The output shaft The appearance of the selector lever, as shown in is not held and is free to rotate and the engine can be Figure 29, will vary between the different vehicle started. The 2. Ignition lever on transaxle. Place the manual control lever on transaxle in 9 to the starter relay. Diagnosis here is easily done neutral position. You should the manual control lever and the hole in flange have continuity across the terminals shown in the chart of the TRS body are aligned.
Panel Conn. A coil built into voltage at output speed sensor terminal 3. A coil built the input shaft speed sensor generates a 0 - 5 volt pulse into the output shaft speed sensor generates a 0 - 5 volt signal when the input shaft rotates.
The pulse signal pulse signal when the output shaft rotates. The pulse frequency increases with a rise in input shaft speed. The PCM interprets this pulse signal as output speed. The input shaft speed sensor generates the pulse shaft speed. The output shaft speed sensor generates the signal as the teeth on the underdrive clutch housing pass pulse signal as the teeth on the direct planetary carrier the magnetic tip of the sensor.
The input speed sensors all operate in the same manner The output speed sensors all operate in the same but all of the PCM terminals are different. You must manner but all of the PCM terminals are different. You refer to the wiring schematic for the model you are must refer to the wiring schematic for the model you are working on. Mitsubishi wire schematic - See Page Hyundai wire schematic - See Page Kia wire schematic - See Page When a DTC is output four times, the short in the output speed sensor circuit, and a DTC is transaxle is locked into 3rd gear as a failsafe measure.
When a DTC is output four times, the transaxle is locked into 3rd as a failsafe measure. The PCM learns the once per second D1 thru D5 if there are any diagnostic driving habits and the preferences of each individual trouble codes stored related to the transaxle system. The PCM then position indicator D1 thru D5 is flashing once per uses this data to adjust shift timing to best suit the second Requires Scanner.
This applies to drivers style. Mitsubishi Only. The PCM monitors its input and output signals, some Note: If the selector lever position indicator light signals at all times and others only under specified D1 thru D5 is flashing "twice" per second, the conditions.
When an irregular signal is initially transaxle fluid temperature is high. Diagnostic trouble codes are kept in memory by direct battery feed. The codes are retained in memory even if ProCarManuals.
A compatable scan tool is required to read and erase diagnostic trouble codes. PCM connector views Page With TCC fully applied pressure should be approximately psi. With DCC fully applied pressure should be approximately psi.
The transaxle should be steam cleaned on the technicians. Attempting repairs or service without the outside, to remove any dirt or grease before appropriate training, tools and equipment could cause disassembly begins.
This transaxle can be disassembled very easily The service procedures we recommend and describe on a work bench without the benefit of any in this manual are effective methods of performing holding fixture for rotation. Some of the 3. Remove the torque converter from transaxle, procedures require the use of special tools that are as shown in Figure Continued on Page 42 ProCarManuals. Remove the fluid level indicator from transaxle 9.
Remove and discard the "O" ring. Remove the manual lever nut, washer, and the 5. Remove air breather assembly from transaxle, as manual lever, as shown in Figure Remove the transaxle range switch retaining 6.
Remove the input shaft speed sensor retaining bolts and transaxle range switch, as shown in bolt and the input shaft speed sensor, as shown Figure Remove the output shaft speed sensor retaining Continued on Page 43 bolt and the output shaft speed sensor, as shown in Figure Remove the speedometer adapter, the vehicle 10 10 20 20 30 30 40 40 speed sensor, or the sealing cap, depending on 50 0 50 which the transaxle is equipped with. As a diagnostic aid, install dial indicator, as shown in Figure 49, measure and record the input shaft end play.
Remove the connectors and drape the wire harness up and over the top of pan rail. Note: We have provided you with color of the wires that we observed. If yours are different, label them now to prevent cross-connecting on re-assembly See Figure Remove the TFT sensor, as shown in Figure 54, remove and discard the "o" ring seal.
