8.4-10. 7 N·m, 80-110 kg·cm)
38. Install inlet pipe and outlet pipe.

39. Install driven gear and vehicle speed sensor.
40. Install crankshaft position sensor.
41. Install bracket and select bracket.
42. Install transaxle range switch.
a. Turn manual shaft to N position.
b. Install transaxle range switch.
c. Tighten transaxle range switch mounting bolts.
Tightening torque:
70-95 Ib·in (7.9-10.7 N·m ,80-110 kg·cm)
d. Verify that the selector lever range position and transaxle range switch correspond.
43. Remove transaxle from SST(0K 130 990 007/0K130 175 011A).
44. Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
45. Install input/turbine speed sensor.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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 Ib·ft (128-176 N·m,13-18 kg·m)
Use protective plates in vise to prevent damage to idler gear.
4. Check and adjust idler gear bearing preload.

a. Turn idler gear assembly and SST(0K130 191 034) over and secure gear in vise.
b. Attach SST(0K130 191 034) and spring scale or torque wrench and measure preload while tightening locknut.
Read preload when idler shaft is rotating.
Tightening torque:
95-130 Ib·ft (128-176 N·m, 13-18 kg·m)
Preload:
0.27-7.8 Ib·in (0.03-0.8 N·m, 0.3-0.9 kg·cm)
a. The maximum allowable number of shims is 7.

b. Preload is reduced by increasing thickness of shims, or increased by reducing thickness.
5. If specified preload cannot be obtained within specified tightening torque, adjust by selecting proper 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 Ib·in (10.8-13.7 N·m, 110-140 kg·cm)
4. Remove bearing outer race and adjustment shims from bearing housing using a pin punch and hammer.
5. Install bearing outer race to bearing housing.
Do not install adjustment shims.

Eliminate gap (arrow) by turning A or B of selector.
6. Set SST(0K201 175 A01) onto converter housing.
7. Install outer race removed in step 1 to SST(0K201 175 A01).
8. Set output gear assembly onto SST(0K130 191 A03).

9. Set four SST(0K130 191 A03) on converter housing in positions shown.
10. Set bearing housing on output gear assembly and install four SST(0K130 175 A04); then tighten them to specified
torque.
Tightening torque:
14-18 Ib·in (19-25 N·m, 1.9-2.6 kg·m)
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 Ib·in (0.03-0.8 N·m, 0.3-9.0 kg·cm)
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 Ib·in (19-25 N·m, 1.9-2.6 kg·m)
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 Ib·in (0.03-0.8 N·m, 0.3-9.0 kg·cm)
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 Ib·ft (89-116 N·m 9.1-11.9 kg·m)
4. Remove floor jack from auto transaxle.
5. Remove SST(0K201 270 014).
6. Install No.2 engine mounting to auto transaxle then install three bolts.
7. Install four drive plate -to-torque converter mounting nuts.

Rotate engine at crank pulley to gain access to all four nuts.
Tightening torque:
25-36 Ib·ft (34-49 N·m, 3.5-5.0 kg·m)
8. Install four engine oil pan-to-transaxle mounting bolts then install access cover.
Tightening torque:
27.5-38.0 Ib·ft (37-52 N·m, 3.8-5.3 kg·m)
9. Install starter and ground strap. (Refer to starting system)

10. Install three No.1 engine mounting-to-chassis bolts.
Tightening torque:
49.2-69 Ib·ft (67-93.2 N·m, 6.8-9.5 kg·m)
11. Install joint shaft and tighten the three bolts. (Refer to section DS)
Tightening torque:
31-46 Ib·ft (42-62 N·m, 4.3-6.3 kg·m)
12. Install new clip on left drive shaft.

13. Push drive shaft into transaxle with opening of clip pointing upward.
Tightening torque:
32-46 Ib·ft (43-52 N·m, 4.4-5.3 kg·m)
14. Install left lower ball joint into spindle then install pinch bolt.
Tightening torque:
32-39 Ib·ft (43-54 N·m, 4.4-5.5 kg·m)
15. Install left stabilizer control link to bracket attached to shock absorber assembly.
Tightening torque:
32-45 Ib·ft (43-61 N·m, 4.4-6.2 kg·m)
16. Install left tie rod end to steering knuckle then install tie rod end nut.
Tightening torque:
22-33 Ib·ft (30-44 N·m, 3.0-4.5 kg·m)
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 Ib·ft (64-89 N·m, 6.5-9.1 kg·m)
19. Install two nuts to No.2 engine mount-to-mounting member.
Tightening torque:
28-38 Ib·ft (38-51 N·m, 3.8-5.3 kg·m)
20. Install catalytic converter. (five nuts)
Tightening torque:
27.4-38.3 Ib·ft (37.2-51.9 N·m, 3.8-5.3 kg·m)
21. Install two catalytic converter bracket nuts to engine.
Tightening torque:
27.4-38.3 Ib·ft (37.2-51.9 N·m, 3.8-5.3 kg·m)
22. Install splash shield to under engine then tighten bolts. (three bolts and three fasteners)
23. Install both right and left wheels then tighten both right and left lug nuts. (four lug nuts each)
Tightening torque:
65-87 Ib·ft (88-118 N·m, 9-12 kg·m)
24. Lower vehicle.

25. Remove SST(0K 201 170 AA0A).
26. Slide ATF inlet and outlet hose onto ATF cooler pipe until it is fully seated against the ridge.
27. Install hose clamp onto hose at center of mark and at angle shown.
28. Connect oxygen sensor connector.
29. Connect crankshaft position sensor connector.
30. Connect solenoid valve connector.
31. Connect auto transaxle range switch connector.

32. Install washer and nut to auto transaxle linkage and tighten nut then insert U-clip.
Tightening torque:
24-83 Ib·ft (32-46 N·m, 3.2-4.7 kg·m)
33. Connect vehicle speed sensor connector.

34. Connect input/turbine speed sensor connector.
35. Install No.4 engine mounting then tighten three nuts and bolt.
Tightening torque:
Nuts: 49-68 Ib·ft (68-93 N·m, 6.8-9.5 kg·m)
Bolt: 47-66 Ib·ft (64-89 N·m, 6.5-9.1 kg·m)
36. Install air cleaner assembly.
37. Connect air temperature sensor connector.
38. Connect MAF sensor connector
39. Insert diagnosis connector.
40. Connect negative and positive battery cable.
41. Fill transaxle with ATF. (Refer to automatic transaxle fluid)
42. Adjust auto transaxle control cable. (Refer to selector lever)
Kick Down Band
2004 > 1.6L DOHC >
BRAKE 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 Ib·ft (40-53 N·m, 4.0-5.0 kg/cm²)
4. Install band strut.

5. Install 2-4 brake band.
6. Apply ATF to new O-rings and install them to servo piston.
D-ring inner diameter:

Piston stem side: 2.303 in (58.5 mm)
Servo retainer side: 1.157 in (29.4 mm)
7. Insert piston stem into servo piston and secure it with a new spring clip.
8. Apply ATF to new O-ring and install it to servo retainer.
O-ring inner diameter: 2.587 in (65.7 mm)
9. Assemble servo piston and servo retainer.
Do not install servo piston and retainer into transaxle case at this time.

Torque Converter
2004 > 1.6L DOHC >
WASHING INSIDE 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.
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).
4. Pour in ATF.
Replace torque converter if it contains any metallic particles.

The Other Automatic
Transaxle System
2004 > 1.6L DOHC >
COMPONENTS
2004 > 1.6L DOHC >
DISASSEMBLY
1. Remove accumulator pistons and springs from clutch housing by applying compressed air through oil passage as
shown in figure.
INSPECTION
Accumulator spring
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 (70-80°C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, 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 lb·ft)
5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).
Check the old fluid for contamination. If it has been contaminated, repeat the steps (6) and (7).
7. Pour the new fluid in through the oil filler tube.

