Daewoo 8140le Repair

[ RM-1 ]

FOREWORD

This REPAIR REPAIR MANUAL covers Disassembly, Disassembly, Inspection and Assembly procedures for the following Automatic Transmission: Transmission: Automotic Transmission

E ngine Type

REF N o.

81-40LE DAEWOO: DAEWOO: 96 48 4 421 AW: 30510-81C008

FAN I 1.5L SOHC

DW-01M-MRM002

All information contained in this this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without notice.

QUALITY ASSURANCE DEPT.

© 2003 All rights reserved. reserved. This book may may not be reproduced or copied, in whole or in part, without the written permission of AISIN AW CO., LTD. First Printing:

Jul, 2003

DAEWOO 81-40LE (30510-81C008) © All Rights Copyright AISIN AW CO., LTD.

03/7 (DW-01M-MRM002)

[ RM-2 ]

ABBREVIATIONS ASSY ........................... ........................................ .......................... .................... ....... Assembly A/T ........................... ........................................ ............... .. Automatic Transmission Transmission ATF ATF ......................... ................................ ....... Automatic Transmission Transmission Fluid B1 ........ ............ ......... ......... ......... ......... ......... ......... ........ .... O/D & 2nd Coast Brake B2 .......................... ........................................ ............................ ......................... ...........2nd 2nd Brake B3 ........ ............. ......... ......... ......... ......... .......... ......... ......... ........ ... 1st & Reverse Reverse Brake C1 ........................... ........................................ ........................... ................. ... Forward Clutch C2 ........................... ........................................ ........................... .................... ...... Direct Clutch C3 ........ ............. .......... ......... ......... ......... ......... ......... ......... .......... ......... ...... .. Reverse Reverse Clutch Clutch F1............. F1 .......................... ........................... .......................... ............ 1 Way Clutch No.1 F2............. F2 .......................... ........................... .......................... ............ 1 Way Clutch No.2 O/D ........................... ......................................... ........................... .................... ....... Over Drive V/B ......................... ....................................... ........................... ....................... .......... Valve Body FIPG ......... ............. ......... ......... ........ ......... ......... ....... ... Formed In Place Gasket SST ......................... ...................................... ...................... .........Service Service Special Tool TT ............................ ......................................... ........................ ........... Tightening Torque T/M............ T/M ......................... .......................... .......................... ..................... ........ Transmission T/C ........................... ........................................ ......................... ............ Torque Converter FR ........................... ........................................ ........................... ........................... ................... ......Front Front RR.............. RR ........................... ........................... ............................ ............................ .................. .... Rear MID ........................... ........................................ ........................... ............................ .............. Middle DIA ............................ .......................................... ........................... ....................... .......... Diameter B/G....................................................................Bearing


03/7 (DW-01M-MRM002)

[ RM-2 ]

ABBREVIATIONS ASSY ........................... ........................................ .......................... .................... ....... Assembly A/T ........................... ........................................ ............... .. Automatic Transmission Transmission ATF ATF ......................... ................................ ....... Automatic Transmission Transmission Fluid B1 ........ ............ ......... ......... ......... ......... ......... ......... ........ .... O/D & 2nd Coast Brake B2 .......................... ........................................ ............................ ......................... ...........2nd 2nd Brake B3 ........ ............. ......... ......... ......... ......... .......... ......... ......... ........ ... 1st & Reverse Reverse Brake C1 ........................... ........................................ ........................... ................. ... Forward Clutch C2 ........................... ........................................ ........................... .................... ...... Direct Clutch C3 ........ ............. .......... ......... ......... ......... ......... ......... ......... .......... ......... ...... .. Reverse Reverse Clutch Clutch F1............. F1 .......................... ........................... .......................... ............ 1 Way Clutch No.1 F2............. F2 .......................... ........................... .......................... ............ 1 Way Clutch No.2 O/D ........................... ......................................... ........................... .................... ....... Over Drive V/B ......................... ....................................... ........................... ....................... .......... Valve Body FIPG ......... ............. ......... ......... ........ ......... ......... ....... ... Formed In Place Gasket SST ......................... ...................................... ...................... .........Service Service Special Tool TT ............................ ......................................... ........................ ........... Tightening Torque T/M............ T/M ......................... .......................... .......................... ..................... ........ Transmission T/C ........................... ........................................ ......................... ............ Torque Converter FR ........................... ........................................ ........................... ........................... ................... ......Front Front RR.............. RR ........................... ........................... ............................ ............................ .................. .... Rear MID ........................... ........................................ ........................... ............................ .............. Middle DIA ............................ .......................................... ........................... ....................... .......... Diameter B/G....................................................................Bearing


03/7 (DW-01M-MRM002)

[ RM-3 ]

ABBREVIATIONS SLT SLT ......... .............. ......... ......... ....... Throttle Throttle Pressure Pressure Control Control Solenoid Solenoid S1,S2 ......................... ..................................... ............Shift Shift Solenoid No.1,No.2 ST ........................... ........................................ ........................... ................ Timing Solenoid SL ........................... ......................................... ........................ .......... Lock-Up Solenoid Th.............. Th ............................ ............................ ........................... ........................ ........... Thickness L ........................... ......................................... ............................ ........................... .................. ..... Length V. ........................... ......................................... ............................ ........................... ................... ...... Valve Acum............... Acum. ............................ ............................ ........................... ............... Accumulator Cont. .......................... ........................................ ........................... ......................... ............ Control Reg. .............................. ............................................ ............................. .................. ... Regulator Press...............................................................Pressure Mod. ............................. ............................................ .............................. .................. ... Modulator Pla............. Pla. .......................... ............................ ........................... ......................... ............ Planetary STD............... STD. ........................... .......................... ........................... ....................... ......... Standard LUB. ............................ .......................................... ............................ ............................ .............. Lube HSG ........................... ........................................ ........................... ......................... ........... Housing Diff .......................... ........................................ ........................... ....................... .......... Differential


03/7 (DW-01M-MRM002)

[ RM-4 ]

BLANK


03/7 (DW-01M-MRM002)

[ RM-5 ]

TABLE OF CONTENTS

FOREWORD ........................................................................................ RM-1 ABBREVIATIONS ................................................................................ RM-2 DESCRIPTION ..................................................................................... RM-6 OPERATION ........................................................................................ RM-7 REPAIR PROCEDURES...................................................................... RM-9 GENERAL REPAIR INSTRUCTIONS ................................................. RM-9 REMOVAL OF COMPONENT PARTS............................................... RM-10 ASSEMBLY AND DISASSEMBLY OF CONPONENTS .................... RM-32 1. OIL PUMP .......................................................................................................... RM-32 2. DIRECT CLUTCH (C2) ...................................................................................... RM-36 3. PLANETARY RING GEAR ................................................................................ RM-43 4. 1 WAY CLUTCH ................................................................................................. RM-45 5. FORWARD AND REVERSE CLUTCH (C1,C3) ................................................. RM-48 6. COUNTER DRIVEN GEAR................................................................................ RM-56 7. VALVE BODY .................................................................................................... RM-59 8. DIFFERENTIAL ................................................................................................. RM-60

INSTALLATION OF COMPONENT PARTS....................................... RM-61 SERVICE SPECIFICATIONS ............................................................. RM-87


03/7 (DW-01M-MRM002)

[ RM-6 ]

DESCRIPTION The new automatic transmission AW 81-40LE is an electronically controlled 4-speed automatic transmission with Lock-up mechanism. The transmission is mainly composed of the torque converter with lock up clutch, newly developed 4-speed planetary gear unit, the hydraulic control system and the electric control system. SECTIONAL VIEW

AW 81-40LE


03/7 (DW-01M-MRM002)

[ RM-7 ]

OPERATION

F1

F2 B2

C1

B3

C2

FROM T/C

Counter Drive Gear Assy

Counter Driven Gear Assy

C3

B1

Differential Gear Assy


03/7 (DW-01M-MRM002)

[ RM-8 ]

OPERATION POSITION

2

L

Brake

1 Way Clutch

S2

ST

C1

C2

C3

B1

B2

B3

F1

F2

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

V<9

ON

ON

OFF

OFF

OFF

ON

OFF

OFF

ON

OFF

OFF

V>=11

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

1st

ON

ON

OFF

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

2nd

ON

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

ON

OFF

3rd

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

OFF

OFF

OFF

3<=>4

OFF

ON

ON

ON<=>OFF

ON

OFF

OFF<=>ON

ON

OFF

OFF

OFF

4th

OFF

ON

OFF

OFF

ON

OFF

ON

ON

OFF

OFF

OFF

1st

ON

ON

OFF

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

2nd

ON

OFF

OFF

ON

OFF

OFF

ON

ON

OFF

ON

OFF

3rd

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

OFF

OFF

OFF

1st

ON

ON

OFF

ON

OFF

OFF

OFF

OFF

ON

OFF

ON

2nd

ON

OFF

OFF

ON

OFF

OFF

ON

ON

OFF

ON

OFF

N D

Clutch

S1

P R

Solenoid


03/7 (DW-01M-MRM002)

[ RM-9 ]

REPAIR PROCEDURES 1. Most repair operations begin with an overview illustration. 2. It identifies the components and shows how the parts fit together. 3. The procedures are presented in a step-by-step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The detailed text tells how to perform the task and gives other information such as specifications and warnings. You never have to leave the procedure to look up your specs.

