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The JATCO JATCO 5 speed automatic automatic transmission transmission is known as the the JF506E in the Jaguar Jaguar X Type and Land Rover’s Rover’s Free Freelan lander der.. In the the Mazd Mazdaa 6 and and MPV it is known known as as the the JA5A JA5A-E -EL L and and with with VW’ VW’s Golf Golf,, GTI GTI and and Jetta Jetta it is the the 09A. Overseas it is known as the 5F1J or the Durashift -5-Tronic transmission used in the Mondeo vehicle star starti ting ng in 2002 2002.5 .5 model model year year.. It is based based on an earl earlie ierr AG5 AG5 tran transm smis issio sion n used used in the 2000 2000 Gala Galaxy xy whic which h is a fully automatic automatic and electro electronically nically controlled controlled front front wheel drive drive transmission. transmission. The JF5 transmis transmission sion ratios ratios are achieved with 3 planetary gear sets tha t are held and/or driven by 4 multi-plate drive clutches, 2 multi-plate brake or holding clutches, 1 band band and 2 one-way holding devices. The internal components locations and names names are identifi identified ed in Figure1. Figure1. This manual contains the procedures necessary to diagnose, overhaul and/or repair the Mazda JF506E transaxle, and is intended for automotive technicians that are familiar with the operation of automatic transmissions.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, withou withoutt permiss permission ion of Automa Automatic tic Trans Transmis missio sion n Service Service Group. Group. This This includ includes es all text illust illustrati rations ons,, tables tables and charts charts..

The JATCO JATCO 5 speed automatic automatic transmission transmission is known as the the JF506E in the Jaguar Jaguar X Type and Land Rover’s Rover’s Free Freelan lander der.. In the the Mazd Mazdaa 6 and and MPV it is known known as as the the JA5A JA5A-E -EL L and and with with VW’ VW’s Golf Golf,, GTI GTI and and Jetta Jetta it is the the 09A. Overseas it is known as the 5F1J or the Durashift -5-Tronic transmission used in the Mondeo vehicle star starti ting ng in 2002 2002.5 .5 model model year year.. It is based based on an earl earlie ierr AG5 AG5 tran transm smis issio sion n used used in the 2000 2000 Gala Galaxy xy whic which h is a fully automatic automatic and electro electronically nically controlled controlled front front wheel drive drive transmission. transmission. The JF5 transmis transmission sion ratios ratios are achieved with 3 planetary gear sets tha t are held and/or driven by 4 multi-plate drive clutches, 2 multi-plate brake or holding clutches, 1 band band and 2 one-way holding devices. The internal components locations and names names are identifi identified ed in Figure1. Figure1. This manual contains the procedures necessary to diagnose, overhaul and/or repair the Mazda JF506E transaxle, and is intended for automotive technicians that are familiar with the operation of automatic transmissions.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, withou withoutt permiss permission ion of Automa Automatic tic Trans Transmis missio sion n Service Service Group. Group. This This includ includes es all text illust illustrati rations ons,, tables tables and charts charts..

Technical Service Information ÓßÆÜß ÖÚëðêÛ ÝÑÓÐÑÒÛÒÌ ÔÑÝßÌ×ÑÒÍ ÔÑÝßÌ×ÑÒÍ

Figure 1

AUTO AU TOMAT MATIC IC T RANS RA NSMI MISS SSIO ION N SER S ERVI VICE CE GR OUP OU P

Technical Service Information ÝÑÓÐÑÒÛÒÌ ßÐÐÔ×ÝßÌ×ÑÒ ×ÒÚÑÎÓßÌ×ÑÒ Refer to Figure 1 for internal component locations and Figure 2 for the application of the components for each gear, along with the shift solenoid sequence for each gear. This will help you in diagnosis of the JF506Etransaxle.

Also in Figure 2, you will find the planetary gear ratios for each of the different manufacturers and you will notice that they will not all interchange. Use care if replacement parts arerequired.

ÝÑÓÐÑÒÛÒÌ ßÐÐÔ×ÝßÌ×ÑÒ ÝØßÎÌÍ

ÖÚëðêÛ ÐÔßÒÛÌßÎÇ ÙÛßÎ ÎßÌ×ÑÍ

Figure 2

AUTOMATIC T RANSMISSION SERVICE GR OUP

Technical Service Information ÙÛÒÛÎßÔ ÜÛÍÝÎ×ÐÌ×ÑÒ

ÍØ×ÚÌ ÏËßÜÎßÒÌÍ

The new JATCO JF506E is a fully automatic, five speed, front wheel drive, electronic controlled transaxle. It consists primarily of a four element torque converter, three planetary gear sets, six multiple disc clutch packs, one brake band, one sprag, one roller clutch, and a hydraulic pressurization and control system. The four element torque converter contains a pump, a turbine, a pressure plate splined to the turbine, and a stator assembly. The torque converter acts as a fluid coupling to smoothly transmit power from the engine to the transmission. It also hydraulically provides additional torque multiplication when required. The pressure plate, when applied, provides a mechanical "direct drive" coupling of the engine to the turbine shaft of thetransmission. The three planetary gear sets provide the five forward gear ratios and reverse. Changing gear ratios is fully automatic and is accomplished through the use of a Transmission Control Module (TCM) located in the vehicle. The TCM receives and monitors various electronic sensor inputs, and uses this information to shift the transmission at the optimum time. The TCM commands six On/Off solenoids and three Duty Cycle solenoids within the transaxle to control desired gear ratio, shift timing, and line prressure. The TCM also controls the apply and release of the torque converter clutch which allows the engine to deliver the maximum fuel efficiency without sacrificing vehicle performance. The hydraulic system primarily consists of a rotor type pump, three control valve bodies, converter housing and case. The pump maintains the working pressures needed to apply the clutch pistons that apply or release the friction components. These friction components, when applied or released, support the shifting qualities of the transmission. The friction components used in this transmission consist of six multiple disc clutches. The multiple disc clutch packs combine with one band, one mechanical sprag clutch, one mechanical roller clutch, to deliver six different gear ratios through the gearsets that then transfer torque through the output shaft. Refer to Figure 1 for component locations and to Figure 2 for the component application chart for this transaxle.

The Mazda "6" has a four detent shift quadrant, as shown in Figure 3, along with a "Manual" mode, that allows thedriverto select the range of gears available, by tapping the selector lever towards the "-" or "+" to downshift or upshift. The Mazda "MPV" has a six detent shift quadrant. as shown in Figure 4, along with an OD/OFF switch on the shift lever to cancel overdrive. The shift lever must be used to manually select any of the lower gears.

When the Park position is selected, there is no powerflow through the transaxle. The parking pawl is engaged which locks the output shaft to the case. The engine can be started and the ignition key can be removed. When the Reverse position is selected, the vehicle can be operated in a rearward direction at a reduced gear ratio. When the Neutral position is selected, there is no powerflow through the transaxle. The output shaft is not held and is free to rotate and the engine can be started. This position can also be selected while the vehicle is moving, to restartthe engineif thatbecomes necessary.

ÓßÆÜß þêþ ÍØ×ÚÌ ÏËßÜÎßÒÌ

Figure 3


Technical Service Information The Drive position is the normal position for most forward gear operations. The Drive position provides automatic upshifts and downshifts, apply and release of the converter clutch, and maximum fuel economy during normal operation. Drive range allows the transaxle to operate in each of the five forward gear ratios. Downshifts are available for safe passing, by depressing the accelerator. When the Manual position is selected, it enables the driver to select the range of gears by tapping the selector lever towards the "-" or "+" to cause the transaxle to downshift or upshift, and is shown in Figure 3. These ranges can be used for conditions where it may be desirable to control the selection of gear ratios. These conditions include trailer towing, hilly terrain, starting on slippery surfaces, and for engine braking when descendingslight grades. When the Park position is selected, there is no powerflow through the transaxle. The parking pawl is engaged which locks the output shaft to the case. The engine can be started and the ignition key can be removed. When the Reverse position is selected, the vehicle can be operated in a rearward direction at a reduced gear ratio.

The Drive position is the normal position for most forward gear operations. The Drive position provides automatic upshifts and downshifts, apply and release of the converter clutch, and maximum fuel economy during normal operation. Drive range allows the transaxle to operate in each of the five forward gear ratios. Downshifts are available for safe passing, by depressing the accelerator. Driver may also cancel overdrive (5th gear), by pressing the OD/OFF button on the end of the shift lever, as shown in Figure 4. This action will illuminate the OD/OFF lamp on the instrument panel Manual "3" position provides a 2nd gear start with an upshift to 3rd at approximately 15 mph, but prevents transaxle from shifting above 3rd gear, and adds more performance and engine braking for hilly terrain. Manual 3 can be selected at any vehicle speed, but will not downshift until vehicle speed calibrated into the TCM has been reached, to prevent engine over-speed. Manual "2" position provides a 2nd gear start and hold for slippery surfaces, and provides engine braking for hilly terrain. Manual 2 can be selected at any vehicle speed, but will not downshift until vehicle speed calibrated into the TCM has been reached, to prevent engine over-speed.

When the Neutral position is selected, there is no powerflow through the transaxle. The output shaft is free to rotate and the engine can be started. This position can also be selected while the vehicle is movingto restart theengine, if necessary.

ÓßÆÜß þÓÐÊþ ÍØ×ÚÌ ÏËßÜÎßÒÌ OD/OFF LIGHT

Figure 4

AUTOMATIC T RANSMISSIO N SERVICE GROU P

Technical Service Information ÚÔË×Ü ÎÛÏË×ÎÛÓÛÒÌÍ

ÛÔÛÝÌÎÑÒ×Ý ÝÑÓÐÑÒÛÒÌÍ

Fluid requirements are the same for the Mazda "6" and the Mazda "MPV". Both units are filled through the dipstick tube. The fluid should be checked while hot at 60-70°C (149-158°F) and should be at the level on dipstick,as shown in Figure 5. The drain plug is on the bottom of the converter housing part of the case, just in front of where the two case pieces split.

The Transaxle Range/Gear Select Switch is located on the outside of transaxle, as shown in Figure 6 and Figure 7. The range selector on the Mazda will have two different indicators depending on whether you have a Mazda "6" or a Mazda "MPV". The Mazda "6" will have four positions (P R N D) and the Mazda "MPV" will have six positions, (PRND32) as shown in Figure 6 and Figure 7.

HOT RANGE ATF TEMPERATURE 60-70°C (146-158°F)

20°C

The electrical connector for the Range Switch is hard wired to, and part of, the Transaxle Range Selector Switch, as shown in Figure 6 and 7, and as you might expect are wired differently, and will not interchange.

65°C

COOL RANGE ATF TEMPERATURE 15-25°C (59-77°F)

Figure 5

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Figure 6

Figure 7


Technical Service Information We have provided you with individual connector views, wire schematics and continuity charts for both the Mazda "6" and "MPV" in Figure 8 and 9. Although the charts in Figure 8 and 9 are used to check the integrity of the switch's range selection, using an Ohmmeter, the best method, is to check the range switch in the vehicle with a Volt meter. By looking at the charts in Figure 8 and 9, it can be seen that terminal "C" is the common terminal for all range selections. This is the voltage supply into the switch. Terminals "H" and "B" are used for


starting purposes only. With the ignition switch "ON", there must battery voltage at terminal "C". If there is not, this must be repaired first. If voltage is present, it should exit the assigned terminal in each gear selection. Notice also the Mazda "6" has a manual switch in the selector lever that allows manual shifting up and down. The Mazda "MPV" is not equipped with the manual mode, but is equipped with an overdrive cancel button.


Meter Ign. 15A

M Range Switch UP Switch

Test Switch

DN Switch

OD OFF

Figure 8

Figure 9

AUTOMATIC T RANSMISSIO N SERVICE GROU P

Technical Service Information ÛÔÛÝÌÎÑÒ×Ý ÝÑÓÐÑÒÛÒÌÍ øÝÑÒÌùÜ÷ The JF506E transaxles all have a complex wire harness set-up, compared to previous units. On the Mazda units there are two case connectors, as shown in Figure 10 and 11. One connector that provides voltage for all of the 9 solenoids, and one connector that provides a path for the three speed sensors and the TFT sensor. Both of these connectors merge into one harness, go through a "Pass-thru" connector, and once again split into two more connectors . One connector with eight terminals for the three speed sensors and the TFT sesnor, and one connector with ten terminals for the 9 solenoids and a ground. Refer to Figure 10 for the Mazda "6" version and Figure 11 for the Mazda "MPV" version. The Mazda "6" has a metal bracket that the connectors snap into and the Mazda "MPV" does not use a bracket. If any of these connectors are damaged, a complete wiring harness is required. Both of the external wiring harness' are illustrated in Figure 12.

There is an internal wire harness that plugs into the 10-way internal connector and runs to each of the 9 solenoids andprovides an internal ground. There is also an internal harness that plugs into the 8way internal connector that provides a path for all three speed sensors and the Transaxle Fluid Temp (TFT) sensor. Of course then there are connectors at each of the 9 solenoids, and more connectors at each of the 3 speed sensors and the TFT sensor. These internal harness' can also be seen in Figure 10 and 11. The internal harness' are the same on both the Mazda "6" and "MPV". The internal solenoid harness is also illustrated in Figure 12. This makes the electronic diagnostic process a challenge, to say the very least, with a variety of connectors that may have corrosion or damage. We have provided you with individual terminal identification for the external and the internal connectors, and a resistance chart in Figure 14 for the Mazda"6",and Figure 15 for the"MPV". Terminal identification for the TCM is found in Figure 16, and is thesamefor bothmodels.



TO SPEED SENSORS AND TEMP SENSOR

TO SPEED SENSORS AND TEMP SENSOR

TO ALL SOLENOIDS

TO ALL SOLENOIDS

Figure 10

Figure 11


Technical Service Information ÓßÆÜß þêþ

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Figure 12

ÛÔÛÝÌÎÑÒ×Ý ÝÑÓÐÑÒÛÒÌÍ øÝÑÒÌùÜ÷ The Transaxle Fluid Temp (TFT) Sensor is located inside of the transaxle case housing, as shown in Figure 13, and requires disassembly if replacement becomes necessary. Resistance of the TFT sensor decreases as thefluid temperature increases, as shown inthechartinFigure13. Input from the TFT is used by theTCM for converter clutch apply, torque reduction and fifth gear operation. To promote engine warm up during cold weather operation, the TCM may inhibit TCC apply until transaxle fluid temperature has reached approximately 104°F (40°C). Fifth gear may also be prohibited during cold weather operation, or when the TFT malfunctions. Torque reduction may also be inhibited when the TFT malfunctions. Use the charts for terminal identification in Figure 14 and 15 to check the TFT sensor, and the resistance chart in Figure 13 to verify. The TFT sensor may produce code P0711 (sensor signal stuck), code P0712 (shorted circuit), or code P0713 (opencircuit).

Figure 13


Technical Service Information îððì ÓßÆÜß þêþ ÌÎßÒÍßÈÔÛ ÌÛÎÓ×ÒßÔ ×òÜò ßÒÜ ÎÛÍ×ÍÌßÒÝÛ ÝØßÎÌ

Figure 14


Technical Servi ce Information îððì ÓßÆÜß þÓÐÊþ ÌÎßÒÍßÈÔÛ ÌÛÎÓ×ÒßÔ ×òÜò ßÒÜ ÎÛÍ×ÍÌßÒÝÛ ÝØßÎÌ

Figure 15

AUTOMATIC TRANSMISSION SERVICE G ROUP

Technical Service Information ÌÝÓ ÌÛÎÓ×ÒßÔ ×Ü É×ÎÛ ØßÎÒÛÍÍ ÝÑÒÒÛÝÌÑÎ Ê×ÛÉ

Figure 16


Technical Service Information ÛÔÛÝÌÎÑÒ×Ý ÝÑÓÐÑÒÛÒÌÍ øÝÑÒÌùÜ÷ ÍÐÛÛÜ ÍÛÒÍÑÎÍ

AUTO

DC

ðëéë

mV

RPM

There are three inductive type speed sensors located inside of the transaxle case housing and are not accessible from outside. Disassembly is required, if replacement becomes necessary. The Turbine Shaft Speed sensor is the only one that can be accessed in the vehicle, by removing the rear cover, as shown in Figure 18. The other two speed sensors require transaxle removal, and splitting the case. The speed sensors are, Turbine Shaft Speed Sensor, Intermediate Shaft Speed Sensor and the Output Shaft Speed Sensor. Electrical connections to all of the speed sensors and TFT sensor come through the external connector and the 8-way internal connector to reach these components. All three speed sensors are the same, but different brackets are used to mount them in their proper locations. Amazingly the Mazda, Jaguar, and Freelander are all using the same speed sensor. All 3 speed sensors should measure the same resistance at 68°F (20°C), as shown in Figure 17, and can also be checked through the appropriate terminals on the external case connector, shown in Figure 14 and 15.

kΩ

Ω

mA A

V

mA A

V

OFF

A

mA

COM

V Ω RPM

10A Max FUSED

Figure 17

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Figure 18


Technical Service Information ÍÐÛÛÜ ÍÛÒÍÑÎÍ øÝÑÒÌùÜ÷ The Turbine Shaft Speed sensor is positioned, as shown in Figure 18, to read the high/reverse clutch housing which is splined to the turbine shaft. The TSS sensor detects a pulse signal from the lugs on the outside of the high/reverse clutch housing. The speed sensors can be checked externally, as shown in Figure 17. The Turbine Shaft Speed sensor is the only one that can be accessed in the vehicle, by removing the rear cover, as shown in Figure 18. The information from the TSS sensor is used by the TCM to monitor gear ratio, line pressure control and to monitor and control TCC apply. This sensor may produce a Diagnostic Trouble Code (DTC) P0715, Turbine Shaft Speed sensor circuitcode.