Remove the valve body to case mounting bolts G as shown in Figure Remove 28 valve body to case bolts and the 2 1K A5 F4 valve body assembly, as shown in Figure Notice the two steel balls in the top of valve body, as shown in Figure Set the valve body assembly aside for the component rebuild section.
Remove the manual shaft retaining pin from pan rail, as shown in Figure Remove and discard the 2nd clutch case seal, 7 as shown in Figure Remove the case worm track oil screen, as shown in Figure Note: Replace case screen as necessary.
If your springs are not identified, label them now as you remove them, for re-assembly ID. Remove the case connector snap ring and F4 A5 1K remove the internal wire harness through the inside of the case, as shown in Figure Remove and discard the case connector "O" ring, as shown in Figure With the manual shaft retaining pin removed, rotate back and forth and remove the inside detent lever and parking rod through the inside of the case, as shown in Figure Remove and discard the two "O"ring seals on the manual shaft, as shown in Figure Rotate the case on the work bench so that the converter housing is facing up, as shown in Figure Remove the 20 torque converter housing bolts, 28 as shown in Figure 63 and Note: Six of these bolts are inside of the converter housing, as shown in Figure Remove and discard the two small "O" rings between the converter housing and the case, as shown in Figure Note: The "O" rings may be stuck to the torque converter housing.
Continued on Page 50 ProCarManuals. Remove and discard the oil filter and "O" ring, as shown in Figure Remove the differential assembly from case, as shown in Figure Set complete differential assembly aside for the component rebuild section. Remove the two reduction band feed pipe retaining bolts, as shown in Figure 66, and remove feed pipe with brackets. Remove the six oil pump retaining bolts, as Remove and discard the oil pump to case gasket, shown in Figure 67, and remove the oil pump as shown in Figure Note: Gasket may be stuck to oil pump.
Set complete oil pump assembly aside for the Remove the underdrive clutch housing by lifting component rebuild section. Remove the number 1 selective thrust washer, as shown in Figure Note: Number 1 selective thrust washer may be stuck to oil pump. Set the complete underdrive clutch housing aside for the component rebuild section. Remove underdrive clutch hub and number 2 47 thrust bearing, as shown in Figure Remove the reduction band servo cover snap ring and cover, as shown in Figure Remove and discard the servo cover "O" ring seal, as shown in Figure Remove reduction band servo piston snap ring 51 and piston assembly, as shown in Figure Remove and discard the servo piston seal, as shown in Figure Remove the reduction band servo piston return 53 spring, as shown in Figure Remove the two parking rod roller support pins, as shown in Figure 71, using needle nose pliers.
Remove the parking rod roller support from the inside of case, as shown in Figure Remove the parking pawl, and return spring as an assembly, as shown in Figure Before removing the direct planetary carrier and transfer driven gear assembly, measure the depth of the transfer gear below the case surface, as shown in Figure 73, and record measurement for final assembly process. BAND Remove the reduction band from the case, as shown in Figure Note: May be necessary to remove the band anchor plug and "O" ring to remove band, as shown in Figure Continued on Page 55 ProCarManuals.
Remove the number 11 thrust bearing, as shown Remove the reduction sprag race cushion spring, in Figure Note: Number 11 thrust bearing may be stuck to Note: Reduction sprag race cushion spring is back side of direct clutch housing.
Remove the number 12 thrust bearing race, as Remove and discard the two direct clutch seal shown in Figure Remove the reduction sprag retaining snap ring Rotate transaxle case on bench so that rear cover from the case, as shown in Figure Remove the reduction OWC-2 sprag assembly Remove the reduction accumulator snap ring, from case, as shown in Figure 77, and set aside for cover, return spring and accumulator piston, as the component rebuild section.