GENERAL REPAIR INSTRUCTIONS 1. During disassembly, keep parts in order to facilitate reassembly. 2.(1) Always replace gaskets, O-rings and oil seals etc. with new ones. (2) Parts which cannot be reused are indicated by the symbol “

”.

3. When necessary, use a sealer on gaskets to prevent leaks. 4. Carefully observe all specification for bolt tightening torque. Always use a torque wrench. 5. Use of SST may be required, depending on the nature of the repair. Be sure to use SST where specified and follow the proper work procedure.


03/7 (DW-01M-MRM002)

[ RM-10 ]

REMOVAL OF COMPONENT PARTS

REMOVAL OF COMPONENT PARTS Clip Breather Hose

No.1 Breather Plug

"O" Ring

Bracket Transaxle Revolution Sensor

Speed Sensor

Union

"O" Ring Union

"O" Ring "O" Ring Screw Plug Gasket

SS-01-81A Non Reusable Part


03/7 (DW-01M-MRM002)


[ RM-11 ]

Oil Seal Apply Gasket Brake Drum Gasket "O" ring

Torque Converter

Spacer Valve Body Assembly

Gasket

Oil Seal

Newtral Start Switch "O" ring

Gasket

"O" ring "O" ring Non Reusable Part

"O" ring


SS-01-01A

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[ RM-12 ]


Apply Gasket

Transaxle Rear Cover

"O" Ring Forward Clutch & Reverse Clutch Assembly

O/D Brake Piston

"O" Ring

Rear Planetary Sun Gear One-Way Clutch Assembly Forward Clutch Hub

"O" Ring

Front Planetary Sun Gear 2nd Brake Piston

"O" Ring Planetary Gear

1st & Reverse Brake Piston Planetary Ring Gear

Non Reusable Part

SS-01-02A


03/7 (DW-01M-MRM002)


[ RM-13 ]

Counter Driven Gear

Oil Seal

Differential Gear

Counter Drive Gear

Direct Clutch Hub

Nut Direct Clutch Assembly

Apply Gasket

Oil Pump

Non Reusable Part SS-01-03A


03/7 (DW-01M-MRM002)

[ RM-14 ]


SEPARATE EXTERNAL PARTS 1. REMOVE TORQUE CONVERTER 2. REMOVE NEUTRAL START SWITCH (1) Remove the nut, washer and control lever. (2) Using a screwdriver, unstake the lock washer. (3) Remove the 2 bolts and nut, and pull out the neutral start switch. SS-01-04A

3. REMOVE UNION (1) Remove the 2 unions. (2) Remove the 2 “O” rings from the unions.

SS-01-05A

4. REMOVE SCREW PLUG (1) Remove the screw plug from the transaxle case. (2) Remove the “O” ring from the screw plug.

SS-01-06A

5. REMOVE BRACKET (1) Remove the 1 bolt and bracket.

SS-01-80A

6. REMOVE INPUT SPEED SENSOR AND NO.1 BREATHER PLUG (1) Remove the 1 bolt and input speed sensor. (2) Remove the clip and breather hose. (3) Remove the No.1 breather plug. (4) Remove the “O” ring from the No.1 breather plug. SS-01-07A


03/7 (DW-01M-MRM002)


[ RM-15 ]

7. PLACE TRANSAXLE ON WOODEN BLOCKS

SS-01-08A

8. REMOVE OIL PAN AND GASKET (1) Remove the 18 bolts. (2) Remove the oil pan and gasket. (3) Remove the gasket and drain plug from the oil pan.

SS-01-09A

9. EXAMINE PARTICLES IN PAN (1) Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle: Steel (magnetic)..... bearing, gear and plate SS-01-10A

ware Brass (non-magnetic)..... bushing wear 10. REMOVE OIL STRAINER (1) Remove the 3 bolts and oil strainer.

SS-01-11A

(2) Remove the gasket from the oil strainer.

SS-01-12A


03/7 (DW-01M-MRM002)

[ RM-16 ]

REMOVAL OF COMPONENT PARTS 11. REMOVE VALVE BODY ASSEMBLY (1) Remove the bolt and ATF temperature sensor with clamp. (2) Disconnect the 5 connectors.

SS-01-13A

(3) Support the valve body assembly and remove the 14 bolts. (4) Disconnect the manual valve control rod from the manual valve lever, then remove the valve body assembly.

SS-01-14A

12. REMOVE CHECK VALVE (1) Remove the check valve and spring.

SS-01-15A

13. REMOVE BRAKE DRUM GASKET (1) Remove the brake drum gasket.

SS-01-16A

14. REMOVE APPLY GASKET

SS-01-17A


03/7 (DW-01M-MRM002)


[ RM-17 ]

15. REMOVE ACCUMULATOR SPRING AND PISTON (1) Apply compressed air (4.0 kgf/cm2) to the oil hole and remove the C2 accumulator piston and spring. (2) Remove the spring. CAUTION: Blowing off the air may cause the SS-01-18A

piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing.

(3) Remove the 2 “O” rings from the C2 accumulator piston.

SS-01-19A

(4) Apply compressed air (4.0 kgf/cm 2) to the oil hole and remove the C1 accumulator piston and spring. (5) Remove the spring. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand SS-01-20A

using a waste cloth. Take care not to splash ATF when air-blowing. (6) Remove the 2 “O” rings from the C1 accumulator piston.

SS-01-21A


03/7 (DW-01M-MRM002)

[ RM-18 ]

REMOVAL OF COMPONENT PARTS (7) Apply compressed air (4.0 kgf/cm 2) to the oil hole and remove the B1 accumulator piston and spring. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not SS-01-22A

to splash ATF when air-blowing. (8) Remove the 2 “O” rings from the B1 accumulator piston.

SS-01-23A

16. REMOVE TRANSAXLE WIRE (1) Remove the 1 bolt. (2) Remove the transaxle wire from the transaxle case.

SS-01-24A

(3) Remove the “O” ring from the transaxle wire.

SS-01-25A


03/7 (DW-01M-MRM002)


[ RM-19 ]

17. REMOVE VEHICLE SPEED SENSOR (1) Remove the 1 bolt and the vehicle speed sensor.

SS-01-82A

18. REMOVE TRANSAXLE HOUSING (1) Remove the 16 bolts. (2) Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. CAUTION: Differential gear assembly may be accidentally removed when the SS-01-26A

transaxle housing is removed. 19. INSPECT INPUT SHAFT END PLAY (1) Using a dial indicator, measure the input shaft end play.

SS-01-27A

20. REMOVE OIL PUMP (1) Remove the 6 bolts and oil pump.

SS-01-28A

21. REMOVE DIFFERENTIAL GEAR ASSEMBLY

SS-01-29A


03/7 (DW-01M-MRM002)

[ RM-20 ]

REMOVAL OF COMPONENT PARTS 22. REMOVE APPLY GASKET

SS-01-30A

23. REMOVE DIRECT CLUTCH ASSEMBLY

SS-01-31A

(1) Remove the direct clutch assembly from the transaxle case. (2) Remove the thrust needle roller bearing from the direct clutch assembly.

SS-01-32A

24. REMOVE DIRECT CLUTCH HUB (1) Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case.

SS-01-33A

25. REMOVE COUNTER DRIVEN GEAR ASSEMBLY

SS-01-34A


03/7 (DW-01M-MRM002)


[ RM-21 ]

26. REMOVE TRANSAXLE REAR COVER (1) Remove the 9 bolts. (2) Tap on the circumference of the transaxle rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.

SS-01-35A

27. REMOVE 4 APPLY GASKETS

SS-01-36A

28. REMOVE 2ND COAST & O/D BRAKE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates from the transaxle case.

SS-01-37A

29. REMOVE FORWARD & REVERSE CLUTCH ASSEMBLY (1) Remove the thrust needle roller bearing and forward & reverse clutch assembly.

SS-01-38A

(2) Remove the thrust needle roller bearing and thrust bearing race from the forward & reverse clutch assembly.

SS-01-39A


03/7 (DW-01M-MRM002)

[ RM-22 ]

REMOVAL OF COMPONENT PARTS 30. REMOVE FORWARD CLUTCH HUB (1) Remove the forward clutch hub from the transaxle case.

SS-01-40A

(2) Remove the thrust bearing race and thrust needle roller bearing from the forward clutch hub.