The Intermediate Shaft Speed sensor is positioned, as shown in Figure 19, to read the transfer "Drive" gear, which is driven by the 1st and 2nd planetary gearset. The sensor detects a pulse signal according to the teeth on the transfer drive gear. Since there are various ratios,the tooth count will vary. The input of the intermediate shaft speed sensor is used by the TCM to calculate the timing of engagements and disengagements of the brake clutches, and to monitor gear ratio. This sensor may produce a Diagnostic Trouble Code (DTC) P0791, Intermediate Shaft Speed sensor circuit code.

The Output Shaft Speed sensor is positioned, as shown in Figure 19, to read the "Park Gear", which is driven by the output shaft. The sensor detects a pulse signal accordingto the lugs on the park gear. The input of the output shaft speed sensor is used by the TCM to provide a vehicle speed signal, calulate shift timing, line pressure control, and to monitor gear ratio. This sensor may produce a Diagnostic Trouble Code (DTC) P0720, Output Shaft Speed sensor circuit code.

×ÒÌÛÎÓÛÜ×ßÌÛ ÍØßÚÌ ßÒÜ ÑËÌÐËÌ ÍØßÚÌ ÍÐÛÛÜ ÍÛÒÍÑÎÍ

Figure 19


Technical Service Information ÍÑÔÛÒÑ×Ü ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ ßÒÜ ÔÑÝßÌ×ÑÒÍ There are a total of nine (9) solenoids used on all models, which can be classified as two different types, because of theway in which they operate. Four of them are duty cycle solenoids, the other five are On/Off solenoids. Solenoid names and functions are different between the manufacturers. All solenoids in all models are actuated (energized) by a voltage feed from theTCM.

The Mazda solenoid locations and names are identified for you in Figure 20, and are the same for both Mazda "6" and Mazda "MPV". The shift solenoid firing sequence is the same on all models, and is also shown in Figure 20.

ÓßÆÜß ÍÑÔÛÒÑ×Ü ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ ßÒÜ ÔÑÝßÌ×ÑÒÍ

JC7 JP

-1 PM-SUB

B021204N

F

Figure 20


Technical Service Information ÍÑÔÛÒÑ×Ü ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ øÝÑÒÌùÜ÷

ÓßÆÜß þêþ ßÒÜ ÓßÆÜß þÓÐÊþ ÑÒñÑÚÚ

On/OffSolenoids are as follows: Shift Solenoids A, B, C, Neutral Shift Solenoid, and theReduction Timing Solenoid, as illustrated in Figure 21 and 22. These On/Off solenoids close the pressure circuit in response to current flow from the TCM. Each solenoid has an internal coil. Current passes through the coil and actuates the needle valve. The needle valve then opens and closes the fluid pressure circuit. Figure 22 Duty Cycle Solenoids are as follows: Line Pressure Solenoid, TCC Solenoid, High Clutch Solenoid, and the 2-4 Brake Solenoid, as shown in Figure 23. The duty cycle solenoids repeatedly turn On/Off in 50Hz cycles. This opens and closes the fluid pressure circuit rapidlyand meters fluid pressure in the circuit, dependant upon vehicle speed, throttle opening, engine load, and transaxle temperature, among otherthings. Use the terminal identification and resistance charts on Page 11 for Mazda "6", and Page 12 for Mazda "MPV" to check the solenoids while still in the transaxle.

ÓßÆÜß þêþ ßÒÜ ÓßÆÜß þÓÐÊþ ÜËÌÇ ÝÇÝÔÛ ÍÑÔÛÒÑ×ÜÍ

ÓßÆÜß þêþ ßÒÜ ÓßÆÜß þÓÐÊþ ÑÒñÑÚÚ

Figure 21

Figure 23


Technical Service Informati on ÌÎßÒÍßÈÔÛ ÌÑ ÌÝÓ É×ÎÛ ÍÝØÛÓßÌ×Ý

M Range Switch UP Switch DN Switch

CAN "H" CAN "L"

Figure 24


Technical Service Information ÌÎßÒÍßÈÔÛ ÌÑ ÌÝÓ É×ÎÛ ÍÝØÛÓßÌ×Ý

Test Switch OD OFF

CAN "H" CAN "L"

Figure 25


Technical Service Information ÓßÆÜß þêþ Ü×ßÙÒÑÍÌ×Ý ÌÎÑËÞÔÛ ÝÑÜÛÍ ÜÌÝ

Ó×Ô ÑÒ

ÜÛÍÝÎ×ÐÌ×ÑÒ

Figure 26


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Technical Service Information ÓßÆÜß þÓÐÊþ Ü×ßÙÒÑÍÌ×Ý ÌÎÑËÞÔÛ ÝÑÜÛÍ ÜÌÝ

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ÜÛÍÝÎ×ÐÌ×ÑÒ

Figure 27


Technical Service Informati on ÖÚëðêÛ ÐÔßÒÛÌßÎÇô Ü×ÚÚÛÎÛÒÌ×ßÔô ÌÎßÒÍÚÛÎ ÙÛßÎ ÎßÌ×Ñ ÝØßÎÌ

Figure 28


Technical Service Information ÍÐÎÑÝÕÛÌ ÎßÌ×Ñ ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ

ÝßÍÛ ÐßÍÍßÙÛ ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ

Figure 28 is a chart for the identification of the two transfer gears in this unit and the differences in the various units, as they willnot interchange.

Figure 29 identifies the case passages under the valve body for possible air checks, or for removing a particular component. Also shown are the location of thetwo seals between the valve body and thecase.

ÝßÍÛ ÐßÍÍßÙÛ ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ

Figure 29


Technical Service Information Ô×ÒÛ ÐÎÛÍÍËÎÛ ÌÛÍÌ

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ÎßÒÙÛ

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×ÜÔÛ

ÍÌßÔÔ

ÎßÒÙÛ


×ÜÔÛ

ÍÌßÔÔ

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Figure 30


Technical Service Information Ô×ÒÛ ÐÎÛÍÍËÎÛ ÌÛÍÌ

ÎÛÊÛÎÍÛ ÌÛÍÌ

ÎßÒÙÛ


×ÜÔÛ

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Figure 31


Technical Service Information ÍßÚÛÌÇ ÐÎÛÝßËÌ×ÑÒÍ

ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ 1. The transaxle should be steam cleaned on the outside, to remove any dirt and grease before disassembly begins. 2. This transaxle canbe disassembled very easily on a work benchwithout the benefitof holding fixture for rotation. 3. Remove the torqueconverter from transaxle, as shown in Figure 32.

4. Remove the retaining bolt, dipstick andtube, as shown in Figure 32, discard"O" ring seal.

1 11 12 13

TORQUECONVERTERASSEMBLY FLUIDDIPSTICKTUBE FLUIDDIPSTICKTUBERETAINING BOLT FLUIDDIPSTICKTUBE"O"RING SEAL

11 12

13

1

Figure 32


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 5. Remove both cooler linebanjofittingbolts and cooler lines,as shown in Figure 33. 6. Remove the external manual shift lever nut, washerand lever,as shown inFigure 33. 7. Remove the twotransaxlerange sensor bolts, as shown in Figure 34,and remove transaxle range sensor.

6 9 7

14 10

8 15

6 7 8 9 10

COOLERLINEBANJ O FITTING BOLTS (2) C OOLERLINEBANJ O FITTING WASHERS (4) C OOLERLINEBANJ O FITTINGS MANUALSHIFTLEVERRETAINING NUT MANUALSHIFTLEVER

Figure 33

14 TRANSAXLERANGESENSORRETAINING BOLTS (2) 15 TRANSAXLERANGESENSOR

Figure 34


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 8. Remove the twenty side cover retaining bolts, as shown in Figure 35, and remove side cover. 9. Disconnectboth inside connectorsand lay the speed sensorconnector wires over the pan rail, as shown in Figure 35. 10. Remove the retaining clipfrom the external "pass-thru" connector and harness assembly, as shown in Figure 35. 11. Remove the external harness and connector assemblyby maneuvering through the hole in case, as shown in Figure 35. 12. Remove and discard the "O" ring seal onthe pass-thru connector.

RETAINING BOLTS 20 REQUIRED

SIDE COVER

"O" RING SEAL

EXTERNAL PASS-THRU CONNECTOR AND HARNESS ASSEMBLY

RETAINING CLIP

SOLENOID CONNECTOR

JC7 JP

-1 PM-SUB

B021204N

F

2. VALVEBODYTO CASEBOLT, 90MM LONG (SILVERIN COLOR) TEN 90MM LONG BOLTSREQUIRED 3. VALVEBODYTO CASEBOLT, 106MM LONG (SILVERIN COLOR) ONE106MM LONG BOLTREQUIRED

SPEED SENSOR CONNECTOR

Figure 35

Figure 36

AUTOMATIC TRANSMISSION SE RVI CE GROU P

Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 13. Disconnect each of the connectorsfrom their respective solenoids. 14. Remove the bolt from terminal holding the groundwires, and removethe internal solenoid harnessassembly, as shown in Figure 37. 15. Remove the eleven, silver in color, valve body to case retaining bolts.

INTERNAL SOLENOID HARNESS ASSEMBLY

2

16. Remove the valve body assemblyby lifting straight up, as shown in Figure 37. 17. Set thevalve body asidefor thecomponent rebuild section. 18. Remove and discard the low/reverse clutch "top-hat" seal and the reduction band seal, as shown in Figure 37. 19. Remove the 22 converterhousing to case bolts, and their locations are shown in Figure 38.

3

VALVE BODY ASSEMBLY REDUCTION BAND SEAL

LOW/REVERSE CLUTCH SEAL

ÝÑÒÊÛÎÌÛÎ ØÑËÍ×ÒÙ ÞÑÔÌ ÔÑÝßÌ×ÑÒÍ

2. VALVEBODYTO CASEBOLT, 90MM LONG (SILVERIN COLOR) TEN 90MM LONG BOLTSREQUIRED 3. VALVEBODYTO CASEBOLT, 106MM LONG (SILVERIN COLOR) ONE 106MM LONG BOLTREQUIRED

Figure 37

Figure 38


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 20.After thebolts areremoved, tap on converter housingwith a rubber mallet to loosen and remove converter housingfrom the case, as shown in Figure 39. 21. Set the converter housing aside for component rebuild section. 22. Remove thefinal drive assembly by lifting straight up, as shown in Figure 40. 23. Set final drive assemblyaside for component rebuild section. 24. Remove thetwo fluid filter retaining bolts, as shown in Figure 41, removeand discard the fluid filterassembly.

16

2

16 FINALDRIVERING GEARANDCARRIERASSEMBLY

Figure 40

2

17

4

3

2 CONVERTERHOUSING TO CASEBOLTS (22REQUIRED) 3 CONVERTERHOUSING ASSEMBLY 4 TRANSAXLEC ASEASSEMBLY

Figure 39

2 FLUIDFILTERTO CASEBOLTS (2 REQUIRED) 17 FLUID FILTERASSEMBLY

Figure 41

AUTOMATIC TRANSM ISSION SERVICE GRO UP

Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 625

617

616 593 594

601

25.Remove the number10 thrust bearing from the pinion gear on the reduction carrier assembly, as shown in Figure 42. 26.Remove the reduction carrier assembly from case by liftingup with slight twisting motion, as shown in Figure 42. 27.Set the reduction carrierassembly aside for the component rebuild section. 28.Remove the reduction sungear from direct clutch housing, as shown in Figure 42. 29. Removethe number12 thrust bearing and the 12Athrust bearingrace (SeeFigure42). 30. Removethe direct clutch housing from case, as shown in Figure 42. 31. Set direct clutch housing aside for component rebuild section. 32. Removethe reduction band assemblyfrom the case, as shown in Figure 42. 33. Removethe "O" ring seal from turbine shaft, as shown in Figure 43.

600

TURBINE SHAFT "O" RING SEAL T

T

593 594 600 601 616 617 625

REDUCTION SUNTODIRECTSUPPORTRACE (NO. 12A) REDUCTION SUNTODIRECTSUPPORTBEARING (NO. 12) REDUCTION BAND DIRECTC LUTCHHOUSING ASSEMBLY REDUCTIONSUNGEAR ASSEMBLY REDUCTIONPLANETARYGEARASSEMBLY PINIONGEARTO CONV. HOUSING BEARING (NO.10)

Figure 42

Figure 43


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷

2

34. Remove theremaining five oil pump retaining bolts, as shown in Figure 44. 35. Remove theoil pump assemblyby lifting straight up, as shown in Figure44. 36. Remove and discard the oil pumpto case gasket, as shown in Figure 44. 37. Remove theturbine shaft by liftingstraight up, as shown inFigure 44.

18

38. Set theoil pump and turbine shaft aside for the component rebuild section. 39. Remove thesnap ring holding the reduction servo coverin place, as shown in Figure 45. 40. Remove thereduction servo cover assembly, as shown inFigure 45.

19

20

21

61

62

T

2 OILPUMPRETAINING BOLTS (5 REQUIRED) 18 OILPUMPASSEMBLY 19 OILPUMPTO CASEGASKET 20 TURBINE SHAFTASSEMBLY 21 TURBINESHAFTSEALRINGS (3 OR 2 REQUIRED)

Figure 44

61 REDUCTION SERVOCOVERRETAINING SNAPRING 62 REDUCTION SERVOCOVERAND"O"RINGSASSEMBLY

Figure 45

AU TOMATIC TRANSMISSION SERVICE GRO UP

Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 41. Compress thereduction servo piston using a 14mm deep socket and a large screwdriver, as shown in Figure 47, and remove thesnap ring, as shown in Figure 48.

42.Remove the reduction servo spacer, theapply piston and return spring, as shown in Figure 48.

43. Set allreduction servo parts aside for the component rebuild section.

ÎÛÜËÝÌ×ÑÒ ÍÛÎÊÑ ÝËÌóßÉßÇ 66

67

68

69

Figure 46

LARGE SCREWDRIVER

66 67 68 69

Figure 47

REDUCTION SERVOPISTON SNAPRING REDUCTION SERVO SPACER REDUCTION SERVO APPLYPISTONASSEMBLY REDUCTION SERVO RETURNSPRING

Figure 48


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 595 19

44.Remove the two 17mm head bolts (595), with the "O" rings, from the end cover, as shown in Figure 49.

45.Remove and discard the two"O" rings. 46.Remove the 14 remaining 12mm head bolts retaining the end cover, as shown in Figure 49. 47.Remove the end cover by tappinggentlywith a plastic mallet toloosen,and set theend cover aside for component rebuild. 48. Remove and discard the end coverto case seal, as shown in Figure 49. 49. Remove thenumber 9 thrust bearingandthe 9A"selective" thrust bearing race, as shown in Figure 49.

3

40

50. Remove the3 fluid feed pipes using a large screwdriver (See Figure 50). Noticethat two of the pipes are clipped together.

18 48

FLUID FEED PIPES

49

CLIPS

18 ENDCOVERTO CASESEAL 19 ENDCOVERTO CASEBOLTS, 12MM HEAD (14REQUIRED) 40 TRANSAXLEENDCOVERASSEMBLY 48 ENDCOVER"SELECTIVE"BEARING RACE (NO. 9A) 49 ENDC OVERTO HIGH/REVDRUM THRUSTBEARING (NO. 9) 595 BOLTWITH"O"RING, 17MM HEAD (2REQUIRED HERE)

Figure 49

Figure 50


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 51. Disconnectthe turbine shaft speed sensor and lay theconnector to theside (SeeFigure 51). 52. Removethe two retaining bolts from the clip and removethe turbine shaft speed sensor, as shown in Figure 51. 53. Remove2-4 brake clutch piston return spring assembly, as shown in Figure 52. 54. Removethe high and reverse clutch housing assembly, as shown in Figure 52. 55. Removethe number8 thrust bearing, as shown in Figure 52. 53

56. Set the high and reverse clutch housing aside for the component rebuild section.

101

63

62

61 276

TSS SENSOR CONNECTOR 61 TURBINESPEEDSENSOR 62 TURBINESPEEDSENSORRETAINING CLIP 63 TURBINESPEEDSENSORRETAINING BOLTS (2REQUIRED)

Figure 51

53 2-4 BRAKEC LUTCHPISTON RETURNSPRING ASSEMBLY 101 HIGH ANDREVERSECLUTCHHOUSING ASSEMBLY 276 CLUTCHHOUSING TO HIGHCLUTCHHUBBEARING (NO. 8)

Figure 52


Technical Servi ce Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 57. Remove thedirect clutch hub andthe number 8Athrust bearingrace,as shown in Figure 53. 58. Remove thenumber 7 thrust bearing, as shown in Figure 53. 59. Remove thenumber 7Athrust bearing race and the input sun gear and hub assembly, as shown in Figure 54. 60. Remove thenumber 6Athrust bearing race, as shown in Figure 54.

271

275 270

274

269

273

271

271 273 274 275

SUN GEARTOCLUTCHHUBTHRUSTBEARING RACE (NO.7A) HIGHCLUTCHHUBTOSUNGEARTHRUSTBEARING (NO. 7) HIGHCLUTCHHUBAND SHAFT HIGHCLUTCHHUBTHRUSTBEARING RACE (NO. 8A)

Figure 53

269 INPUTSUNGEARTHRUSTBEARING RACE (NO. 6A) 270 INPUTSUNGEARANDHUBASSEMBLY 271 SUNGEARTO CLUTCHHUBTHRUSTBEARING RACE (NO.7A)

Figure 54


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 61.Remove the number 6 thrust bearing and the input carrierassembly, as shown in Figure 55. 62.Remove the number 5 thrust bearing assembly, as shown in Figure 55. 63.Remove the outputsun gear, number 4 thrust bearing and output carrier assembly, as shown in Figure 56. 64.Remove the number 3Athrust bearingrace, as shown in Figure 56.

