Daihatsu SIRION M300 Service Manual (No.9890) – AUTOMATIC TRANSMISSION/AUTOMATIC TRANSAXLE

Page 1
A4B ---------------------------------------------------- F3 - 1
AUTOMATIC TRANSAXLE ------------------ F3 - 1
BASIC CHECK AND ADJUSTMENT--- F3 - 1 FUNCTION CHECK ------------------------ F3 - 5
AUTOMATIC TRANSAXLE AY ------------ F3 - 11
REMOVAL AND INSTALLATION ------ F3 - 11
DIFFERENTIAL SIDE OIL SEAL --------- F3 - 18
OIL COOLER HOSE------------------------- F3 - 20
OIL PAN ----------------------------------------- F3 - 22
OIL STRAINER-------------------------------- F3 - 24
VALVE BODY---------------------------------- F3 - 25
NEUTRAL START SWITCH --------------- F3 - 30
SHIFT LEVER (FLOOR SHIFT) ---------- F3 - 32
CONTROL CABLE (FLOOR SHIFT) ---- F3 - 33
FUNCTION CHECK----------------------- F3 - 36
BASIC CHECK AND ADJUSTMENT- F3 - 36 SHIFT LOCK RELEASE CABLE (FLOOR SHIFT) ------------------------------------------- F3 - 37
F3 AUTOMATIC
TRANSMISSION/AUTOMATIC TRANSAXLE
F3
TO INDEX
Page 2
ÄÄ
A4B
1 AUTOMATIC TRANSAXLE
1-1 BASIC CHECK AND ADJUSTMENT
1-1-1 ARTICLES TO BE PREPARED
SST
Instrument
1-1-2 PREPARATION PRIOR TO CHECKS
1.Park the vehicle on a flat space.
2.Confirm safety before and after the vehicle.
1-1-3 CHECK OF OIL LEVEL (1) Check of oil level
1.Check of engine idling speed. (1) Vehicle mounted with Type 1KR-FE engine
Refer to Page B1-9.
(2) Vehicle mounted with Type K3-VE engine
Refer to Page B1-25.
2.Warm up the transmission until its oil temperature reaches to a fully warmed-up state (70 - 90°C).
3.Apply the parking brake.
4.Depress the brake pedal. With the engine idling, move the shift lever slowly through all ranges. Finally, return the lever to the H range.
5.With the engine idling, pull out the level gauge. Wipe out oil, using cloth, and blow air to remove lint. Then, insert the level gauge again to check whether the oil level is within the range of "H" of the level gauge.
NOTE
In cases where it is necessary to conduct the check using a low oil temperature (20 - 30°C), for example, at time of oil change, first adjust up to the "C" range on the level gauge. Then, carry out the check in a fully warmed-up state.
If the level differs between the front and rear sides of the level gauge, use the side having the
lower level.
LUBRICANT: ATF Dexron
®
A
NOTE
Total capacity: Approx. 5.0% Drain amount from oil pan: Approx. 2.2%
TIGHTENING TORQUE: 24.5&4.9N;m {250&50kgf;cm}
(drain bolt )
Torque wrench
Shape Part No. Part name
09302-87201-000 Gauge,neutral start switch adjust
F3–1
Page 3
CAUTION
Never reuse the removed gasket.
If the oil level is too low or too high, it could cause mal-
functions."
(2) Check of oil leakage
1.Visually check the oil cooler, unions, transaxle main body, etc. to ensure that they exhibit no oil leak­age.
1-1-4 CHECK OF SHIFT LEVER POSITION
1.Check the shift lock operation.
Refer to Page F3-36.
2.Shift the shift lever to each range. Here, check that the shift lever functions as indicated in the right figure and the shift lever moves freely to each range with a clear detent feel­ing. Furthermore, the LCD indication can be made accurately in each range. Check that the LCD range indication will not differ within the play of the shift lever. Also, check that there is no lighting of the frame only nor flashing.
3.Start the engine. Ensure that the vehicle moves forward when you move the shift lever to theD, L and F ranges, respectively. Make sure that the vehicle moves backward when you move the shift lever to the I range.
4.Turn ON the IG switch. When the shift is made up to I, check that the back-up lamp lights and the reverse warn­ing buzzer is set off.
1-1-5 CHECK AND ADJUSTMENT OF CONTROL CABLE
1.Check the connecting section of the control cable and control shaft lever assembly for wear. Also, check other connecting sections for wear and deformation.
2.Put an up/bottom identification mark. Remove the retaining bolts of the control cable and control shaft lever Ay.
F3–2
H range
(70$C(90$C)
C range
R11K6013ET10
: Set the IG switch to the "ACC" or the "ON" position. Depress the brake pedal. Move while pushing the shift lever button.
: Move without pushing the shift lever button.
Vehicles not equipped with shift lock cable
Shift lock cable equipped vehicles
: Move while pushing the shift lever button.
T11K5505ET16
T11K5039ET10
Marking at underside of vehicle
Page 4
3.Turn the control shaft lever assembly counterclockwise,
until it stops (H range). From this condition, back off the control shaft lever assembly 2 stages (G range).
4.Set the shift lever to the G range.
5.Install the control cable, with the slack taken up, to the transmission control shaft lever Ay.
TIGHTENING TORQUE: 8.4&1.4N;m {85&14kgf;cm}
CAUTION
Do not pull the end of the cable during installation.
6.After completion of the adjustment, check the operating feeling and operation.
1-1-6 CHECK AND ADJUSTMENT OF NEUTRAL START
SWITCH
(1) Check of neutral start switch operation
1.Apply the parking brake and turn ON the ignition switch.
2.Depress the brake pedal and ensure that the engine starts only when the shift lever is shifted to the G or H range and should not start in any other range.
3.Ensure that the backup lamp goes on and the reverse warning buzzer is set off only when the shift lever is placed in the I range.
4.If there is a problem, perform the installation position check, adjustment, and continuity check for the neutral start switch.
(2) Check and adjustment of neutral start switch installation position
1.Set the shift lever to the G range.
2.Remove the bolts retaining the control cable to the control shaft lever assembly.
3.Remove the control shaft lever assembly.
4.Install the SST. Ensure that the gauge section of the SST is aligned with the line of the neutral start switch.