SS-01-41A

31. REMOVE REAR PLANETARY SUN GEAR AND 1 WAY CLUTCH ASSEMBLY (1) Remove the rear planetary sun gear and 1 way clutch assembly.

SS-01-42A

(2) Remove the thrust bearing race from the rear planetary sun gear and 1 way clutch assembly.

SS-01-43A

(3) Remove the thrust needle roller bearing and planetary carrier thrust washer from the rear planetary sun gear and 1 way clutch assembly.

SS-01-44A


03/7 (DW-01M-MRM002)


[ RM-23 ]

(4) Remove the 1 way clutch assembly and thrust washer from the rear planetary sun gear.

SS-01-45A

32. REMOVE FRONT PLANETARY SUN GEAR (1) Remove the front planetary sun gear from the transaxle case. (2) Remove the thrust bearing race from the front planetary sun gear.

SS-01-46A

33. REMOVE 2ND BRAKE (1) Using SST and a press, remove the 2 snap rings, 2ND brake and 2ND brake piston return spring. SST

CAUTION: Stop the press when the 2nd brake is lowered 1 - 2 mm from the snap ring groove, preventing the 2nd brake from being deformed.

SS-01-83A

(2) Apply compressed air (4.0 kgf/cm 2) to the 2nd brake to remove the 2nd brake piston from the 2nd brake clutch cylinder. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing.

SS-01-47A

(3) Remove the 2 “O” rings from the 2nd brake piston.

SS-01-48A


03/7 (DW-01M-MRM002)

[ RM-24 ]

REMOVAL OF COMPONENT PARTS (4) Remove the 2 plates, 2 discs and flange.

SS-01-49A

34. REMOVE NO.2 1 WAY CLUTCH AND PLANETARY GEAR (1) Remove the No.2 1 way clutch and planetary gear from the transaxle case.

SS-01-50A

(2) Remove the No.2 one-way clutch from the planetary gear. (3) Remove the anti-rattle clip.

SS-01-51A

35. REMOVE COUNTER DRIVE GEAR AND PLANETARY RING GEAR (1) Fix the counter drive gear with the parking lock pawl.

SS-01-52A


03/7 (DW-01M-MRM002)


[ RM-25 ]

(2) Using SST, lift the transaxle case.

SST

SS-01-86C

(3) Using SST and a hammer, unstake the

SST

counter drive gear nut.

SS-01-84A

(4) Remove the nut. CAUTION: Remove the nut without unstaking the planetary ring gear. If chisel or other tool is used to unstake the planetary ring gear, such impact may damage the bearing. SS-01-53A


03/7 (DW-01M-MRM002)

[ RM-26 ]

REMOVAL OF COMPONENT PARTS (5) Install the 3 bolts to the counter drove gear. Bolt (M6): L = 40 - 80 mm Pitch = 1.0 mm (6) Rotate 3 bolts in order and remove the counter drive gear and planetary ring gear.

SS-01-62A

SST SS-01-63C

36. REMOVE PARKING LOCK PAWL (1) Remove the 2 bolts and parking lock pawl bracket.

SS-01-54A

(2) Remove the parking lock pawl shaft, torsion spring and parking lock pawl.

SS-01-55A


03/7 (DW-01M-MRM002)


[ RM-27 ]

37. REMOVE MANUAL VALVE LEVER SHAFT (1) Remove the 1 bolt and manual detent spring.

SS-01-56A

(2) Using a chisel and hammer, unstake and remove the spacer.

SS-01-57A

(3) Using a pin punch and hammer, drive out the pin.

SS-01-58A

(4) Remove the manual valve lever shaft and manual valve lever.

SS-01-59A

(5) Remove the parking lock rod from the manual valve lever.

SS-01-60A


03/7 (DW-01M-MRM002)

[ RM-28 ]

REMOVAL OF COMPONENT PARTS (6) Using a screwdriver, remove the oil seal.

SS-01-61A

38. REMOVE 1ST & REVERSE BRAKE (1) Using SST and a press, remove the snap ring. SST

SS-01-83A

(2) Remove the flange, 4 plates, 4 discs and return spring.

SS-01-64A

(3) Apply compressed air (4.0 kgf/cm 2) to the transaxle case to remove the 1st & reverse brake piston. CAUTION: Blowing off the air may cause the piston's jump-out. When removing thee piston, hold it with your hand using a waste cloth. Take care not SS-01-65A

to splash ATF when air-blowing. (4) Remove the 2 “O” rings from the 1st & reverse brake piston.

SS-01-66A


03/7 (DW-01M-MRM002)


[ RM-29 ]

39. REMOVE NO.1 TRANSAXLE CASE PLATE (1) Remove the 1 bolt and No.1 transaxle case plate from the transaxle case.

SS-01-67A

40. REMOVE OUTER TAPERED ROLLER BEARING RACE AND SHIM FROM TRANSAXLE CASE (1) Using SST, remove the outer tapered roller bearing race and shim.

SST

SS-01-68A

41. REMOVE OIL RESERVOIR LOCK PLATE (1) Remove the 3 bolts and oil reservoir lock plate from the transxle housing.

SS-01-70A

42. REMOVE APPLY PIPE (1) Remove the 1 bolt and No.1 transaxle apply pipe clamp from the transaxle housing. (2) Remove the transaxle lube apply pipe and differential gear lube apply pipe from the transaxle housing.

SS-01-71A

43. REMOVE OIL SEAL (1) Using SST and a hammer, remove the oil seal from the transaxle housing.

SST

SS-01-72A


03/7 (DW-01M-MRM002)

[ RM-30 ]

REMOVAL OF COMPONENT PARTS 44. REMOVE OIL SEAL OF TRANSAXLE HOUSING (1) Using SST and a hammer, remove the oil seal.

SST SS-01-73A

45. REMOVE O/D BRAKE PISTON (1) Using SST and a press, remove the snap

SST

ring. CAUTION: Stop the press when the O/D brake piston is lowered 1 - 2 mm from the snap ring grove, preventing the O/D brake piston from being deformed.

SS-01-85A

(2) Remove the O/D brake return spring.

SS-01-75A

(3) Apply compressed air (4.0 kgf/cm 2) to the transaxle rear cover to remove the O/D brake piston. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing.

SS-01-76A

(4) Remove the 2 “O” rings from the O/D brake piston.

SS-01-77A


03/7 (DW-01M-MRM002)


[ RM-31 ]

46. DISASSEMBLE TRANSAXLE REAR COVER (1) Remove the 2 seal rings from the transaxle rear cover. CAUTION: Do not expand the seal ring excessively.

SS-01-78A

(2) Remove the 4 screw plugs and 4 “O” rings from the transaxle rear cover.

SS-01-79A


03/7 (DW-01M-MRM002)

[ RM-32 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 1. OIL PUMP Stator Shaft

Oil Pump Body

Oil Pump Drive Gear Oil Pump Drive Gear

SS-02-01A


03/7 (DW-01M-MRM002)


[ RM-33 ]

DISASSEMBLY OF OIL PUMP 1. CHECK OIL PUMP DRIVE GEAR ROTATION (1) Turn the drive gear with the 2 screwdrivers and make sure it rotates smoothly. CAUTION: Be careful not to damage the oil lip.

SS-02-02A

2. REMOVE REMOV E STATOR STATOR SHAFT (1) Remove the 8 bolts and stator shaft. CAUTION: Be careful not not to let the drive gear drop as it might come off attached to the stator shaft.

SS-02-03A

3. REMOVE OIL PUMP DRiVE GEAR AND DRIVEN GEAR

SS-02-04A

INSPECTION OF OIL PUMP 1. CHECK BODY CLEARANCE OF DRIVEN GEAR (1) Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Body Clearance SS-02-05A

ST D.

0.10-0.17 mm

MAX

0.22 mm

2. CHECK TIP CLEARANCE OF DRIVEN GEAR (1) Measure the tip clearance between the driven gear teeth and drive gear teeth. T ip Cle arance Dr Driv e n

ST D.

0.07-0.15 mm

MAX

0.20 mm

SS-02-06A


03/7 (DW-01M-MRM002)

[ RM-34 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 3. CHECK SIDE CLEARANCE OF BOTH GEAR (1) Using a steel straight edge and feeler gauge, measure the side clearance of both gears. If the side clearance is greater the the maximum, select the drive and driven gear.

SS-02-07A

Side Clearance of

ST D.

0.02-0.05 mm

Drive and Driv en Gear

M AX

0.10 mm

G e ar T hickne ss

Mark

Driv e Ge ar

1

T h= 8.440-8.449 mm

2

T h= 8.450-8.459 mm

3

T h= 8.460-8.470 mm

4

T h= 8.471-8.480 mm

5

T h= 8.481-8.490 mm

Mark

D riv e n Ge ar

1

T h= 8.440-8.449 mm

2

T h= 8.450-8.459 mm

3

T h= 8.460-8.470 mm

4

T h= 8.471-8.480 mm

5

T h= 8.481-8.490 mm

T ype

4. CHECK OIL PUMP BODY BUSHING (1) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Body Bush

ST D.