8. Reconnect the hose which was disconnected in step (1) above, and firmly replace the oil level gauge.
9. Start the engine and run it at idle for 1-2 minutes.
10. Move the select lever through all positions, and then move it to the N position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C), and then check the 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 : 80-100°C
c. Engine coolant temperature : 80-100°C
2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal fully depressed.
4. Start the engine.
5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the 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. Stall speed is too high in both D and R ranges
a. Low line pressure
b. Low reverse brake slippage
b. Stall speed is too high in D range only
a. Underdrive clutch slippage
c. Stall speed is too high in R range only
a. Reverse clutch slippage
d. Stall speed too low in both D and R ranges
a. Malfunction of torque converter
b. Insufficient engine output
HYDRAULIC PRESSURE TEST

1. Warm up the engine until the automatic transmission fluid temperature is 80-100°C.
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools oil pressure gauge to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,
and check that the measured values are with in the standard value ranges.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis
table.
STANDARD HYDRAULIC PRESSURE TEST
Measurement condition Standard hydraulic pressure kPa

Selector Shift position Engine Under drive Reverse Overdrive Low and Second Torque
lever speed clutch clutch clutch reverse brake converter
position (rpm) pressure pressure pressure brake pressure pressure
pressure
P - 2,500 - - - 260-340 - 220-360
R Reverse 2,500 - 1.270- - 1,270- - 500-700
1,770 1,770
N Neutral - - - - 260-340 - 220-360
D 1st gear 2,500 1,010- - - 1,010- - 500-700
1,050 1,050
2nd gear 2,500 1,010- - - - 1,010- 500-700
1,050 1,050
3rd gear 2,500 780-880 - 780-880 - - 450-650
4th gear 2,500 - - 780-880 - 780-880 450-650
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic presures are low Incorrect transmission control cable adjustment
Malfunction of the oil pump
Clogged internal oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal in "R" range Malfunction of the regulator valve
only
Clogged orifice
Hydraulic pressure is abnormal in "3" or "4" Malfunction of the regulator valve
range only
Clogged orifice
Malfunction of the overdrive solenoid valve
Malfuction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic pressure is Malfunction of the oil seal K
abnormal
Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic pressure is Malfunction of the oil seal A
abnormal
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only low and reverse hydraulic pressure is Malfunction of the oil seal D
abnormal
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Clogged orifice
Only second hydraulic pressure is abnormal Malfunction of the oil seal I
Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Clogged orifice
Only torque converter presure is abnormal Malfunction of the oil seal G
Pressure applied to non operating element
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only torque converter presure is abnormal Malfunction of the oil cooler
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non operating element Incorrect valve body installation
Incorrect transmission control cable adjustment
Malfunction of the manual valve
DIAGNOSIS 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 fail-
safe code description will be stored in the RAM.
Three of these diagnostic trouble codes can be stored.
4. The cancelation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position,
but the diagnostic trouble code is stored in the RAM.
5. 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 50°C 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. Condition Operation Judgement : Value Check item
1 Ignition switch : OFF Ignition switch Battery voltage (mV) Control relay
(1) ON
2 Ignition switch : ON Selector lever position (1) P,(2) R,(3)N, Transaxle range switch
Engine : Stopped (1) P,(2) R, (4) D,(5)3,(6) 2,
Select lever position : P (2) N, (4) D (7) L
(3) 3, (6) 2, (7) L
Accelerator pedal (1) 400-1,000 mV Throttle position sensor
(1) Released (2) Gradually rises from
(2) Half depressed (1)
(3) Depressed (3) 4,500-5,000 mV
Brake pedal (1) ON Stop lamp switch
(1) Depressed (2) OFF
(2) Released
3 Ignition switch ST Starting test with lever P or Starting should be Starting possible or
Engine Stopped N range possible impossible
4 Warming up Drive for 15 minutes or Gradually rises to 70- Oil temperature sensor
more so that the automatic 90°C
fluid temperature becomes
70-90°C
5 Engine : Idling A/C switch (1) ON Triple pressure switch
Selector lever position N (1) ON (2) OFF
(2) OFF
Accelerator pedal (1) ON Idle position switch
(1) Released (2) OFF
(2) Half depressed
(1) 600-925rpm
(2) Gradually rises from
(1)
(1) Data changes Communication with
engine-ECU
Selector lever position Should be no abnormal Malfunction when
(1) N→D shifting shocks Time lag starting
(2) N→R should be within 2
seconds
6 Selector lever position : N Selector lever position and (2) 1st, (4) 3rd, (3) 2nd, Shift condition
(Carry out on a flat and vehicle speed (5) 4th
straight road) 1. Idling in 1st gear(Vehicle
(2)0%, (4) 100%, (3) Low and reverse
stopped)
100%, (5) 100 % solenoid valve
2. Driving at constant speed
of 20km/h in 1st gear (2) 0%,(4) 0%,(3) 0%, Underdrive solenoid
3. Driving at constant speed (5)100% valve
of 30 km/h in 2nd gear (2)100%, (4)100%,(3) 0%,
4. Driving at 50 km/h in 3rd (5) 0% Second solenoid valve
gear with accelerator fully
closed (2) 100%, (4) 0%, (3) 100
5. Driving at constant speed %, (5) 0 % Overdrive solenoid valve
of 50 km/h in 4th gear (1) 0 km/h
(Each condition should be (4) 50 km/h Vehicle speed sensor
maintained for 10 seconds
(4) 1,800-2,100 rpm
or more)
(4) 1,800-2,100 rpm Input shaft speed sensor
(3) 0% Output shaft speed
(5) Approx. 70-90% sensor
(5) Approx. 70-90% sensor
Damper clutch control
(3) Approx. 100-300rpm
solenoid valve
(5) Approx. 0-10rpm
7 Selector lever position : D 1. Accelerate to 4th gear at For (1),(2) and (3), the Malfunction when
(Carry out on a flat and a throttle position sensor reading should be the shifting
straight road) output of 1.5V (accelerator same as the specified
Displaced shift points
opening angle of 30 %). output shaft torque, and
2. Gently decelerate to a no abnormal shocks Does not shift
standstill should occur. Does not shift from 1 to
3. Accelerate to 4th gear at For (4),(5) and (6), 2 or 2 to 1
a throttle position sensor downshifting should occur
output of 2.5 V (accelerator immediately after the Does not shift from 2 to
opening angle of 50%). shifting operation is 3 or 3 to 2
4. While driving at 60 km/h made. Does not shift from 3 to
in 4th gear, shift down to 4 or 4 to 3
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.
8 Selector lever position : N Move selector lever to R The ratio between input Does not shift
(Carry out on a flat and range drive at constant and output speed senor
straight road). speed of 10 km/h data should be the same
as the gear ratio when
reversing.
MIL REQUEST ITEM AND DIAGNOSIS CODE

OBD-II FAIL
No. FAIL CAUSE DTC *2 REMARK
DTC *1 MIL SAFE
OIL OPEN OR +B SHORT O 0713 -

1 0710
TEMPERATURESENSOR GND SHORT O 0712 -
2 INPUT SPEED (PG A) OPEN OR SHORT (GND, +B) 0715 O 0715 O
3 OUTPUT SPEED (PG B) OPEN OR SHORT (GND, +B) 0720 O 0720 O
4 BRAKE SW OPEN OR +B SHORT - - 0703 -
5 LR (DIR) SOLENOID OPEN OR GND SHORT 0750 O 0750 O
6 UD SOLENOID OPEN OR GND SHORT 0755 O 0755 O
7 2ND SOLENOID OPEN OR GND SHORT 0760 O 0760 O
8 OD SOLENOID OPEN OR GND SHORT 0765 O 0765 O
9 DCC SOLENOID OPEN OR GND SHORT 0743 O 0743 O
OPEN OR GND SHORT O 0707 -
10 INHIBITOR SW +B SHORT OR SHORT OF 0705
O 0708 -
SWITCHS
11 1st Control System Abnormal 1st 0731 O 0731 O
12 2nd Control System Abnormal 2nd 0732 O 0732 O
13 3rd Control System Abnormal 3rd 0733 O 0733 O
14 4th Control System Abnormal 4th 0734 O 0734 O
15 Reverse Control System Abnormal Reverse 0736 O 0736 O
Abnormal System or STUCK
0741 O 0741 -
OFF
16 DAMPER CLUTCH
Abnormal System or STUCK
0742 O 0742 -
ON
17 A/T CONTROL RELAY OPEN OR GND SHORT 1723 O 1723 O
TCU FAIL OR TCU SIDE
18 CAN-BUS OFF - *3- 1630 -
OPEN/SHORT
ECU FAIL OR ECU SIDE
19 CAN-TIME OUT ECU - O 1613 -
OPEN/SHORT
TCU CAN MI-
20 CAN MI-COMMALFUNCTION - *3- 1764 -
COMMALFUNCTION
21 Vehicle Speed Sensor OPEN OR SHORT (GND, +B) - O 1500 -
*1) : TCU transfers only the DTCs related OBD-II to GST through TEST MODE 03.
*2) : TCU transfers all stored DTCs through TEST MODE 13.
*3) : When the CAN communication line is error, CAN ECU illuminates CHECK ENG LAMP.
DIAGNOSTIC TROUBLE CODE DESCRIPTION