5.If not aligned, loosen the bolt and turn the switch section until an alignment is attained. After the adjustment, tight­en the bolt to the specified torque.
TIGHTENING TORQUE: 18.2&3.4N;m
{185&35kgf;cm}
CAUTION
Do not use an impact wrench for tightening the secur­ing bolt of the neutral start switch.
SST: 09302-87201-000
6.Remove the SST and install the control shaft lever assem­bly.
TIGHTENING TORQUE: 12.8&2.9N;m
{130&30kgf;cm}
7.In cases where the operation in Step 5 has been carried out, confirm the operation of the control shaft lever, fol­lowing the procedure given below. (1) Move the control shaft lever to the H range. Then,
move the lever about 2 to 3 mm in the direction of the I range by hand. At this time, ensure that the lever returns to the H range fully.
(2) If the full return can not be made, once loosen the
retaining bolt of the neutral start switch and perform the adjustment and retighten again.
F3–3
P
R
N
L11K5055T10
L11K5102ET10
SST
Reference line
Page 5
8.Install the control cable, with the slack taken up, to the transmission control shaft lever Ay.
TIGHTENING TORQUE: 8.4&1.4N;m {85&14kgf;cm}
CAUTION
When installing, do not pull the tip-end of the control cable.
9.After the installation, check the position of the shift lever.
Refer to Page F3-2.
(3) Continuity check of neutral start switch
1.Disconnect the connector from the neutral start switch. Then, perform the continuity check according to the con­nection table.
P
R
N
D
2
L
Shift position
Terminal No.
E
:Continuity should exist
R11K6110EL10
R
RB
P
N
D
2
L
F3–4
R11K6021T10
P
D
2R
L
RB
EN
Page 6
1-2 FUNCTION CHECK
1-2-1 ITEMS TO BE OBSERVED
1.Each test should be conducted after performing the basic inspection and adjustments.
2.The fluid should be at the normal running temperature. (70 - 90°C)
3.Be sure to turn OFF the air conditioner .
1-2-2 STALL TEST
1.Place chocks at the four wheels.
2.Install an engine tachometer and fully apply the parking brake.
3.Start the engine.
4.While depressing the brake pedal strongly by your left foot, move the shift lever from the D . Depress
the accelerator pedal fully by your right foot. Quickly read the highest engine rpm at this time. Perform the same test in the I range.
CAUTION
Do not conduct this test continuously for more than five seconds.
Wait at least one minute before the switching is made from the D range to the I range.
SPECIFIED VALUE: Engine type K3-VE
Stall speed (rpm) 1900 - 2400
NOTE
If the stall speed fails to conform to the specified value, most likely the following malfunctions are taking place.
If the stall speed is the same for both ranges (D, I) but lower than the specified value
;Lack of engine output ;One-way clutch (At the stator section inside the torque converter )
malfunctioning
If the stall speed is the same for both ranges (D, I) but higher than the specified value
;Lack of transmission fluid ;Low line pressure ;Slippage of forward clutch, direct clutch, one-way clutch and 1st &
reverse brakes, or faulty operation of one-way clutch
If the stall speed at the D range is higher than the specified value.
;Low line pressure ;Forward clutch slipping, one-way clutch malfunctioning
If the stall speed in the I range is higher than the specified value.
;Line pressure too low ;Direct clutch slipping ;First & reverse brake slipping
F3–5
Page 7
1-2-3 TIME LAG TEST
1.Apply the parking brake and place chocks at the four wheels.
2.Start the engine.
3.While depressing the brake pedal , move the shift lever from the G to the D range. Using a stopwatch,
measure the time required from the lever shifting to the time when you feel a shock. In the same man­ner, measure the time lag when shifting is made from theG to I range.
CAUTION
Be sure to allow one minute intervals between tests.
Conduct the measurement three times and take the average value.
SPECIFIED VALUE: G!D:Not to exceed 1.0 second
G!I:Not to exceed 1.0 second
NOTE
If the time lag fails to conform to the specified value, most likely the following malfunctions are tak­ing place.
1-2-4 HYDRAULIC TEST (1) Articles to be prepared
SST
Instrument
Lubricant,adhesive,others
ATF DexronOA
Oil pressure gauge
Shape Part No. Part name
09325-87201-000 Adapter,A/T pressure gauge No.1
If the G!D time lag is longer than the specified value.
;Slippage of forward clutch ;Low line pressure
If the G!I time lag is longer than the specified value.
;Slippage of direct clutch ;Slippage of 1st & reverse brakes ;Low line pressure
F3–6
Page 8
(2) Position of the hydraulic pressure test plug
(3) Pressure gauge installation procedure
CAUTION
Be sure to use new gasket for the SST and instrument.
The test plug is a non-reusable part.
1.Remove the battery and battery carrier.
Refer to Page J5-3.
2.Remove the test plug and install the Pressure gauge.
SST: 09325-87201-000
3.Install the battery and battery carrier.
Refer to Page J5-3.
4.After completing the hydraulic test, remove the pressure gauge and replace the test plug.
TIGHTENING TORQUE: 9.8&2.9N;m {100&30kgf;cm}
5.The ABS memorizes diagnosis codes. Therefore, first confirm the code output and ensure that there exist only abnormality codes related to the rear wheel system. Then, erase the diagnosis codes. (1) ABS-equipped vehicles
Refer to Page E3-19.
T11K5003ES25
LUC ON pressure
Pressure C2
Pressure C1
LUC OFF pressure
Pressure C3
Pressure B1
F3–7
Page 9
(4) Hydraulic pressure measuring procedure 1 Pressure C2
1.Apply the parking brake and place chocks at the four wheels.
2.Start the engine.
3.Strongly depress the brake pedal with your left foot. Move the shift lever to the D range, operate the
accelerator pedal with your right foot so as to measure the hydraulic pressure.
2 Pressure C1
1.Apply the parking brake and place chocks at the four wheels.
2.Start the engine.
3.Strongly depress the brake pedal with your left foot. Move the shift lever to the I range and operate
the accelerator pedal with your right foot so as to measure each hydraulic pressure.
3 Pressure B1
1.Jack up the four wheels. Support the vehicle with rigid racks.
2.Start the engine.
3.Move the shift lever to the D range and gradually depress the accelerator pedal until the transmission
may be shifted to the 2nd gear. Measure the hydraulic pressure with the engine speed set to 2000 rpm.