38.113-38.138 mm

MAX

38.188 mm

SS-02-08A

5. CHECK STATOR SHAFT BUSHING (1) Using a dial indicator, measure the inside diameter of the stator shaft bushings. Stator Shaft Bush

ST D.

18.424-18.450 mm

M AX

18.50 mm

SS-02-09A


03/7 (DW-01M-MRM002)


[ RM-35 ]

ASSEMBLY OF OIL PUMP 1. INSTALL OIL PUMP DRIVE GEAR AND DRIVEN GEAR

SS-02-04A

2. INSTALL STATOR SHAFT (1) Align the stator shaft with each bolt hole. (2) Install the 8 bolts. TT =

7.8-11.8 N.m N. m (80-120 kgf.cm)

SS-02-03A

3. CHECK PUMP DRIVE GEAR ROTATION (1) Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. CAUTION: Be careful not to damage the oil lip.

SS-02-02A


03/7 (DW-01M-MRM002)

[ RM-36 ]


2. DIRECT CLUTCH Return Spring "O" Ring "O" Ring Input Shaft Sub-assembly

Snap Ring Seal Ring

Piston Disc

Snap Ring Flange

Plate



03/7 (DW-01M-MRM002)


[ RM-37 ]

DISASSEMBLY OF DIRECT CLUTCH 1. CHECK PISTON STROKE OF DIRECT CLUTCH (1) Install the direct clutch and thrust needle roller bearing on the oil pump. (2) Using a dial indicator, measure the direct clutch piston stroke while applying and SS-03-02A

releasing compressed compressed air (4.0 kgf/cm 2).

Piston Stroke

0.40-0.70 mm

2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.

SS-03-03A

3. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates.

SS-03-04A


03/7 (DW-01M-MRM002)

[ RM-38 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 4. REMOVE DIRECT CLUTCH RETURN SST

SPRING (1) Place SST on the return spring and compress. (2) Using a snap ring expander, remove the snap ring. CAUTION: Stop the press when the piston

SS-03-05A

return spring is lowered to the place 1-2 mm from the snap ring groove, preventing the piston return spring from being deformed. Do not expand the snap ring excessively.

(3) Remove the direct clutch return spring.

SS-03-06A

5. REMOVE DIRECT CLUTCH PISTON (1) Install the direct clutch on the oil pump. (2) Apply compressed air (4.0 kgf/cm 2) to the oil pump to remove the direct clutch piston. CAUTION: Blowing off the air may cause the piston' jump-put. When removing the piston, hold it with your hand SS-03-07A

using a waste cloth. Take care not to splash ATF when air-blowing. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using needle nose pliers with vinyl tape on the tip.


03/7 (DW-01M-MRM002)


[ RM-39 ]

6. REMOVE “O” RING (1) Using a small screwdriver, remove the “O” ring from the direct clutch piston.

SS-03-08A

(2) Remove the “O” ring from the input shaft.

SS-03-09A

7. REMOVE SEAL RING (1) Remove the 2 seal rings from the input shaft. CAUTION: Do not expand the ring ends excessively.

SS-03-10A

INSPECTION OF DIRECT CLUTCH 1. INSPECT DISC AND FLANGE (1) Check to see if the sliding surface of the disc, plate and flange are worm or burnt. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs. SS-03-11A

Before assembling new discs, soak them in ATF for at least 15 minutes. 2. CHECK DIRECT CLUTCH RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring sheet.

Piston Return Spring Free Length

STD 36.04 mm

SS-03-12A


03/7 (DW-01M-MRM002)

[ RM-40 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 3. CHECK DIRECT CLUTCH PISTON (1) Check that the check ball is free by shaking the piston. (2) Check that the valve does not leak by applying low-pressure compressed air.

SS-03-13A

ASSEMBLY OF DIRECT CLUTCH 1. INSTALL SEAL RING (1) Install the 2 seal rings to the input shaft. CAUTION: Do not expand the ring ends excessively.

SS-03-10A

2. INSTALL O-RING (1) Coat a new “O” ring with ATF, and install the “O” ring to the input shaft.

SS-03-09A

(2) Coat a new “O” ring with ATF, and install the “O” ring to the direct clutch piston.

SS-03-08A

3. INSTALL DIRECT CLUTCH PISTON (1) Coat the direct clutch piston with ATF, install it to the direct clutch drum. CAUTION: Be careful no to damage the lip seal of direct clutch piston.

SS-03-14A


03/7 (DW-01M-MRM002)


[ RM-41 ]

4. INSTALL DIRECT CLUTCH RETURN SPRING. (1) Install the direct clutch return spring.

SS-03-06A

(2) Place SST on the return spring and compress.

SST

(3) Using a snap ring expander, install the snap ring. CAUTION: Stop the press when the piston return spring is lowered to the place 1 - 2 mm from the snap ring groove, preventing the piston return spring

SS-03-05A

from being deformed. Do not expand the snap ring excessively.

5. INSTALL PLATE, DISC AND FLANGE (1) Install the 2 plates, 2 discs and flange.

F D

HINT: Before installing the discs, coat them with ATF. P

SS-03-15A

(2) Using a screwdriver, remove the snap ring. (3) Check that the end gap of the snap ring is not aligned with one of the cutouts.

SS-03-03A


03/7 (DW-01M-MRM002)

[ RM-42 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 6. CHECK PISTON STROKE OF DIRECT CLUTCH (1) Install the direct clutch on the oil pump. (2) Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (4.0kgf/cm 2).

Piston Stroke SS-03-02A

0.40-0.70 mm

HINT: If the piston stroke is out of standards, select another flange.

Flange Thickness

Th= 3.0 mm

Type

Th= 3.2 mm Th= 3.4 mm


03/7 (DW-01M-MRM002)


[ RM-43 ]

3. PLANETARY RING GEAR

Planetary Ring Gear

Snap Ring

Planetary Ring Gear Flange


DISASSEMBLY DISASSEMBLYOF OFPLANETARY PLANETARYRING RINGGEAR GEAR 1. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.

SS-04-02A

2. REMOVE PLANETARY RING GEAR FLANGE (1) Remove the planetary ring gear flange from the planetary ring gear.

SS-04-03A


03/7 (DW-01M-MRM002)

[ RM-44 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS ASSEMBLY OF PLANETARY RING GEAR 1. INSTALL PLANETARY RING GEAR FLANGE (1) Install a new planetary ring gear flange to the planetary ring gear.

SS-04-03A

2. INSTALL SNAP RING (2) Using a screwdriver, install the snap ring.

SS-04-02A


03/7 (DW-01M-MRM002)


[ RM-45 ]

4. 1 WAY CLUTCH

2nd Brake Hub

Retainer

Snap Ring

1 Way Clutch SS-05-01A

Freely

DISASSEMBLY OF 1 WAY CLUTCH 1. CHECK OPERATION OF 1 WAY CLUTCH (1) Install the 1 way clutch and thrust washer to the rear planetary sun gear. (2) Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely clockwise and should lock

Lock

SS-05-02A

counterclockwise. 2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.

SS-05-03A


03/7 (DW-01M-MRM002)

[ RM-46 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 3. REMOVE 1 WAY CLUTCH

SS-05-04A

4. REMOVE RETAINER (1) Using a small screwdriver, remove the retainer.

SS-05-05A

ASSEMBLY OF 1 WAY CLUTCH 1. INSTALL RETAINER (1) Install the retainer to the 2nd brake hub. HINT: Install the retainer closely.

2. INSTALL 1 WAY CLUTCH

SS-05-04A

3. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring.

SS-05-03A


03/7 (DW-01M-MRM002)


Freely

[ RM-47 ]

4. CHECK OPERATION OF 1 WAY CLUTCH (1) Install the 1 way clutch and thrust washer to the rear planetary sun gear. (2) Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely clockwise and should lock counterclockwise.

Lock

SS-05-02A


03/7 (DW-01M-MRM002)

[ RM-48 ]


5. FORWARD AND REVERSE CLUTCH

Flange

Disc Flange Snap Ring

Plate

Plate

Disc Flange Snap Ring Snap Ring Seal Ring "O" Ring "O" Ring

Forward Clutch Drum

Intermediate Shaft Sub-assembly

Forward Clutch Piston Forward Clutch Return Spring Clutch Balancer SS-06-01C

Non Reusable Part


03/7 (DW-01M-MRM002)


[ RM-49 ]

DISASSEMBLY OF FORWARD AND REVERSE CLUTCH 1. CHECK PISTON STROKE OF REVERSE CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. SS-06-02A

(2) Using a dial indicator, measure the reverse clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm 2).