Remove and discard the cover "O" ring seal and the accumulator piston seal ring. Remove the fourteen rear cover retaining bolts, Remove and discard the case cover to the direct as shown in Figure Remove the transaxle rear cover, as shown in Figure Figure 79, and set aside for component rebuild Remove the direct clutch accumulator piston and section.
Remove and discard the six rear cover to case Remove and discard direct clutch accumulator "O" ring seals, as shown in Figure Remove number 8 selective thrust race and the Remove the number 6 thrust bearing and the number 7 thrust bearing assembly, as shown in overdrive clutch hub, as shown in Figure Figure Set the overdrive clutch hub and the number 6 Note: Number 8 selective thrust race may be bearing aside for component rebuild section.
Remove the number 5 thrust bearing and the Set the number 5 thrust bearing and the sun for the component rebuild section. Continued on Page 58 ProCarManuals. Remove 2nd clutch retainer snap ring, as shown in Figure Refer to Page 59 for the various stack-ups observed, and there may be more than shown at this time. Remove the planetary gear set and low sprag assembly OWC-1 , as shown in Figure 89, and set aside for the component rebuild section. Remove the next snap ring from the groove in the case, as shown in Figure Continued on Page 61 ProCarManuals.
Remove the low sprag OWC-1 inner race snap ring , as shown in Figure Slowly release compression tool and remove the tool from the case.
Remove the low sprag inner race OWC-1 , as shown in Figure 92, remove and discard the "Lip Type" seal on the back side of inner race.
Remove the transfer drive gear by accessing Remove the transfer drive gear assembly, as the retaining bolts through the access holes shown in Figure The exploded views If bearing service is not necessary, the transfer provided in this manual of the transfer drive gear and drive gear does not need to be removed. Rotate the transfer gear as necessary so the only.
Rotate the transfer gear 45 degrees and remove Continued on Page 63 the remaining four bolts Total of 8. Clean the transaxle case thoroughly and dry with compressed air. Install alignment dowel MD, as shown in Figure 96, as a guide for proper alignment. Align your reference marks from disassembly process and install transfer drive gear assembly, as shown in Figure Install three retaining bolts, remove alignment tool and install the fourth bolt.
Rotate the transfer drive gear 45 degrees and install the remaining four bolts. Continued on Page 64 ProCarManuals. Install new differential bearing cup as necessary using the proper driver, as shown in Figure Note: We will cover the differential pre-load adjustment during the final assembly process. Install new caged needle bearing, as necessary, into case, as shown in Figure 98 using proper driver and adapter. Note: Caged needle bearing must be installed 0. Disassemble reduction sprag OWC-2 assembly Install one reduction sprag end bearing, as shown using Figure as a guide.
Clean and inspect reduction sprag parts thoroughly Note: ID groove on outer race must face up. Install one reduction sprag retainer on bottom of reduction sprag outer race, as shown in Figure Note: ID groove on outer race must face up. Install the completed reduction sprag OWC-2 Install the reduction sprag assembly into the outer assembly, as shown in Figure , into transaxle race, as shown in Figure , with the "lip" on case with the ID groove facing up.
Install the reduction sprag assembly retaining snap Note: The reduction sprag cage has no arrows ring, as shown in Figure , and ensure that it on it to help with direction of installation. Note: There have been many engineering changes in this transmission since its introduction.
ATSG also has available an "Update Handbook" which includes the many changes and is required along with this manual for a proper overhaul or repair. ATSG also has available an "Update Handbook" which includes the many changes and is required along with this manual for a proper overhaul or repair.. JavaScript seem to be disabled in your browser. You must have JavaScript enabled in your browser to utilize the functionality of this website. Enter Member Area Bookstore Login.
Call Us Now My Cart. You have no items in your shopping cart. Search Catalog. Popular manuals. Ltd in Japan. In the initial stages of the breakdown you can eliminate the problem relatively painlessly.
As a result, the pump or torque converter itself requires a complete replacement. Quite often solenoids break down, which are recommended to be replaced after , kilometers.