4 Pressure C3
1.Jack up the four wheels. Support the vehicle with rigid racks.
2.Start the engine.
3.Move the shift lever to the D range and gradually depress the accelerator pedal until the transmission
may be shifted to the 3rd gear. When the accelerator pedal is released, measure the hydraulic pres­sure.
5 LUC OFF pressure
1.Jack up the four wheels. Support the vehicle with rigid racks.
2.Start the engine.
3.Move the shift lever to the D range and measure the hydraulic pressure. (Hydraulic pressure at the
time of lock-up OFF)
4.Gradually depress the accelerator pedal until the transmission may be shifted to the 4th gear. Then, continue gradual acceleration. When the lock up takes place, measure the hydraulic pressure. (Hydraulic pressure at the time of lock-up ON)
NOTE
Under conditions of a vehicle speed of 57 to 78 km/h and a throttle opening of 5 to 20 %, the 4th lock-up turns ON.
SPECIFIED VALUE:
Condition
Detected item
Range Running condition
Specified value{kPa{kg/cm2}
C2 D Stall revolving condition 930 - 1130{9.4- 11.4}
C1 I Stall revolving condition 1520 - 2110{15.5 - 21.5}
C3 D
3rd gear, accelerator pedal
"OFF"
(at the time of lock-up OFF)
440 - 640{4.5 -6.5}
B1 D
2nd gear;Engine speed
2000rpm
930 - 1130{9.4 - 11.4}
At the time of lock-up OFF 590 - 750{6.0 - 7.6}
LUC OFF pressure D
At the time of lock-up ON 20{0.2} or less
F3–8
Page 10
1-2-5 ROAD TEST (1) Items to be observed
CAUTION
Thoroughly confirm the safety on the road during the tests.
The fluid should be at the normal running temperature. (70 - 90°C)
(2) D range test
1.Start off the vehicle, using the D range. Check to see if the upshift or downshift takes place as follows. 1st#2nd, 2nd#3rd, 3rd#4th(O/D) . Furthermore, the gear shift points of 1st#2nd and 2nd#3rd meet the requirements. Also, ensure that there are no abnormal shocks, slippage, etc.
2.Perform kickdown operations while the vehicle is running in the 4th(O/D), 3rd and 2nd gears using the D range. Check to see if the kickdown takes place as follows.. 4th(O/D)!3rd, 3rd!2nd, 2nd!1st gears. Furthermore, the kickdown possible vehicle speed limits for 3rd!2nd and 2nd!1st gears meet the requirements. Also, ensure that there are no abnormal shocks, slippage, etc.
3.While the vehicle is running in the 4th (O/D) gear, turn OFF the O/D switch. Ensure that the gear down­shift takes place from the 4th (O/D) to the 3rd gear.
(3) L range test
1.Start off the vehicle, using the L range. Check to see if the upshift or downshift takes place between 1st#2nd gears. Furthermore, the gear shift point meets the requirements. Also, ensure that there are no abnormal shocks, slippage, etc.
2.Start off the vehicle in the L range. Check that the upshift takes place from1st!2nd gear, but, no upshift to the 3rd gear takes place.
3.While the vehicle is running in the L range / 2nd gear, perform the kickdown operation. Check that the kickdown takes place from the 2nd!1st gear. Furthermore, the kickdown possible vehicle speed limit meets the requirement. Also, ensure that there are no abnormal shocks, slippage, etc.
4.While the vehicle is running in the D range / 3rd gear, perform a downshift to the L range. Check that a downshift takes place from the 3rd to 2nd gear and engine braking is applied. Furthermore, ensure that the shift point meets the requirement.
(4) F range test
1.Start off the vehicle in the F range. Check that no upshift to the 2nd gear takes place.
2.While the vehicle is running in the D range / 3rd gear, perform a downshift to F range. Check that downshifts of 3rd!2nd!1st gear take place and the engine braking is applied. Furthermore, ensure that the shift point meets the requirement.
(5) Lock-up test
1.While the vehicle is running in the 3rd gear, gradually accelerate the vehicle. Check that the lock-up is turned ON. Ensure that the vehicle speed at which the engine speed starts to drop meets the speci­fied lock-up ON timing. Furthermore, check that the engine speed will not change significantly when the accelerator pedal is depressed lightly.
2.Conduct the same check in the 4th gear.
F3–9
Page 11
(6) H range test
1.Stop the vehicle on an upgrade (Approx. 5 degrees or more). Shift the shift lever to the H range and
release the parking brake lever. At this time, check that the parking lock mechanism functions and the vehicle will not move.
2.In cases where the vehicle is stopped on a downgrade, perform the check, following the same proce­dure.
3.Under the condition above, shift the shift lever from the H range to other range. At this time, check that the vehicle moves.
SPECIFIED VALUE:
Gear shifting vehicle speed (Type K3-VE engine-mounted vehicle)
;The gear shifting vehicle speed for the 1st#2nd gear in the L range and in the throttle opening of 100%;0% is the same as with the D range.
SPECIFIED VALUE:
Lock-up vehicle speed (Type K3-VE engine-mounted vehicle)
NOTE: Be sure to gradually depress the accelerator pedal.
Throttle opening
degree
Gear posi-
tion
Lock up
Vehicle speed (km/h)
3rd ON 82 - 97
4th ON 58 - 76
3rd OFF 40 - 55
5(20%
4th OFF 52 - 67
Throttle opening
degree
Range Gear shifting Vehicle speed (km/h)
1st!2nd 51 - 66
2nd!3rd 93 - 108
3rd!4th 159 - 174 4th!3rd 150 - 165
3rd!2nd 83 - 98
100% D
2nd!1st 37 - 52 1st!2nd 13 - 28
2nd!3rd 25 - 40
3rd!4th 38 - 53
4th!3rd 22 - 37
3rd!2nd 8 - 23
0% D
2nd!1st 8 - 23
4th!3rd 159 - 174
3rd!2nd 93 - 108
0(100% D!L;F
2nd!1st 51 - 66
F3–10
Page 12
2 AUTOMATIC TRANSAXLE AY
2-1 REMOVAL AND INSTALLATION
2-1-1 ARTICLES TO BE PREPARED
SST
Tool
Instrument
Lubricant,adhesive,others
2-1-2 OPERATION BEFORE REMOVAL
1.Remove the battery and battery carrier.