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

Code Diagnosis item Probable cause
P0713 Oil temperature sensor system Open circuit Malfunction of the oil temperature
P0712 If the oil temperature sensor output voltage is sensor
4.57 V or more even after driving for 10 minutes Malfunction of connector
or more (if the oil temperature does not Malfunction of the TCM
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 Malfunction of the input shaft
If no output pulse is detected from the input shaft circuit speed sensor
speed sensor for 1 second or more while driving Malfunction of the underdrive
in 3rd or 4th gear at a speed of 30 km/h or more, clutch retainer
there is judged to be an open circuit or short. Malfunction of connector
Circuit in the input shaft speed sensor and Malfunction of the TCM
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 Malfunction of the wide open
If the output from the output shaft speed sensor circuit throttle switch
is continuously 50% lower than the vehicle speed Malfunction of connector
for 1 second or more while driving in 3rd or 4th Malfunction of the TCM
gear at a speed of 30km/h or more, there is Malfunction of solenoid valve
judged to be an open circuit or short-circuit in the Malfunction of connector
output shaft speed sensor and diagnosis code Malfunction of the TCM
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 (2-
range or L-range) as a fail-safe measure.
P1703 Stop lamp switch system Short circuit / Open Malfunction of the stop lamp
If the stop lamp switch is on for 5 minutes or circuit switch
more while driving, it is judged that there is a Malfunction of connector
short circuit in the stop lamp switch and diagnosis Malfunction of the TCM
code P0703 is output.
Short circuit /Open Malfunction of solenoid valve
P0750 Low and reverse solenoid valve system
circuit Malfunction of connector
Malfunction of the TCM
Short circuit /Open
P0755 Underdrive solenoid valve system
circuit
Short circuit /Open
P0760 Second solenoid valve system
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 Malfunction of the damper clutch
circuit control solenoid valve
Malfunction of connector
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 Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 3rd speed sensor
gear ratio is not the same as the output from theinput shaft speed Malfunction of the output shaft
sensor after shifting to 3rd gear has been completed, diagnosis code speed sensor
P0732 is output. If diagnosis code P0732 is output four times, the Malfunction of the underdrive
transmission is locked into 3rd gear as a fail-safe measure. 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
P0732 2nd gear ratio does not meet the specification Malfunction of the input shaft
gear or driven gear
clutch system
Malfunction of the overdrive clutch
system
Noise generated
P0733 3rd gear ratio does not meet the specification Malfunction of the input shaft
gear or driven gear
clutch system
system
Noise generated
P0734 4th gear ratio does not meet the specification Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 4th speed sensor
sensor after shifting to 4th gear has been completed, diagnosis code speed sensor
gear or driven gear
Malfunction of the second brake
system
system
Noise generated
P0736 Reverse gear ratio does not meet the specification Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the reverse speed sensor
gear ratio is not the same as the output fromthe input shaft speed Malfunction of the output shaft
sensor after shifting to reverse gear has been completed, diagnosis code speed sensor
gear or driven gear
Malfunction of the low and
reverse brake system
Malfunction of the reverse clutch
system
Noise generated
P1723 A/T control relay system Short circuit to Malfunction of the A/T control
If the A/T control relay voltage is less than 7 V earth/Open circuit relay
after the ignition switch has been turned ON, it is Malfunction of connector
judged that there is an open circuit or a short- Malfunction of the TCM
circuit 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 Malfunction of transaxle range
P0708 No signal is continuous for > 30 seconds switch
Above 2 kinds signals are continuous for > 30 second
P1630 CAN-BUS OFF a. TCM Fail
a. NO 3 SPEED HOLD FAIL b. TCM side open & short
b. NO PGA, B FAIL * PGA : Input shaft speed
c. BATTRY VOLTAGE > 10V CONTINUOUSLY FOR 0.5 SECOND sensor
d. NO ENGINE STOP PGB : Output shaft speed
e. RECEIVE BUS OFF INFORMATION FROM CAN CONTROLLER sensor
P1631 CAN-TIME OUT ECM a. ECM fail

a. No 3 speed hold fail b. ECM side open & short
b. No PGA, B fail
c. Battry voltage > 10V continuously for 0.5 second
d. No engine stop
e. No output signal for 1.5 second
f. Receive BUS OFF information from CAN CONTROLLER
P1764 TCM CAN CONTROLLER MALFUNCTION a. CAN CONTROLLER circuit
a. No 3 speed hold fail malfunction
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
INSPECTION CHART FOR THROUBLE SYMPTOMS

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

INSPECTION PROCEDURE 1
Communication with the scan tool Probable cause

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

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

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 Inspection Action
1 Is selector lever operation OK? Yes Go to next step.
No Adjust selector lever.
2 Operate selector lever. Are selector lever and Yes Go to next step.
range indicator positions aligned?
No Adjust transaxle range switch.
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.
a. Selector lever installation or adjustment incorrect.
b. Transaxle range switch worn or misadjusted.
2 Operate selector lever. Are selector lever and Yes Go to next step.
3 Operate selector lever. Does transaxle operate Yes Go to next step.
normally and are selector lever and transaxle
No Repair or replace parts as necessary.
positions aligned?
4 Are measurements at TCM OK? 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
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
1 Check that no diagnostic trouble codes exist by Yes Go to next step.
retrieving DTC's with a scan tool.
No Diagnostic trouble code(s) displayed on scan
tool.
a. Check for cause of diagnostic trouble
code(s)
If problem remains, go to next step.
2 Are measurements at TCM terminal OK? Yes Go to next step.
No Check for malfunctioning parts
a. Throttle position (TP) sensor.
b. Wiring
3 Are measurements at TCM OK? Yes Go to next step.

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 Yes Go to next step.
valve and output voltage of TCM terminal OK?
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.
6 Is engine stall speed OK? Yes Check ECM parts & Engine.
No Repair or replace as necessary.
Stall speed: 2000~2500 rpm
3 Engine stalls on deceleration
Description Engine stalls when brake pedal depressed while driving at low speed or stopping
a. Idle air control (IAC) valve malfunction.
b. Torque converter clutch solenoid malfunction.
c. Idle speed and ignition timing misadjust.
tool.
code(s)
valve and output voltage of TCM terminal H-01/4
No If resistance is not OK, check for
OK?
malfunctioning parts and wiring
a. Torque converter clutch solenoid
wiring and / or replace TCM.
3 Is engine stall speed OK? Yes Check TCM and / or engine parts.
4 Engine rough on deceleration
Description Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration
Exhaust afterburn
a. Idle speed and ignition timing misadjust
1 Is engine stall speed OK? Yes Check TCM and / or Engine parts component.
No Repair or replace transaxle as necessary.
Stall speed : 2000 ~ 2500 rpm
5 Poor acceleration at drive-away
Description Engine speed increases normally but vehicle speed slowly increases during acceleration
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
tool.
code(s)
2 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
Light to dark brown (oxidation): Overheated or
to next step.
old fluid
If there is leakage, repair or replace parts as
necessary, then go to next step.
b. Wiring
4 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.

No If resistance is not OK, check for malfunctioning
OK?
parts and wiring.
a. Torque converter clutch solenoid.
wiring and /or TCM.
6 Is engine stall speed OK? Yes Check EMS parts, Engine and TCM.
6 Poor acceleration on acceleration
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
tool.
code(s)
No If ATF level is not OK, add fluid as necessary
leakage?
next step
to next step
old fluid
b. Wiring
4 Is line pressure OK? Yes Check TCM.

body assembly.
5 Is engine stall speed OK? Yes Check Engine parts.