264

263 267 262 266

261 265

265 SUNGEARTO INTPUTCARRIERTHRUSTBEARING (NO. 5) 266 INPUTCARRIERASSEMBLY 267 INPUTCARRIERTO SUNGEARTHRUSTBEARING (NO. 6)

Figure 55

261 262 263 264

OUTPUTC ARRIERTHRUSTBEARING RACE (NO. 3A) OUTPUTC ARRIER/INPUTINTERNALRING GEARASSEMBLY OUTPUTC ARRIERTO SUN GEARTHRUSTBEARING (NO. 4) OUTPUTC ARRIERSUNGEAR

Figure 56


Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 260

259

258

233

65. Remove output carrierinternal ring gear/low clutch hub (259), as shown in Figure57. 66. Remove the number 3 thrust bearing (260),as shown in Figure 57. 67. Remove number 2Athrust bearing race (258), as shown in Figure 57. 68. Remove the low clutch housing assembly(233) as shown in Figure 57. 69. Set thelow clutch housing aside for component rebuild section. 70. Remove the low clutch housing to case thrust bearing (232), which is the number 1 bearing, as shown in Figure 57.

71.Remove number 2 thrust bearing(225) from the low clutch support in case, as shown in Figure 58. 72. Set all gear traincomponents aside for the component rebuild section.

232

225

225

225 232 233 258 259 260

LOWCLUTCHSUPPORTTO RING GEARBEARING (NO.2) LOWCLUTCHHOUSING TO CASETHRUSTBEARING (NO. 1) LOWCLUTCHHOUSING ASSEMBLY RING GEARTO SUPPORT, THRUSTBEARING RACE (NO. 2A) OUTPUTCARRIERINTERNALRING GEAR/LOWCLUTCHHUB RING GEARTO OUTPUTCARRIERTHRUSTBEARING (NO, 3)

Figure 57

225 LOWCLUTCHSUPPORTTO RING GEARBEARING (NO. 2)

Figure 58

AUTOMATIC TRANSM ISSION SERVICE GRO UP

Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷

34

35 36

73. Remove 2-4brake clutch pressure plate snap ring, as shown inFigure 59. 74. Remove both 2-4brake clutch pressure plates, as shown in Figure 59. 75. Remove 2-4brake clutch pack from transaxle case, as shown in Figure 59. 76. Remove 2-4brake clutch backing plate from case, as shown in Figure 59. 77. Install universal compressor tool, as shown in Figure 60, to compress the low/reverseclutch piston retainer.

37

38

39

COMPRESSOR TOOL

34 35 36 37 38 39

2-4 BRAKEC LUTCHSNAPRING 2-4 BRAKECLUTCH"SELECTIVE"PRESSUREPLATE 2-4 BRAKECLUTCHPRESSUREPLATE 2-4 BRAKECLUTCHSTEELPLATES (2 REQUIRED) 2-4 BRAKEC LUTCHFRICTION PLATES (3REQUIRED) 2-4 BRAKEC LUTCHBACKING PLATE

Figure 59

Figure 60


Technical Servi ce Information 250

257

249

256

252

248

247

246

251

251 252 256 257

LOW/REVERSEPISTONRETURN SPRING SEAT LOW/REVERSEPISTONRETURNSPRING LOW/REVERSECLUTCHPISTONRETAINER LOW/REVERSEPISTONRETAINERSNAPRING

Figure 61

246 247 248 249 250

LOW/REVERSEC LUTCHSTEPPEDBACKING PLATE LOW/REVERSEFRICTIONPLATES LOW/REVERSESTEELPLATES LOW/REVERSE"SELECTIVE"PRESSUREPLATE LOW/REVERSE"CONE"C USHION PLATE

Figure 62

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information ÌÎßÒÍßÈÔÛ Ü×ÍßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 78.Remove the low/reverse clutch retainer snap ring, as shown in Figure 61. 79.Remove the compressor tool slowly. 80. Remove low/reverse clutch retainer assembly, as shown in Figure 61. 81.Remove the low/reverse clutch piston return spring and spring seat,as shown in Figure 61. 82.Remove low/reverse "cone"cushion plate,as shown in Figure 62. 83. Remove low/reverse clutch "selective" pressure plate, as shown in Figure 62. 84.Remove low/reverse clutch plates,as shown in Figure 62. 85. Remove low/reverse clutch "stepped" backing plate, as shown in Figure 62.

86. Remove the lowroller clutch retaining snap ring, as shown inFigure 63. 87. Remove low roller clutch assembly, as shown in Figure 63. 88. Remove direct clutch accumulator snap ring and remove all direct clutch accummulator parts, as shown in Figure 64.

81

80

231 78

77

76

230

230 LOWROLLERC LUTCHASSEMBLY 231 LOWROLLERC LUTCHRETAINING SNAPRING

Figure 63

76 77 78 80 81

DIRECTC LUTCHACC UMMULATORPISTON DIRECTC LUTCHACC UMMULATORINNERSPRING DIRECTC LUTCHACCUMMULATOROUTERSPRING DIRECTCLUTCHACC UMMULATORCOVER DIRECTC LUTCHACC UMMULATORCOVERSNAPRING

Figure 64


Technical Service Infor mation ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ 1. Remove theeight 5mm allen head retaining bolts from bottom of the case, as shown in Figure 65. 2.A press is then required to removeassembly from the case, using a 3/4" drive, 2" socket to press against support, as shown in Figure 66.

3. Set thelow clutch support and transfer gear assemblyaside fordisassembly and rebuild. 4. Remove the two 17mm head bolts (595) with "O" rings, as shown in Figure 67. 5. Remove the 13mm head bolt (596) without the "O" ring,as shown in Figure 67.

595

596

230 5MM HEADALLENBOLTS (8REQUIRED)

Figure 65

597

598

595 596 597 598

Figure 66

BOLTWITH"O"RING, 17MM HEAD (2REQUIREDHERE) BOLTWITHOUT"O"RING, 13MM HEAD (1REQUIRED) DIRECTC LUTCHHOUSING SUPPORT DIRECTCLUTCHSUPPORT"STEPPED"SEALING RINGS (2)

Figure 67


Technical Service Information T

599

598

597

597 DIRECTC LUTCHHOUSING SUPPORT 598 DIRECTC LUTCHSUPPORT"STEPPED"SEALING RINGS (2) 599 DIRECTC LUTCHSUPPORTCAGED BEARING ASSEMBLY

Figure 68

6. Remove thedirectclutch support from case, as shown in Figure 67. 7. Remove and discard thedirect clutch "stepped" sealing rings, as shown in Figure68. 8. Replacethe caged needlebearing as necessary using the proper drivers (See Figure 68). 9. Installtwo new direct clutch "stepped" sealing rings onto direct clutch support, as shown in Figure 68, ensuring steps are engaged properly. 10. Re-install direct clutch support, ensuringthat the lube holes are alignedproperly, as shown in Figure 69. 11.Start the13mm head bolt first and tightenonly finger tight (SeeFigure69). 12. Install new "O" rings on thetwo 17mmhead bolts and lubricate with a small amount of Trans-Jel® (See Figure 69). 13. Torque thethree bolts to38 N·m (28 ft.lb.), as shown in Figure 70.

595

596

COMPLETED DIRECT CLUTCH SUPPORT

595 BOLTWITH"O"RING, 17MM HEAD (2REQUIREDHERE) 596 BOLTWITHOUT"O"RING, 13MM HEAD (1REQUIRED)

Figure 69

Figure 70


Technical Servi ce Information ÌÎßÒÍÚÛÎ ÙÛßÎ þßþ ÐßÎÌÍ ÛÈÐÔÑÜÛÜ Ê×ÛÉ

227 229

228

227

223

225 226

221 222 223 224 225

230

TRANSFERGEAR"A" (OUTPUT) TAPEREDROLLERBEARING CONE RETAINING SNAPRING TAPEREDROLLERBEARING CONE (DOUBLE) LOWCLUTCHHOUSING SUPPORT CLUTCHSUPPORTTO RING GEARTHRUSTBEARING (NO. 2)

222

224 226 227 228 229 230

221

LOWC LUTCH"STEPPED"SEALING RINGS TAPEREDROLLERBEARINGS (2REQUIRED) LOCKING WASHERWITHTABS RETAINING SPANNERNUT 5MM HEADALLENBOLTS (8REQUIRED)

Figure 71

ÎÛÓÑÊÛ ÔÑÉ ÝÔËÌÝØ ÍËÐÐÑÎÌ 14. Usinga small punch bend downthe lockingtab on thetabbedlocking washer, used to lockthe spanner nutin place (SeeFigure 71). 15. Loosen the spannernutusing a punch and then remove thespanner nutand locking washer, as shown in Figure 71. 16.A press is then required,along with a 15/16" deep socket anda bearingremover, as shown in Figure 72, to remove the transfergear and shaft from the low clutch support. 17.Clean all transfergear parts thoroughly and dry with compressed air. 18.Install new "stepped" sealingrings in grooves of the lowclutchsupport and ensure that steps are properly engaged, as shown in Figure 71. 19.Replace bearings and races as necessary, lube the bearings and install lowclutch support on top ofthe transfer gear and shaft. 20.Install roller bearing over the shaft,as shown in Figure 73.

Figure 72


Technical Service Information 21. Use press to install roller bearing, as shown in Figure 73, and this is where we will set the roller bearingpre-load. This will require that you releasethe press severaltimes to check the bearing pre-load.

22. Install thelocking washerwith tabs and the spannernut, as shown in Figure 74.

23.Torquethe spanner nut, using"manufactured" socket to 35-40 N·m (25-35 ft.lb.).

The "Special Tools" that are needed for this transaxle are not available to the new car dealer or the after market. Therefore, in an effort to make the rebuilding process a little easier, the AAMCO tecnical department came up with some great ideas that we are goingto share withyou. In order to tighten the "Spanner" nut to the proper torque specificationon TransferGear "A" assembly, it was necessary to make a socket. First bend down the locking tab on the locking washer for the nut and loosen the nut using a punch. Purchase a short piece of 1-3/4" exhaust pipe and using the nut as a template, mark the end of the pipe. Very carefully cut and notch thepipe to match the nut, as shown inFigure 74. Weld a short piece of metal to the opposite end of the pipe, with a large nut welded to it, as shown in Figure 74. The overall length of the new socket with nut is approximately 4-1/2 inches.

×ÒÍÌßÔÔ×ÒÙ ÎÑÔÔÛÎ ÞÛßÎ×ÒÙ

229

228

228 LOC KING WASHERWITHTABS 229 RETAINING SPANNERNUT

Figure 73

Figure 74


Technical Service Information 24.Install transfer gear "A" assembly, using eight of the 90mmlength valvebodyto case bolts, as shown in Figure 75.

25.Press transfer gear "A" and low clutch support into case, using the 3/4"drive, 2"socket, as shown in Figure 76. 26.Remove the eight, 90mm length, valve body bolts, as shown in Figure 77.

Figure 75

×ÒÍÌßÔÔ×ÒÙ ÌÎßÒÍÚÛÎ ÙÛßÎ ßÒÜ ÔÑÉ ÝÔËÌÝØ ÍËÐÐÑÎÌ

T

Figure 76

Figure 77

AU TOMATIC TRANSM ISSION SERVICE GROUP

Technical Service Information 27. Install theeight 5mm allen head low clutch support retaining bolts, as shown in Figure 78, and torqueto 9 N·m (80 in.lb.) 28.Install new seals on direct clutch accummulator piston, as shown in Figure 79, and lube with a small amount of Trans-Jel®. 29.Install direct clutch accummulator piston into case, as shown in Figure79. 30.Install inner and outer accummulator springs into case bore, as shown inFigure 79. 31.Install new seal on direct clutch accummulator cover, as shown inFigure 79, and lubewith a small amount of Trans-Jel®. 32.Install direct clutch accummulator cover into case bore, as shown inFigure 79. 33. Compress direct clutch accummulator cover and install snap ring (See Figure 79).

81

80 79

78

77

76 75 230

230 5MM ALLENHEADRETAINING BOLTS (8REQUIRED)

Figure 78

75 76 77 78 79 80 81

DIRECTC LUTCHPISTON ACC UMMULATORSEALS (2REQ'D) DIRECTC LUTCHACC UMMULATORPISTON DIRECTC LUTCHACC UMMULATORINNERSPRING DIRECTC LUTCHACCUMMULATOROUTERSPRING DIRECTC LUTCHACC UMMULATORCOVERSEAL DIRECTCLUTCHACC UMMULATORCOVER DIRECTC LUTCHACC UMMULATORCOVERSNAPRING

Figure 79


Technical Service Information ×ÒÍÐÛÝÌ ßÔÔ ÐßÎÕ×ÒÙ Ô×ÒÕßÙÛ DETENT SPRING

PARK PAWL AND SPRING

T

PARK ROD INSIDE DETENT LEVER

Figure 80

34.Inspect all parking linkage for any wear and/or damage, and forproper operation. Repair or replaceas necessary. Refer to Figure 80.

35. Install a new manual shaftseal and ensureit is approximately 1/16" below case surface, as shown in Figure 81. 36. Measurewidth of thelow/reverse clutch snap ring groove,as shown in Figure 82, usinga dialcaliper.

MANUAL SHAFT SEAL MEASURE SNAP RING GROOVE

1.6-2.6 MM (.063" - .102")

Figure 81

Figure 82

AUTOMATIC TRANSM ISSION SERVICE G ROUP

Technical Service Information 37.Now measurethe thickness of thelow/reverse clutch snapring, using a dialcaliper. 38.Subtract thickness of snap ring from snapring groove thickness to get"snap ring clearance". 39."Snap ring clearance"shouldbe 0.0 to 0.2mm (.000" - .008"), as shown in Figure 83. 40. Select a snap ring thickness fromthe chartin Figure 83, as necessary. 41. Install thelarge and small"O" rings ontothe reduction servo cover, as shown in Figure 84. 42.Install the "O"ring onto thereduction servo cushion springretainer, lube with small amount of Trans-Jel®, as shown in Figure 84. 43.Install cushion springand the cushion spring retainer intothe servo cover (See Figure 84). 44.Compress cushion spring retainer and install thesnapring, as shown inFigure 84. 45.Install new "O"ring seal onto thereduction servo apply piston, as shown in Figure 84.

68

67

66

65

64 63

62

72

71

62 63 64 65 66 67 68 71 72

Figure 83

REDUCTION SERVO COVER REDUCTION SERVO COVERLARGE "O"RING REDUCTION SERVO COVERSMALL"O"RING REDUCTION SERVO CUSHION SPRING REDUCTION SERVOCUSHION SPRING RETAINER REDUCTION SERVO CUSHION SPRING RETAINER"O"RING CUSHION SPRING RETAINERSNAPRING REDUCTION SERVOAPPLYPISTONASSEMBLY REDUCTION SERVOAPPLYPISTONSEAL

Figure 84


Technical Service Information 46. Install the reduction servo piston return spring into case bore, as shown inFigure 85. 47. Install the reduction servo piston assemblyinto case bore, as shown inFigure 85. 48. Install thereduction servo spacer ontop of the piston, as shown in Figure 85. 49. Install 14mm deep socketon adjusting nut, as shown in Figure 86. 50. Compress the piston and returnspring, using a large screwdriver and install the snap ring, as shown in Figure 86.

SERVO COVER SNAP RING

SERVO COVER ASSEMBLY

66

51. The transaxlecaseis now ready for the final assembly process. 67

68

69

LARGE SCREWDRIVER

66 67 68 69

REDUCTION SERVO PISTON SNAPRING REDUCTIONSERVOSPACER REDUCTIONSERVOAPPLYPISTONASSEMBLY REDUCTIONSERVORETURNSPRING

Figure 85

Figure 86


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ There are currently two different input shafts, one with three sealing rings and one with two sealing rings, as shown in Figure 88. The third sealing ring goes into Transfer Gear "A", located directly behind the oil pump assembly and seals lube oil from escaping, which of course changes the inside diameter of the transfer gear. ATSG feels that this 3rd sealing ring may be an upgrade, as we have seen one shaft that was just not yet machined, as shown in Figure 88. Some transfer gears are bored to accept 3rd sealing ring, as shown in Figure 87, and some are not. You must measure the inside diameter, as shown in Figure 87, to determine whether it is used with a 2 ring input shaft, or a 3 ring input shaft. The transfer gears also vary in tooth count between the various models, as shown in the chart in Figure 28. Be very careful with the selection process, if replacement parts are necessary. Figure 87

¬©± ®·²¹ ¿²¼ ¬¸®»» ®·²¹ ·²°«¬ -¸¿º¬-

Figure 88


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Clean the input shaft thoroughly and dry with compressed air. 2. Blow compressedair through all lube passages in theinput shaft (See Figure 89). 3. Installnew butt-cut sealingrings on the input shaft, as shown inFigure 89. 4. Set thecompleted input shaft asideforthe final assembly process.

21

1. Inspect all internal wiring harnesscomponents for anywear and/ordamage (See Figure 90). 2.Install new "O" ring seal onthe "pass-thru" connector, as shown in Figure 90,and lube with a small amountof Trans-Jel®. 3. Set the wiring harness' aside forfinal assembly.


"O" RING SEAL 20

20 INPUTSHAFTASSEMBLY 21 INPUTSHAFTSEALRINGS (3OR2 REQUIRED)

Figure 89

Figure 90


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Clean all converter housing parts thoroughly and dry with compressed air. 2. Inspect all converter housing parts thoroughly for anywear and/ordamage. 3. Install new differential tapered roller bearing cone, if necessary, as shown in Figure 91. 4. Install the converterhousing oil pipe, as shown in Figure 92, ifit was removed. 5.Install theoil baffle,as shown in Figure 93, if it was removed.