Refer to Page J5-3.
2.Drain the automatic transaxle fluid.
3.Remove the pipe exhaust.
Refer to Page B4-3.
4.Remove the Oil cooler hose.
Refer to Page E3-20.
5.Remove the drive shaft.
Refer to Page D2-8.
6.Disconnect the control cable at the transaxle side.
Refer to Page F3-33.
7.Remove the starter.
Refer to Page B11-2.
ATF DexronOA,MP grease,Engine hanger No.1 (Replacement parts),Engine hanger No.2 (Replacement parts)
Torque wrench,Dial gauge
Low transmission jack
Shape Part No. Part name
09210-87701-000 Holder,fly wheel
09090-04020-000
(09090-04010-000)
Device,engine sling
09350-87202-000 Tool set,automatic transmission
F3–11
Page 13
2-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~: Non-reusable parts k: MP grease Unit: N;m{kgf;cm}
(2) Removal and installation procedures
ji1 a Bracket, engine mounting, rear ji2 b Bracket, engine mounting, LH ji3 c Transaxle Ay, automatic
i 4 d Converter Ay, torque
ji5 e Plate, pump impeller drive
T11K5044ES33
B
B
B
B
B
B
B
c
b
a
d
e
T:27.5&4.9 {280&49}
T:78.0&4.7 {795&47}
T:36.8&7.3 {375&74}
T:63.7&14.7 {650&149}
T:63.7&14.7 {650&149}
T:63.7&14.7 {650&149}
T:63.7&14.7 {650&149}
T:58.8&9.8 {600&99}
T:31.0&9.3 {316&94}
T:19.2&3.4 {195&34}
B
T:8.5&2.5 {87&25}
T:80.0&10.6 {816&107}
T:80.0&10.6 {816&107}
T:120.0&18.0 {1224&183}
B
B
B
B
B
B
B
~
~
(Seal bolt)
(Seal bolt)
F3–12
Page 14
2-1-4 POINTS OF REMOVAL (1) Bracket, engine mounting, rear
1.Install the engine hanger at a point in the figure. (1) Type K3-VE engine-mounted vehicles
NOTE
Part number of engine hanger No.1:12281-97401-000
Part number of engine hanger No.2:12282-97403-000
2.Suspend the engine Ay with a chain block and engine sling device.
SST: 09090-04020-000
3.Support the transaxle Ay, using a low transmission jack.
TOOL: Low transmisson jack
4.Remove the connecting bolt (A) that connects the engine mounting control rod S/A with the bracket.
5.Remove the retaining bolt (B) of the bracket.
(2) Bracket, engine mounting, LH
1.Remove the retaining bolt of the bracket.
F3–13
T11E5004ET10
T11K5023T10
T11K5021T10
T11K5034T10
B
B
B
A
T11K5022T10
Engine hanger,No.1
Engine hanger,No.2
Page 15
(3) Transaxle Ay, automatic
1.Through the starter Ay retaining hole, remove the bolt
(Plate, pump impeller drive ) converter Ay, torque).
2.Remove the connecting bolts that connect the transaxle Ay with the engine Ay so as to separate the transaxle Ay from the engine Ay.
(4) Plate, pump impeller drive
1.While preventing rotation, using the SST, remove the drive plate.
SST: 09210-87701-000
2-1-5 INSPECTION
1.Using the SST and instruments, check the runout of the drive plate.
SST: 09351-87210-000 [09351-87210-000] SPECIFIED VALUE: 0.25mm
2.Install the torque converter Ay to the drive plate.
F3–14
T11K5025T10
T11K5059ET16
Transaxle side
Engine side
SST
T11K5026T10
T11K5028T10
SST
Page 16
3.Using the SST and instruments, check the runout of the shaft.
SST: 09351-87210-000 [09351-87210-000] SPECIFIED VALUE: 0.30mm
2-1-6 POINTS OF INSTALLATION (1) Plate, pump impeller drive
1.While preventing rotation, using the SST, install the drive plate.
SST: 09210-87701-000
(2) Converter Ay, torque
1.Install the torque converter. (1) Insert the torque converter into the transaxle assembly
while turning it. Ensure that the torque converter is inserted positively.
SPECIFIED VALUE: Dimension A at least 16.5 mm
(The dimension A is a distance from the edge surface of the housing to the drive plate attaching surface of the torque converter.)
(2) Apply MP grease to the tip end of the torque convert-
er.
LUBRICANT: MP grease
F3–15
T11K5029T10
SST
SST
T11K5027T10
T11K5030T10
A
Page 17
(3) Transaxle Ay, automatic
1.Connect the transaxle Ay to the engine Ay. (1) Clean the seal bolt holes of the engine block.
(2) Mark the edge position of the torque converter on the
transaxle case. While confirming that the position is not deviated, connect the transaxle assembly to the engine block.
NOTE
If the position is out of place, remove the transaxle and recheck how far the torque converter should be insert­ed.
2.While ensuring that the torque converter Ay turns lightly, tighten the connecting bolts of the transaxle Ay and engine Ay.
NOTE
If the torque converter does not turn easily, the torque converter is not in the specified position, so remove the transaxle Ay and check how far the torque convert­er should be inserted. If the connection bolts are tightened when the torque converter is not in the correct position, the oil pump could be damaged.
CAUTION
If the connecting bolts are tightened with the torque converter Ay deviated from the specified position, there is the possibility that the starter shaft & oil pump Ay may be damaged.
3.Through the starter Ay retaining hole, tighten the bolt
(Plate, pump impeller drive ) converter Ay, torque). (1) Tighten first the reference bolt (Silver color) of the
pump impeller drive plate.
CAUTION
Never use bolts other than the specified bolts. (If bolts other than the specified bolts are used, it will cause poor tightening or deform the converter inner shape, resulting in curtailed performance. )
F3–16
T11K5031ET10
Seal bolt holes
T11K5037ET10
Torque converter
Marking
T11K5059ET16
Transaxle side
Engine side
T11K5025T10
Page 18
(4) Bracket, engine mounting, LH
1.Temporarily tighten the bracket, using the bolt C indicated in the right figure.
