Mitsubishi F5A5A F5A51 A5GF1 A5HF1 Transmission Repair Manual

Original Printing

WWW.ALL-TRANS.BY

January, 2012

INTRODUCTION

MITSUBISHI F5A5A (F5A51) & HYUNDIA/KIA A5GF1, A5HF1 (F5A51)

This is a five speed, Front Wheel Drive transaxle, with fully electronic controls for the upshifts and downshifts, with 5th gear being overdrive. The individual gear ratios are achieved through three planetary gear sets. The components of the planetary gear sets are driven or held by means of four multi-plate drive clutch packs, two multi-plate brake clutch packs, one reduction brake band and two one way clutches. To minimize fuel consumption, the torque converter clutch is applied by the PCM, depending on throttle position and vehicle speed. These units are currently found in several Mitsubishi models, some Hyundai models and some Kia models, as shown in Figure 1 and 2. The 2007 and later Hyundai models and the 2006 and later Kia models have an added line pressure control solenoid, along with a revised shift solenoid application.

We wish to thank Mitsubishi Motor Company for the information and illustrations

that have made this booklet possible. A special thanks also to Bob Nuttall for

information and suggestions that have made this a very accurate booklet.

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, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

WAYNE COLONNA

TECHNICAL CONSULTANT

PETER LUBAN

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

GREG CATANZARO

TECHNICAL CONSULTANT

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

DALE ENGLAND

TECHNICAL CONSULTANT

JIM DIAL

TECHNICAL CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157

(305) 670-4161

1

IDENTIFICATION CODE STAMPING LOCATION ..........................................................................................................

WWW.ALL-TRANS.BY

GENERAL DESCRIPTION AND OPERATION ..................................................................................................................

VEHICLE APPLICATION CHART ......................................................................................................................................

INTERNAL COMPONENT LOCATIONS ............................................................................................................................

COMPONENT AND SOLENOID APPLICATION CHARTS, (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only)...........

COMPONENT AND SOLENOID APPLICATION CHARTS, (2006-Up Kia and 2007-Up Hyundai Only) .......................

SOLENOID LOCATIONS .....................................................................................................................................................

SOLENOID OPERATION AND FUNCTION ......................................................................................................................

TRANSAXLE FLUID TEMPERATURE SENSOR .............................................................................................................

INTERNAL WIRE HARNESS ..............................................................................................................................................

CASE CONNECTOR PIN ID & RESISTANCE CHART, (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only) .................

WIRE SCHEMATIC (Mitsubishi Only) ...............................................................................................................................

CASE CONNECTOR PIN ID & RESISTANCE CHART, (2006-Up Kia and 2007-Up Hyundai Only) ..............................

WIRE SCHEMATIC (Hyundai Only) ..................................................................................................................................

WIRE SCHEMATIC (Kia Only) ...........................................................................................................................................

TRANSAXLE RANGE SWITCH (Mitsubishi Only) ...........................................................................................................

CONNECTOR VIEWS (Mitsubishi Only) ...........................................................................................................................

TRANSAXLE RANGE SWITCH (Hyundai Only) ..............................................................................................................

CONNECTOR VIEWS (Hyundai Only) ...............................................................................................................................

TRANSAXLE RANGE SWITCH (Kia Only) .......................................................................................................................

CONNECTOR VIEWS (Kia Only) ........................................................................................................................................

INPUT AND OUTPUT SPEED SENSORS ..........................................................................................................................

PCM AND PCM LOCATIONS ..............................................................................................................................................

DIAGNOSTIC TROUBLE CODES (Mitsubishi Only) ........................................................................................................

DIAGNOSTIC TROUBLE CODES (Hyundai and Kia Only) ..............................................................................................

FLUID PASSAGE IDENTIFICATION ................................................................................................................................

PRESSURE TAP LOCATIONS .............................................................................................................................................

AIR CHECK LOCATIONS ....................................................................................................................................................

LINE PRESSURE SPECIFICATIONS ................................................................................................................................

TRANSAXLE DISASSEMBLY .............................................................................................................................................

COMPONENT REBUILD

TRANSAXLE CASE ASSEMBLY ...............................................................................................................................

REDUCTION (OWC-2) SPRAG ASSEMBLY ............................................................................................................

REAR COVER ASSEMBLY .........................................................................................................................................