DIFFERENTIAL TAPERED ROLLER BEARING CONE

Figure 91

RETAINING BOLTS (3 REQUIRED) RETAINING BOLTS (2 REQUIRED) OIL BAFFLE

OIL PIPE

Figure 92

Figure 93


Technical Service Information RETAINING BOLTS

ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 6.Install theoil baffle,as shown in Figure 94, if it was removed. 7.Torqueall ofthe oilpipe and oilbaffle bolts just installed to 9 N·m (80 in.lb.), as shown in Figure95. 8. Install axleseal intothe converter housing, as shown in Figure96, using the proper driver. 9. Set completed converter housing aside for the final assembly process.

OIL BAFFLE

Figure 94

ÌÑÎÏËÛ ÞÑÔÌÍ ÌÑ ç ÒiÓ øèð ×ÒòÔÞò÷

AXLE SEAL

Figure 95

Figure 96


Technical Service Information ÛÒÜ ÝÑÊÛÎ ßÒÜ îóì ÝÔËÌÝØ Ð×ÍÌÑÒ Ü×ÚÚÛÎÛÒÝÛÍ There are currently two different 2-4 Brake Clutch Pistons, that are different only on the inside diameter, as shown in Figure 98. You will need a dial caliper capableof measuring 6 plus inches.

52

Currently we have confirmed it only in the Volkswagen Sharan, but we have suspicion thatit may be in other models as well. It is not known whether it is strictly model differences or a model year change, but we do know that it is out there. Obviously this would also affectthe inside diameter of the piston area in theend cover, also shown in Figure 98. The smaller inside diameter piston would create a larger surface area for the 2-4 clutch apply fluid to work with. The smaller inside diameter piston cannot be installed in the cover for the larger diameter piston You can go the other way very easily, but you will not like the result.

51

50

40 40 50 51 52

TRANSAXLEENDCOVER 2-4BRAKEC LUTCHPISTONOUTERSEAL 2-4 BRAKECLUTCHPISTON 2-4 BRAKECLUTCHPISTON INNERSEAL

Figure 97

Figure 98


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷

5. Install 2-4 accummulator piston into end cover bore, as shown in Figure 99. 6. Install 2-4 accumulator springin the piston, as shown in Figure 99 7. Install new "O"ring seal on 2-4 accummulator cover, as shown inFigure 99, and lubewith a small amount of Trans-Jel®. 8. Install accummulatorcover, compress cover and install snap ring, as shown in Figure 99.

1.Disassemble the end coverusing Figure 99as a guide. 2. Clean all end cover parts thoroughly anddry with compressed air. 3. Inspect all endcover parts thoroughly forany wear and/ordamage. 4.Install twonew scarf cut seals on the 2-4 accummulator piston, as shown in Figure 99, and lube with small amountof Trans-Jel®.

ÌÎßÒÍßÈÔÛ ÛÒÜ ÝÑÊÛÎ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 46

44

45 49

43 48

41 42

47

40

40 41 42 43 44 45

TRANSAXLEENDCOVER 2-4 BRAKEACC UMMULATOR PISTON 2-4 BRAKEACC UMMULATOR PISTON SEALS (2REQUIRED) 2-4 BRAKEACCUMMULATOR PISTON RETURNSPRING 2-4BRAKEACC UMMULATOR COVER 2-4 BRAKEACC UMMULATOR COVER"O"RING SEAL

46 47 48 49

2-4 BRAKEACC UMMULATORCOVERSNAPRING ENDCOVERSEALING RINGS (3REQUIRED) ENDCOVERTO REARBEARING "SELECTIVE"THRUSTWASHER END COVERTO REVERSECLUTCHHOUSING THRUSTBEARING

Figure 99


Technical Service Information 9.Install the"V" cut sealingrings onto the end cover support as shown in Figure 99.

52

51

10. Lubricate "V" cut sealswitha small amount of Trans-Jel®. 11. Install new outer "D" ring seal onto 2-4 brake clutch piston, as shown in Figure 100,and lube with small amount ofTrans-Jel®. 12. Install new inner "D" ring seal onto 2-4 brake clutch piston, as shown in Figure 100,and lube with small amount ofTrans-Jel®. 50

13.Install the completed 2-4brake clutch piston in theend cover as shown in Figure 100. 14. Set thecompleted end coveraside for the final assembly process (See Figure 101).

ÝÑÓÐÔÛÌÛÜ ÛÒÜ ÝÑÊÛÎ

40 50 51 52

TRANSAXLEENDCOVER 2-4BRAKEC LUTCHPISTONOUTERSEAL 2-4 BRAKECLUTCHPISTON 2-4 BRAKECLUTCHPISTON INNERSEAL

Figure 100

Figure 101


Technical Service Informati on ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 4. Disassemble theremaining parts of reduction carrierusing Figure 102 as a guide.

1. Bend backthe "stake" on the retainingnutback using a small punch. 2. Remove the nut using a 1-1/4"socket.

5. Clean all reduction carrierparts thoroughly and drywith compressedair. 6. Inspect all reduction carrier parts thoroughly and replace as necessary.

3. Remove the differential piniongear andthe converter housingbearing inner race using a press.

ÎÛÜËÝÌ×ÑÒ ÐÔßÒÛÌßÎÇ ÝßÎÎ×ÛÎ ßÍÍÛÓÞÔÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 621 622

625 624

620

618

623

619

617

618

616 REDUCTION SUN GEAR 617 REDUCTION PLANETARYC ARRIERANDPARKGEAR ASSEMBLY 618 TAPEREDROLLERBEARINGS (2 REQUIRED) 619 REDUCTION PLANETARYINTERNALRING GEAR 620 REDUCTION INTERNALRING GEARSNAPRING

621 622 623 624 625

616

TRANSFERGEAR"B"ASSEMBLY DIFFERENTIALPINIONGEAR CONVERTERHOUSING ROLLERBEARING INNERRACE RETAINING NUTTO SETBEARING PRE-LOAD DIFFERENTIALPINIONGEAR TO COVERTHRUSTBEARING

Figure 102


Technical Service Information 7. Install new taperedrollerbearings and cones, as necessary.

8. Install transfer gear "B" andinternal ring gear assemblyonto planetary carrier, as shown in Figure103. 9. Install tapered roller bearingover the shaft, as shown in Figure 104. 10.Install the differential pinionover the shaft, with thegrooved side facing up, as shown in Figure104.

11. Install the converterhousing bearing inner race on topof thedifferential pinion gear,as shown in Figure 104. 12. We will now use the press again to installthese parts and set bearing pre-load.

621 623

622

618 618

617

617 REDUCTION PLANETARYC ARRIERANDPARKGEARASSEMBLY 618 TAPEREDROLLERBEARINGS (2 REQUIRED) 621 TRANSFERGEAR"B"ANDRING GEARASSEMBLY

Figure 103

618 TAPEREDROLLERBEARINGS (2REQUIRED) 622 DIFFERENTIALPINIONGEAR 623 CONVERTERHOUSING ROLLERBEARING INNERRACE

Figure 104


Technical Service Information 13. Use a press to install theroller bearing, pinion gear and Conv. housing bearinginner race, as shown in Figure 105, and this is where wewill set the roller bearingpre-load. This willrequire that you release the press several times to check the bearing pre-load.

16. Set completed reduction carrier assembly aside for thefinal assemblyprocess, as shown in Figure107.

625

14. Install the nut usinga 1-1/4"socket, as shown in Figure 106, and torque thenut to 62N·m (45 ft.lb.), and "stake" the nutinto the groove witha punch. 15. Install differential pinion gear to cover thrust bearing, as shown in Figure 106, and retain withsmall amountof Trans-Jel®.

624

624 RETAINING NUTTO SETBEARING PRE-LOAD 625 DIFFERENTIALPINIONGEAR TO COVERTHRUSTBEARING

Figure 106

ÝÑÓÐÔÛÌÛÜ ÎÛÜËÝÌ×ÑÒ ÝßÎÎ×ÛÎ ßÍÍÛÓÞÔÇ

Figure 105

Figure 107


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Clean all planetary gear train parts thoroughly and dry with compressedair. 2. Inspect all planetary gear train parts thoroughly for any wear and/ordamage. 3. Disassemble any gear train parts necessary for replacement, using Figure 108as a guide.

4.There are manythings we cando toprepare for the final assemblyprocess that will make final assembly easier.

ÖÚëðêÛ ÐÔßÒÛÌßÎÇ ÙÛßÎ ÌÎß×Ò ÛÈÐÔÑÜÛÜ Ê×ÛÉ 272

271

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266 267

258 259 260 261 262 263 264 265 266 267

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RING GEARTO SUPPORT, THRUSTBEARING RACE (NO. 2A) OUTPUTC ARRIERINTERNALRING GEAR/LOWC LUTCHHUB RING GEARTO OUTPUTCARRIERTHRUSTBEARING (NO, 3) OUTPUTC ARRIERTHRUSTBEARING RACE (NO. 3A) OUTPUTC ARRIER/INPUTINTERNALRING GEARASSEMBLY OUTPUTC ARRIERTO SUN GEARTHRUSTBEARING (NO. 4) OUTPUTC ARRIERSUNGEAR SUNGEARTO INTPUTCARRIERTHRUSTBEARING (NO. 5) INPUTCARRIERASSEMBLY INPUTCARRIERTO SUNGEARTHRUSTBEARING (NO. 6)

268 269 270 271 272 273 274 275

260

258

INPUTSUN GEARTOHUBSNAPRING INPUTSUN GEARTHRUSTBEARING RACE (NO. 6A) INPUTSUN GEAR SUN GEARTO CLUTCHHUBTHRUSTBEARING RACE (NO.7A) REVERSEAND2-4 BRAKECLUTCHHUB HIGHCLUTCHHUBTO SUNGEARTHRUSTBEARING (NO. 7) HIGHCLUTCHHUBAND SHAFT HIGHCLUTCHHUBTHRUSTBEARING RACE (NO. 8A)

Figure 108


Technical Service Information 5. Install number 2Athrust bearingrace onto the outputringgearand lowclutchhub,as shown in Figure 109, and retain with a small amount ofTrans-Jel®.

6.Turn clutch hub over and installthe number 3 thrustbearing into theclutch hub, as shown in Figure 109,and retain with a small amountof Trans-Jel®.

258

7. Install number 3Athrust bearingrace on back sideof outputcarrier, as shown in Figure 110, and retain with small amount ofTrans-Jel®.

8. Install number 4 thrust bearing infront side of outputcarrier, as shown in Figure 110, retain witha small amount ofTrans-Jel®. 9. Install number 6 thrust bearing on input carrier, as shown in Figure 111,and retain withsmall amount of Trans-Jel®. 10.Assemble theinput sun gear to reverseand 2-4 brake clutch hub, as shown in Figure 112, and install snapring.

260 267

259 266

258 RING GEARTO SUPPORT, THRUSTBEARING RACE (NO. 2A) 259 OUTPUTC ARRIERINTERNALRING GEAR/LOWCLUTCHHUB 260 RING GEARTO OUTPUTCARRIERTHRUSTBEARING (NO, 3)

266 INPUTCARRIERASSEMBLY 267 INPUTCARRIERTO SUNGEARTHRUSTBEARING (NO. 6)

Figure 109

Figure 111

268

263

270

262 272

261

261 OUTPUTC ARRIERTHRUSTBEARING RACE (NO. 3A) 262 OUTPUTC ARRIER/INPUTINTERNALRING GEARASSEMBLY 263 OUTPUTC ARRIERTO SUN GEARTHRUSTBEARING (NO. 4)

Figure 110

268 INPUTSUNGEARTO HUBSNAPRING 270 INPUTSUNGEAR 272 REVERSEAND2-4 BRAKEC LUTCHHUB

Figure 112


Technical Service Information 11. Installnumber 6Athrust bearing race onto the input sungear and hub, as shown in Figure 113 and retain with small amount of Trans-Jel®.

273 275

12.Install number 7Athrust bearingrace onto the input sungear and hub, as shown in Figure 113 and retain with small amount of Trans-Jel®.

13. Install number 8Athrust bearingrace onto the high clutch hub,as shown in Figure 114, and retain with small amount of Trans-Jel®. 14. Install number 7 thrust bearingonto back side of high clutch hub, as shown inFigure 114, and retain with small amount of Trans-Jel®. 15. Set all of thepre-assembled gear train parts aside for thefinal assemblyprocess.

274

273 HIGHCLUTCHHUBTO SUNGEARTHRUSTBEARING (NO.7) 274 HIGHCLUTCHHUBANDSHAFT 275 HIGHCLUTCHHUBTHRUSTBEARING RACE (NO. 8A)

Figure 114

271

270

269

269 INPUTSUN GEARTHRUSTBEARING RACE (NO.6A) 270 INPUTSUN GEARAND 2-4 BRAKECLUTCHHUB 271 SUN GEARTO CLUTCHHUBTHRUSTBEARING RACE (NO.7A)

Figure 113


Technical Service Information Ü×ÎÛÝÌ ÝÔËÌÝØ ØÑËÍ×ÒÙ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 615

614

613 611

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612

601 607

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601 605

601 602 603 604 605 606 607 608

604

DIRECTCLUTCHHOUSING DIRECTCLUTCHHOUSING THRUSTBEARING (NO. 13) REDUCTION SPRAG ASSEMBLY (28ELEMENT) REDUCTION SPRAG ENDBEARING REDUCTION SPRAG SNAPRING DIRECTCLUTCHPISTONOUTERSEAL DIRECTCLUTCHPISTONASSEMBLY DIRECTCLUTCHPISTON INNERSEAL

603

602

609 DIRECTC LUTCHPISTONRETURN SPRING 610 DIRECTC LUTCHRETURN SPRING RETAINER 611 DIRECTC LUTCHRETURN SPRING SNAPRING 612 DIRECTC LUTCHSTEELPLATE (4REQUIRED) 613 DIRECTC LUTCHFRICTION PLATE (4REQUIRED) 614 DIRECTC LUTCH"SELECTIVE"BACKING PLATE 615 DIRECTC LUTCHBACKING PLATESNAPRING

Figure 115


609

Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Disassemble the direct clutch housingusing Figure 115 as a guide. 2. Clean all direct clutch parts thoroughly and dry with compressed air. 3. Inspect all direct clutch parts thoroughly for any wear and/or damage, replace as necessary. 4. Inspect check ballin the direct clutch piston to ensure the ball is free (Should Rattle). 5. Install a new inner "D" ring seal into groove in piston, as shown in Figure 116. 6. Install a new outer "D" ring seal into groove in piston, as shown in Figure 116,and lube both seals with small amount of Trans-Jel®. 7. Install the piston andseal assemblyinto direct clutch housing, as shown in Figure 117. 8. Install the direct clutch piston returnspring into direct clutch housing, as shown in Figure 117. 9. Install the direct clutch piston returnspring retainer ontop ofthe return spring, as shown in Figure 117.

10. Using theproper adapters, compress the return spring and retainer andinstall the snap ring (See Figure117).

611

610

609

607

608

601 607

606

606 DIRECTCLUTCHPISTON OUTER"D"RING SEAL 607 DIRECTC LUTCHPISTON ASSEMBLY 608 DIRECTCLUTCHPISTON INNER"D"RING SEAL

Figure 116

601 DIRECTCLUTCHHOUSING 607 DIRECTC LUTCHPISTON ASSEMBLY 609 DIRECTC LUTCHPISTON RETURN SPRING 610 DIRECTC LUTCHRETURN SPRING RETAINER 611 DIRECTCLUTCHRETURNSPRING SNAPRING

Figure 117


Technical Service Information 11. Ensurethat snap ring is fully seatedin groove and the retainer, as shown in Figure 118. 12.Install the direct clutch plates beginning with a steel plate and alternating withfriction plates, as shown in Figure 119, until you havefourof eachinstalled, for theMazda.

13.Install the "selective"direct clutch backing plate, as shown in Figure 119, with the flat sidefacingdown. 14. Install the direct clutch backing plate snapring as shown in Figure 119. 15. Check thedirectclutch clearance using a feeler between the backing plate and snap ring, as shown in Figure 120.

615

614

16. Change "selective" backing plate as necessary usingthe chartin Figure 120. 613 612

601

601 DIRECTCLUTCHHOUSING 612 DIRECTC LUTCHSTEELPLATE (4 REQUIRED) 613 DIRECTCLUTCHFRICTION PLATE (4REQUIRED) 614 DIRECTC LUTCH"SELECTIVE"BACKING PLATE 615 DIRECTCLUTCHBACKING PLATESNAPRING

Figure 118

Figure 119


Technical Service Information 17.Turn the direct clutch housing over, as shown in Figure 121, and install the number 13thrust bearing with the black side facing up. 18.Install the reductionsprag assembly intodirect clutch housing, with the"lips" facingup, as shown in Figure 121. 19.Install the reductionsprag end bearing into the direct clutch housing, as shown in Figure 121.

605

604

603

20. Install the reductionsprag end bearing snap ring, as shown in Figure121. 21. Set thecompleteddirectclutch housing aside for the final assemblyprocess.