2.Securely tighten the bolts A, B and C in this order.
(5) Bracket, engine mounting, rear
1.Temporarily install the bracket on the automatic transaxle Ay by tightening the bolts (B) and (A) in this order as shown in the right figure.
2.Securely tighten the bolts (B), (C) and A in this order.
3.Install the connecting bolt that connects the engine mount­ing control rod S/A with the bracket.
2-1-7 OPERATION AFTER INSTALLATION
1.Install the starter.
Refer to Page B11-2.
2.Install the transmission control cable Ay at the transaxle side.
Refer to Page F3-33.
3.Install the drive shaft.
Refer to Page D2-8.
4.Install the Oil cooler hose.
Refer to Page F3-20.
5.Install the pipu exhaust.
Refer to Page B4-3.
6.Install the battery and battery carrier.
Refer to Page J5-3.
7.Fill automatic transaxle fluid.
Refer to Page F3-1.
8.Carry out the basic check and adjustments.
Refer to Page F3-1.
9.When the automatic transaxle Ay has been replaced, erase the learning values of the A/T ECU (Transmission control computer)..
Refer to Page F5-17.
F3–17
T11K5032ET10
Bolt A
Bolt C
Bolt B
T11K5035T10
A
C
B
Page 19
3 DIFFERENTIAL SIDE OIL SEAL
3-1 REMOVAL AND INSTALLATION
3-1-1 ARTICLES TO BE PREPARED
SST
Lubricant,adhesive,others
3-1-2 OPERATION BEFORE REMOVAL
1.Remove the drive shaft.
Refer to Page D2-8.
3-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~:Non - reusable parts
(2) Removal and installation procedures
ji1 a Seal, type T oil
T11K5509S20
~a
~a
ATF DexronOA
Shape Part No. Part name
09308-00010-000 Puller,oil seal
09518-87709-000 Replacer,oil seal No.8
F3–18
Page 20
3-1-4 POINTS OF REMOVAL (1) Seal, type T oil
1.Remove the seal, using the SST.
SST: 09308-00010-000
3-1-5 POINTS OF INSTALLATION (1) Seal, type T oil
1.Drive the seal into place, using the SST.
SST: 09518-87709-000
3-1-6 OPERATION AFTER INSTALLATION
1.Install the drive shaft.
Refer to Page D2-8.
F3–19
T11K5045T10
SST
T11K5046T10
SST
Page 21
4 OIL COOLER HOSE
4-1 REMOVAL AND INSTALLATION
4-1-1 ARTICLES TO BE PREPARED 4-1-2 OPERATION BEFORE REMOVAL
1.Remove the battery and battery carrier.
Refer to Page J5-3.
4-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~:Non - reusable parts
(2) Removal and installation procedures
4-1-4 POINTS OF INSTALLATION (1) Hose, oil cooler inlet / Hose, oil cooler outlet
1.Clean the oil cooler union at the radiator side and the tube at the transaxle side, using white gasoline.
i 1 a Hose, oil cooler inlet i 2 b Hose, oil cooler outlet
T11K5014S25
~b
~a
F3–20
Page 22
2.Install the inlet hose and outlet hose at the radiator side. (1) With the marking at the hose facing toward the lower
side of the vehicle, insert the hose up to the second spool of the union at the radiator side.
(2) Install the clip with the protrusion of the clip facing
toward the lower side of the vehicle and aligning with the marking position.
CAUTION
Care must be exercised so that the hose may not be overlapped on the second spool.
3.Install the inlet hose and outlet hose at the transaxle side. (1) With the marking at the hose facing toward the upper
side of the vehicle, insert the hose up to the second spool of the union at the transaxle side.
(2) Install the clip with the protrusion of the clip facing
toward the upper side of the vehicle and aligning with the marking position.
CAUTION
Care must be exercised so that the hose may not be overlapped on the second spool.
4.Ensure that each hose is not twisted, not interfering with other parts, and not having extremely small gaps wither other parts.
4-1-5 OPERATION AFTER INSTALLATION
1.Install the batty and battery carrier.
Refer to Page J5-3.
2.Start the engine. Check that there is no fluid leakage from the automatic transaxle.
3.Check the fluid level. If the fluid level is too low, replenish.
Refer to Page F3-1.
F3–21
M21K5042ET10
0 - 2 mm
Marking
Second spool
T11K5038ET10
Marking
Second spool
0(2mm
Page 23
5 OIL PAN
5-1 REMOVAL AND INSTALLATION
5-1-1 ARTICLES TO BE PREPARED
Instrument
Lubricant,adhesive,others
5-1-2 OPERATION BEFORE REMOVAL
1.Drain the automatic transaxle fluid.
5-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~:Non - reusable parts Unit:N;m{kgf;cm}
(2) Removal and installation procedures
5-1-4 POINTS OF REMOVAL (1) Pan S/A, transaxle oil
1.After removing the pan S/A retaining bolts, remove the pan S/A by tapping lightly the flange section of it with a plastic hammer, while holding the pan S/A by hand.
CAUTION
Oil is remaining in the pan S/A. Therefore, be very careful not to allow the oil to spill over.
ji1 a Pan S/A, transaxle oil 2 b Magnet, transmission
T:24.5&4.9 {250&50}
T:8.35&1.45 {85&15}
~a
B
~B (Seal bolt)
~
b
C11K5069ES20
ATF DexronOA,Three Bond1281B
Torque wrench
F3–22
Page 24
5-1-5 POINTS OF INSTALLATION (1) Pan S/A, transaxle oil
1.Clean and degrease the mating surface. Apply liquid gas­ket to the areas indicated in the right figure.
ADHESIVE: Three Bond1281B
CAUTION
Do not apply the liquid gasket too much. (If a great quantity of liquid gasket is mixed into ATF, ATF will be deteriorated.)
5-1-6 OPERATION AFTER INSTALLATION
1.Fill automatic transaxle fluid.
Refer to Page F3-1.
2.Check that no oil leakage is present.
F3–23
T04K5046T10
02.0&0.5mm
Page 25
6 OIL STRAINER
6-1 REMOVAL AND INSTALLATION
6-1-1 OPERATION BEFORE REMOVAL
1.Remove the oil pan.
Refer to Page F3-22.