Piston Stroke

0.86-1.26 mm

2. CHECK PISTON STROKE OF FORWARD

SST

CLUTCH SST

(1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator and measuring terminal (SST), measure the forward clutch

SS-06-03A

piston stroke while applying and releasing compressed air (4.0 kgf/cm 2).

Piston Stroke 1.30-1.50 mm HINT: The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch. 3. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.

SS-06-04A


03/7 (DW-01M-MRM002)

[ RM-50 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 4. REMOVE FLANGE, DISC AND PLATE (1) Remove the 2 flanges, 2 discs and plate from the reverse clutch drum.

SS-06-05A

5. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.

SS-06-06A

6. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 4 discs and 4 plates from the forward clutch drum.

SS-06-07A

7. REMOVE FORWARD CLUTCH RETURN SPRING

SST

(1) Place SST on the clutch balancer and compress the springs with a press. (2) Using a snap ring expander, remove the snap ring. CAUTION: Stop the press when the clutch SS-06-19A

balancer is lowered to the place 1 2 mm from the snap ring groove, preventing the clutch balancer from being deformed. Do not expand the snap ring excessively. (3) Remove the clutch balancer and forward clutch return spring.

SS-06-08A


03/7 (DW-01M-MRM002)


[ RM-51 ]

8. REMOVE FORWARD CLUTCH PISTON (1) Install the forward and reverse multiple disc clutch on the transaxle rear cover. (2) Apply compressed air (4.0 kgf/cm 2) to the transaxle rear cover to remove the forward clutch piston. CAUTION: Blowing off the air may cause the SS-06-09A

piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using a needle nose pliers with vinyl tape on the tip.

9. REMOVE FORWARD CLUTCH DRUM (1) Apply compressed air (4.0 kgf/cm 2) to the transaxle rear cover to remove the forward clutch drum. CAUTION: Blowing off the air may cause the drum's jump-out. When removing the drum, hold it with your hand SS-06-10A

using a waster cloth. Take care not to splash ATF when air-blowing. HINT: When the drum cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the drum using a needle nose pliers with vinyl tape on the tip.

10. REMOVE “O” RING (1) Using a small screwdriver, remove the “O” ring from the forward clutch drum.

SS-06-11A


03/7 (DW-01M-MRM002)

[ RM-52 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS (2) Using a small screwdriver, remove the “O” ring from the intermediate shaft subassembly.

SS-06-12A

INSPECTION OF FORWARD AND REVERSE CLUTCH 1. INSPECT DISC AND FLANGE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed SS-06-13A

number is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 2. CHECK FORWARD CLUTCH RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring seat.

SS-06-14A


STD 24.04 mm

ASSEMBLY OF FORWARD AND REVERSE CLUTCH 1. INSTALL “O” RING (1) Coat a new “O” ring with ATF, and install it to the intermediate shaft sub-assembly.

SS-06-12A

(2) Coat a new “O” ring with ATF, and install it to the forward clutch drum.

SS-06-11A


03/7 (DW-01M-MRM002)


[ RM-53 ]

2. INSTALL FORWARD CLUTCH DRUM (1) Coat the forward clutch drum with ATF, install the forward clutch drum. CAUTION: Be careful not to damage the “O” ring and lip seal of forward clutch drum. SS-06-15A

3. INSTALL FORWARD CLUTCH PISTON (1) Coat the forward clutch piston with ATF, install the forward clutch piston. CAUTION: Be careful not to damage the lip seal of forward clutch piston.

SS-06-16A

4. INSTALL FORWARD CLUTCH RETURN SPRING (1) Install thee forward clutch return spring and clutch balancer. CAUTION: Be careful not to damage the lip seal of forward clutch return spring.

SS-06-08A

(2) Place SST, on the clutch balancer and compress the piston return spring with a

SST

press. (3) Using a snap ring expander, install the snap ring. CAUTION: Stop the press when the clutch balancer is lowered to the place 1 SS-06-19A

2 mm from the snap ring groove, preventing the clutch balancer form being deformed. Do not expand the snap ring excessively.


03/7 (DW-01M-MRM002)

[ RM-54 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 5. INSTALL PLATE, DISC AND FLANGE P

F

(1) Install the 4 plates, 4 discs and flange.

D

SS-06-18A

6. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring. (2) Check that the end gap of the snap ring is not aligned with one of the cutouts.

SS-06-06A

7. INSTALL PLATE, DISC AND FLANGE F

(1) Install the plate, 2 discs and 2 flanges.

D P D F SS-06-17A

8. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring. (2) Check that the end gap of the snap ring is not aligned with one of the cutouts.

SS-06-04A


03/7 (DW-01M-MRM002)


[ RM-55 ]

9. CHECK PISTON STROKE OF REVERSE CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator, measure the reverse clutch piston stroke while applying and SS-06-02A

releasing compressed air (4.0 kgf/cm 2).

Piston Stroke

0.86-1.26 mm


Flange Thickness

Th= 3.0 mm

Type

Th= 3.2 mm Th= 3.4 mm Th= 3.6 mm

10. CHECK PISTON STROKE OF FORWARD

SST

CLUTCH SST

(1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator and measuring terminal (SST), measure the forward clutch

SS-06-03A

piston stroke while applying and releasing compressed air (4.0 kgf/cm 2).

Piston Stroke

1.30-1.50 mm


Flange Thickness

Th= 3.0 mm

Type

Th= 3.1 mm Th= 3.2 mm Th= 3.3 mm Th= 3.4 mm Th= 3.5 mm Th= 3.6 mm

HINT: The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch.


03/7 (DW-01M-MRM002)

[ RM-56 ]


6. COUNTER DRIVEN GEAR

Outer Tapered Roller Bearing Race

Outer Tapered Roller Bearing Race

Counter Driven Gear SS-07-01A

DISASSEMBLY OF COUNTER DRIVEN GEAR 1. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING SST

(1) Using SST and a press, remove the front drive pinion tapered roller bearing rear inner race counter driven gear from the differential drive pinion. SS-07-02C

(2) Using SST, remove the front drive pinion tapered roller bearing rear outer race and drive pinion washer from the transaxle case.

SS-07-03C


03/7 (DW-01M-MRM002)


[ RM-57 ]

2. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (1) Using SST and a press, remove the front drive pinion tapered roller bearing front inner SST

race from the differential drive pinion.

SS-07-04C

(2) Using SST, remove the front drive pinion tapered roller bearing front outer race from the transaxle housing.

SS-07-05C

3. REMOVE SIFFERENTIAL DRIVEN PINION PLUG (1) Using extension bar and hammer, remove the differential drive pinion plug.

SS-07-06C

ASSEMBLY OF COUNTER DRIVEN GEAR 1. INSTALL FRONT DRIVE PINION PLUG (1) Using a socket wrench (10 mm) and hammer, install a new differential drive pinion plug to the differential drive pinion.

Pinion plug

2.3-2.8 mm

SS-07-07C

2. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (1) Using SST and a press, install the front drive pinion tapered roller bearing front inner race

SST

to the differential drive pinion.

SS-07-08C


03/7 (DW-01M-MRM002)

[ RM-58 ]

ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS (2) Using SST and a hammer, install the front drive pinion tapered roller bearing front outer race to the transaxle housing.

SST SS-07-09C

3. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear to the differential drive pinion. SST

SS-07-10C

4. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (1) Using SST and a press, install the front drive pinion tapered roller bearing rear inner race to the differential drive pinion.

SST

SS-07-11C

(2) Using SST and a hammer, install the pinion washer and front drive pinion tapered roller bearing rear outer race to the transaxle case.

SST SS-07-12C


03/7 (DW-01M-MRM002)


[ RM-59 ]

7. VALVE BODY

SS-08-17A

DISASSEMBLY OF VALVE BODY

SL Solenoid

1. REMOVE SHIFT SOLENOID (NO.1, NO.2, ST, SL) (1) Remove the each bolt and the solenoids.

No.2 Solenoid No.1 Solenoid ST Solenoid

SS-11-01AM

ASSEMBLY OF VALVE BODY 1. INSTALL SHIFT SOLENOID (NO.1, NO.2, ST,

SL Solenoid (28 mm, 49mm)

SL) (1) Replace the “O” ring of each solenoid and install the solenoid. No.2 Solenoid (20 mm, 49 mm) No.1 Solenoid (20 mm, 49 mm)

ST Solenoid (20 mm)

SS-11-04AM

CAUTION: Make sure to use new “O” ring and not to damage the “O” ring. (2) Tighten the 7 bolts. TT =

10.0-12.0 N.m (100-200 kgf.cm)


03/7 (DW-01M-MRM002)

[ RM-60 ]


8. DIFFERENTIAL

Differential Assembly Side Bearing Outer Race

Side Bearing Outer Race

SS-10-01A


03/7 (DW-01M-MRM002)

INSTALLATION OF COMPONENT PARTS

[ RM-61 ]

INSTALLATION OF COMPONENT PARTS RACE AND BEARING SPECIFICATIONS C

B

D

E

A

F G

SS-09-01A

(mm)

A

B

C

D

E

F

G

RASE

Outer Dia.