602

601

601 602 603 604 605

DIRECTCLUTCHHOUSING DIRECTC LUTCHHOUSING THRUSTBEARING (NO. 13) REDUCTION SPRAG ASSEMBLY (28ELEMENT) REDUCTION SPRAG ENDBEARING REDUCTION SPRAG SNAPRING

T

Figure 120

Figure 121


Technical Service Information ÔÑÉñÎÛÊÛÎÍÛ ÝÔËÌÝØ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 256

257

252

255

251

248

254

250

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249

246 246

INSTALL WITH STEP FACING DOWN

247

246 247 248 249 250 251 252

LOW/REVERSECLUTCHBACKING PLATE LOW/REVERSEFRICTIONPLATES LOW/REVERSESTEELPLATES LOW/REVERSE"SELECTIVE"PRESSUREPLATE LOW.REVERSE"CONE"C USHION PLATE LOW/REVERSEPISTON RETURNSPRING SEAT LOW/REVERSEPISTON RETURNSPRING

253 254 255 256 257

LOW/REVERSEAPPLYPISTONOUTER"D"RING SEAL LOW/REVERSECLUTCHAPPLYPISTON LOW/REVERSEAPPLYPISTONINNER"D"RING SEAL LOW/REVERSECLUTCHPISTONRETAINER LOW/REVERSEPISTON RETAINERSNAPRING

Figure 122


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Disassemble the low and reverse clutch using Figure122asaguide. 2. Clean all low and reverse parts thoroughly and dry with compressed air. 3. Inspect alllow and reverse clutch parts for any wearand/ordamage, replace as necessary. 4. The onlyparts to pre-assemble are the low and reverseretainer, apply piston andseals.

255

5. Place allother lowand reverse parts asidefor the final assemblyprocess.

6. Place thelow and reverse clutch retainer ona flatwork surface,as shown in Figure 123. 7. Install the inner "D" ring seal ontothe lowand reversepiston, as shown in Figure123. 8. Install the outer "D" ring seal ontothe lowand reversepiston, as shown in Figure123. 9. Lubricate bothof the seals witha small amount of Trans-Jel®, and installthe piston assembly into thelow and reverse retainer, as shown in Figure123. 10. Set completed low and reverse clutch retainer aside for thefinal assembly process, as shown in Figure 124.

254

253

ÝÑÓÐÔÛÌÛÜ ÔÑÉ ßÒÜ ÎÛÊÛÎÍÛ ÎÛÌß×ÒÛÎ

256

253 LOW/REVERSEAPPLYPISTONOUTER"D"RING SEAL 254 LOW/REVERSECLUTCHAPPLYPISTON 255 LOW/REVERSEAPPLYPISTONINNER"D"RING SEAL

Figure 123

Figure 124


Technical Service Information ÔÑÉ ÝÔËÌÝØ ØÑËÍ×ÒÙ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 243

241

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233 234

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232 LOWCLUTCHHOUSING TO CASETHRUSTBEARING (NO. 1) 233 LOWCLUTCHHOUSING 234 LOWCLUTCHPISTONOUTERLIP SEAL 235 LOWCLUTCHPISTON 236 LOWCLUTCHPISTON INNER"D"RING 237 LOWCLUTCHPISTONRETURN SPRING 238 LOWCLUTCHBALANCEPISTON OUTER"D"RING SEAL 239 LOWCLUTCHBALANCEPISTON

240 241 242 243 244 245

LOW CLUTCHBALANCEPISTON SNAPRING LOW CLUTCH"CONE"CUSHION SPRING LOWCLUTCHFRICTION PLATES (6 REQUIRED) LOW CLUTCHSTEELPLATES (6REQUIRED) LOW CLUTCH"SELECTIVE"BACKING PLATE LOW CLUTCHBACKING PLATESNAPRING

Figure 125


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Disassemble the low clutch housing, using Figure125asaguide. 2. Clean all low clutch housing parts thoroughly and dry with compressedair. 3. Inspect alllow clutch housingparts for any wear and/ordamage. 4. Install new "D" ring seal onthe lowclutch balance piston, as shown in Figure 126, and lube with small amount of Trans-Jel®.

5. Install new inner "D" ring seal onlow clutch apply piston, as shown in Figure 127. 6. Install new outer "lip" seal on thelow clutch applypiston, as shown inFigure 127, and lube both seals with small amount of Trans-Jel®. 7. Install thelow clutch piston and seal assembly intothe lowclutchhousing (See Figure 128).

240

239 239

238

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238 LOWCLUTCHBALANCEPISTON OUTER"D"RING SEAL 239 LOWCLUTCHBALANCEPISTON

Figure 126 235

236

233 235

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234 LOWC LUTCHPISTONOUTERLIP SEAL 235 LOWCLUTCHPISTON 236 LOWCLUTCHPISTON INNER"D"RING

Figure 127

233 LOWCLUTCHHOUSING 235 LOWCLUTCHPISTON 237 LOWCLUTCHPISTONRETURN SPRING 239 LOWCLUTCHBALANCEPISTON 240 LOWCLUTCHBALANCEPISTON SNAPRING

Figure 128


Technical Service Information 8. Install thelow clutch piston return spring,as shown in Figure 128. 9. Install thelow clutch balance piston inside of thelow apply piston, as shown inFigure 128. 10. Compress the low clutch balance piston using the proper adapters andinstall the snap ring, as shown in Figure 128. 11. Install the low clutch "cone" cushion spring so theoutside diameter will contact the steel plate and the inside diameter will contact the piston, as shown in Figure 129. 12. Install thelow clutch plates beginningwith a steel plate and alternating witha friction plate untilyou have installedsix of each, as shown in Figure 129.

245

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243

13. Install the"selective" lowclutch backing plate as shown in Figure 129. 14. Install thelow clutch backing plate snapring, as shown in Figure 129.

241

233

233 LOWCLUTCHHOUSING 241 LOWCLUTCH"CONE"CUSHION SPRING 242 LOWCLUTCHFRICTIONPLATES (6REQUIRED) 243 LOWC LUTCHSTEELPLATES (6 REQUIRED) 244 LOWCLUTCH"SELECTIVE"BACKING PLATE 245 LOWCLUTCHBACKING PLATESNAPRING

Figure 129


Technical Service Information 15.Measure low clutch clearance using a feeler gage,as shown in Figure 130.

16.Change selective backing plate as necessary usingthe chartin Figure 130. 17.Turn the low clutch housing over and install thenumber1 thrust bearing, with theblack or gold side facingup,as shown in Figure 131, and retain with a small amountof Trans-Jel®. 18.Set thecompletedlow clutch housing aside for the final assemblyprocess (See Figure 132).

232

233

232 LOWCLUTCHHOUSING TO CASETHRUSTBEARING (NO. 1) 233 LOWCLUTCHHOUSING

Figure 131

ÝÑÓÐÔÛÌÛÜ ÔÑÉ ÝÔËÌÝØ ØÑËÍ×ÒÙ

Figure 132

Figure 130


Technical Service Information Ø×ÙØ ßÒÜ ÎÛÊÛÎÍÛ ÝÔËÌÝØ ØÑËÍ×ÒÙ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 115

117

118

114

113

112

111 116

109

106

108

105

107

110

101 102

103

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101 102 103 104 105 106 107 108 109

REVERSECLUTCHHOUSING ASSEMBLY REVERSECLUTCHPISTON OUTER"D"RING SEAL HIGH CLUTCHHOUSING/REVERSEPISTONASSEMBLY REVERSECLUTCHPISTON INNER"D"RING SEAL HIGHCLUTCHPISTON OUTER"D"RING SEAL HIGHCLUTCHPISTON HIGHCLUTCHPISTON INNER"D"RING SEAL HIGH CLUTCHPISTON RETURNSPRING HIGHCLUTCHBALANCEPISTON

110 111 112 113 114 115 116 117 118

HIGHCLUTCHBALANCEPISTON SNAPRING HIGHC LUTCHFRICTION PLATES HIGHCLUTCHSTEELPLATES HIGHC LUTCHBACKING PLATE HIGHCLUTCHBACKING PLATESNAPRING REVERSECLUTCHSTEELPLATES REVERSECLUTCHFRICTIONPLATES REVERSECLUTCHBACKING PLATE REVERSECLUTCHBACKING PLATESNAP RING

Figure 133

AUTOMATIC TRAN SMISSION SERVICE GROUP

Technical Service Information

Figure 134

ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. Disassemble high and reverse clutch housing usingFigure 133 as a guide. 2. Clean all high and reverse clutch housingparts thoroughly and drywith compressedair. 3. Inspect all high and reverse clutch housing parts for any wear and/or damage, replace as necessary.

4. Check toensure that you have a 2nd design reversepiston, as shown in Figure 134. 5. Install new inner and outer "D" ring seals onto the reverse piston, as shown in Figure 135, and lube with small amount ofTrans-Jel®. 6. Install new inner and outer "D" ring seals onto thehigh clutch piston, as shown in Figure 136, and lube with small amountof Trans-Jel®.

104

103 107

106

102 105

102 REVERSECLUTCHPISTON OUTER"D"RING SEAL 103 HIGHCLUTCHHOUSING/REVERSEPISTON ASSEMBLY 104 REVERSECLUTCHPISTON INNER"D"RING SEAL

Figure 135

105 HIGHCLUTCHPISTON OUTER"D"RING SEAL 106 HIGHCLUTCHPISTON 107 HIGHCLUTCHPISTON INNER"D"RING SEAL

Figure 136


Technical Service Information 110

109

108

106

7. Install thehigh clutch housing/reverse piston assemblyinto the reverse clutch housing, as shown in Figure 137. 8. Install thehigh clutch apply piston intohigh clutchhousing/reverse pistonassembly, as shown in Figure137, and ensure that both of the pistons arefully seated. 9. Install thereturnspring assembly, as shown in Figure137. 10. Install the high clutch balancepistonon top of return spring,as shown in Figure 137. 11. Compress thebalance piston and return spring using the properadapters and install the snap ring, as shown inFigure 137. 12. Release the compression, remove compression tools and ensure that snapringis properly and fully seated,as shown in Figure 138.

103

101

101 103 106 108 109 110

REVERSECLUTCHHOUSING ASSEMBLY HIGHCLUTCHHOUSING/REVERSEPISTON ASSEMBLY HIGHCLUTCHPISTON HIGHCLUTCHPISTONRETURN SPRING HIGHCLUTCHBALANCEPISTON HIGHCLUTCHBALANCEPISTON SNAPRING

Figure 137

Figure 138


Technical Service Information 13. Install the high clutch plates beginning with a steel plate and alternating with friction plates until you have installedfiveof each,as shown in Figure 139.

14. Install theselective high clutch backing plate, as shown in Figure 139. 15. Install thehigh clutch backing plate snapring, as shown in Figure 139. 16. Measure high clutch clearance using a feeler gage,as shown inFigure 140.

17. Change the selectivehigh clutch backing plate as necessary using the chart in Figure 140. 110

109

108 107

101

101 107 108 109 110

HIGH ANDREVERSECLUTCHHOUSING ASSEMBLY HIGHCLUTCHSTEELPLATES HIGHCLUTCHFRICTION PLATES HIGHCLUTCHSELECTIVEBACKING PLATE HIGHCLUTCHBACKING PLATESNAPRING

Figure 139

Figure 140


Technical Service Information 18. Install thereverse clutch plates beginning with a steel plate andalternating with frictions until you haveinstalled two ofeachplate,as shown in Figure 141.

19. Install reverse clutch selectivebacking plate, as shown in Figure 141. 20. Install reverse clutch backing plate snapring, as shown in Figure 141. 21. Measure reverse clutch clearance using feeler gage betweenbacking plate andsnap ring, as shown in Figure 142.

22. Change selective backing plate as necessary usingthe chartin Figure 142. 118

117

116 115

101

101 115 116 117 118

HIGH ANDREVERSECLUTCHHOUSING ASSEMBLY REVERSECLUTCHSTEELPLATES REVERSECLUTCHFRICTION PLATES REVERSECLUTCHSELECTIVEBACKING PLATE REVERSECLUTCHBACKING PLATESNAPRING

Figure 141

Figure 142


Technical Service Information 23.Install the number8 thrust bearing inside the high and reverse clutch housing, as shown in Figure 143,and retain witha small amount of Trans-Jel®. 24.Turn the high and reverseclutch housing over, as shown in Figure 144,and install number 9 thrust bearing andnumber 9Athrust bearing race, retain with a small amountof Trans-Jel®. 25. Set completed high and reverse clutch housing assemblyaside for the final assembly process.

48

49

48 ENDC OVERTHRUSTBEARING RACE (NO. 9A) 49 ENDC OVER THRUSTBEARING (NO. 9)

Figure 144

276

276 HIGHCLUTCHHUBTHRUSTBEARING RACE (NO. 8A)

Figure 143


Technical Servi ce Information Ñ×Ô ÐËÓÐ ßÍÍÛÓÞÔÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ

308 309 306

305

307

301

303 302 304

301 OILPUMP TO CONVERTERHOUSING "O"RING SEAL 302 OILPUMP CONVERTERSEAL 303 OILPUMP BODY 304 OILPUMP BODYBUSHING 305 OILPUMPOUTERGEROTOR 306 OILPUMP INNERGEROTOR

307 OILPUMPSTATOR SHAFTBUSHING 308 OILPUMPCOVERAND STATOR SHAFTASSEMBLY 309 OILPUMP COVERTO OIL PUMP BOLTS (8REQUIRED)

Figure 145


Technical Service Information ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ 1. The Oil Pump Assemblyhas theGerotor style pump gears, without a pump cresent, as shown in Figure 145. 2. Disassemble theoil pumpby removing the8 retaining bolts, as shown in Figure 145, then removing theoil pump cover. 3. Mark the inner and outer gerotor withsome type of a permanentmarker, like a "Sharpie", from thepump body, as shown in Figure 146,so that they can be re-installed with thesamesidefacingup as original.

4. Removeand discard the converter seal andthe pump body to converter housing "O" ring seal. 5. Clean alloil pumpparts thoroughly and dry with compressed air. 6. Inspectall oilpump parts thoroughly for any wear and/ordamage. 7. Measure thegear to face clearance using feeler gage and straight edge,as shown in Figure 147. 8. Measure the outergear to bodywiththe feeler gage and use the specifications that areshown in Figure 147to determine replacement needs. 9. Installnew pump body bushingas necessary, as shown in Figure 148, using proper driver.

INNER GEAR TO FACE

.0008" - .0015"

OUTER GEAR TO FACE

.0008" - .002"

OUTER GEAR TO BODY

.004" - .006"

Figure 147

304

303

303 OIL PUMP BODY 304 OIL PUMP BODYBUSHING

Figure 146

Figure 148


Technical Service Information 10. Stakethe new pumpbodybushing inplace, as shown in Figure 149, using a smallpunch. 11. Turn theoil pumpbodyover and install a new converter hubseal, as shown in Figure 150, using the proper seal driver. 12.Lubricate theinner and outer gerotor with the proper fluid for the vehicle and install them in theoil pump body, as shown in Figure 151.

Figure 149

302

303 306

305

302 OILPUMP CONVERTERSEAL 303 OILPUMP BODY

Figure 150

303

303 OIL PUMP BODY 305 OIL PUMP OUTERGEROTOR 306 OILPUMP INNERGEROTOR

Figure 151


Technical Service Information 13. Installoil pump cover and statorshaft assembly onto oilpumpbody, as shown in Figure 152. 14. Installthe eight 5mm allen head retaining bolts, as shown in Figure 152, and hand tighten only. 15. Now torque the eight 5mm allen head bolts to 10 N·m (90in.lb.), as shown in Figure 153, using a criss-cross pattern. 16. Installthe oil pump body to converter housing "O" ring seal,as shown in Figure 154, and lube with a small amountof Trans-Jel®. 17. Set the completed oil pump assembly aside for the final assemblyprocess.