6-1-2 REMOVAL AND INSTALLATION PROCEDURES (1) Components
k: Apply ATF. ~: Non-reusable parts
(2) Removal and installation procedures
6-1-3 POINTS OF REMOVAL (1) Strainer S/A, oil
1.Remove the oil strainer.
CAUTION
The strainer S/A is attached to the transmission valve body Ay with pawls indicated in the figure. Therefore, carefully remove the strainer S/A , while expanding the pawls, and paying attention not to apply undue force to the strainer S/A.
6-1-4 POINTS OF INSTALLATION (1) Strainer S/A, oil
1.Apply ATF to the strainer S/A and assemble the O-ring.
6-1-5 OPERATION AFTER INSTALLATION
1.Install the oil pan.
Refer to Page F3-22.
ji1 a Strainer S/A, oil
2 b Ring, o
~b
a
C11K5070S16
F3–24
T04K5001T10
Page 26
7 VALVE BODY
7-1 REMOVAL AND INSTALLATION
7-1-1 ARTICLES TO BE PREPARED
SST
Instrument
Lubricant,adhesive,others
7-1-2 OPERATION BEFORE REMOVAL
1.Remove the oil pan.
Refer to Page F3-22.
2.Remove the oil strainer.
Refer to Page F3-24.
7-1-3 REMOVAL AND INSTALLATION PROCEDURES
CAUTION
Prior to the operations, be sure to completely remove sands and mud that have adhered to the external of the transmission so that no foreign matters enter the transmission.
Perform the operations at a clean place free of dirt and dust.
Perform the operations with bare hands or by wearing vinyl gloves. Do not use working gloves nor
cloth to prevent admission of lint. (Use nylon cloth, or paper cloth.)
Place removed parts in order at all times. Keep them away from dust.
Thoroughly wash the removed parts before assembling. After drying, apply ATF. However, do not
wash aluminum and rubber parts with alkali chemicals. Never wash rubber parts, such as O-rings, gaskets, oil seals, with cleaning solvent (White gasoline or the like)
Do not use parts that have undergone impacts, such as ones dropped. (In particular, the character­istics of the solenoid valves may be changed.)
ATF DexronOA
Torque wrench
Shape Part No. Part name
09350-87202-000 Tool set,automatic transmission
F3–25
Page 27
(1) Components
k: Apply ATF. ~: Non-reusable parts Unit: N;m{kgf;cm}
(2) Removal and installation procedures
i 1 a Spring S/A, manual detent ji2 b Body Ay, transmission valve ji3 c Wire Ay, solenoid
4 d Solenoid Ay, clutch control No.1 (Solenoid No.2)
(Connector white)
5 e Solenoid Ay, clutch control No.2 (Solenoid No.1)
(Connector black)
6 f Solenoid Ay, clutch control No.1 (Solenoid No.3)
(Connector white)
7 g Solenoid Ay, transmission 3way (switch solenoid)
8 h Ring, o 9 i Ring, o 10 j Solenoid Ay, transmission 3way (LUC solenoid) 11 k Ring, o 12 l Ring, o 13 m Solenoid Ay, lock up control (Duty solenoid)
ji14 n Seal, 2nd & 4th brake cylinder
T11K5054S33
B
B
B
B
B
B
B
B
B
T:8.35&1.45 {85&15}
T:5.9&1.0 {60&10}
T:5.9&1.0 {60&10}
~n
~l
~k
~i
~h
T:8.35&1.45 {85&15}
a
c
d
e
f
b
m
j
g
T:5.9&1.0 {60&10}
F3–26
Page 28
7-1-4 POINTS OF REMOVAL (1) Wire Ay, solenoid
1.Remove the vehicle side wire Ay.
2.Remove the retaining bolt of the A/T side connector.
3.Remove the A/T side connector from the A/T. Remove the connector (White).
CAUTION
The O-ring of the A/T side connector can not be re­used.
(2) Body Ay, transmission valve
1.Remove the body Ay by loosening the six bolts evenly.
2.Remove gently the manual valve from the valve body Ay.
(3) Seal, 2nd & 4th brake cylinder
1.Remove the seal.
F3–27
Vehicle side connector
A/T side connector
M21K5153ET10
M21K5151ET10
O ring
A/T side connector
M21K5152ET10
Protrusions
Groove
T04K5008T10
T04K5051ET10
Seal,2nd&4th brake cylinder
Page 29
7-1-5 POINTS OF INSTALLATION (1) Seal, 2nd & 4th brake cylinder
1.Install the seal.
(2) Body Ay, Transmission valve
1.Apply ATF to the manual valve. Slowly assemble the man­ual valve by its own weight into the body Ay. After the assembling, lightly move the body Ay in a fore-and-aft direction. Check that there is no abnormal binding.
LUBRICANT: AFT Dexron
®
A
2.Pass the connector through the transmission case hole.
3.While aligning the protrusion of the manual valve lever S/A with the groove of the manual valve, assemble the valve body assembly to the transaxle case.
NOTE
Tilt the manual valve lever S/A toward the L range direction.
4.After the six bolts have been installed temporarily, tighten
the two reference bolts (The ~ marked one in the figure) to the specified torque.
NOTE
The bolt A has a nominal length of 65 mm. Other bolts have a nominal length of 35 mm.
CAUTION
Before assembling, clean the bolts with compressed air.
5.Tighten the remaining bolts up to the specified torque.
(3) Wire Ay, solenoid
1.After a new O-ring has been installed to the A/T side con­nector, install the connector (White).
CAUTION
The O-ring of the A/T side connector can not be re­used.
F3–28
T04K5051ET10
Seal,2nd&4th brake cylinder
T04K5009T10
M21K5154T10
A
M21K5151ET10
O ring
A/T side connector
Page 30
(4) Spring S/A, manual detent
1.Using the SST, align the manual valve groove with trans­mission valve body hole (N range position) and assemble the spring S/A. Tighten the bolt A (Nominal length 12 mm) and bolt B (Nominal length 35 mm) in this order.
SST: 09351-87211-000 [09351-87211-000]
CAUTION
When tightening the bolt A, ensure that the roller locat­ed at the end of the spring S/A is properly positioned in the hollow of the manual valve lever S/A shown in the illustration.
7-1-6 OPERATION AFTER INSTALLATION
1.Install the oil strainer.