Check torque converter.
6 Drive vehicle if D & 1 range. Yes Check Engine parts.
Is vehicle starting from stop in 1st gear?
No Check torque converter.
7 Surges while cruising
Description Momentary minor irregularity in engine output at steady vehicle speed
8 Poor acceleration on acceleration
b. Throttle position (TP) sensor malfunction or not adjusted
c. Torque converter clutch solenoid malfunction
tool.
a. Check for cause of diagnostic trouble code(s)
leakage?
next step
b. or conditions - Replace ATF; then go to
next step
old fluid
b. Wiring
4 Are resistance of torque converter clutch Yes Go to next step.

solenoid valve and output voltage of TCM
terminal H-01/4 OK?
parts and wiring.
parts and wiring.
If resistance is OK but Voltage is not, check
wiring and TCM.
9 Poor fuel economy
Description Fuel economy unsatisfactory
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
tool.
code(s)
leakage?
next step
to next step
old fluid
3 Is input voltage of throttle position (TP) sensor at Yes Go to next step.
TCM terminal OK?
No Check throttle position (TP) sensor and wiring.
4 Are resistance of torque converter clutch solenoid Yes Repair or replace parts as necessary.
and output voltage of TCM terminals H-01/4 OK?
parts and wiring.
wiring and TCM.

body assembly.
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
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)
f. Control valve stuck
g. Torque converter worn
leakage?
next step
to next step
old fluid
3 Operate selector lever; are selector lever and Yes Go to next step.
4 Operate selector lever; does transaxle operate Yes Go to next step.
position aligned?
OK?
parts and wiring.
If resistance is OK but Voltage is not, check
wiring and TCM.

body assembly.
8 Stop vehicle on flat paved surface with engine Yes Repair or replace parts as necessary.
OFF.
No Shift mechanism malfunction.
Does vehicle move when pushed
Repair or replace as necessary.
(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
a. Selector lever installation or adjustment incorrect
b. Powertrain damaged (forward clutch, coasting clutch, 3-4 clutch)
position aligned?
12 Vehicle moves in P range
Description a. Vehicle rolls in P range
a. Selector lever installation or adjustment incorrect
b. Parking mechanism worn
c. Powertrain damaged (forward clutch, coasting, 3-4 clutch)
position aligned?
4 Stop vehicle on flat paved surface with engine Yes Repair or replace parts as necessary.
OFF. Does vehicle move when pushed
No Shift mechanism malfunction.
(except P range, parking brake released)?
Repair or replace parts as necessary.
13 Excessive creep
Description a. Vehicle moves quickly in D, 2, 1 and R ranges (accelerator pedal depressed)
Excessive N to R range and N to D range shift shock felt
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)
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
No Diagnostic trouble code(s) displayed on O/D
indicator or scan tool.
2 Are resistance and output voltage of shift Yes Go to next step.
solenoids (A, B, C) at TCM terminals OK?
parts and wiring.
a. Shift solenoid A
b. Shift solenoid B
c. Shift solenoid C
TCM.
Go to step 4.
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 Yes Go to next step.

position (TP) sensor at TCM terminals OK?
parts and wiring.
a. Throttle positionsensor
TCM.
Go to next step.
a. H-01/38 terminal: Throttle position (TP)

sensor
4 Replace with known operational TCM. Yes Replace TCM.

Is problem corrected?
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)
b. TCM malfunction
2 Are measurements at TCM terminals OK? Yes Go to next step.
No Check for malfunctioning parts and wiring.
a. Throttle position (TP) sensor

sensor (from ECM)
3 Replace with known operational TCM. Yes Replace TCM.

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

sensor ground
b. H-01/44 terminal: Input/turbine speed
sensor ground
c. H-01/16 terminal: Input/turbine speed
sensor signal

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


position aligned?

No Adjust and/or replace transaxle range switch.
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.

18 No lock-up
Description No lock-up when vehicle speed reaches lock-up range
b. Input / turbine speed sensor malfunction
c. Selector lever installation or adjustment incorrect
e. Transaxle range switch worn or maladjusted
f. Torque converter clutch solenoid malfunction
g. TCM malfunction
h. Control valve stuck
tool.
code(s)
2 Are resistance of torque converter clutch solenoid Yes Replace control valve body assembly.
and output voltage of TCM terminal OK?
parts and wiring.
wiring and / or replace TCM.
parts and wiring.
a. Throttle position sensor
c. Vehicle speed sensor
d. Transaxle range switch
TCM.

sensor
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

No Adjust transaxle range switch
position aligned?
linear solenoid valve inspection, replace control
valve body assembly.
8 Is input voltage of engine coolant tempera ture Yes Go to next step.

sensor signal at TCM terminals OK?
18 No kickdown
Description Does not downshift when accelerator pedal depressed more than 7/8 while within kickdown range
a. Throttle position sensor malfunction or not adjusted correctly
c. TCM malfunction
d. Control valve stuck
tool.
code(s)
3 Is accelerator cable installed correctly and does it Yes Go to next step.
operate smoothly?
No Adjust or replace accelerator cable.
5 Replace with known good TCM. Yes Replace TCM.

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?
a. Throttle position sensor malfunction or not adjusted correctly
c. TCM malfunction
d. Control valve stuck
tool.
code(s)
3 Is accelerator cable installed correctly and does it Yes Go to next step.

operate smoothly?
No Adjust or replace accelerator cable.
5 Replace with known good TCM. Yes Replace TCM.

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
a. ATF level low
d. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2, 3-4 clutch)
e. Torque converter worn
leakage?
next step
to next step
old fluid
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
a. ATF level low
b. Line pressure incorrect
c. Throttle (TP) sensor malfunction or misadjusted
d. Input/turbine speed sensor malfunction
e. TCM malfunction
f. Servo piston malfunction
g. Orifice valve malfunction
h. 1-2, 2-3 accumulator malfunction
i. Control valve stuck
j. Powertrain damaged (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch No. 1)
k. Oil pump malfunction
tool.
code(s)
leakage?
next step
to next step
old fluid
No Check that linear solenoid valve.
4 Are measurements at TCM terminals OK? Yes Temporarily install known good TCM.
Go to next step.
If problem is corrected, replace TCM.
parts and wiring.
TCM.
a. H-01/38 terminal: Throttle position sensor

sensor ground
sensor signal
5 Return vehicle to original condition. Clear all DTC's. Verify repairs by driving vehicle with scan tool
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
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
code(s)
leakage?
next step
to next step
old fluid
position aligned?
6 Drive vehicle in D and 1 range; does vehicle start Yes Go to next step.
from stop in 1st gear?
parts and wiring.
c. Vehicle speed sensor
d. Transaxle range switch
TCM.

sensor
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

9 Is line pressure OK? Yes Temporarily install known good TCM.
Go to next step.
Go to next step.
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
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)
tool.
code(s)
leakage?
next step
to next step
old fluid
parts and wiring.
a. Shift solenoid A
b. Shift solenoid B
c. Shift solenoid C
TCM.

sensor
sensor ground
sensor signal
d. H-01/22 terminal: Transaxle fluid
temperature sensor
e. H-01/21 terminal: Ground

parts and wiring.
a. Shift solenoid A
b. Shift solenoid B
c. Shift solenoid C
TCM.


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
a. Shift solenoids (B, C) malfunction
b. Transaxle range switch worn or not adjusted correctly
c. TCM malfunction
e. Control valve stuck
f. Powertrain slippage (3-4 clutch, coasting clutch, low and reverse brake)
tool.
code(s)
2 Are resistance and output voltage of solenoid Yes Go to next step.
valves (1-2, 2-3, 3-4 shift) at TCM terminals OK?
parts and wiring.
a. Shift solenoid B
b. Shift solenoid C
TCM.
a. H-01/33 terminal: Shift solenoid B

b. H-01/32 terminal: Shift solenoid C

No Overhaul transaxle and repair or replace parts
position aligned?
as necessary.
7 Are measurements at TCM terminals OK? Yes Replace TCM.