ÌÑÎÏËÛ Ñ×Ô ÐËÓÐ ÞÑÔÌÍ ÌÑ ïð ÒiÓ øçð ×ÒòÔÞò÷

Figure 153 309

301

308

303

303 OILPUMP BODYANDGEROTORASSEMBLY 308 OILPUMP COVERANDSTATORSHAFTASSEMBLY 309 OILPUMP COVERTO OIL PUMP BOLTS (8REQUIRED)

Figure 152

301 OILPUMP TO CONVERTERHOUSING "O"RING SEAL

Figure 154


Technical Service Information ÓßÆÜß ÖÚëðêÛ ÊßÔÊÛ ÞÑÜÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 23

6 5 6 7 2

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45 64 17

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Figure 155


Technical Service Information ÓßÆÜß ÖÚëðêÛ þÍËÞ ÔÑÉÛÎþ ßÒÜ þÔÑÉÛÎþ ÊßÔÊÛ ÞÑÜÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ 64

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64 38 60 5

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2 42

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Figure 156


Technical Service Information ÓßÆÜß ÖÚëðêÛ þ×ÒÌÛÎÒßÔþ ÊßÔÊÛ ÞÑÜÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ

50 51

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

VALVEB VEBODYB ODY BRACKET VALVEB VEBODYB ODY BOLT, 37MM LENGT NGTH NUTFORVAL NUTFOR VALVEBODYB VEBODY BOLTFROM BOTTOM VALVEB VEBODYB ODY BOLT, 67MM LENGT NGTH VALVEB VEBODYB ODY BOLT, 90MM LENGT NGTH VALVEB VEBODYB ODY BOLT, 24MM LENGT NGTH LINEPRE LINE PRESSURE SOLENOI SOLENOID D (DUTY C YCLE) YCLE) HIGHC HIGH C LUTC H SOLENOID (DUT (DUTY C YCLE) NEUTRALSHIFTSOLENOID (ON/OFF) (ON/O FF) 2/4B 2/4 BRAKE SOLENOID (DUTY C YCLE) SUBLOWERVALVEBODYC VEBODY C ASTING PILOTFILT PILOTFILTERWIT ERWITH "LEAF"SPRING AF" SPRING SPACER PACERPLAT PLATE "A"WITHGASKE "A"WITHG ASKETS 2/4B 2/4 BRAKESOLENOID BRASSRETAINING BRACKET C OIL SPRING SPRING LOADED OADED FILTERS (2RE (2 REQUIRED) TC C SOLENOID (DUT (DUTY C YCLE) SHIFTSOL HIFTSOLENOID ENOID"A "A"" (ON/OFF) REDU REDUC C TION TIMING SOLENOID (ON/OFF (ON/O FF)) SHIFTSOLENOID "B" (ON/OFF) (ON/O FF) SHIFTSOL HIFTSOLENOID ENOID"C" "C" (ON/OFF) (O N/OFF) LOWERVALV LOWERVALVE BODYC ODY C ASTING MANUALSH MANUAL SHIFTVALVE SPACERPLAT AC ERPLATE "B" (NO GASKETSUSED) INTER INTERNAL NALVAL VALVEBODYC VEBODY C ASTING PLAS PLASTIC C HEC K BALL ALL (.218"DIAMETER, 5 REQUIRED) STEEL EEL C HEC K BALL (.218"DIAMET (.218" DIAMETER, 4 REQUIRED) REQUIRED) INTER INTERNAL NALVAL VALVEBODYFLA VEBODY FLATSCREEN(2 TSCREEN (2RE REQ QUIRED) SPACERPLAT AC ERPLATE "C"WIT "C" WITH BONDEDGASKET ONDED GASKETS HIGHC HIGH C LUTC HSOLENOI SOLENOID D BRASSRETAINING BRACKET PLAS PLASTIC C HEC K BALL ALL (.218"DIAMETER, 4 REQUIRED) UPPERVAL UPPERVALVEB VEBODYC ODY C AST ASTING MODIFIERAC MODIFI ERAC C UMULA UMULATOR VALVETRAIN VETRAIN

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

PRESSUREMO REMODIFI DIFIER ERVAL VALVET VETRAIN TORQUEC ORQ UEC ONVERT ONVERTERPRES ERPRESSUREREGULAT REREGULATOR VALVET VETRAIN THROTTLEAC LE ACC C UMULATOR "A"VALVETRAIN "A"VALVETRAIN ACC AC C UMULATOR C ONTROLVALVE"A"VAL VE"A"VALVET VE TRAIN THROTTLEAC LE ACC C UMULATOR "C" "C" VALVET VETRAIN ACC AC C UMULATOR C ONTROLVALVE"C" VE"C"VAL VALVET VETRAIN REDU REDUC TION REDUCING DUCING VALVETRAIN VETRAIN REDU REDUC TION TIMING IMING VALVET VE TRAIN LINEPRESSURERE RE RELIEFB LIEFBALLAND SPRING SPRING PRESSUREREGULAT REREGULATOR VALVET VETRAIN VALVEBODYBOLT VEBODYBOLT, 75MM LENGTH (BLAC LAC K IN C OLOR) ACC AC C UMULATOR C ONTROLVALVE"B VE"B"VALVET VETRAIN VALVEBODYBOLT VEBODYBOLT, 105.5MM LENGTH NGTH (BLACK (BLACK INC IN C OLOR) THROTTLEAC LEACC C UMULATOR "B"VALVET VETRAIN HIGHC HIGH C LUTC HAC C UMULAT MULATORPIS OR PIST TON ANDS AND SPRING PRING LOWC OW C LUTC HAC C UMULAT LATORPIS OR PIST TON ANDSP AND SPRING RING SHIFTVALVE "C" "C"VALVET VETRAIN SHIFTVALVE"A"VAL IFTVALVE"A"VALVET VETRAIN TC C C ONTROL VAL VALVETRAI VETRAIN N NEUTRALSH RALSHIFTVALVETRAIN MANUALSHIFTVALVE PILOTVAL PILOTVALVET VE TRAIN ACC AC C UMULATOR SWITC HVALVETRAIN VETRAIN NEUTRALC ONT ONTROLVAL ROL VALVETRAIN VETRAIN REVERSE INHIBITVALVE INHIBITVALVE TRAIN SHIFTVALVE"B"VALVE IFTVALVE"B"VALVET TRAIN FAILSAFEVAL AFE VALVET VETRAIN INTERNALC NAL C ONNECT ONNEC TORRE OR RETAINING BRAC RAC KET KET INTERNALSOLE NAL SOLENOI NOID D WIREHARNESSC LIP INTER INTERNALSP NAL SPEEDSENS EEDSENSORWIREHARNE OR WIREHARNES SSC LIP INTER INTERNALSP NAL SPEEDSENS EEDSENSORWIREHARNE OR WIREHARNES SSC LIP VALVEBODYTO VEBODYTO C ASE ASE BOLT, 90MM LONG

Figure 157


Technical Service Information ÓßÆÜß ÍÓßÔÔ ÐßÎÌÍ ßÒÜ ÝØÛÝÕÞßÔÔ ÔÑÝßÌ×ÑÒÍ

Figure 158


Technical Servi ce Information Informat ion ×ÒÜ×Ê×ÜËßÔ ÊßÔÊÛ ÜÛÍÝÎ×ÐÌ×ÑÒ Reduces Reduces oil pumpdischarge pressure pressure according according to pressure pressure modifier modifier pressure pressure and adjusts adjusts to line pressure. pressure. Reduces Reduces pilotpressure according according to throttle throttle pressure pressure and adjusts adjusts to pressure pressure modifier modifier pressure. pressure. Reduces Reduces linepressure and adjusts adjusts the pilotpressure. Reduces Reduces linepressure and adjusts adjusts to accumulato accumulatorr control control pressure.

Reduces Reduces linepressure and adjusts adjusts to torque torque converter converter pressure. Controls Controls low clutchoperatingpressure clutchoperatingpressure.. Adjusts line pressure to reduction reducing pressure for optimum optimum control control of reduction reduction brakepressure operation. operation. Prevents Prevents line pressure pressure fromexceedinga specified specified level. Applies or releases torque converter clutch according to operation operation of TCC solenoid. solenoid. Switch Switches es oilpath accordi accordingto ngto shift shift soleno solenoidopera idoperationto tionto perfor perform m automa automaticshifti ticshifting ng of 1stthru 5thgear. 5thgear.

Switch Switches es oilpath of high high clutch clutch,, low low clutchand clutchand revers reverse e brake. brake. When When vehicl vehicle e is inforward inforward motionand motionand mistake mistakenlyshift nlyshifted ed to rever reverse,it se,it shiftsto shiftsto N positi positionaccor onaccordin ding g to N shift shift soleno solenoid. id. Switch Switches es oilpath of lowclutchpressurebasedon lowclutchpressurebasedon 2-4brake solenoid operation. Direct Directs s line line pressu pressure re to each each contro controll valve valve accord accordingto ingto gear gear selector selector position. position.

Switches Switches timingof reduction reduction brakeoperation whendepressing accele accelera ratorin torin 5thgear, 5thgear, andwhen theselectorleveris theselectorleveris shifte shifted d from from D to3, or2 toforce toforce engin engine e braki braking. ng.

Reduces Reduces pulsation pulsation of control control pressure pressure to accumulator accumulator control control valve"B" Reduces Reduces pulsation pulsation of control control pressure pressure to accumulato accumulatorr control control valve"C" Regulates Regulates pressure pressure to low clutchfor smoother smoother operation. operation. Regulates Regulates pressure pressure to high clutchfor smoother smoother operation. operation.

Figure 159

AUTO AU TOMAT MATIC IC TRAN TR ANSM SMIS ISSI SION ON SERV SE RVIC ICE E GRO G ROUP UP

Technical Service Information 6 6 32

7

33

11

6 VALVEBODYB VEBODY BOLT, 24MM LENGT NG TH 7 LINEPRESSURESOLENOID 11 SUBLOWERVALVEBODYC VEBODY C ASTING 32 MODIFIERAC MODIFIERAC C UMULATOR VALVETRAIN VETRAIN 33 PRESSUREMOD UREMODIFIER IFIERVAL VALVET VETRAIN 34 TORQUEC ORQ UEC ONVER ON VERTERPRES ERPRESSUREREGULAT REREGULATOR VALVET VETRAIN 35 THROT ROTTLEAC LEACC C UMULATOR "A"VALVE TRAIN 36 AC C UMULA UMULATOR C ONT ONTROLVAL ROL VALVE"A"VALVETR VE"A"VALVETRAIN AIN 37 THROTTLEAC LEACC C UMULATOR "C" "C"VALVET VETRAIN 38 ACC AC C UMULA UMULATOR C ONT ONTROLVAL ROL VALVE"C" VE"C "VALVETRAIN VETRAIN

34 35 36 37 38

Figure 160

ÝÑÓÐÑÒÛÒÌ ÎÛÞË×ÔÜ øÝÑÒÌùÜ÷ FLUK E 88 AUTO

ðîòçë

mV

RPM

1. Disasse Disassembl mblee the valve valve body body assemblyusing assemblyusing Figu Figure re 155 155 as a guide guide..

DC Ω

Ω

2. Clean Clean valve valve body body compon componentparts entparts thorou thoroughl ghly y and dry with with compre compressed ssed air. air. 3. Starti Starting ng with with the sublower valve valve body body, shown shown in Figure Figure 160, 160, disass disassemb emble le andplace valves valves,, springs springs,, bore bore plugs plugs andretainers andretainers in approp appropria riate te trays trays exactl exactly y as theywere remove removed. d. 4. Clean Clean sublower valve valve body body parts parts thorou thoroughl ghly y and dry with with compre compressed ssed air. air. 5.Assemblesub 5.Assemblesub lower lower valve valve body body parts parts as show shown n in Figur Figuree 160, 160, and and lube lube withA withATF TF as they are installed. installed.

mA A

V

mA A

V

OFF

A

mA

COM

V Ω RPM

10AMax FUSED

6. Check Check the linepressure linepressure solenoi solenoid d for the proper proper resista resistance,as nce,as shown shown in Figure Figure 161. 161. Figure 161


Technical Service Information 7. Installnew "O"rings,lube with ATF, andinstall the pressure control solenoid, as shown in Figure 160. Torque bolts to 10 N·m (88 in.lb).

ÝÑÓÐÔÛÌÛÜ ÍËÞ ÔÑÉÛÎ ÊßÔÊÛ ÞÑÜÇ ßÍÍÛÓÞÔÇ

8. Set completed sub lower valve body assembly aside for final valve body assembly, as shown in Figure 162. 9. Disassemble the lower valve body, as shown in Figure 163, andplace thevalves, bore plugs and retainers in appropriate trays exactlyas they were removed. 10. Clean lower valve body parts thoroughly and dry with compressed air. 11.Assemble lower valve body parts exactly as they areshownin Figure 163,and lube with properATF as they are installed.

12. Install theflat valve body screen into position as shown in Figure 163. Figure 162

39 40

42

41

21

FLAT VALVE BODY SCREEN

44

49

21 39 40 41 42 44 46 47 48 49

LOWERVALVEBODYCASTING REDUCTION REDUCING VALVETRAIN REDUCTION TIMING VALVETRAIN LINEPRESSURERELIEFBALLANDSPRING PRESSUREREGULATOR VALVETRAIN ACCUMULATOR CONTROLVALVE"B"VALVETRAIN THROTTLEACCUMULATOR "B"VALVETRAIN HIGHCLUTCHAC CUMULATORPISTON ANDSPRING LOWCLUTCHAC CUMULATORPISTON ANDSPRING SHIFTVALVE"C"VALVETRAIN

48

46

Figure 163


47

Technical Service Information 13. Install two new scarf-cutsealrings on both the high and thelow clutch accumulator pistons, as shown in Figure 164, and ensure thescarf-cut is configuredproperly. 14.Lubricate both pistons and seals with a small amountof the properATF and installthem into thebores,as shown inFigure 163. 15. Install new "O" ring on both the high and the low clutch accumulator covers, as shown in Figure 164,and lube with small amount of the properATF for thr vehicle. 16. Install both high and lowclutch accumulator springs, that were previouslylabeled, in their proper positions, as shown in Figure 163. 17. Install high clutch accumulator cover, using care so as not todamage the "O" ring. 18. Compress the cover andinstall the snap ring shown in Figure 163. 19. Install low clutch accumulator cover, using care so as not todamage the "O" ring. 20. Compress the cover andinstall the snap ring shown in Figure 163. 21. Ensure that the flat valve bodyscreenis still in place, as shown in Figure 165, and set the completed lower valve body aside forthe final valve body assembly process.

ÝÑÓÐÔÛÌÛÜ ÔÑÉÛÎ ÊßÔÊÛ ÞÑÜÇ ßÍÍÛÓÞÔÇ

Figure 165

Figure 164


Technical Service Information ÓßÆÜß ÖÚëðê þ×ÒÌÛÎÒßÔþ ÊßÔÊÛ ÞÑÜÇ ÛÈÐÔÑÜÛÜ Ê×ÛÉ

50 51

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54 24 25 26 27 50 51 52

58 57

55

INTERNALVALVEBODYCASTING PLASTIC CHECKBALL (.218"DIAMETER, 5 REQUIRED) STEELCHECKBALL (.218"DIAMETER, 4 REQUIRED) INTERNALVALVEBODYFLATSCREEN SHIFTVALVE"A"VALVETRAIN TCC CONTROL VALVETRAIN NEUTRALSHIFTVALVETRAIN

53 54 55 56 57 58 59

56 MANUALSHIFTVALVE PILOTVALVETRAIN ACCUMULATORSWITCHVALVETRAIN NEUTRALC ONTROLVALVETRAIN REVERSEINHIBITVALVETRAIN SHIFTVALVE"B"VALVETRAIN FAILSAFEVALVETRAIN

Figure 166

22.Disassemble theinternal valve body, as shown in Figure 166, and place valves, bore plugs and retainers in appropriate trays exactly as theywere removed from casting.

23.Clean all internal valve body parts thoroughly and drywith compressedair. 24.Assembleinternal valve body parts exactly as they are shown in Figure 166, and lube with the properATF as they are installed.

25.Install the flat valve body screen intoposition, as shown in Figure 166.

26.Install the manualvalve into theinternal valve body in the direction shown in Figure 166. 27.Install an appropriate size clevis pininto the groove in the exposedend ofmanualvalve, as shown in Figure 167.


Technical Service Information 28.Install the four steel check balls in their proper positions, as shown in Figure 168. 29.Install the five plastic check balls in their proper positions, as shown in Figure 168. 30. Ensure that the flat screen is stillin position, as shown in Figure 169, and set thecompleted internal valve body assemblyaside for final valve body assembly.

Figure 168

ÝÑÓÐÔÛÌÛÜ ×ÒÌÛÎÒßÔ ÊßÔÊÛ ÞÑÜÇ ßÍÍÛÓÞÔÇ FLAT SCREEN IN PLACE

CLEVIS PIN ON MANUAL VALVE

Figure 167

Figure 169


Technical Service Information 31. Install one 67mmbolt and one 90mmvalve body bolt through the upper valve body casting as shown in Figure 171. 23

32. Lay the assembly on a flat work surface with theworm track sidefacingup, as shown in Figure171. 33.Install four plasticcheck balls in their proper locations, as shown in Figure 170. 34.Install spacerplate "C" with bondedgaskets over thetwo bolts and ontothe upper valve body, as shown in Figure 171. 35. Install the completed internal valve body over thetwo bolts and onto spacerplate "C", as shown in Figure 171, and ensure flatscreen and check balls arestill in position.

24

36. Install spacerplate "B" overthe two bolts, as shown in Figure 171.

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4 30

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Figure 170

VALVEBODYBOLT, 67MM LENGTH VALVEBODYBOLT, 90MM LENGTH SPACERPLATE"B" (NO GASKETSUSED) INTERNALVALVEBODYCASTING SPACERPLATE"C"WITHBONDEDGASKETS PLASTIC CHECKBALL (.218"DIAMETER, 4REQUIRED) UPPERVALVEBODYCASTING

Figure 171


Technical Service Information 37.Install completed lower valve body assembly over thetwo bolts, on top of spacerplate "B", as shown in Figure 172,and ensure that flat valvebodyscreen is still inplace. 38.Install the twotapered coilspring loaded filters intotheir pockets in the lower valve body, with thespringsidedown, as shown inFigure 173. 39.Install spacerplate "A"with bonded gaskets over one bolt onto the lower valvebody, as shown in Figure 173.

40. Install the pilot filterwith the "leaf spring" facingup, and the wide leg ofthe "leaf spring" facingthe bottom of valve body, as shown in Figure173.

12

13

15

FLATSCREEN IN PLACE

12 PILOTFILTERWITH"LEAF"SPRING 13 SPACERPLATE"A"WITHGASKETS 15 TAPEREDC OILSPRING LOADEDFILTERS (2REQUIRED)

FLAT SCREEN IN PLACE

Figure 173

Figure 172


Technical Service Information 41. Installthe completedsub lower valve body overthe bolt and on top ofspacerplate "A", as shown in Figure 174.

42. Install thevalvebodybracket over bolt and on top of the sub lowervalve body, as shown in Figure 174. 43. Install90mm valve body bolt through bracket, as shown in Figure174,and handtightenonly atthistime.

5

3

1

44. Installnut on the90mm bolt comingthrough from the bottom, as shown in Figure 174, and hand tighten only at thistime. 45. Install a 37mm bolt (2), from the bottom, in the lower leftside of thevalvebody, as shown in Figure175, installnut (3)and hand tighten onlyatthistime. 46. Installsix 37mm bolts (2), in locations shown in Figure 175, and hand tighten only.

47. Installone 24mm bolt (6), in location shown in Figure 175, and hand tighten only. 48. Installone 67mm bolt (4), in location shown Figure 175, and hand tighten only. 49. Installthe 106.5mm bolt (65), along with the wire harness retainer (62), in location shown Figure 175, and hand tighten only.