Refer to Page F3-24.
2.Install the oil pan.
Refer to Page F3-22.
3.When the valve body Ay or the solenoid valve has been replaced, erase the learning values of the A/T ECU.
Refer to Page F5-17.
F3–29
T04K5010ET16
B
A
SST
Groove
Reference hole
M21K9178T10
Page 31
8 NEUTRAL START SWITCH
8-1 REMOVAL AND INSTALLATION
8-1-1 ARTICLES TO BE PREPARED
SST
Instrument
8-1-2 OPERATION BEFORE REMOVAL
1.Disconnect the control cable at the transaxle side.
Refer to Page F3-33.
8-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~:Non - reusable parts Unit:N;m{kgf;cm}
(2) Removal and installation procedures
1 a Lever S/A, transmission control shaft
i 2 b Switch Ay, neutral start
T11K5508S25
B
B
N
~
T:12.8&2.9 {130&30}
T:8.4&1.4 {85&14}
T:18.2&3.4 {185&35}
a
b
Torque wrench
Shape Part No. Part name
09302-87201-000 Gauge,neutral start switch adjust
F3–30
Page 32
8-1-4 INSPECTION
1.Check that the cable installation section (The resin sec­tion) of the transmission control shaft lever assembly can be turned lightly. Also, ensure that it does not exhibit any damage.
8-1-5 POINTS OF INSTALLATION (1) Switch Ay, neutral start
1.Install the neutral start switch. (1) Temporarily install the neutral start switch assembly and control shaft lever assembly. (2) Turn the transmission control shaft lever S/A counter-
clockwise, until it stops (H range). From this condi­tion, back off the control shaft lever S/A two stages (G range).
(3) Using the SST, turn the switch section in such a way
that the gauge section of the SST is aligned with the reference line of the switch Ay. Then, tighten the bolt to the specified torque
SST: 09302-87201-000
2.After completion of the installation of the transmission con­trol lever S/A, confirm the operation of the transmission control shaft lever S/A, following the procedure given below. (1) Move the transmission control shaft lever S/A to the H
range. Then, move the lever S/A about 2 to 3 mm in the direction of the I range by hand. At this time, ensure that the lever fully returns to the H range.
(2) If the lever fails to return fully, once loosen the retain-
ing bolt of the switch Ay and carry out the adjusting operation. Then, retighten the bolt.
8-1-6 OPERATION AFTER INSTALLATION
1.Connect the control cable at the transaxle side.
Refer to Page F3-33.
2.Check the shift lever position and perform the check of the neutral start switch.
Refer to Page F3-1.
F3–31
L11K5101T10
P
R
N
L11K5055T10
L11K5102ET10
SST
Reference line
Page 33
9 SHIFT LEVER(FLOOR SHIFT)
9-1 REMOVAL AND INSTALLATION
9-1-1 ARTICLES TO BE PREPARED
Instrument
9-1-2 OPERATION BEFORE REMOVAL
1.Remove the transmission floor shift Ay side of the shift lock release cable Ay.
Refer to Page F3-37.
2.Remove the transmission floor shift Ay side of the transmission control cable Ay.
Refer to Page F3-33.
9-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
Unit:N;m{kgf;cm}
(2) Removal and installation procedures
9-1-4 OPERATION AFTER INSTALLATION
1.Install the transmission floor shift Ay side of the transmission control cable Ay.
Refer to Page F3-33.
2.Install the transmission floor shift Ay side of the shift lock release cable Ay.
Refer to Page F3-37.
Check the shift lever position.
Refer to Page F3-1.
1 a Floor shift Ay, transmission
T11K5527S20
B
N
a
T:12.8&2.9 {130&30}
T:12.8&2.9 {130&30}
Torque wrench
F3–32
Page 34
10 CONTROL CABLE(FLOOR SHIFT)
10-1 REMOVAL AND INSTALLATION
10-1-1 ARTICLES TO BE PREPARED
Instrument
10-1-2 OPERATION BEFORE REMOVAL
1.Remove the front console box S/A.
Refer to Page I2-31.
10-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
~:Non - reusable parts Unit:N;m{kgf;cm}
(2) Removal and installation procedures
ji1 a Cable Ay, transmission control
T11K5526S25
B
~
~
a
T:8.35&1.45 {85&15}
Torque wrench
F3–33
Page 35
10-1-4 POINTS OF REMOVAL (1) Cable Ay, transmission control
CAUTION
Do not apply load to the end of the cable Ay (Both the shift lever and the transmission sides), or swing it more than 8 degrees.
1.Set the shift lever to the G range.
2.Mark the end of the transaxle side of the cable Ay to iden­tify upper and lower sides, and then remove the cable Ay.
10-1-5 INSPECTION
1.Check that the inner cable of the cable Ay slides smooth­ly and that the boot is free from any damage or deforma­tion.
10-1-6 POINTS OF INSTALLATION (1) Cable Ay, transmission control
CAUTION
Do not apply load to the end of the cable Ay (Both the shift lever and the transmission sides), or swing it more than 8 degrees.
1.Install the shift lever side of the cable Ay. (1) Insert the clip into the slot of the cable Ay to secure the
hub.
(2) Install the eye end in such a way that the marking of
the eye end faces toward the upper side of the vehi­cle.
F3–34
8$
8$
L11K5104T10
T11K5039ET10
Marking at underside of vehicle
L11K5107ET10
Rupture
8$
8$
L11K5104T10
T11K5506ET10
Clip
Hub
Eye end
Marking
Page 36
2.Ensure that upper/lower identification marking of the transaxle side of the cable Ay faces down and that there is no sagging in the cable. Then install the cable Ay to the transmission control shaft lever S/A.
CAUTION
Check that the boot is not twisted.
10-1-7 OPERATION AFTER INSTALLATION
1.Check the shift lever position.
Refer to Page F3-1.
2.Install the front console box S/A.
Refer to Page I2-31.
F3–35
T11K5039ET10
Marking at underside of vehicle
Page 37
11 SHIFT LOCK WITH KEY-INTERLOCKING (MECHANICAL TYPE)
11-1 FUNCTION CHECK
11-1-1 CHECK THE SHIFT LOCK OPERATION
1.Set the IG switch to the "ACC" or "ON" position.
2.Move the shift lever to the H range and release the shift lever button.