Due to poor quality oil the oil pump cover can wear down which leads to oil leakage. Figure 29 Using a soft faced hammer or plastic mallet gently tap and loosen the converter housing as shown in Figure Remove the converter housing from the 11 transmission case by lifting straight up. Set the converter housing aside for cleaning and 11 11 11 component rebuild. Remove the ATF fluid filter retaining bolt as Remove the two transmission case fluid passage shown in Figure Remove and discard the ATF fluid filter by lifting Remove the transmission case fluid passage cover straight up as shown in Figure Remove the front differential carrier assembly by lifting straight up as shown in Figure Set differential carrier assembly aside for cleaning and component rebuild.
Remove the 2nd coast clutch hub outer race and the 2nd coast clutch hub as shown in Figure Set the 2nd coast clutch outer race and hub assembly aside for cleaning and component rebuild. Remove the three transmission fluid baffle retaining bolts as shown in Figure Remove the transmission fluid baffle as shown in Figure Remove the transmission case fluid passage seal as shown in Figure Lift the manual valve detent spring upward away Remove the parking pawl retaining shaft by from the manual valve detent lever and slide the lifting straight up as shown in Figure Remove the parking pawl retaining shaft return in Figure Rotate the manual valve detent lever forward in Remove the parking pawl actuating bracket and order to disengage the parking pawl actuator rod the parking pawl lever as shown in Figure Remove the two manual valve detent lever spring retaining bolts as shown in Figure Remove the manual valve detent lever spring by lifting and sliding in direction of the arrow as shown in Figure Remove the parking pawl pin spring retaining bolt Remove the clutch drum assembly as shown as shown in Figure Remove the parking pawl pin spring and the guide Remove the parking pawl spring guide pin as Remove the third gear B4 band assembly from shown in Figure Remove the front differential transfer drive gear thrust bearing race from the transfer drive gear assembly as shown in Figure Using Universal Clamp Press J or other adequate puller device, attach the clamp and carefully remove the front differential transfer drive gear assembly from the transmission case as shown in Figure Set the transfer drive gear assembly aside for cleaning and component rebuild.
Using a pair of snap ring pliers, remove the snap thrust washer as shown on the previous page in ring that retains the cover of the 3rd gear B4 Figure Remove the 3rd gear B4 band servo cover as as shown in Figure Remove and discard the o-rings from the servo thrust washer as shown in Figure Remove the 3rd gear B4 band servo and return cleaning and component rebuild.
Set the servo assembly aside for cleaning and bearing assembly as shown in Figure Using a soft faced hammer or plastic mallet gently Remove the rear internal gear assembly as shown tap and loosen the transmission rear case cover as in Figure Remove the rear internal gear thrust bearing Set the transmission rear case cover aside for assembly as shown in Figure Remove the front planet carrier thrust bearing Remove and discard the five case fluid passage race as shown in Figure Remove the front planet carrier and sun gear Remove the forward C1 and direct C2 clutch assembly as shown in Figure Remove the forward C1 and direct C2 clutch housing as shown in Figure 53 and set aside for cleaning and component rebuild.
Remove the input shaft thrust bearing assembly as shown in Figure Remove the rear sun gear assembly and the rear sun gear thrust bearing assembly as shown in Figure Remove the rear sun gear thrust bearing race as shown in Figure Using a screwdriver remove the low and reverse Remove and discard the low and reverse clutch clutch snap ring as shown in Figure Remove the low and reverse clutch upper backing Remove the output gear assembly retaining snap plate, the lined and steel plates and the lower ring and remove the output gear assembly from backing plate as shown in Figure Remove the front internal gear thrust bearing Remove the lube pipe hold down bracket assembly as shown in Figure Remove the front internal gear assembly as shown shown in Figure Remove the front internal gear thrust bearing assembly and the front internal gear thrust washer race located on the back side of the front internal gear as shown in Figure Using a screwdriver remove the low and reverse clutch piston return spring retaining snap ring as shown in Figure Remove the low and reverse clutch piston return spring as shown in Figure Remove the low and reverse clutch piston as shown in Figure Disassemble the Torque Converter Housing using the diagram in Figure 62 as a guide.