REDUCTION BAND SERVO ......................................................................................................................................

REVERSE/OVERDRIVE CLUTCH HOUSING ASSEMBLY ..................................................................................

OVERDRIVE CLUTCH HUB ASSEMBLY ...............................................................................................................

PLANETARY GEAR TRAIN ASSEMBLY ..................................................................................................................

UNDERDRIVE CLUTCH HOUSING ASSEMBLY ...................................................................................................

DIFFERENTIAL (RING GEAR) ASSEMBLY ..........................................................................................................

DIRECT PLANETARY CARRIER ASSEMBLY ........................................................................................................

DIRECT CLUTCH HOUSING ASSEMBLY ...............................................................................................................

SECOND CLUTCH RETAINER ASSEMBLY ............................................................................................................

OIL PUMP ASSEMBLY ...............................................................................................................................................

VALVE BODY ASSEMBLY (Mitsubishi, Pre-06 Kia and Pre-07 Hyundai Only) .....................................................

VALVE BODY ASSEMBLY (2006-Up Kia and 2007-Up Hyundai Only) ..................................................................

TRANSAXLE FINAL ASSEMBLY .......................................................................................................................................

LOW SPRAG (OWC-1) FREEWHEEL DIRECTION .........................................................................................................

REDUCTION (OWC-2) SPRAG FREEWHEEL DIRECTION ..........................................................................................

REDUCTION BRAKE BAND ADJUSTMENT ....................................................................................................................

BOLT CHART (Except Valve body) (See Valve Body Section For VB Bolts) ........................................................................

SPECIAL TOOLS ...................................................................................................................................................................

THRUST BEARING AND WASHER IDENTIFICATION AND LOCATIONS ..................................................................

TORQUE SPECIFICATIONS ...............................................................................................................................................

FLUID AND END-PLAY SPECIFICATIONS .....................................................................................................................

MITSUBISHI

HYUNDAI & KIA

INDEX

3 4 4 5 6 7 8

9 10 11 12 13 14 15 16 17 20 21 22 25 28 29 31 32 33 35 38 39 40 41

64 65 68 69 71 79 80 84 90 94

100 105 106 110 119 128 130 144 147 165 166 170 172 172

2

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157

(305) 670-4161

"Mitsubishi"

WWW.ALL-TRANS.BY

F 5 A 51 K 2 E 5 B 1

Technical Service Information

IDENTIFICATION CODE STAMPING LOCATION

"Stamping In Case"

B1

E5

1K 5

F5A 2

AT F

Drive Axle

F = Front Wheel Drive R = Rear Wheel Drive

Forward Speeds

4 = Four Speeds 5 = Five Speeds

Transmission Type

A = Automatic M = Manual

Trans Capacity

42 = Standard Duty 51 = Heavy Duty

"Hyundai/Kia"

Manufacturing Plant

K = Kyoto Works (Not always stamped)

G 2U

6K D

U 5 K BD 0 0 0 0 0 1

"Stamping In Case"

131380

AT F

1 Model, U = A5HF1, Q = A5GF1 2 Production Year, 5 = 2005, 6 = 2006 3 FD Ratio, K = 3.333 4 Classification, 5 Spare, 6 Serial Number, 000001 - 999999

1 2 3 5 64

A5HF1 = 7 Solenoid Valve Body (Line Pressure Solenoid)

A5GF1 = 6 Solenoid Valve Body (No Line Pressure Solenoid)

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

3

Technical Service Information

WWW.ALL-TRANS.BY

GENERAL DESCRIPTION GENERAL OPERATION

This is a five speed, Front Wheel Drive transaxle, with fully electronic controls for the upshifts and downshifts, and is a re-designed F4A51 with an added planetary, reduction sprag, direct clutch pack, and reduction brake band. The individual gear ratios are now achieved through three planetary gear sets, and there are three different planetary gear ratios. Refer to the individual component application charts (Figure 4 and 5) for the gear ratios. The components of the planetary gear sets are driven or held by means of four multi-plate drive clutch packs, two multi-plate brake clutch packs, one reduction brake band and two one way clutches (sprags). Refer to Figure 3 for the internal component locations. To minimize fuel consumption, the torque converter clutch is applied by the Powertrain Control Module (PCM), depending on throttle position, transaxle temperature, and vehicle speed. These units are currently found in several Mitsubishi models, and referred to as the "F5A5A" in Mitsubishi. It is also found in some Hyundai and Kia models, and they both refer to it as the "A5HF1", and this version operates much differently than the Mitsubishi models. Refer to Figure 1 for identification tag information and Figure 2 for vehicle application chart.