3.Confirm that it is impossible to push-in the shift lever button and shifting can not be made to ranges
other than the H range when the brake pedal is not depressed.
4.Confirm that it is possible to push-in the shift lever button when the brake pedal is depressed and shift-
ing can be made to ranges other than the H range.
5.Move the shift lever to the H range and release the shift lever button.
6.Set the IG switch to the "LOCK" position.
7.Confirm that the shift lever button can not be pushed-in whether the brake pedal is depressed or not
and shifting can not be made to ranges other than the H range.
11-1-2 CHECK OF KEY-INTERLOCKING MECHANISM
1.Set the IG switch to the "ACC" position.
2.Depress the brake pedal and move the shift lever to ranges other than the H range.
3.Confirm that the IG switch can not be set to the "LOCK" position.
4.Move the shift lever to the H range.
5.Confirm that the IG switch can be set to the "LOCK" posi­tion and the key can be pulled out.
11-2 BASIC CHECK AND ADJUSTMENT
11-2-1 AJUSTMENT OF SHIFT LOCK RELEASE CABLE
AY MOUNTING POSITION(FLOOR SHIFT)
1.Loosen the nut and adjust the amount of the projection of the lock mechanism to 1.5&0.5mm when the brake pedal is not depressed. Then secure with the nut.
2.Ensure that play of the brake pedal is within the specified value.
Refer to Page E1-2.
SPECIFIED VALUE: 1.5&0.5mm (Amount of projection of
the lock mechanism)
TIGHTENING TORQUE: 24.5&5.9N;m
{250&59kgf;cm}
F3–36
M21K5117T10
Page 38
12 SHIFT LOCK RELEASE CABLE(FLOOR SHIFT)
12-1 REMOVAL AND INSTALLATION
12-1-1 ARTICLES TO BE PREPARED
Instrument
12-1-2 OPERATION BEFORE REMOVAL
1.Remove the front console box S/A.
Refer to Page I2-31.
2.Remove the lower instrument panel finish panel S/A.
Refer to Page I2-23.
3.Remove the lower steering column cover.
Refer to Page G1-5.
4.Remove the front floor carpet Ay. (Driver's side only)
Refer to Page I2-57.
12-1-3 REMOVAL AND INSTALLATION PROCEDURES (1) Components
Unit:N;m{kgf;cm}
(2) Removal and installation procedures
12-1-4 POINTS OF REMOVAL (1) Cable Ay, shift lock release
1.Set the shift lever to the H range.
2.Set the ignition key to the "ACC" position.
ji1 a Cable Ay, shift lock release
T11K5530S20
a
B
T:8.4&1.4 {85&14}
Torque wrench
F3–37
Page 39
3.Remove the steering column bracket side of the cable Ay. (1) Insert a flat screwdriver or the like into the hole of the
cable Ay end portion and pry lightly in the direction shown by the arrow in the illustration, and remove the cable Ay.
4.Remove the shift lever side of the cable Ay. (1) Remove the eye end first, and then remove the casing
cap.
CAUTION
If removed in the reverse order, excess force may be applied to the casing cap, resulting in damage.
5.Remove the cable assembly.
CAUTION
Do not bend the cable more than is necessary.
12-1-5 INSPECTION
L11K5116ES15
Pushing (Brake pedal is released)
Free (Brake pedal is depressd)
Shift lock cable
Pulling(Except for P range position)
Pulling(Lock)
Free(Acc)
Pushing( P range position)
Key lock cable
F3–38
M21K5113T10
T11K5528ET10
Shift lock cam
Eye end
Casing cap
Page 40
1.Check that there is no unnatural bending in each cable.
2.Ensure that the brake lock actuator moves smoothly, with strokes of about 8 mm.
3.Check that the key lock cable functions as specified in the operation table according to each state of the shift lock cable.
Key lock cable operation table
4.Check that the shift lock cable functions as specified in the operation table according to each state of the key lock cable and brake lock actuator.
Shift lock cable operation table
12-1-6 POINTS OF INSTALLATION (1) Cable Ay, shift lock release
1.Install the cable assembly.
CAUTION
Do not bend the cable more than is necessary.
(1) Install the lock mechanism to the pedal bracket Ay. (2) Securely insert the clamp of the shift lock cable into
the square hole of the reinforcement S/A.
(3) Root the shift lock cable so that it may pass the vehi-
cle right side of the airbag ECU harness.
2.Install the steering column bracket side of the cable Ay. (1) Set the ignition key to the ACC position and position
the key lock pin as shown in the illustration.
(2) Match the hole of the key lock cable end with the key
lock pin, and securely insert into the slot of the steer­ing column bracket.
Key lock cable
State of the brake actuator
State of the shift lock cable
Key lock cable Free Brake actuator Free
Able to push and pull.
Key lock cable Free Brake actuator Push
Able to push (only once).
Unable to pull after locked. Key lock cable Pull Brake actuator Free
Unable to pull.
Key lock cable Pull Brake actuator Push
Unable to pull.
State of the shift lock cable State of the key lock cable
Push Able to pull.
Pull Unable to pull.
F3–39
T11K5532ET10
Reinfocement S/A
Key lock cable
Brake pedal
Lock mechanizm consists
Clamp
Shift lock cable
T11K5531ET10
Clamp
Shift lock cable
Airbag ECU wire
T11K5529ET10
Key lock pin
Groove
Front end of key lock cable
Hole
Page 41
3.Install the shift lever side of the cable Ay.
(1) Set the shift lever to the H range. (2) Install the eye end into the shift lock cam. (3) Insert the casing cap into the notch of the bracket.
12-1-7 OPERATION AFTER INSTALLATION
1.Adjust the mounting position of the shift lock release cable Ay.
Refer to Page F3-36.
2.Check the shift lock operation and the key interlocking operation.
Refer to Page F3-36.
3.Install the front floor carpet Ay. (Driver's side only)
Refer to Page I2-57.
4.Install the lower steering column cover.
Refer to Page G1-5.
5.Install the lower instrument panel finish panel S/A.
Refer to Page I2-23.
6.Install the front console box S/A.
Refer to Page I2-31.
F3–40
T11K5528ET10
Shift lock cam
Eye end
Casing cap
TO INDEX TO NEXT SECTION
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