---

30.60

45.50

---

29.00

---

---

(Front)

Inner Dia.

---

19.30

34.95

---

19.30

---

---

29.60

46.50

57.50

---

48.50

30.20

BEARING Outer Dia. 62.00 Inner Dia.

43.20

18.10

33.30

42.50

---

32.50 or 32.90

17.80

RACE

Outer Dia.

---

28.20

---

---

---

---

32.60

(REAR)

Inner Dia.

---

18.10

---

---

---

---

20.50


03/7 (DW-01M-MRM002)

[ RM-62 ]

INSTALLATION OF COMPONENT PARTS 1. ASSEMBLY TRANSAXLE TEAR COVER (1) Install 4 new “O” rings to the 4 screw plugs. (2) Install the 4 screw plugs with the “O” rings to the transaxle rear cover. TT =

5.9-8.8 N.m (60-90 kgf.cm)

SS-01-79A

(3) Install the 2 seal rings to the transaxle rear cover.

SS-01-78A

2. CHECK O/D & 2ND COAST BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring seat.


STD 18.99 mm

SS-09-02A

3. INSTALL O/D & 2ND COAST BRAKE PISTON (1) Coat 2 new “O” rings with ATF, install them to the O/D & 2nd coast brake piston.

SS-01-77A

(2) Coat the O/D & 2nd coast brake piston with ATF, install it to the transaxle rear cover. CAUTION: Be careful not to damage the “O” rings of the O/D & 2nd coast brake piston.

SS-09-03A


03/7 (DW-01M-MRM002)


[ RM-63 ]

(3) Using SST and a press, install the O/D & 2nd coast brake return spring and snap ring

SST

to transaxle rear cover. CAUTION: Stop the press when the O/D & 2nd coast brake piston is lowered 1 - 2 mm from the snap ring groove, preventing the O/D & 2nd coast brake piston from being deformed.

SS-01-85A

4. INSTALL TRANSAXLE HOUSING OIL SEAL (1) Using SST and a hammer, drive in a new oil seal.

SST

Oil seal in depth

SST

2.6-3.6 mm

SS-09-05A

SST

5. INSTALL OIL SEAL (1) Using SST and a hammer, drive in a new oil seal.

A

A = 0 mm (2) Coat the lip of oil seal with MP grease.

SS-09-07A

6. INSTALL APPLY PIPE (1) Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing. (2) Install the No.1 transaxle apply pipe clamp to the transaxle housing with 1 bolt. TT =

3.9-6.9 N.m (40-70 kgf.cm)

SS-01-71A

7. INSTALL OIL RESERVOIR LOCK PLATE (1) Install the oil reservoir lock plate to the transaxle housing with the 3 bolts. TT =

3.9-6.9 N.m (40-70 kgf.cm)

SS-01-70A


03/7 (DW-01M-MRM002)

[ RM-64 ]

INSTALLATION OF COMPONENT PARTS 8. INSTALL TRANSAXLE CASE OIL SEAL (1) Using SST and a hammer, drive in a new oil seal.

Oil seal in depth

SST

3.8-4.8 mm

SST

SS-09-09A

9. INSTALL NO.1 TRANSAXLE CASE PLATE (1) Install the No.1 transaxle case plate to the transaxle case with the bolt. TT =

7.8-11.8 N.m (80-120 kgf.cm)

SS-01-67A

10. ADJUST COUNTER DRIVEN GEAR PRELOAD (1) Install the differential gear to the transaxle case.

SS-09-11A

(2) Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily. (3) Tighten 8 or 9 bolts out of 16 bolts of the transaxle housing completely. TT =

23.5-35.5 N.m (240-360 kgf.cm)

SS-01-26A

(4) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.

SS-09-12A


03/7 (DW-01M-MRM002)


[ RM-65 ]

(5) Using SST and small torque wrench, measure the preload of the differential gear. HINT: Note down the measured valve.

SS-09-13A

(6) Remove the transaxle housing and install the counter driven gear.

SS-09-14A

(7) Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily. (8) Tighten the bolts of the transaxle housing in the same manner as in step (3). TT =

23.5-35.5 N.m (240-360 kgf.cm)

SS-01-26A

9) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.

SS-09-12A

(10) Using SST and a small torque wrench, measure the preload of the differential gear. From this valve deduct the value measured in step (4). This is the preload of the counter driven gear. New Bearing

0.78-13.7 N.m (8.0-14.0 kgf.cm)

Reused Bearing

0.39-0.69 N.m (4.0-7.0 kgf.cm)

SS-09-13A


03/7 (DW-01M-MRM002)

[ RM-66 ]

INSTALLATION OF COMPONENT PARTS (11) If the preload of counter driven gear does not satisfy the specification, select the adjuster shim from the table below and remeasure the value. Until the valve is within the specification, repeat the procedure. HINT: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than the specification, select a thicker adjuster shim.

Mark

Thickness

Mark

Thickness

A

Th= 1.80 mm

N

Th= 2.26 mm

B

Th= 1.85 mm

P

Th= 2.29 mm

C

Th= 1.90 mm

Q

Th= 2.32 mm

D

Th= 1.95 mm

R

Th= 2.35 mm

E

Th= 2.00 mm

S

Th= 2.40 mm

F

Th= 2.05 mm

T

Th= 2.45 mm

G

Th= 2.08 mm

U

Th= 2.50 mm

H

Th= 2.11 mm

V

Th= 2.55 mm

J

Th= 2.14 mm

W

Th= 2.60 mm

K

Th= 2.17 mm

X

Th= 2.65 mm

L

Th= 2.20 mm

Y

Th= 2.70 mm

M

Th= 2.23 mm

11. CHECK 1ST & REVERSE BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with spring seat.


STD 21.71 mm

SS-09-15A

12. INSPECT DISC, PLATE AND FLANGE OF 1ST & REVERSE BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs. SS-09-16A

Before assembling new discs, soak them in ATF for at least 15 minutes.


03/7 (DW-01M-MRM002)


[ RM-67 ]

13. INSTALL 1ST & REVERSE BRAKE (1) Coat 2 new “O” rings with ATF, install them to the 1st & reverse piston.

SS-01-66A

(2) Install the 1st reverse brake piston to the transaxle case. CAUTION: Be careful not to damage the “O” rings of the 1st & reverse brake piston.

SS-09-17A

(3) Install the return spring to the transaxle case.

SS-09-18A

(4) Install the 4 plates, 4 discs and flange. D

F

P

SS-09-19A

(5) Using SST and a press, install the snap ring. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. SST

SS-01-83A


03/7 (DW-01M-MRM002)

[ RM-68 ]

INSTALLATION OF COMPONENT PARTS 14. CHECK PISTON STROKE OF 1ST & REVERSE BRAKE (1) Using a dial indicator and measuring terminal (SST), measure the 1st & reverse brake piston stroke while applying and releasing compressed air (4.0 kgf/cm2).

Piston Stroke

0.791-1.489 mm

SS-09-20A

15. INSTALL MANUAL VALVE LEVER SHAFT (a) Coat a new oil seal with ATF. (b) Install the oil seal to the transaxle case.

Oil seal in depth

A

0.75-1.25 mm

SS-09-22A

(3) Install the parking lock rod to the manual valve lever.

SS-01-60A

(4) Install a new spacer to the manual valve lever.

SS-09-23A

(5) Install the manual valve lever shaft and manual valve lever.

SS-09-68A


03/7 (DW-01M-MRM002)


[ RM-69 ]

(6) Using a pin punch and hammer, drive in a new pin.

SS-01-58A

(7) Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft. (8) Using a pin punch, stake the spacer through the small hole. (9) Check that the spacer does not turn. SS-09-24A

(10) Install the manual detent spring with 1 bolt. TT =

7.8-11.8 N.m (80-120 kgf.cm)

SS-01-56A

16. INSTALL PARKING LOCK PAWL (1) Install the parking lock pawl shaft, torsion spring and parking lock pawl.

SS-01-55A

CAUTION: Check that the edge of torsion spring fits into the groove securely.

SS-09-25A


03/7 (DW-01M-MRM002)

[ RM-70 ]

INSTALLATION OF COMPONENT PARTS (2) Install the parking lock pawl bracket with the 2 bolts. TT =

5.9-8.8 N.m (60-90 kgf.cm)

SS-01-54A

17. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear. CAUTION: Be careful not to apply excessive SST

force to thee transaxle case.