Mitsubishi, Pre-07 Hyundai, Pre-2006 Kia Operation

The Mitsubishi version uses the basic 4 speed valve body with an added solenoid to control the reduction band, so it now has six solenoids instead of five. The Low/Reverse solenoid is now a double duty solenoid and is used to also apply the added direct clutch pack, based on position of the switch valve in valve body. The valve body has an added control valve for the reduction band and an added Fail-safe "C" valve. The component and the solenoid application charts for Mitsubishi, Pre-07 Hyundai and Pre-06 Kia models are found in Figure 4.

2007-Up Hyundia, 2006-Up Kia Operation

The later Hyundai and Kia version uses the same six solenoid valve body as the earlier models except, it has an additional solenoid, (Total of 7), used strictly to control line pressure. The Low/Reverse solenoid is still a double duty solenoid and is used to apply the added direct clutch pack, based on the position of the switch valve in the valve body.

However, the 2007-Up Hyundai and 2006-Up Kia internal component and solenoid applications are

different than the earlier version. The component and

solenoid application charts for the 2007-Up Hyundai and 2006-Up Kia are found in Figure 5.

MITSUBISHI VEHICLE APPLICATION CHART

YEAR

2000-2001

2006-2008

2006-2009

2007-2010

2007-2011

2006-2009

2006-2011

2009-2011

MODEL

Diamante

Eclipse

Galant

HYUNDAI VEHICLE APPLICATION CHART

Sonata

Santa Fe

Azera

Entourage

KIA VEHICLE APPLICATION CHART

Amanti

Sedona

Sorento

ENGINE

V6-2.5L

V6-3.8L

V6-3.3L,

V6-3.3L, 3.5L

V6-3.5L, 3.8L

L4-2.2L

Figure 2

TRANSAXLE

F5A5A (F5A51)

A5HF1 (F5A51)

4

AUTOMATIC TRANSMISSION SERVICE GROUP

REVERSE

WWW.ALL-TRANS.BY

CLUTCH

OVERDRIVE

CLUTCH

Technical Service Information

INTERNAL COMPONENT LOCATIONS

SECOND CLUTCH

LOW REVERSE

CLUTCH

LOW (OWC-1)

SPRAG

UNDERDRIVE

CLUTCH

REDUCTION

(OWC-2) SPRAG

DIRECT

CLUTCH

REDUCTION

BRAKE BAND

Figure 3

AUTOMATIC TRANSMISSION SERVICE GROUP

5

Gear

WWW.ALL-TRANS.BY

Range

Reverse

Clutch

"MITSUBISHI, pre-2007 hyundai, pre-2006 kia ONLY"

Underdrive

Clutch

Technical Service Information

INTERNAL COMPONENT APPLICATION CHART

2nd

Clutch

Overdrive

Clutch

Low/Rev

Clutch

Direct

Clutch

Reduct

Band

Low

(OWC-1)

Sprag

Reduct

(OWC-2)

Sprag

TCC

Gear Ratio

Mitsubishi

Park

Reverse

ON

Neutral

Dr-1st

Dr-2nd

Dr-3rd

Dr-4th

Dr-5th

* Low/Reverse clutch is applied below 6 mph, released above 6 mph. ** TCC dependant on throttle position, temperature and vehicle speed. Note: Reverse Clutch is applied with fluid pressure from the manual valve. Note: (OWC = One Way Clutch)..

ON

ON ON

ON

ON*

ON

FLUID REQUIREMENTS Mitsubishi Diamond SP III

"MITSUBISHI, pre-2007 hyundai, pre-2006 kia ONLY"

SOLENOID APPLICATION CHART

Gear

Range

U.D.

Sol

2nd

Sol

O.D.

Sol

TCC

Sol

ON

L/R-Dir.

HOLD HOLD

HOLD

RED.

Sol***

Sol

ON**

3.117

3.789

2.162

1.421

1.000

0.686

Final Drive

Ratio 3.325

* Low/Reverse clutch is applied below 6 mph, and released above 6 mph.