a. H-01/47, H-01/8, H-01/36, H-01/37

terminals:
Transaxle range switch
25 No mode change
Description O/D OFF mode not selected or not canceled
Inspect parts and wiring and repair, or replace malfunctioning parts as necessary
a. O/D switch malfunction
b. Transaxle control module malfunction
26 Transaxle noise in all ranges
Description Transaxle noisy in all ranges when vehicle is idling
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 Transaxle noise in D, 2, 1 and R ranges
Description Abnormal noise from transaxle in D, 2, 1, and R ranges
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
a. ATF level low
b. TCM malfunction
Do transaxle seals, sealant, and gaskets
prevent leakage?
a. condition - Overhaul transaxle and repair or
replace parts as necessary; then go to next
step
b. or conditions - Replace ATF; then go to
Light to dark brown (oxidation): Overheated
next step
or old fluid
2 Check that no diagnostic trouble codes exist Yes Temporarily install known good TCM.
by retrieving DTC's with a scan tool. Go to next step.
No Diagnostic trouble code(s) displayed on 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. Diagnosed circuit MIL
P0601 TCM ROM malfunction (Only Europe) ON
P0604 TCM RAM malfunction (Only Europe) ON
P0707 Transaxle range signal (P, R, N, D, 2, 1) malfunction no signal (Only Europe) ON
P0708 Transaxle range signal (P, R, N, D, 2, 1) malfunction many signal (Only Europe) ON
P0712 ATF temperature sensor low ON
P0713 ATF temperature sensor high ON
P0716 Input/turbine speed sensor signal malfunction (Only Europe) ON
P0717 Input/turbine speed sensor circuit malfunction ON
P0726 Engine speed input signal malfunction (Only Europe) ON
P0727 Engine speed input malfunction ON
P0731 Incorrect first gear ratio(Only Europe) ON
P0732 Incorrect second gear ratio (Only Europe) ON
P0733 Incorrect third gear ratio (Only Europe) ON
P0734 Incorrect fourth gear ratio (Only Europe) ON
P0741 Torque converter clutch system malfunction stuck off (Only Europe) ON
P0742 Torque converter clutch system malfunction stuck on (Only Europe) ON
P0743 Torque converter clutch system circuit malfunction ON
P0748 Linear solenoid electrical ON
P0753 Shift solenoid A electrical ON
P0758 Shift solenoid B electrical ON
P0763 Shift solenoid C electrical ON
P1121 TPS signal circuit from ECM to TCM ON
P1500 Vehicle speed signal malfunction ON
P1700 O/D lamp circuit malfunction (Only Europe) OFF
P1780 Torgue reduction signal malfunction OFF
According to TCM logic, transaxle range (P0705) trouble code accompanies vehicle speed sensor (P1500) 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 140-158°F (60-70°C).
3. Check, and correct as necessary, engine coolant, engine oil, and ATF levels before testing.
4. Connect a tachometer to engine.
procedure
1. Start engine.
2. Check idle speed in P range. (Refer to emission control system)
Idle speed: 750-850 rpm (with parking brake applied)
3. Shift selector lever to R range.
Perform steps 4 and 5 within 5 seconds to prevent possible transaxle damage.
4. Firmly depress foot brake with left foot and gradually depress accelerator pedal fully with right foot.
5. When engine speed no longer increases, quickly read engine to speed and release accelerator.
6. Move selector lever to N range and allow engine to idle for at leastone minute.
a. Idling for at least one minute cools ATF and prevents its deterioration.
b. Allow sufficient cooling time between each stall test.
7. Perform stall tests for remaining ranges in same manner.

a. D 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
In 2 range 2-4 brake band slipping
In R range 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
Below specification in R position and all ranges Engine out of tune
One-way clutch slipping within torque converter
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 Idle Stall
D, 2, 1 56.98-127.98 (392.4-882.9, 4.0-9.0) 113.76-184.86 (784.8-1275.3, 8.0-13.0)
R 71.1-142.2 (490.5-981.0, 5.0-10.0) 199.08-270.18 (1373.4-1863.9, 14.0-19.0)
8. Install a new square-head "L" plug in inspection port, refer to line pressure test.
Tightening torque:
44-86 Ib·in (5.0-9.8 N·m, 51-100 kg·cm)
Line pressure Possible location of problem

Low pressure in every position Worn oil pump
Fluid leaking from oil pump, control valve, or transaxle
case
Pressure regulator valve sticking
Linear solenoid valve sticking
Low pressure in D and 2 only Fluid leaking from hydraulic circuit of forward clutch
Low pressure in R only Fluid leaking from hydraulic circuit of low and reverse
brake or reverse clutch
Higher than specification Pressure regulator valve stick or Linear solenoid valve
sticking
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: 300-400Ω (@68°F/20°C)
6. If not as specified, replace input/turbine speed sensor.
Tightening torque:
69.6-94.8 Ib·in (8-11 N·m, 80-110 kg·cm)
7. Install air cleaner assembly.

8. Install data link connector to MAF sensor.
9. Connect negative battery cable.
VEHICLE SPEED 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 140-158°F (60-70°C).
3. Firmly depress the foot brake, and shift the selector lever P→R→N→D→1→2→1→D→N→R→P.
(stay at each range for over 3 second)
Use COOL 68°F (20°C) range only as a rough reference.
4. Ensure that the ATF level is in HOT 149°F (65°C) range. Add ATF to specification, if necessary.
ATF type:
DIAMOND ATF SP-III or SK ATF SP-III
Fluid condition
a. Carefully check condition of ATF and determine whether or not automatic transaxle should be disassembled.
b. If ATF is muddy and varnished, it could indicate burned drive plates or brake band.
1. Check ATF for discoloration.

2. Check ATF for any unusual smell.
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 Ib·ft (39-54 N·m, 4.0-5.5 kg·m)
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 Ib·ft (32-47 N·m, 3.3-4.8 kg·m)
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
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 lb·in (32-47 N·m, 3.2-4.8 kg·m)
3. Align marks and install outer and inner rotors.
4. Install oil pump flange.

5. Mount oil pump cover onto oil pump housing.
6. Tighten six bolts evenly and gradually in order shown.
Tightening torque:
72-97.2 lb·in (8.1-10.9 N·m, 82-112 kg·m)
7. Install oil pump shaft and rotate pump rotors to verity smooth oil pump operation.
8. Install four seal rings.
9. Apply petroleum jelly to bearing race and secure it on oil pump cover.
Bearing race outer diameter: 3.46 in (88.0mm)

Valve Body System
Valve Body
2004 > 1.6L DOHC >
INSIDE VALVE BODY
OUTSIDE VALVE BODY

COMPONENTS
UNDERDRIVE CLUTCH AND INPUT SHAFT
CONTROL VALVE BODY
a. Be especially careful when handling control valve because it consists of most precise and delicate parts 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. Do not drop or lose valves or internal parts.
e. Before assembly, make sure all parts are thoroughly clean.
f. Apply ATF to all parts and bores.
g. Note proper direction of valves and internal parts.
h. Do not reuse any part that has been dropped.
i. Wrap a screwdriver or rod with tape before using it to insert a valve.
1. Disassemble in order shown in figure.
OIL STRAINER INSTALLATION POSITIONS

Low control valve body
Premain control valve body
Lower control valve body side
Main control valve body side
MAIN CONTROL VALVE BODY

Premain control valve body side
Upper control valve body side
Upper control valve body
BOLT INSTALLATION POSITIONS AND EXTERNAL PARTS LOCATIONS

Identification Length Tightening torque
mark in (mm) Ib·in (N·m, kg·cm)
0.551 (14)
A 1.181 (30)
B 1.575 (40)
70~95
C 1.969 (50)
(7.9~10.7, 80~110)
D 3.228 (82)
E 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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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.

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 Ib·in (1.27-1.86 N·m, 13-19 kg·cm)
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.
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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
17. Install shift solenoids B and C, oil strainers, and bracket.
18. Tighten mounting bolts.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
19. Install torque converter clutch solenoid and oil strainer.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
20. Install shift solenoid A and oil strainer onto upper valve body.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
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 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
2. Install oil strainer, and (3) bolts.
Tightening torque:
69.6-94.8 Ib·in (7.9-10.7 N·m, 80-110 kg·cm)
3. Connect connectors.
4. Install oil pan (19 bolts) and a new gasket.
Tightening torque:
74.4-94.8 Ib·in (8.4-10.7 N·m, 85-110 kg·cm)
5. Loosely install nuts A and bolts B of engine mounting member.

6. Install engine mounting member.
Tightening torque:
A: 28-38 Ib·ft (38-51 N·m, 3.8-5.3 kg·m)
B: 48-65 Ib·ft (64-89 N·m, 6.5-9.1 kg·m)
7. Install both gravel shield to under engine.

8. Pour in ATF. Check ATF level with engine idling and check for leaks, refer to Automatic Transmission Fluid.
9. Drive vehicle and check shift points, shift schedule, and shift quality.
Upper Control Valve Body
2004 > 1.6L DOHC >
COMPONENT

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.
1. Disassemble in order shown in the figure.

2004 > 1.6L DOHC >
INSPECTION
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.