SST

SS-09-21A

18. INSTALL PLANETARY RING GEAR HINT: Before installing the planetary ring gear, be sure to replace the planetary ring gear flange of the planetary ring gear with a new

SST

one. (1) Using SST and a press, install the planetary ring gear.

SST

SS-09-26A


03/7 (DW-01M-MRM002)


[ RM-71 ]

(3) Install a new nut.

SS-01-53A

(4) Using a small torque wrench, while turning to counter drive gear 100 turn par minute and measure the preload. New Bearing Reused Bearing

0.05-0.35 N.m (0.5-3.6 kgf.cm) 0.05-0.35 N.m (0.5-3.6 kgf.cm)

HINT: When the preload is smaller than the specification, tighten the nut more and SS-09-29A

adjust the preload. (5) Using SST, lift the transaxle case.

SST

SS-01-86C

(5) Using a chisel and a hammer, stake the counter drive gear nut

SS-09-71A


03/7 (DW-01M-MRM002)

[ RM-72 ]

INSTALLATION OF COMPONENT PARTS (6) Fix the counter drive gear with parking lock pawl.

SS-01-52A

19. INSTALL PLANETARY GEAR (1) Install the planetary gear to the transaxle housing.

SS-09-30A

(2) Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear.

SS-09-31A

20. INSTALL NO.2 ONE-WAY CLUTCH (1) Install the No.2 one-way clutch to the transaxle.

SS-09-32A

(2) Check that the planetary gear turns freely counterclockwise and locks clockwise.

Freely

Lock

SS-09-33A


03/7 (DW-01M-MRM002)


[ RM-73 ]

(3) Install the anti-rattle clip in the place shown in the illustration (the space between the No.2 one-way clutch outer race and transaxle case), push the anti-rattle clip in until you hear the "click".

SS-09-34A

21. CHECK 2ND BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of thee spring together with spring seat.

SS-09-35A

22. INSPECT DISC, PLATE AND FLANGE OF 2ND BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs. SS-09-36A

Before assembling new discs, soak them in ATF for at least 15 minutes. 23. INSTALL 2ND BRAKE

F

(1) Install the flange, 2 discs and 2 plates.

P

(2) Install the 2nd brake return spring. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. D SS-09-37A

(3) Coat 2 new “O” rings with ATF, install them to the 2nd brake piston.

SS-01-48A


03/7 (DW-01M-MRM002)

[ RM-74 ]

INSTALLATION OF COMPONENT PARTS (4) Install the 2nd brake piston into the 2nd brake clutch cylinder. CAUTION: Be careful not to damage to “O” rings.

SS-09-38A

(5) Install the 2nd brake.

SS-09-39A

(6) Place SST on the 2nd brake and compress the piston return spring with a press. (7) Using a screwdriver, install thee snap ring. CAUTION: Make sure that the snap ring is SST

installed in the groove of the transaxle case correctly.

SS-01-83A

24. INSTALL FRONT PLANETARY SUN GEAR (1) Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear.

SS-09-40A

(2) Install the front planetary sun gear to the transaxle case.

SS-01-46A


03/7 (DW-01M-MRM002)


[ RM-75 ]

25. INSTALL REAR PLANETARY SUN GEAR AND ONE-WAY CLUTCH ASSEMBLY (1) Install the thrust washer and one-way clutch assembly to the rear planetary sun gear.

SS-01-45A

(2) Coat the thrust bearing race with petroleum jelly and install it onto the rear planetary sun gear and one-way clutch assembly. CAUTION: Check the direction on the bearing.

SS-09-41A

(3) Install the rear planetary sun gear and oneway clutch assembly to the transaxle case.

SS-01-42A

26. INSTALL FORWARD CLUTCH HUB (1) Coat the thrust bearing race with petroleum jelly and install it onto the transaxle case. CAUTION: Check the direction of race.

SS-09-42A

(2) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch hub. CAUTION: Check the direction of bearing.

SS-09-43A


03/7 (DW-01M-MRM002)

[ RM-76 ]

INSTALLATION OF COMPONENT PARTS (3) Install the forward clutch hub to the transaxle case.

SS-01-40A

(4) Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.

SS-09-44A

27. INSTALL FORWARD & REVERSE CLUTCH ASSEMBLY (1) Install the thrust bearing race and thrust needle roller bearing to the forward & reverse clutch assembly.

SS-01-39A

(2) Install the forward & reverse clutch assembly to the transaxle case.

SS-09-45A


03/7 (DW-01M-MRM002)


[ RM-77 ]

28. INSPECT DISC, PLATE AND FLANGE OF O/D & 2ND COAST BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all SS-09-16A

discs. Before assembly new discs, soak them in ATF for at least 15 minutes.

29. INSTALL O/D & 2ND COAST BRAKE FLANGE, DISC AND PLATE (1) Using a screwdriver, install the snap ring to the transaxle case. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. SS-09-46A

(2) Install the flange, 2 discs and 2 plates to the

P

transaxle case. (3) Clean the connected part the transaxle case

F

and transaxle rear cover.

D

SS-09-70A

(4) As shown in the illustration, place a straight edge on the transaxle case and measure the A

distance between the 2nd coast & o/d brake flange and straight edge using vernier calipers. (Dimension A)

SS-09-47A


03/7 (DW-01M-MRM002)

[ RM-78 ]

INSTALLATION OF COMPONENT PARTS (5) As shown in the illustration, place a straight edge on the o/d brake piston and measure the distance between the transaxle rear B

cover and straight edge using vernier calipers, (Dimension B) (6) Calculate the piston stroke value using the following formula. Select flange which

SS-09-48A

satisfies the piston stroke value and install it. Piston stroke = Dimension A - Dimension B

Piston Stroke

0.65-1.05 mm

30. INSTALL TRANSAXLE REAR COVER (1) Install new 4 apply gaskets to the transaxle rear cover.

SS-01-36A

(2) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward & reverse clutch assembly. (3) Remove any packing material and be careful not to get oil on the contacting surfaces on the transaxle rear cover on transaxle case.

SS-09-49A

(4) Apply FIPG to the transaxle rear cover.

SS-09-50A


03/7 (DW-01M-MRM002)


[ RM-79 ]

(5) Install the transaxle rear cover to the transaxle case with the 9 bolts. TT =

19.6-29.4 N.m (200-300 kgf.cm)

SS-01-35A

31. INSTALL COUNTER DRIVEN GEAR ASSEMBLY

SS-01-34A

32. INSTALL DIFFERENTIAL GEAR ASSEMBLY

SS-01-29A

33. INSTALL DIRECT CLUTCH HUB (1) Install the direct clutch hub to the transaxle case.

SS-09-51A

34. INSTALL DIRECT CLUTCH (1) Install thee thrust bearing race and thrust needle roller bearing to the transaxle case.

SS-09-52A


03/7 (DW-01M-MRM002)

[ RM-80 ]

INSTALLATION OF COMPONENT PARTS (2) Install the direct clutch assembly to the transaxle case.

SS-01-31A

35. INSTALL NEW APPLY GASKET

SS-01-30A

36. INSTALL OIL PUMP (1) Install the thrust needle roller bearing to the transaxle case. CAUTION: Check the direction of the bearing. (2) Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case. SS-09-53A

(3) Install the 6 bolts. TT =

19.6-29.4 N.m (200-300 kgf.cm)

SS-01-28A

37. MEASURE INPUT SHAFT END PLAY (1) Measure the end play in axial direction. End Play

0.3-0.9 mm

SS-01-27A


03/7 (DW-01M-MRM002)


[ RM-81 ]

38. CHECK INPUT SHAFT ROTATION (1) Make sure that the input shaft rotates smoothly.

SS-09-54A

39. INSTALL TRANSAXLE HOUSING (1) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case. (2) Apply FIPG to the transaxle housing.

SS-09-55A

(3) Install the transaxle housing to the transaxle case with the 16 bolts. TT =

23.5-35.5 N.m (240-360 kgf.cm)

HINT: Apply seal packing or equivalent to the 3 bolts indicated by arrows.

SS-09-67A

40. INSTALL TRANSAXLE WIRE (1) Coat a new “O” ring with ATF install it to the transaxle wire.

SS-01-25A

(2) Install the transaxle wire the to the transaxle case with the 1 bolt. TT =

3.9-6.9 N.m (40-70 kgf.cm)

SS-01-24A


03/7 (DW-01M-MRM002)

[ RM-82 ]

INSTALLATION OF COMPONENT PARTS 41. INSTALL ACCUMULATOR PISTON AND SPRING (1) Coat new 6 “O” rings with ATF and install them to the pistons.

B1 Acum.

(2) Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes. PART NAME

C1 Acum.

SPRING Free (mm) Outer (mm)

Color

C2 Acum.

57.20

17.50

Light Green

C1 Acum.

54.70

17.20

Blue

B1 Acum.

47.13

16.00

Pink

C2 Acum.