Using SST J or other equivalent seal removal tool remove the torque converter housing axle seal from the torque converter housing as shown in Figure Remove the transmission fluid lube tube bracket retaining bolt and remove the bracket as shown in Figure Remove three transmission fluid baffle retaining bolts and the baffle as shown in Figure Carefully remove the transmission fluid lube tube as shown in Figure Remove the transfer drive gear front lube seal as shown in Figure Inspect the transfer drive gear front bearing assembly and the front differential assembly bearing race as shown in Figure 66 and replace as necessary.
Inspect and clean all torque converter housing parts thoroughly and dry with compressed air replacing parts as necessary. Install a new transfer drive gear front lube seal as shown in Figure Carefully install the transmission lube fluid tube with a plastic hammer using care not to bend the tube as shown in Figure Install the automatic transmission fluid baffle as Coat the inside of the seal with a small amount of shown in Figure Install and hand tighten the lube fluid tube hold assembly aside for final assembly.
Install and hand tighten the three automatic transmission fluid baffle retaining bolts as shown in Figure Using a torque wrench tighten the lube fluid tube hold down bracket retaining bolt and torque the bolt to 5 N. Using a torque wrench, tighten the three automatic transmission fluid baffle retaining bolts and torque the bolts to 5 N. Using a plastic hammer, tapping evenly, install the torque converter housing axle seal as shown in Figure Disassemble the transmission case assembly using the diagram in Figure 72 and Figure 73 as a guide.
Using a screwdriver carefully pry upward and A S A remove the manual shift shaft seal as shown in Figure Using SST J or other similar driver and a hammer, drive the manual shift shaft bearing assembly through the case bore and remove the bearing assembly as shown in Figure Using SST J or other adequate seal puller, remove the automatic transmission axle seal as shown in Figure Clean all case assembly parts thoroughly with solvent and dry with compressed air.
CAUTION: It is vital to check the transmission case assembly for wear in the area where the drive transfer gear bearing support sleeve contacts the case as shown in Figure If the case is worn in this area it will need to be repaired or replaced.
Failure to do so will result in premature transmission failure. Using SST J or other adequate seal installer and a hammer, install a new automatic transmission axle seal as shown in Figure Using SST J or other adequate driver and a Figure 78 hammer, install a new shift shaft bearing assembly then install a new shift shaft seal as shown in Figure Using SST J A or other adequate seal installer and a hammer, install two new transmission fluid cooler line seals as shown in Figure This is an extremely critical area that needs to be addressed.
Rotate the transmission case assembly so the 11 converter housing side is facing upward, and 11 install the front differential assembly into the 11 empty case as shown in Figure Install the converter housing onto the transmission case assembly and install the twelve 11 converter housing attaching bolts hand tightening only as shown in Figure Using an appropriate torque wrench, torque the twelve converter housing attaching bolts to 29 11 11 11 11 Nm 21 ft.
Remove the rotational torque adapter tool from torque adapter tool insert the tool into the axle the front differential and remove the torque shaft opening in the converter housing and turn converter housing and differential assembly from the adapter so it engages the differential pinion the transmission case assembly. Using SST J differential bearing race 5. Using an appropriate torque wrench, measure the remover and J removal bridge or other rotational torque required to slowly rotate the adequate bearing race removal tool, remove the front differential assembly.
Make a notation of the rotational torque reading. Rotational Torque Specification: Remove the front differential bearing race Rotational torque should be between 0. If rotational torque is not within specification it will be necessary to replace the front differential bearing race selective shim.