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.
Pre Main Control Valve
Body
2004 > 1.6L DOHC >
COMPONENT
1. Disassemble in order shown in figure.
2004 > 1.6L DOHC >
INSPECTION
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.
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.
Shift Control Solenoid
Valve (nodeSV)
2004 > 1.6L DOHC >
RESISTANCE INSPECTION
3. Measure resistance between each terminal and a ground.
Resistance: 14-18 Ω
a. 2: Torque converter clutch solenoid

b. 1: Shift solenoid valve A
c. 4: Shift solenoid valve B
d. 7: 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
3. Measure resistance between ground terminals and of connector terminal H-03-3.
Resistance: 4.1-5.1Ω
4. If not connect, check wiring for an open or short-circuit, replace pressure control valve.
5. Connect solenoid valve connector.
Clutch & Brake
Reverse and Overdrive
Clutch
2004 > 1.6L DOHC >
COMPONENT
COMPONENT
2004 > 1.6L DOHC >
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.

10. Remove the clutch return spring.
11. Remove the overdrive clutch piston using compressed air.
13. Remove the Reverse clutch piston.
14. Remove the 3 D-ring seals.
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.

5. Install the overdrive clutch piston.
6. Install the clutch return spring.
8. Install the clutch spring retainer.
9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer 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.
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.)
manual.
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
manual.
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.

9. Remove SST(0K201 190 AA1) then remove spring and retainer assembly.
12. Remove coasting clutch drive plates and driven plates. (each two)
13. Remove coasting clutch drum from reverse/forward drum by applying compressed air through fluid passage.
14. Remove coasting clutch piston from coasting clutch drum by applying compressed air through fluid passage.
15. Remove outer seal and inner seal from coasting piston.
16. Remove two seal rings and outer seal from coasting clutch drum.
17. Install SST(0K201 190 AA1) in reverse/forward drum as shown.
18. Compress piston return spring.
19. Remove snap ring from groove with snap ring pliers.
20. Remove SST(0K201 190 AA1) from reverse/forward drum.

21. Remove snap ring with a screwdriver.

23. Remove reverse clutch driven plates and driven plates. (each two)
25. Remove return spring stopper and piston.
26. Place reverse/forward drum on oil pump.
27. Remove reverse piston by applying compressed air through reverse clutch fluid passage.
28. Remove two seal rings from reverse piston.

RE-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.

7. Install snap ring with a screwdriver.
8. Remove SST(0K201 190 AA1).
9. Install dished plate with dished side facing downward into drum as shown.
10. Install drive and driven plates. (two each)
Installation order:
Driven-Drive-Driven-Drive

13. Measure reverse clutch clearance.
a. Measure clearance between snap ring and retaining plate of reverse clutch.
b. If clearance is not within specification, adjust it by selecting correct thickness snap ring.
Reverse clutch clearance:

0.035-0.047 in (0.9-1.2 mm)
14. Install coasting clutch drum.
a. Apply ATF to inner and outer faces of seal, and install it onto coasting clutch drum.
b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into
drum.
c. Install coasting clutch drum in correct position in reverse/forward drum as shown.

d. Push evenly around circumference, being careful not to damage outer seal.
15. Install coasting clutch piston.

a. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston.
b. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into
drum.
16. Install spring and retainer assembly.
17. Install SST(0K201 190 AA1) in coasting clutch as shown.

21. Install dished plate with dished side facing out of drum as shown.
22. Install drive and driven plate.
Installation order:
Driven-Drive-Driven-Drive

25. Measure coasting clutch clearance.

a. Measure clearance between snap ring and retaining plate of coasting clutch.
Coasting clutch clearance:

0.039-0.048 in (1.0-1.2 mm)
26. Install dished plate with dished side facing downward into drum, as shown.
27. Install drive and driven plates.
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive

30. Measure forward clutch clearance.

a. Measure clearance between snap ring and retaining plate of forward clutch.
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:
32. Apply petroleum jelly to thrust bearings, and secure them on each side of reverse/forward drum.

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.

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.
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:
Coasting clutch piston

Air pressure:
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:
INSPECTION
Drive plates
1. Measure facing thickness in three places and determine average of three readings.



Reverse clutch piston

Air pressure:
Coasting clutch piston

Air pressure:
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:
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.

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.

3.39 in (86.0 mm)
RE-ASSEMBLY
1. Assembly planetary carrier to inner race.
Install tangs of bearing race into alignment holes.
3. Apply petroleum jelly to bearing race and secure them to each side of one-way clutch No.2 and planetary 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
3. Remove drive plates and driven plates. (each four)
4. Install SST(0K2CA 190 AA1) in transaxle case as shown.

7. Remove SST(0K201 190 AA1), then remove spring and spring retainer assembly.
8. Remove low and reverse brake piston by applying compressed air through fluid passage.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)
9. Remove outer seal and inner seal from low and reverse brake piston.
INSPECTION
Drive plates
1. Measure facing thickness in three places, and determine average of three readings.

2. If not within specification, replace drive plate(s).

Free length of spring: 0.563 in (14.3 mm)
RE-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.

5. Install snap ring with snap-ring pliers.
6. Remove SST(0K201 190AA1).
7. Check low and reverse brake piston operation.
a. Pour in ATF until low and reverse brake piston is fully submerged.
b. Check that no bubbles come from between piston and seals when applying compressed air through fluid
passage.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm²)
8. Install drive and driven plates.(each four)
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
11. Measure low and reverse brake clearance.

a. Measure clearance between snap ring and low and reverse brake retaining plate.
b. If clearance is not within specification, adjust it by selecting a proper snap ring.
Low and reverse brake clearance:

0.094- 0.083 in (2.1- 2.4 mm)
12. Check low and reverse brake operation by applying compressed air through fluid passage as shown in figure.
Air pressure:
13. Remove snap ring, retaining plate, drive and driven plates and set aside for later assembly.
INSPECTION
Drive plates


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.
5. Remove SST(0K201 190 AA1), then remove spring and retainer.
8. Remove drive and driven plates. (each three)
9. Install SST(0K201 190 016) onto 3-4 clutch drum and remove 3-4 clutch piston using compressed air.
Air pressure:
10. Remove SST(0K201 190 016).

11. Remove outer seal and inner seal 3-4 clutch piston.
INSPECTION
Drive plate

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:
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.

7. Install drive and driven plates. (each three)
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive

10. Measure 3-4 clutch clearance.
a. Measure clearance between snap ring and retaining plate of 3-4 clutch.
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:
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

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:
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)

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)

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)

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
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 N·m, 0.8~1.1 kg-m)
2. Install spacer and bolt into adjust slot and then tighten adjust nut after inserting U - clip.
Tightening torque:
69.4~95.9 Ib-in (7.8~10.8 N·m, 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 N·m, 3.2~4.7 kg-m)
4. Assemble clamp assembly with washer and E - ring and then insert it into the column shaft and tighten three bolts.
5. Insert U - clip to fix control cable to column shaft bracket.
6. Install clamp assembly to control cable and tighten bolt and nut.
Tightening torque:
69.4~95.9 Ib-in (7.8~10.8 N·m, 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 N·m, 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 N·m, 1.6~2.3 kg-m)
14. Align mark and install properly steering wheel to column shaft.
15. Insert snap ring and install retaining nut.
Tightening torque:
29~36 Ib-in (39~493 N·m, 4~5 kg-m)
16. Connect horn switch and air bag module connector.

17. Install air bag module steering wheel and tighten four bolts.
18. Connect (-) terminal of battery.
Overdrive Switch
2004 > 1.6L DOHC >
Operation 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
2. Pull data link connector upward from MAF sensor.
3. Disconnect air temperature sensor connector and MAF sensor connector.
4. Remove fresh air duct and air cleaner assembly.
5. Remove nut. Disconnect selector cable.
6. Rotate manual shaft to N position.
7. Disconnect transaxle range switch connector.
8. Loosen transaxle range switch mounting bolts.
9. Connect ohmmeter between terminals 5 and 7.
10. Adjust switch to point where there is continuity between terminals.
11. Tighten two transaxle range switch mounting bolts.
Tightening torque:
70~95 Ib-in (7.9~10.7 N·m, 80~110 kg-cm)
12. Verify that the selector lever range position and transaxle range switch correspond.
13. Connect transaxle range switch connector.
14. Connect selector cable and tighten nut.
Tightening torque:
24~33 Ib-in (32~46 N·m,3.2~4.7 kg-cm)
15. Install air cleaner assembly, and fresh air duct.