2 65

2 2

2

6 61 62

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3

2

2 2

1 VALVEBODYBRACKET 3 NUTFORVALVEBODYBOLTFROM BOTTOM 5 VALVEBODYBOLT, 90MM LENGTH

Figure 174

2 3 4 6 61 62 65

VALVEBODYBOLT, 37MM LENGTH NUTFORVALVEBODYBOLTFROM BOTTOM VALVEBODYBOLT, 67MM LENGTH VALVEBODYBOLT, 24MM LENGTH INTERNALSOLENOIDWIREHARNESSCLIP INTERNALSPEEDSENSORWIREHARNESSCLIP VALVEBODYBOLT, 106.5MMLONG (GOLDIN COLOR)

Figure 175


Technical Service Information 50. Install a 67mm bolt inthe location shown in Figure 176, andhand tighten only. 51.Install four 90mm bolts in the locations shown in Figure 176, andhand tighten only. 5 5

5

52. Install the eleven valve bodyto case bolts in their proper holes foralignment purposes.

53. Beginningin the center andworking your way outward, torque all installed valve body bolts to 10 N·m (90 in.lb.),as shown in Figure 177.

5

4

54. Now you can remove the eleven silver valve body to case bolts used for alignment. 55. Install thehigh clutch solenoid and the brass retaining bracket, using two24mm bolts, as shown in Figure 178.

56.Torquethe two retaining bracket bolts to, 10 N·m (90 in.lb.).

4 VALVEBODYBOLT, 67MM LENGTH 5 VALVEBODYBOLT, 90MM LENGTH

6

Figure 176

29 8

ÌÑÎÏËÛ ×ÒÍÌßÔÔÛÜ ÞÑÔÌÍ ÌÑ ïð ÒiÓ øèè ×ÒòÔÞò÷

6

6 VALVEBODYBOLT, 24MM LENGTH 8 HIGHCLUTCHSOLENOID 29 HIGH CLUTCHSOLENOIDBRASSRETAINING BRACKET

Figure 177

Figure 178



5

10

14 9 5 VALVEBODYBOLT, 90MM LENGTH 6 VALVEBODYBOLT, 24MM LENGTH 9 NEUTRALSHIFTSOLENOID 10 2/4 BRAKESOLENOID 14 2/4 BRAKESOLENOID BRASSRETAINING BRACKET

6

Figure 179

4

57. Install new"O" ring, lube withATF, and install neutral shift solenoid intothe valve body, as shown in Figure 179.

17

58. Install new "O" rings on the 2-4 brake solenoid and lube with theproper ATF.

59.Assemblethe brass retaining bracket onto the 2-4 brake solenoid, and installboth pieces as an assembly onto the valvebody, as shown in Figure179. 60. Install one 90mmboltand one 24mm bolt in the positions shown in Figure 179. 61. Install new"O" rings, lube with small amount of properATF, and installshift solenoid "A" into thevalve body, using a 67mm bolt, as shown in Figure 180.

62. Handtighten only the 67mm bolt at this time. 4 VALVEBODYBOLT, 67MM LENGTH 17 SHIFTSOLENOID "A"

Figure 180


Technical Service Information 63.Install new "O"ring, lube withATF, and install reduction timing solenoid intothe valve body, as shown in Figure 181.

64.The reduction timing solenoid is "stacked" with TCC solenoid and goes in first, as shown in Figure181. 65. Install new "O" rings on the TCC solenoidand lube with the proper ATF.

66. Ensure that all mounting bushings arein place and installthe TCCsolenoid intovalve body as shown in Figure 181. 67. Install the105.5mm bolt, black in color, thru both TCC and reduction timing solenoids, as shown in Figure 181. 68. Install the75mm bolt, black in color, and place it through groundwire terminal for the pressure control solenoid, as shown in Figure 181. 69. Install the24mm bolt and hand tighten only, as shown in Figure 181. 70. Install new"O" rings, lube with small amount of properATF, and installshift solenoid "B" into thevalve body, usinga 67mm bolt, as shown in Figure 182.

71. Handtighten only the 67mm bolt at this time. 45 43

6

16

4 18

19

6 VALVEBODYBOLT, 24MM LENGTH 16 TCC SOLENOID 18 REDUCTION TIMING SOLENOID 43 VALVEBODYBOLT, 75MM LENGTH (BLACK IN COLOR) 45 VALVEBODYBOLT, 105.5MM LENGTH (BLACK IN COLOR)

Figure 181

4 VALVEBODYBOLT, 67MM LENGTH 19 SHIFTSOLENOID"B"

Figure 182


Technical Servi ce Information ÊßÔÊÛ ÞÑÜÇ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 72. Installnew "O" rings, lube with small amount of properATF, and install shift solenoid "C" into thevalvebody, as shown in Figure 183.

ÌÑÎÏËÛ ÎÛÓß×Ò×ÒÙ ÍÑÔÛÒÑ×Ü ÞÑÔÌÍ ÌÑ ïð ÒiÓ øèè ×ÒòÔÞò÷

73. Shift solenoid"C" is bolted inthe valve body using a nut onthe 67mm bolt from the bottom and one 90mm longvalve body tocase bolt (Silver in color), as shown in Figure 183.

74. Now, you cantorque the remaining solenoid retaining bolts to 10 N·m (90 in.lb.), as shown in Figure 184. 75. Set the completed valve body assemblyaside, as shown inFigure 185, for thefinal transaxle assembly process.

Figure 184 64

ÝÑÓÐÔÛÌÛÜ ÊßÔÊÛ ÞÑÜÇ ßÍÍÛÓÞÔÇ 3

20

3 NUTFORVALVEBODYBOLTFROM BOTTOM 20 SHIFTSOLENOID"C" 64 VALVEBODYTO CASEBOLT, 90MM LONG (SILVERIN COLOR)

Figure 185

Figure 183


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ 1. Install the lowroller clutch assemblyinto the case, as shown in Figure 186,with the narrow lugto the narrow case groove. 2. Install the retainingsnap ring into thecase, as shown in Figure 186.

4. Install thelow/reverse clutch stepped backing plate, as shown in Figure 188.

3. Install the number2 thrust bearing on support, as shown in Figure 186,and retainwith small amount of Trans-Jel®.

225

231

Figure 187 NARROW LUG 230 246

NARROW CASE GROOVE

225 LOWCLUTCHSUPPORTTO RING GEARBEARING (NO.2) 230 LOWROLLERC LUTCHASSEMBLY 231 LOWROLLERC LUTCHRETAINING SNAPRING

Figure 186

246 LOW/REVERSECLUTCHSTEPPEDBACKING PLATE

Figure 188


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 5. Install thelow/reverse clutch plates beginning with a friction plateon top of the backing plate and alternating withsteel plates, as shown in Figure189. 250

6. Install thelow/reverse clutch selective pressure plate, as shown in Figure 189. 7. Install thelow/reverse clutch "cone"cushion plate, as shown in Figure 189, so that outside diameter is restingon pressure plate. 8. Install thelow/reverse clutch returnspring seat, as shown in Figure 190. 9. Install low/reverse clutch piston return spring, as shown in Figure 190. 10. Install the pre-assembled low/reverse clutch retainer and piston assembly, as shown in Figure190.

249

11. Install universal compression tool, as shown in Figure 191, andcompress theretainer. 248

247

12. Install thelow/reverse clutch retainer snap ring, as shown in Figure 190.

247 LOW/REVERSEFRICTIONPLATES 248 LOW/REVERSESTEELPLATES 249 LOW/REVERSE"SELECTIVE"PRESSUREPLATE

Figure 189


Technical Service Information 257

COMPRESSOR TOOL

256

252

Figure 191

251

251 LOW/REVERSEPISTON RETURNSPRING SEAT 252 LOW/REVERSEPISTON RETURNSPRING 256 LOW/REVERSECLUTCHPISTON RETAINER

Figure 190

Figure 192


Technical Servi ce Information 13. Measure thelow/reverse clutch clearance using feeler gage, as shown in Figure 193, between the pressure plate and top friction. 34

14. Changeselective pressure plate as necessary using the chart in Figure 193. 15. Installthe 2-4 brake clutch backing plate, as shown in Figure 194. 16. Installthe 2-4 brake clutch plates beginning with a friction plate and alternating with steel plates, as shown in Figure 194.

35 36

17. Installthe pressure plate and selective pressure plate, as shown in Figure 194. 18. Installthe 2-4 brake clutch pressure plate snap ring, as shown in Figure 194. 37

38

39

34 35 36 37 38 39

Figure 193

2-4 BRAKECLUTCHSNAPRING 2-4 BRAKECLUTCH"SELECTIVE"PRESSUREPLATE 2-4 BRAKECLUTCHPRESSUREPLATE 2-4 BRAKECLUTCHSTEELPLATES (2 REQUIRED) 2-4 BRAKECLUTCHFRICTION PLATES (3REQUIRED) 2-4 BRAKECLUTCHBACKING PLATE

Figure 194


Technical Service Information 19. Measur Measuree the 2-4 brake brake clutch clutch cleara clearance nce using using a feeler feeler gage gage betwee between n theselective theselective pressu pressure re plate plate and and snapring snapring,, as show shown n in Figu Figure re 196. 196.

20. Change Change select selective ive pressu pressure re plate plate as necessa necessary ry usingthe usingthe chartin chartin Figu Figure re 196. 196. 21. 21. Ensur Ensuree that that numb number1 er1 thru thrust st beari bearingis ngis still still in place on the back side of low clutch housing, and installthe installthe low clutch clutch housin housing g by rotati rotating ng back and forth to engage all low/reverse clutch frictio friction n plates plates and low roller roller clutch,as clutch,as shown shown in Figure Figure 197. 197.

Figure 195

233 233

232 232

232 LOWC OW C LUTC HHOUSING HHOUSING TO C ASE ASE THRUSTBEARING (NO. 1) 233 LOWC LOW C LUTC HHOUSING ASSEMBL EMBLY

Figure 196

Figure 197


Technical Service S ervice Inform ation Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 22.Afterinstallat 22.Afterinstallation ion,, check check therotation therotation of the low clutch clutch housin housing, g, as shown shown in Figure Figure 198. 198.

23.Ensurethat number2A number2A thrust thrust bearingrace bearingrace and numb number er 3 thrust thrust bear bearingarestillin ingarestillin plac placee on the pre-assembled output ring gear/low clutch hub, as shown shown in Figu Figure re 199. 199. 24.Install 24.Install the outputring outputring gear/lo gear/low w clutch clutch hub assemblyby assemblyby rotati rotating ng back back and forth forth to engage engage all all ofthe lowclutchfric lowclutchfrictio tion n plate plates, s, as show shown n in Figure Figure 199. 199. 25. 25. Ensu Ensure re that that lowclutc lowclutch h hub hub is full fully y seat seated. ed. 260 260

259 259

258 258

258 RING GEARTO SUPPORT, THRUSTBEAR TBEARING RAC RAC E (NO. 2A) 259 OUTPUTCARRIE PUTCARRIERINTER INTERNAL NALRING RING GEAR/LOWC GEAR/LOWC LUTC HHUB 260 RING GEARTO OUTPUTC PUTCARR ARRIERTH IERTHRUSTBEAR TBEARING (NO, 3)

Figure 198

Figure 199

AUTO AU TOMAT MATIC IC TRAN TR ANSM SMIS ISSI SION ON SERV SE RVIC ICE E G ROUP RO UP

Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 26. Ensure Ensure thatnumber thatnumber 3Athrust 3Athrust bearingrace bearingrace and numb number4 er4 thrus thrustt bear bearingare ingare stillin stillin placeon placeon the the output output carrier carrier,, as shown shown in Figure Figure 200, 200, and installthe installthe outputcarri outputcarrier er assemblyby assemblyby rotatin rotating g into position. position. 27. 27. Insta Install ll the the outp outputsun utsun gear gear by rota rotati ting ng into into the output output carrier carrier,, as shown shown in Figure Figure 200. 200.

28. 28. Ensur Ensuree that that the the numb number er 5 thru thrust st beari bearingand ngand the numb number er 6 thrus thrustt bear bearingarein ingarein placeon placeon the input input carrier carrier,, as shown shown in Figure Figure 201, 201, and and then install install the input input carrie carrierr assemblyby assemblyby rotatin rotating g into position. position.

264 264

263 263 267 267 262 262 266 266

261 261 265 265

261 262 263 264

OUT O UTPUTC PUTC ARRIER THRUSTBEARING TBEARING RACE (NO. 3A) OUTPUTC PUTC ARRIER/INPUTINTERNAL ERNALRING RING GEARAS GEAR ASSE SEMBLY OUTPUTC PUTC ARRIER TO SUN GEART GEAR THRUSTBEARING (NO. (NO . 4) OUTPUTC PUTC ARRIER SUN GEAR

Figure 200

265 SUNGEAR UN GEART TO INTPUTCARRIERTH INTPUTCARRIERTHRUSTB RUSTBEARING (NO. 5) 266 INPUTCARR INPUTC ARRIERASSE IERASSEMBLY 267 INPUTC INPUTCARR ARRIERTO IERTO SUNGEART UNG EARTHRUSTBEARING ARING (NO. 6)

Figure 201


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 29.Ensurethat number6A thrust bearingrace and number 7Athrust bearing race arestill in place on the input sun gear, as shown in Figure 202. 30.Install the input sun gear/clutch hub assembly, as shown in Figure 202, byrotating back and forth to engage the2-4 brake clutch frictions and the input carrier.

31. Ensure thatnumber 8Athrust bearingrace and number 7 thrustbearing are stillin place on the high clutch hub, as shown in Figure 203. 32. Install the high clutch hub andshaft assembly by rotating into position (See Figure 203).

271 275

270

274

273

269

271

269 INPUTSUN GEARTHRUSTBEARING RACE (NO. 6A) 270 INPUTSUNGEARANDHUBASSEMBLY 271 SUNGEARTO CLUTCHHUBTHRUSTBEARING RACE (NO.7A)

Figure 202

271 273 274 275

SUNGEARTO CLUTCHHUBTHRUSTBEARING RACE (NO.7A) HIGHCLUTCHHUBTO SUNGEARTHRUSTBEARING (NO. 7) HIGHCLUTCHHUBANDSHAFT HIGHCLUTCHHUBTHRUSTBEARING RACE (NO. 8A)

Figure 203


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 33. Ensure that number 8 thrust bearing is still in place in the high and reverse clutch housing, as shown in Figure 204. 34.Install the high and reverse clutch housing, as shown in Figure 204, byrotating it back and forth until fully seated.

35. Install 2-4 brake clutch return spring assembly, as shown in Figure 204,with opening for the turbine speed sensor positionedas shown. 36. Install theturbine speed sensor, as shown in Figure 205,and torque thetwo boltsdown to 9 N·m (80in.lb.).

37. Install theconnectorwith theblue wires onto the turbine speed sensor. 53

101

63

62

61 276

TSS SENSOR CONNECTOR 53 2-4 BRAKEC LUTCHPISTON RETURNSPRING ASSEMBLY 101 HIGH ANDREVERSECLUTCHHOUSING ASSEMBLY 276 CLUTCHHOUSING TO HIGHCLUTCHHUBBEARING (NO. 8)

Figure 204

61 TURBINESPEEDSENSOR 62 TURBINESPEEDSENSORRETAINING CLIP 63 TURBINESPEEDSENSORRETAINING BOLTS (2REQUIRED)

Figure 205


Technical Service Infor mation Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 49

38. Installthe fluid feed pipes into transaxle case, as shown inFigure 206, and seat themgently with a soft mallet. 39. Ensurethat the number9 thrust bearing is installed into thehigh and reverse clutch housing, withthe needles facing up,as shown in Figure 207. 40. Install the"H" Gage on transaxle, as shown in Figure 208, and lower adjustingrod into high and reverse clutch housingso that it is setting on oneneedle (SeeInset Figure 208) 41.Tighten the locking screw so thatadjustingrod remainsin thatsame position.

49 ENDCOVERTO HIGH/REVDRUM THRUSTBEARING (NO. 9)

Figure 207

"H" GAGE

FLUID FEED PIPES ADJ USTING ROD

CLIPS

Figure 206

Figure 208

AUTOMATI C TRANSMISSION SERVICE GROU P

Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 42.Place the pre-assembled end cover on flat work surface, as shown in Figure 209. 43.Place the end cover "selective" thrust bearing race on thedirectclutchsupport, as shown in Figure209. 44.Turn the "H" Gage over withprevious setting and set it onend cover, as shown in Figure 210. 45.Measure the clearance between theadjusting rod and theselective thrust bearing race, as shown in Figure 210.

46.Change the selectivethrust bearingrace using thechartinFigure210. 47. Place the correct thrust bearingrace onto end cover support and retain with Trans-Jel®.

48 40

Figure 210

40 TRANSAXLEEND COVERASSEMBLY 48 END COVER"SELECTIVE"BEARING RACE (NO. 9A)

Figure 209


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷

595 19

48. Install theend cover tocase seal (18) into the pocket in the case, as shown in Figure 211,and retain withsmall amount of Trans-Jel®. 49.Apply a light coat ofsiliconesealant to the contact surfaces of thetransaxlecase and the end cover. 50. Install two new "O" rings onthe bolts(595) with the 17mm head,as shown in Figure211. 51. Lubricate the "O" rings with a small amount of Trans-Jel®. 52. Installthe completedend cover assemblyonto case, as shown in Figure 211.

53.Torque both the 12mm head bolts and17mm head bolts to22 N·m (16 ft.lb.),as shown in Figure 212.