Rotational Torque Specification: 90 0. If front differential bearing race selective shim Selective Shim replacement is needed, select an appropriate shim using the chart in Figure 85 as a guide. If rotational torque measurement is less than specification, a thicker shim will be required.
If rotational torque measurement is greater than specification, a thinner shim will be required. Once proper shim has been selected and rotational torque measurement is within specification, install the appropriate shim into the transmission case assembly as shown in Figure Using SST J and J or other adequate driver and handle, install a new front differential bearing race into the case as shown in Figure The exploded view diagram shown in Figure 88 is provided for illustration purposes only.
Clean the differential assembly with solvent and dry with compressed air. Inspect the differential assembly for wear or damage using the diagram in Figure 88 as a reference. If any wear or damage is observed, replace the differential assembly. The exploded view diagram shown in Figure 89 is provided for illustration purposes only. If any wear or damage is observed, replace the assembly. Using a pair of snap ring pliers, remove the safety glasses in order to help prevent injury to Second Brake B2 Piston Return Spring the eyes.
Assembly Retaining Snap Ring as shown in 5. While pulling upward on the piston assembly, Figure While pulling upward on the piston assemblies, Assembly and the Second Brake B2 Piston Remove the 13 M6 x 1.
Remove the 1 M5 x 0. Clean all Oil Pump parts thoroughly and dry with compressed air. Use the specifications shown in Figure 99 to determine if the pump gears and pump body are within clearance specifications. If excessive wear is indicated, replace the pump assembly.
Drive Gear Tip to Pump Body 0. Driven Gear Tip to Pump Body 0. Drive Gear and Driven Gear 0. Apply a small amount of Automatic Transmission Pump Body as shown in Figure The index mark on shown in Figure Torque the bolts using an appropriate torque in Figure Install and hand tighten 12 of the 13 Oil Pump indicated in Figure Oil Pump Cover Attaching Bolt Once the Oil Pump Cover Attaching Bolts are tightened to the proper torque specification, inspect the pump gears for smooth rotation.
Install the pump assembly on the torque converter as shown in Figure Rotate the pump assembly to insure smooth rotation of the pump gears as shown in Figure Be careful not to damage the pump seal during this operation.
Install the Second Brake B2 Piston Return Spring Retaining Snap ring onto the pump assembly as shown in Figure , making certain the retaining snap ring is fully seated.
Note: All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation. Install the Second Brake B2 Steel Plates and Lined Plates starting with a steel plate then alternating lined plates and steel plates, ending with a lined plate as shown in Figure Make sure the Retaining Snap Ring is fully seated and the ends not aligned with any of the cutouts as shown in Figure Figure and measure piston travel make Carefully install the Second Coast Brake B1 Piston travel clutch clearance should be Piston Assembly into the pump assembly using a between 1.
If clutch clearance is not within specification, Install the Second Coast Brake B1 Piston Return select another backing plate using the chart in Spring Assembly aligning the springs into the Figure as a reference. Make certain the retaining snap ring is fully seated Piston Return Spring into the snap ring groove in the pump body assembly. Note: All frictions should be soaked in the 02 03 01 0 01 02 03 appropriate ATF for at least 30 minutes prior to 04 05 0 05 04 installation.
Install the Second Coast Brake B1 clutch plates starting with a Steel Plate and alternating lined plates and steel plates, ending with a lined plate as shown in Figure Using SST J and J or other adequate hole for Second dial indicator, set the dial indicator base onto the Brake B2 pump body assembly where the attaching bolt was omitted as shown in Figure Caution: When using compressed air, wear 3. Backing Plate Thicknesses 4.
Carefully pply a small amount of compressed air dial indicator, set the dial indicator base onto the to the Second Coast Brake B1 passage as shown pump body assembly where the attaching bolt was in Figure and measure piston travel make omitted as shown in Figure Put the dial indicator on the Second Coast Brake Piston travel clutch clearance should be B1 piston and set the dial indicator to a zero between 1.
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