16. Connect air temperature sensor connector and MAF sensor connector.
17. Install data link connector to MAF sensor.
Transaxle Oil Temperature
Sensor
2004 > 1.6L DOHC >
RESISTANCE 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 >
3. Check for continuity at transaxle range switch.
4. If not as specified, replace or adjust transaxle range switch.

3. Check for continuity at transaxle range switch.
4. If not as specified, replace or adjust transaxle range switch.

Troubleshooting
2004 > 1.6L DOHC >
INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES

Diagnostic trouble code
P0707 a. Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signal)
P0708 b. Transaxle range signal (P, R, N, D, 2, 1) malfunction (No signals)
Details a. Corroded or faulty Range Switch.
b. Open between Meter Fuse and Range Switch.
c. Open between Range Switch and TCM on one or more circuits.
d. Short to Battery between Range Switch and TCM on one or more circuits.
e. Short between two or more wires between Range Switch and TCM.
If a P1500 is stored along with a P0750, there is a problem with the Meter
Fuse circuit. Any shorts or opens in the Meter Fuse circuit should be repaired
before continuing with this troubleshooting tree.
Possible 1. Transaxle range switch malfunction.

cause 2. Damaged wiring or connectors between transaxle range switch and
transaxlecontrol module.
3. Transaxle control module malfunction.

1 With ignition off, disconnect A-03 from Range Yes Spray inside of A-03 and Range Switch with
Switch. Check for any signs of corrosion or water.Is silicone lubricant and blow out connector and
any water or corrosion present? 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.
2 Verify Meter Fuse is okay. Turn ignition on and, Yes Go to step 3.
measure voltage at A-03/I (B+).
No Locate source of open between Meter Fuse and A-
Is battery voltage available?
03/I.
Repair as necessary.
3 Turn ignition off and reconnect A-03 to Range Yes Go to step 4.
Switch. Remove connector cover from H-01 (TCM)
No If voltage is below specs in R, D, 2 or 1 (or more
(leave H-01 connected to TCM to do tests). Turn
than 0v in P or N), referring to chart "A", measure
ignition on and measure voltages per chart "A".
resistance acrossRange Switch with ignition off and
Are voltages correct per chart "A"?
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 A-
03 from Range Switch and measure voltage at H-
01/18 again. Replace Range Switch if voltage
01/18 again. Replace Range Switch if 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 Probable cause
If the oil temperature sensor output voltage is 2.6 V or more even a. Malfunction of the oil temperature sensor
after driving for 10 minutes or more (If the oil temperature does not b. Malfunction of connector
increase), it is judged that there is an open circuit in the oil c. Malfunction of the TCM
temperature sensor and diagnostic trouble code No.P0710 is output.
If the oil temperature sensor output detects the voltage which
corresponds to 200°C(392°F) 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.
2004 > 1.6L DOHC >
ATF SENSOR
P0712 a. ATF sensor low
P0713 b. ATF sensor high
Details a. ATF sensor malfunction
Possible a. Short circuit in wiring
cause b. ATF sensor malfunction

1 Are all connections at connector and connector pins Yes Go to next step.
OK?
No Repair or replace connector(s).
2 Measure terminal voltage of transaxle control Yes Go to step 5.
module at terminal H-01/22.
No Go to next step.
Standard voltage:
ATF 68°F (20°C): Approx. 4.0
ATF 266°F (130°C): Approx. 1.5
Is terminal voltage as specified?

3 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 68°F (20°C): 24.461~29.205kΩ
ATF 140°F (68°C): 4.29~5.61kΩ
ATF 176°F (80°C): 3.05~3.6kΩ
4 Are connectors and wiring between transaxle Yes Go to next step.
control module and ATF sensor OK?
No Replace or repair connector and wiring.
5 After diagnostic trouble code has been cleared, Yes Temporarily install known good TCM.
does reinspection diagnostic trouble code appear? Go to next step.
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.P0715 input shaft speed sensor system Probable cause
If no output pulse is detected from the input shaft speed sensor for 1 a. Malfunction of the input shaft speed
second or more while driving in 3rd or 4th gear at a speed of 30 km/h sensor
(19 mph) or more, it is judged to be an open circuit or short-circuit in b. Malfunction of the underdrive clutch
the input shaft speed sensor and diagnostic trouble code No.P0715 is retainer
output. If diagnostic trouble code P0715 is output four times, the c. Malfunction of connector
transaxle is locked into 3rd gar or 2nd gear as a fail-safe measure. d. Malfunction of the TCM
2004 > 1.6L DOHC >

P0716 a. Input/turbine speed sensor signal malfunction
P0717 b. Input/turbine speed sensor circuit malfunction
Details 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.
Possible a. Input/turbine speed sensor malfunction.
cause b. Damaged wiring or connectors between input/turbine speed sensor transaxle
control module.

1 Are all connections at connectors and connector Yes Go to next step.
pins OK?
module at terminal H-01/44 and H-01/16.
No Go to next step.
Standard voltage:
Engine running (P, N position): Approx. 2.5 V
Ignition switch ON: Approx. 2.3 V

3 Measure input/turbine speed sensor resistance Yes Go to step 6.
terminals H-01/44 and H-01/16 of harness
No Go to next step.
connector as follows:
a. Disconnect negative battery cable.
b. DisconnDisconnect transaxle control module
connector.
c. Measure resistance.
Standard resistance: 300~400Ω(@68°F/20°C)
Is resistance within standard?

4 Measure input/turbine speed sensor resistance at Yes Go to next step.
input/turbine speed sensor itself as follows:
No Replace input/turbine speed sensor.
b. Remove air cleaner assembly.
c. Disconnect input/turbine speed sensor
connector.
d. Measure resistance.
Standard resistance: 300~400Ω(@68°F/20°C)

5 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.
further.
2004 > 1.6L DOHC >

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

P0726 a. Engine speed input signal malfunction
P0727 b. Engine speed input malfunction
Details a. (P0726): Loss of engine speed sensor signal to the transaxle control module.
DTC is triggered if engine rpm is above 750 rpm
b. (P0727): Loss of engine speed sensor signal to the transaxle control module.
DTC is triggered if turbine output is above600 rpm and engine output is below
96 rpm and vehicle is not in P or N ranges.
Possible 1. Damaged wiring or connectors between engine control module and transaxle
cause control module.

1 Is terminal voltage as specified? Yes Repair
No Go to next step.
2 Are all connections at connector and connector pin Yes Go to next step.
OK?
3 Measure terminal voltage of engine control module. Yes Go to step 5.
No Go to next step.
Is terminal as specified?
4 Are connectors and wiring between engine control Yes Go to next step.
module (B-01/59) and transaxle control module (H-
01/40) OK?
further.
2004 > 1.6L DOHC >

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

Code No.P0732 2nd gear incorrect ratio Probable cause
If the output from the output shaft speed sensor multiplied by the 2nd a. Malfunction of the input shaft speed
sensor after shifting to 2nd gear has been completed, diagnostic b. Malfunction of the output shaft speed
trouble code No.P0732 is output. If diagnostic trouble code No.P0732 sensor
d. Malfunction of the transfer drive gear or
driven gear
e. Malfunction of the second brake system
system
g. Noise generated
2004 > 1.6L DOHC >

Code No.P0733 3rd gear incorrect ratio Probable cause
If the output from the output shaft speed sensor multiplied by the 3rd a. Malfunction of the input shaft speed
sensor after shifting to 3rd gear has been completed, diagnostic b. Malfunction of the output shaft speed
driven gear
system
system
g. Noise generated
2004 > 1.6L DOHC >

Code No.P0734 4th gear incorrect ratio Probable cause
If the output from the output shaft speed sensor multiplied by the 4th a. Malfunction of the input shaft speed
sensor after shifting to 4th gear has been completed, diagnostic b. Malfunction of the output shaft speed
driven gear
system
system
g. Noise generated
2004 > 1.6L DOHC >

Code No.P0736 reverse gear incorrect ratio Probable cause
If the output from the output shaft speed sensor multiplied by the a. Malfunction of the input shaft speed
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 output shaft speed
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 underdrive clutch
a fail-safe measure. retainer
driven gear
system
system
g. Noise generated
2004 > 1.6L DOHC >

P0741 a. Torque converter clutch system malfunction (Stuck OFF)
P0742 b. Torque converter clutch system malfunction (Stuck ON)
Details 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.
Possible 1. Air leak between Throttle Position Sensor (TPS) and Mass Air Flow Sensor
cause (MAFS).
2. ATF level low.
3. Line pressure low.
4. Torque converter clutch slipping.
5. Torque converter control valve or torque converter relief valve stuck.
6. Torque converter clutch (TCC) solenoid valve malfunction.
If any codes relating to TPS or MAFS are present, do ALL repairs 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.