3

40

18

ÌÑÎÏËÛ ßÔÔ ÛÒÜ ÝÑÊÛÎ ÞÑÔÌÍ ÌÑ îî ÒiÓ øïê ÚÌòÔÞò÷

3

18 ENDCOVERTO CASESEAL 19 ENDCOVERTO CASEBOLTS, 12MM HEAD (14REQUIRED) 40 TRANSAXLEENDCOVERASSEMBLY 595 BOLTWITH"O"RING, 17MM HEAD (2REQUIRED HERE)

Figure 211

Figure 212

AU TOMATIC TRAN SMISSION SERVICE GROUP

Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 54. Install the case half axle seal at this time,as shown in Figure 213, using the properdriver.

1.Turn thetransaxlecaseoverand set it on end coverso front is facing up(See Figure 214). 2. Install the outputshaft speed sensor, as shown in Figure 214, andtorque the retaining bolt to 9 N·m (80 in.lb.).

AXLE SEAL

3. Install the intermediate speed sensor, as shown in Figure 214, andtorque the retaining bolt to 9N·m (80 in.lb.). 3

4. Install the wire harness retaining bracket (68), as shown in Figure 214, and torqueretaining bolt to 9 N·m (80 in.lb.). 5. Install the TFT. sensor, as shown in Figure 214, and torque bolt to 9 N·m (80 in.lb.). Figure 213

64

63 66

63

67

65

63 68

63 RETAINING BOLT 64 OUTPUTSHAFTSPEEDSENSOR 65 OUTPUTSHAFTSPEEDSENSORRETAINING BRACKET

66 INTERMEDIATESHAFTSPEEDSENSOR 67 INTERMEDIATESHAFTSPEEDSENSOR RETAINING BRACKET 68 WIREHOLDDOWNBRACKET (OUTPUTSENSOR WIRE)

Figure 214


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 6. Install thenumber 12 thrust bearing and the number 12Athrust bearingrace onto thedirect clutch support, as shown in Figure 215. 7. Lubricate the insidesealing ring area of direct clutch housingwith theproper fluid and install thecompleteddirect clutch housing, as shown in Figure 215.

8. Installthe reduction band assembly, as shown in Figure 215, and engage with the previously installed servo pin and band anchor. 9. Remove the pressure plug and "O" ring, bythe reductionservo, from transaxle case, as shown in Figure 217.

10. Installthe factoryservo piston holding tool, as shown in Figure 217.

11. Install 14mm deep socketover the adjusting screw locking nutand loosen (See Figure 217).

SERVO PISTON HOLDING TOOL MAZDA PART NUMBER 49 L019 012

Figure 216

600

14 MM DEEP SOCKET

601

593 594

SERVO PISTON HOLDING TOOL MAZDA NO. 49 L019 012 PISTON AND SNAP RING INSTALLED

T

593 REDUCTION SUNTODIRECTSUPPORTRACE (NO. 12A) 594 REDUCTION SUNTODIRECTSUPPORTBEARING (NO. 12) 600 REDUCTION BAND 601 DIRECTC LUTCHHOUSING ASSEMBLY

Figure 215

Figure 217


PLUG AND "O" RING


1

1

3

3

5

5

2

2

4

4

6

6

7

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8

8

9

9

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1

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3

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7 I 8 N

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2

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N 8 I 9

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1

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STRAIGHT EDGE

Figure 218

12. Usinga digital caliper measure from thetopof 14 mmdeepsocket,down to a straight edge placed on machined surface of transaxle case, as shown in Figure 218. 13.Record thismeasurement as "Dimension A". 14.Fully compress theservo piston and the 14mm socket, using a large screwdriver,as shown in Figure219. 15.With piston fully compressed, measureagain from thetopof socket down tostraightedge, and record the measurement as "Dimension B". 16. Subtract "Dimension B" from "Dimension A". 17. Turnadjusting screw as necessary to achieve, a minimum of 3.175mm (0.125") to a maximum of 4.75mm (0.187").

STRAIGHT EDGE

Figure 219

18.Torquethe adjusting screw locking nut down to 39-50N·m (30-35 ft.lb.).

19. Remove servo piston holding tool and re-install thepressure plug with a new "O" ring.


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 20. Lubricate the "O" rings on the servo coverwith a small amountof Trans-Jel®. 21. Installthe pre-assembled reductionservo cover assembly, as shown in Figure 220. 22. Compress thecover and installthe snap ring, as shown in Figure 220. 23. Installthe reduction sungear, as shown in Figure 221. 24. Installthe reduction planetary gear assembly, as shown in Figure 221,by rotating back and forth until the direct clutch hub has engaged in all direct clutch frictions. 25. Ensurethat thenumber 10 thrust bearing (625) is stillin placeon thepiniongear.

625

617

61

616

62

61 REDUCTION SERVOCOVERRETAINING SNAPRING 62 REDUCTION SERVOCOVERAND"O"RINGSASSEMBLY

Figure 220

616 REDUCTION SUN GEAR ASSEMBLY 617 REDUCTION PLANETARYGEARASSEMBLY 625 PINIONGEARTO CONV. HOUSING BEARING (NO.10)

Figure 221



2

26. Lubricate sealingrings on turbine shaft with a small amountof the properfluid and installthe turbine shaft, as shown in Figure 222. 27. Install a new oil pumpto case gasket onto the case, as shown in Figure 222.

18

28. Install thepre-assembled oil pump assembly, as shown in Figure 222. 29. Install fiveoil pump to case bolts in positions shown in Figure 222. 30. Torque thefiveoil pump tocasebolts to; 22 N·m (16 ft.lb.), as shown in Figure 223.

19

20

21

ÌÑÎÏËÛ ÐËÓÐ ÞÑÔÌÍ ÌÑ îî ÒiÓ øïê ÚÌòÔÞò÷

2 18 19 20 21

OIL PUMP RETAINING BOLTS (5REQUIRED) OILPUMPASSEMBLY OIL PUMP TO CASEGASKET INPUTSHAFTASSEMBLY INPUTSHAFTSEALRINGS (3OR 2 REQUIRED)

Figure 222

Figure 223


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 2

31. Install new "O" ringseal on the turbine shaft, as shown in Figure224. 32. Installnew fluid filter with the tworetaining bolts, as shown in Figure 225. 33.Torque thetwo fluid filter retaining bolts to; 22 N·m (16 ft.lb.), also shown in Figure 225.

17

2 FLUIDFILTERTO CASEBOLTS (2 REQUIRED) 17 FLUID FILTERASSEMBLY

ÌÑÎÏËÛ ÚÔË×Ü Ú×ÔÌÛÎ ÞÑÔÌÍ ÌÑ îî ÒiÓ øïê ÚÌòÔÞò÷

TURBINE SHAFT "O" RING SEAL

Figure 225

Figure 224


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 2

34. Install the pre-assembled final drive assembly, as shown in Figure 226.

35.Apply a light coat ofsiliconesealant tothe contact surfaces of the converter housingand the transaxle case. 36.Apply a small amount of Trans-Jel® to inside diameter of pump bore in converter housing. 37.Install the converterhousing onto the transaxle case, as shown in Figure 227,and install the 22 retaining bolts. 38.Exact bolt locations areshown in Figure 228.

4 3

2 CONVERTERHOUSING TO CASEBOLTS (22REQUIRED) 3 CONVERTERHOUSING ASSEMBLY 4 TRANSAXLECASEASSEMBLY 16

Figure 227

ÝÑÒÊÛÎÌÛÎ ØÑËÍ×ÒÙ ÞÑÔÌ ÔÑÝßÌ×ÑÒÍ

16 FINALDRIVERING GEARAND CARRIERASSEMBLY

Figure 226

Figure 228


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 39.Torqueall of the converter housingboltsto 30 N·m (22 ft.lb.), as shown in Figure 229, using a criss-cross pattern. 40. Place the speed sensor wiring harness outside of the pan rail,as shown in Figure 230,in preparation for valve body installation. 41. Install a new reduction band seal intothe case pocket, as shown in Figure 230, and retain with a small amount of Trans-Jel®. 42. Install thelow/reverse clutch "top-hat" seal, as shown in Figure230, and retain with a small amount of Trans-Jel®. 43. Place the transaxle in Manual Low position by rotating themanualshaft all the way to the left, as shown in Figure 231.


REDUCTION BAND SEAL


Figure 230

ÌÑÎÏËÛ ÝÑÒÊÛÎÌÛÎ ØÑËÍ×ÒÙ ÞÑÔÌÍ ÌÑ íð ÒiÓ øîî ÚÌòÔÞò÷

ÎÑÌßÌÛ ÓßÒËßÔ ÍØßÚÌ ÌÑ ÌØÛ ÔÛÚÌ ßÍ ÚßÎ ßÍ ×Ì É×ÔÔ ÙÑ

Figure 229

Figure 231



"O" RING SEAL

EXTERNAL PASS-THRU CONNECTOR AND HARNESS ASSEMBLY

RETAINING CLIP

3

2

44. Install thepre-assembled valve body assembly, as shown in Figure 232, while holding manual valve with clevis pin against valve body.

45. Afterthe valvebody is in place, check that the manualvalve is properly located on the linkage pin by moving the manual lever. 46. Install the11 silvercolored valve body to case bolts, as shown in Figure 232.

47. Install new"O" ring on theexternal pass-thru connector and lube withTrans-Jel®. 48. Install theexternal pass-thru connectorand harnessassembly and install retaining clip, as shown in Figure 232.

VALVE BODY ASSEMBLY

GROUND TERMINAL

REDUCTION BAND SEAL


JC7 JP

-1 PM-SUB

B021204N

F

2. VALVEBODYTO CASEBOLT, 90MM LONG (SILVERIN COLOR) TEN 90MM LONG BOLTSREQUIRED 3. VALVEBODYTO CASEBOLT, 106MM LONG (SILVERIN COLOR) ONE 106MM LONG BOLTREQUIRED

Figure 232

2. VALVEBODYTO CASEBOLT, 90MM LONG (SILVERIN COLOR) TEN 90MM LONG BOLTSREQUIRED 3. VALVEBODYTO CASEBOLT, 106MM LONG (SILVERIN COLOR)

Figure 233


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 49. Installthe internal solenoid harness assembly, as shown inFigure 235, ensuring that you get the wires indicated in Figure 236 under valve body bracket.

50. Now torque all silver valve bodyto case bolts to 9 N·m (80 in.lb.),as shown in Figure 234. 51. Connectthe internal speed sensor harness to the 8-way internal connector. 52. Connectthe internal solenoid harness to the 10-wayinternal connector. 53.Apply a lightcoatof siliconesealant to the contactsurfaces of theside cover and transaxle case. 54. Install thesidecover onthe transaxle case, as shown in Figure 235,and installthe 20 side cover retaining bolts.

ÌÑÎÏËÛ ÊßÔÊÛ ÞÑÜÇ ÌÑ ÝßÍÛ ÞÑÔÌÍ ÌÑ ç ÒiÓ øèð ×ÒòÔÞò÷

RETAINING BOLTS 20 REQUIRED

SIDE COVER INTERNAL SOLENOID HARNESS ASSEMBLY

GROUND TERMINAL


Figure 234

Figure 235

AUTOMATI C TRANSMISSION SERVICE GROU P

Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 55. Torque alltwenty of the side cover boltsto 10 N·m (90 in.lb.),as shown inFigure 237.

GROUND TERMINAL

1. Install thetransaxlerange sensor, as shown in Figure 238, andhand tighten only the retaining bolts.

WIRES UNDER BRACKET

Figure 236

14

ÌÑÎÏËÛ ßÔÔ Í×ÜÛ ÝÑÊÛÎ ÞÑÔÌÍ ÌÑ ïð ÒiÓ øçð ×ÒòÔÞò÷ 15

14 TRANSAXLERANGESENSORRETAINING BOLTS (2) 15 TRANSAXLERANGESENSOR

Figure 237

Figure 238


Technical Service Information Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 2. Rotate themanual shaft fullyto theright, then return 2 notches, to set the neutral position. 3. Installthe Mazda transaxle range switch special tool number49-L019-013, as it is shown in Figure239. 4. Rotate the transaxle range sensor until the rod of the toolenters the neutralhole, as shown in Figure239. 5. With the tool in place, torque thetwo bolts to 7 N·m (60 in.lb.).

6. Installthe transaxle external manualshift lever, as shown inFigure 240, install washer and nut and torque nut to 38 N·m (28 ft.lb.). 7. Installboth cooler linebanjo fittings, withnew washers, as shown in Figure 240, andtorque coolerline banjo bolts to 34 N·m (25 ft.lb.).

ÓßÆÜß þêþ Ð Î Ò Ü 6 9 7

10

8

6 7 8 9 10

Figure 239

COOLERLINEBANJ O FITTING BOLTS (2) C OOLERLINEBANJ O FITTING WASHERS (4) COOLERLINEBANJ O FITTINGS MANUALSHIFTLEVERRETAINING NUT MANUALSHIFTLEVER

Figure 240


Technical Service Information 11 12 1 11 12 13

TORQUECONVERTERASSEMBLY FLUIDDIPSTICKTUBE FLUIDDIPSTICKTUBERETAINING BOLT FLUIDDIPSTICKTUBE"O"RING SEAL

13

1

Figure 241

Ú×ÒßÔ ÌÎßÒÍßÈÔÛ ßÍÍÛÓÞÔÇ øÝÑÒÌùÜ÷ 8. Install new "O" ring on dipstick tube, as shown in Figure 241, and lube with a small amountof Trans-Jel®. 9. Install the dipstick and tube assembly, as shown in Figure 241, and torque theretaining bolt to 10 N·m (90 in.lb.). 10.Prime thetorque converterwith 2-3 quarts of the appropriateATF, to soak converter clutch a minimum of 15 minutes prior to installation. 11. Installthe torque converter assembly, using a rotating motion so as to engage oil pump gear, as shown in Figure 241.

CONVERTER HOUSING SURFACE

þÝÑÒÙÎßÌËÔßÌ×ÑÒÍ ÇÑË ßÎÛ Ú×Ò×ÍØÛÜþ Figure 242


TORQUE CONVERTER

Technical Service Information ÌØÎËÍÌ ÞÛßÎ×ÒÙ ßÒÜ ÌØÎËÍÌ ÞÛßÎ×ÒÙ ÎßÝÛ ×ÜÛÒÌ×Ú×ÝßÌ×ÑÒ 232 258

NO. 2A

NO. 1

269

267

NO. 6A

NO. 6

261

225

NO. 2

273

260

NO. 3A

NO. 3

271

NO. 7

263

NO. 4

276

NO. 7A

265

NO. 8

275

NO. 8A

NO. 5

48

49

NO. 9A

NO. 9

602

625 617

616

"NO. 11" BEARING AND BEARING RACE ARE "CAPTURED" INSIDE OF REDUCTION CARRIER

NO. 10

NO. 12

NO. 12A

NO. 13

NO. 1 LOWCLUTCHHOUSING TO CASETHRUSTBEARING (ILLUSTRATION NO. 232) NO. 2 LOWC LUTCHSUPPORTTO LOWC LUTCHHUB/RING GEAR THRUSTBEARING (ILLUSTRATION NO. 225) NO. 2A LOWC LUTCHHUB/RING GEARTO SUPPORTTHRUSTBEARING RACE (ILLUSTRATIONNO. 258) NO. 3 LOWCLUTCHHUB/RING GEARTO OUTPUTCARRIERTHRUSTBEARING (ILLUSTRATIONNO. 260) NO. 3A OUTPUTCARRIERTOLOWC LUTCHHUB/RING GEAR THRUSTBEARING RACE (ILLUSTRATION NO. 261) NO. 4 OUTPUTCARRIERTOOUTPUTSUNGEARTHRUSTBEARING (ILLUSTRATIONNO. 263) NO. 5 OUTPUTSUNGEAR TO INPUTCARRIERTHRUSTBEARING (ILLUSTRATIONNO. 265) NO. 6 INPUTCARRIERTO INPUTSUNGEAR THRUSTBEARING (ILLUSTRATION NO. 267) NO. 6A INPUTSUNGEAR TO INPUTCARRIERTHRUSTBEARING RACE (ILLUSTRATIONNO. 269) NO. 7 INPUTSUNGEARTO HIGHC LUTCHHUBTHRUSTBEARING RACE (ILLUSTRATION NO. 273) NO. 7A INPUTSUNGEAR TO HIGHCLUTCHHUBTHRUSTBEARING (ILLUSTRATION NO. 271) NO. 8 HIGHCLUTCHHUBTO HIGH ANDREVERSECLUTCHHOUSING THRUSTBEARING (ILLUSTRATION NO. 276) NO. 8A HIGHCLUTCHHUBTO HIGHANDREVERSECLUTCHHOUSING THRUSTBEARING RACE (ILLUSTRATION NO. 275) NO. 9 HIGHANDREVERSECLUTCHHOUSING TO ENDC OVERTHRUSTBEARING (ILLUSTRATION NO. 49) NO.9A HIGHANDREVERSEC LUTCH HOUSINGTO ENDC OVER THRUSTBEARINGRACE (ILLUSTRATION NO.48) NO. 10 DIFFERENTIALPINION GEAR TO CONVERTERHOUSING THRUSTBEARING (ILLUSTRATIONNO. 625) NO. 11 THENUMBER11 THRUSTBEARING ANDTHRUSTBEARING RACE ARE"CAPTURED"INSIDEOFTHEREDUCTION CARRIERASSEMBLY NO. 12 REDUCTION SUNGEAR TO DIRECTC LUTCHHOUSING SUPPORTTHRUSTBEARING (ILLUSTRATION NO. 617) NO. 12A REDUCTION SUN GEAR TO DIRECTCLUTCHHOUSING SUPPORTTHRUSTBEARING RACE (ILLUSTRATIONNO. 616) NO. 13 DIRECTC LUTCHHOUSING TO DIRECTC LUTCHHOUSING SUPPORTTHRUSTBEARING (ILLUSTRATIONNO. 602)

Figure 243


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Figure 244


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