SS-09-56A

42. INSTALL APPLY GASKET (1) Coat a new apply gasket with ATF, install it to the transaxle case.

SS-01-17A

43. INSTALL BRAKE DRUM GASKET (1) Coat a new brake drum gasket with ATF, install it to the transaxle case.

SS-01-16A

44. INSTALL CHECK VALVE (1) Install the spring and check valve.

SS-01-15A


03/7 (DW-01M-MRM002)


[ RM-83 ]

45. INSTALL VALVE BODY ASSEMBLY (1) Connect the manual valve control rod to the manual valve lever as shown in the illustration.

SS-09-57A

40 mm

(2) Install the transaxle wire connectors and

20 mm

harness to the valve body assembly with the

28 mm

14 bolts. TT =

9.8-11.8 N.m (100-120 kgf.cm)

CAUTION: When installing the valve body to 28 mm

20 mm 49 mm

36 mm

the transaxle case, do not let each of accumulator pistons B1, C1 and

SS-09-69A

C2 incline. When installing the valve body to the transaxle case, do not hold the solenoids.

(3) Connect the 5 connectors. (4) Install the ATF temperature sensor with clamp and 3 bolts. CAUTION: Make sure that the transaxle wire does not come out from the oil pan installation surface.

SS-01-13A

46. INSTALL OIL STRAINER (1) Install a new gasket to the oil strainer.

SS-01-12A


03/7 (DW-01M-MRM002)

[ RM-84 ]

INSTALLATION OF COMPONENT PARTS (2) Install the oil strainer to the valve body with the 3 bolts. TT =

7.8-11.8 N.m (80-120 kgf.cm)

SS-01-11A

47. INSTALL OIL PAN (1) Install the 2 magnets in the oil pan.

SS-09-58A

(2) Install a new gasket to the oil pan and install them to the transaxle case with the 18 bolts. TT =

6.0-7.9 N.m (60-80 kgf.cm)

SS-01-09A

48. INSTALL INPUT SPEED SENSOR AND NO.1 BREATHER PLUG (1) Install the No.1 breather plug. (2) Install the input speed sensor with the 1 bolt. TT =

3.9-6.9 N.m (40-70 kgf.cm)

SS-01-07A

49. INSTALL VEHICLE SPEED SENSOR (1) Install the vehicle speed sensor to the transaxle case with the 1 bolt. TT =

5.9-8.8 N.m (60-90 kgf.cm)

SS-01-82A


03/7 (DW-01M-MRM002)


[ RM-85 ]

50. INSTALL BRACKET (1) Install the bracket to the transaxle case with the 1 bolt. TT =

19.6-29.4 N.m (200-300 kgf.cm)

SS-01-80A

51. INSTALL SCREW PLUG (1) Coat a new “O” ring with ATF, install it to the screw plug. (2) Install the screw plug to the transaxle case. TT =

5.9-8.8 N.m (60-90 kgf.cm)

SS-01-06A

52. INSTALL UNION (1) Coat new 2 “O” rings with ATF, install them to the unions. (2) Install the 2 unions to the transaxle case. TT =

19.6-29.4 N.m (200-300 kgf.cm)

SS-01-05A

53. INSTALL NEUTRAL START SWITCH (1) Install the neutral start switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. (2) Install a new lock washer and nuts. TT =

4.3-6.5 N.m (44-66 kgf.cm)

SS-09-59A

(3) Temporarily install the control lever.

SS-09-60A


03/7 (DW-01M-MRM002)

[ RM-86 ]

INSTALLATION OF COMPONENT PARTS (4) Remove control lever. (5) Set the SST and inspect that SST pointer align neutral basic line. (6) Align the groove with neutral basic line. (7) Tighten the 2 bolts.

SST

TT =

4.3-6.5 N.m (44-66 kgf.cm)

SS-09-73A

Neutral basic line SST pointer

SST SS-09-74A

(8) Using a screwdriver, stake the nut with the lock washer.

SS-09-63A

(9) Install the control lever, washer and nut. TT =

9.8-14.7 N.m (100-150 kgf.cm)

SS-09-64A

54. INSTALL TORQUE CONVERTER

Transaxle Housing

(1) Install the torque converter. A

(2) Check the distance of A. A=

Torque Converter

11.1 mm

CAUTION: If the distance is out of standards, adjust within standartds again.

SS-09-72A


03/7 (DW-01M-MRM002)

SERVICE SPECIFICATIONS

[ RM-87 ]

SERVICE SPECIFICATIONS GENERAL 81-40LE 30510-81C008

A/T TYPE BASE A/T

GEAR RATIO

ATF TYPE VOLUME ATF

1st 2.875 2nd 1.568 3rd 1.000 4th 0.697 Reverse 2.300 Counter 1.019 Differential 3.750 Esso JWS-3309: ISU DEXRON Ⅲ = 1:1 5.6L (75 degree C)

CLUTCH & BRAKE Flange (F)

Plate (P)

Disc (D)

C1 (Forward Clutch)

1

4

4

C2 (Direct Clutch)

1

2

2

C3 (Rear Clutch)

2

1

2

B1 (O/D & 2nd Coast Brake)

1

2

2

B2 (2nd Brake)

1

2

2

B3 (1st & Reverse Brake)

1

4

4

Clutch / Brake

C1 ( FORWARD CLUTCH) PART NAME

SPEC.

Piston Stroke

1.30-1.50 mm

Pack Clearance

1.30-1.50 mm

Flange Thickness

Th= 3.0 mm

Type

Th= 3.1 mm Th= 3.2 mm Th= 3.3 mm Th= 3.4 mm Th= 3.5 mm Th= 3.6 mm


STD 24.04 mm


03/7 (DW-01M-MRM002)

[ RM-88 ]


C2 ( DIRECT CLUTCH) PART NAME

C3 ( REVERSE CLUTCH)

SPEC.

PART NAME

SPEC.

Piston Stroke

0.40-0.70 mm

Piston Stroke

Pack Clearance

0.40-0.70 mm

Pack Clearance

0.4-1.0 mm

0.86-1.26 mm

Flange Thickness

Th= 3.0 mm

Flange Thickness

Th= 3.0 mm

Type

Th= 3.2 mm

Type

Th= 3.2 mm


Th= 3.4 mm

Th= 3.4 mm

STD 36.04 mm

Th= 3.6 mm

B2 ( 2ND BRAKE)

B1 ( O/D & 2ND COAST BRAKE) PART NAME Piston Stroke Pack Clearance Piston Return Spring Free Length

SPEC. 0.65-1.05 mm 0.65-1.05 mm STD 18.99 mm

PART NAME

SPEC.

Piston Stroke

0.395-1.245 mm

Pack Clearance

0.395-1.245 mm


STD 15.85 mm

B3 ( 1ST & REVERSE BRAKE) PART NAME

SPEC.

Piston Stroke

0.791-1.489 mm

Pack Clearance

0.791-1.489 mm


STD 21.71 mm

OIL PUMP SPEC.

PART NAME Body Bush

STD.

38.113-38.138 mm

MAX

38.188 mm

STD.

18.424-18.450 mm

MAX

18.50 mm

STD.

0.10-0.17 mm

MAX

0.22 mm

STD.

0.07-0.15 mm

MAX

0.20 mm

STD.

0.07-0.15 mm

MAX

0.20 mm

Side Clearance of

STD.

0.02-0.05 mm

Drive and Driven Gear

MAX

0.10 mm

Stator Shaft Bush Body Clearance Tip Clearance Drive Tip Clearance Driven


03/7 (DW-01M-MRM002)


[ RM-89 ]

OIL SEAL PART NAME

SPEC.

T/A Housing

Oil seal in depth

2.6-3.6 mm

T/A Case

Oil seal in depth

3.8-4.8 mm

Manual Shaft

Oil seal in depth

0.75-1.25 mm

PLANETARY GEAR BUSHING SPEC.

PART NAME Pla. Gear Bush

Fr Mid Rr STD.

30.00-30.026 mm

Fr Mid Rr MAX

30.076 mm

Pla. FR Sun

Fr Rr STD.

21.500-21.526 mm

Gear Bush

Fr Rr MAX

21.576 mm

Pla. RR Sun

Fr Rr STD.

21.500-21.526 mm

Gear Bush

Fr Rr MAX

21.576 mm

SOLENOID PART NAME

SPEC.

S1

12-16 ohm (20 degree C)

S2


ST


SL


T/A HOUSING - T/C BOSS DISTANCE SPEC. T/A Housing-T/C Distance

11.1 mm

ACCUMULATOR SPRING PART NAME

SPRING Free (mm) Outer (mm)

Color

C2 Acum.

57.20

17.50

Light Green

C1 Acum.

54.70

17.20

Blue

B1 Acum.

47.13

16.00

Pink


03/7 (DW-01M-MRM002)

Daewoo 8140le Repair

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