1 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?
2 Check ATF level (transaxle at normal operating Yes Check for any signs of leakage from transaxle.
temperature). Repair as necessary and fill transaxle to full level.
Is ATF level low?
No Go to step 3.
3 Check ATF condition and com Yes For ATF condition #2, replace transaxle.
pare to following chart. For ATF condition #3, replace fluid, repair source of
1. Clear reddish pink: Normal condition. contamination and perform pressure tests. If water
2. Dark or black (with friction material): Internal contamination is severe, replace transaxle.
transaxle malfunction or excessive wear. For ATF condition #4, replace fluid and perform
pressure tests.
3. Milky pink: Water contamination.
No Go to step 4.
4. Light to dark brown (oxidized): Overheated or
worn out fluid.
Is fluid condition other than normal.

4 Check line pressure and compare to the following Yes Go to step 5.
chart.
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.
3. Disconnect coupler ass? from transaxle and Clear codes and verify any repairs by driving
attach a 10 amp fused jumper wire to the #2 pin vehicle with Hi scan pro connected to OBD-II
at the transaxle (make the jumper wire long connector
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. The torque converter can only be checked by the
use of special equipment. If replacing valve body
5. Start engine and warm it up to operating
does not repair vehicle, replace transaxle.
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?
2004 > 1.6L DOHC >

Code No.P0743/P0740 Damper clutch solenoid system Probable cause
If the resistance value for the torque converter clutch solenoid is too a. Malfunction of the damper clutch solenoid
large or too small, it is judged that there is a short-circuit or an open b. Malfunction of connector
circuit in the damper clutch solenoid and diagnostic trouble code c. Malfunction of the TCM
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.
2004 > 1.6L DOHC >

P0748 Linear solenoid electrical
Details
Possible 1. Short or open circuit in wiring.
cause 2. Short or open circuit in transaxle control module internal transistors.
3. Short or open circuit in linear solenoid valve.

OK?
No Go to next step.

3 Measure solenoid valve resistance between Yes Go to step 6.
terminal H-01/5 of connector and a ground as
No Go to next step.
follows:
b. Disconnect transaxle control module connector.
Standard resistance: 4.1-5.1 Ω

4 Measure solenoid valve resistance at torque Yes Go to next step.
converter clutch solenoid valve terminal of solenoid
No Replace linear solenoid valve.
valve connector as follows:
b. Disconnect solenoid valve connector.
Standard resistance: 4.1-5.1 Ω

5 Is the wiring between transaxle control module and Yes Go to next step.
solenoid valve OK?
further.
2004 > 1.6L DOHC >

Code No.P0750 Low and reverse solenoid valve system
Code No.P0755 Underdrive solenoid valve system
Probable cause
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 a. Malfunction of solenoid valve
is judged that there is a short-circuit or an open circuit in the solenoid b. Malfunction of connector
valve and the respective diagnostic trouble code is output. The c. Malfunction of the TCM
transaxle is locked into 3rd gear as a fail-safe measure.
2004 > 1.6L DOHC >

P0753 Shift solenoid A electrica
Details
3. Short or open circuit in shift solenoid A.

OK?
No Go to next step.
Standard voltage:
Solenoid valve ON: B+
Solenoid valve OFF: 0 V

No Go to next step.
follows:
Standard resistance: 14-18 Ω

4 Measure solenoid valve resistance at terminal A of Yes Go to next step.
solenoid valve connector as follows:
No Replace shift solenoid A.

5 Is wiring between transaxle control module and Yes Go to next step.
solenoid valve OK?
further.
2004 > 1.6L DOHC >

P0758 Shift solenoid B electrical
Details
3. Short or open circuit in shift solenoid B.

OK?
No Go to next step.
Standard voltage:

No Go to next step.
follows:

4 Measure solenoid valve resistance at terminal B of Yes Go to next step.
No Replace shift solenoid B.

solenoid valve OK?
No Replace or replace TCM concerning connectors and
wiring.
further.
2004 > 1.6L DOHC >

P0763 Shift solenoid C electrical
Details
3. Short or open circuit in shift solenoid C.

OK?
No Go to next step.
Standard voltage:

No Go to next step.
follows:

4 Measure solenoid valve resistance at terminal C of Yes Go to next step.
No Replace shift solenoid C.

solenoid valve OK?
further.
2004 > 1.6L DOHC >

P1700 O/D OFF lamp circuit malfunction
1. Short circuit to ground
Details
2. O/D off lamp switch malfunction
Possible 1. Short circuit to ground.
cause 2. O/D OFF lamp switch malfunction

1 Are all connections at connectors and connector Yes Go to next step.
pins OK?
No Repair or replace.
No Go to next step.

3 Measure terminal voltage of O/D OFF switch. Yes Go to next step.
No Replace or repair O/D OFF switch.

4 Are connectors and wiring between O/D off switch Yes Go to next step.
and transaxle control module (TCM) OK?
further.
2004 > 1.6L DOHC >

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

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CHAPTER 6:

Special service tools

0K130 990 007 Used to disassemble and assemble transaxle.

0K201 323 021 Used to hold primary shaft.

0K201 170 AA1 Used to install oil sear.

0K 670 990 AA0 Used to romeve bearing.

0K201 172 008 Used to remove gears.

0K130 283 021 Used to remove tie-rod end.

0K130 175 011 Used to disassemble and assemble transaxle.

0K130 170 012 Used to remove bearing.

0K130 175 008 Used to remove gears.

0K900 175 AA1 Used to install bearing.

0K130 175 A11 Used to install bearing.

0K011 270 A02 Used to install ear.

0K900 175 AA0 Used to adjust bearing preload.

0K900 175 A01 Used to adjust bearing preload.

0K900 175 A02 Used to adjust bearing preload.

0K900 175 A03 Used to adjust bearing preload.

0K130 175 A02 Used to adjust bearing preload.

0K130 175 A03 Used to adjust bearing preload.

0K130 191 A07 Used to adjust bearing preload.

0K130 191 A05 Used to adjust bearing preload.

0K130 322 020 Used to measure preload.

0K201 270 014 Used to hold differential side gears.

SPECIAL SERVICE TOOLS

09432-22000 Installation of output shaft's gear and sleeve

09432-22100 Installation of input and output shaft bearing

09432-33200 Removal of input shaft's gear and ball bearing

09495-33100 Installation of input shaft bearing

09432-33400 Installation of input shaft bearing outer race

09455-21100 Installation of differential ball bearing

09455-32200/0K011 190 Removal of differential bearing spacer

09495-33000 Removal of ball bearing and gear

09517-21400 Separation of T/M housing from T/M assembly

09532-11000 Removal and installation of differential bearing

09532-11500 Installation of output shaft and differential

09200-38001(J28467-B) Removal and installation of transaxle

SPECIAL SERVICE TOOLS

09452-21401/0K011 171 Installation of oil pump

09453-33100 Measurement of the low and reverse brake

09431-39000 Installation of differential oil seal

09432-33200 Removal of transfer shaft bearing

09432-33800 a. Removal of transfer driven gear taper

09433-21000 a. Removal of transafer driven gear taper

09500-11000 Installation of differential bearing outer race

09455-33200 Installation of differential ball bearing and

09453-21100 Removal and installation of the low-reverse

09455-21000/0K011 430 Removal of ball bearing and tansfer drive

09455-21100 a. Intallation of ball bearing and transfer

09532-11500 Installation of differential bearing outer

09453-21000 a. Removal and installation of low-reverse

09456-39000 Removal and installation of low-reverse brake

09432-21701 Installation of output shaft outer race

09452-33100 Removal of the oil pump

09452-21200 Installation of the oil pump oil seal

09200-38001 Removal and installation of transaxle

09456-39100 Measurement of low-reverse brake and

09457-39000 Removal and installation of output shaft lock

SPECIAL SERVICE TOOLS

0K130 283 021 Used to remove tie-rod end.

0K130 990 007 Used to disassemble transaxle.

0K670 990 AA0 Used to remove bearing

0K201 190 AA0 Used to measure line pressure