** Torque Converter Clutch (TCC) dependant on throttle position, temperature and vehicle speed.

*** Low/Reverse Clutch or Direct Clutch depending on switch valve position.

Solenoid ON = Energized Solenoid OFF = De-Energized

Failsafe: Two failsafe strategies are available, 2nd gear and 3rd gear. Should all solenoids be turned Off (i.e. electrical failure), 3rd gear will be the result. 2nd gear failsafe "may" be commanded by the TCM, energizing the appropriate solenoids. Reverse always available.

Park

Reverse

Neutral

Dr-1st

Dr-2nd

Dr-3rd

Dr-4th

Dr-5th

ON ON ON

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Figure 4

OFF

ON**

OFF OFF

OFF

OFF*

ON

OFF

ON

6

AUTOMATIC TRANSMISSION SERVICE GROUP

Gear

WWW.ALL-TRANS.BY

Range

Reverse

Clutch

Underdrive

Clutch

Technical Service Information

"2007-up HYUNDAI, 2006-up KIA ONLY"

INTERNAL COMPONENT APPLICATION CHART

2nd

Clutch

Overdrive

Clutch

Low/Rev

Clutch

Direct

Clutch

Reduct

Band

Low

(OWC-1)

Sprag

Reduct

(OWC-2)

Sprag

DCC

Gear Ratio

Hyundai Kia

Park

Reverse

ON

Neutral

Dr-1st

Dr-2nd

Dr-3rd

Dr-4th

Dr-5th

* Low/Reverse clutch is applied below 6 mph, released above 6 mph. ** Damper Converter Clutch (DCC) dependant on throttle position, temperature and vehicle speed. Note: Reverse Clutch is applied with fluid pressure from the manual valve. Note: (OWC = One Way Clutch)..

ON

ON ON

ON

ON ON

ON

ON*

ON

HOLD HOLD

HOLD

FLUID REQUIREMENTS

Hyundai/Kia Diamond SP III

"2007-up HYUNDAI, 2006-up KIA ONLY"

SOLENOID APPLICATION CHART

Gear

Range

U.D.

Sol

2nd

Sol

O.D.

Sol

DCC

Sol

L/R-Dir.

Sol***

RED.

Sol

ON**

Line

VFS Sol

4.5863.859

4.4573.840

2.4422.092

1.6861.440

1.2331.048

0.8680.728

Final Drive Ratio 3.333

{

* Low/Reverse clutch is applied below 6 mph, and released above 6 mph.

** Damper Converter Clutch (DCC) dependant on throttle position, temperature and vehicle speed.

*** Low/Reverse Clutch or Direct Clutch depending on switch valve position.

**** VFS is constantly modulating to control Line Pressure depending on throttle opening, engine load and vehicle speed.

Solenoid ON = Energized Solenoid OFF = De-Energized

Failsafe: Two failsafe strategies are available, 2nd gear and 3rd gear. Should all solenoids be turned Off (i.e. electrical failure), 3rd gear will be the result. 2nd gear failsafe "may" be commanded by the TCM, energizing the appropriate solenoids. Reverse always available.

Park

Reverse

Neutral

Dr-1st

Dr-2nd

Dr-3rd

Dr-4th

Dr-5th

ON ON ON

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON**

Figure 5

OFF OFF

OFF

OFF*

ON

OFF

ON

****

AUTOMATIC TRANSMISSION SERVICE GROUP

7

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS

Shift Solenoid Application

The Mitsubishi, Hyundai and Kia all use 6 solenoids mounted on the valve body, to upshift and downshift the transaxle, as well as the apply and release of the TCC/DCC. However, two different shift solenoid application

patterns are used, as shown on Page 6 and 7.

Refer to Page 6 for internal component and solenoid application charts for "Mitsubishi" and the earlier "Hyundai/Kia" models. Refer to Page 7 for internal component and solenoid application charts for later "Hyundai/Kia" models. The individual shift solenoid locations are the same between the two and are shown in Figure 6. Function of each solenoid is described in detail on Page 9.

3 DIFFERENT

SIZE "O" RINGS

MD758981

Line Pressure Control

The 2007-Up Hyundai and 2006-Up Kia vehicles only, use an added VFS Solenoid to control line pressure on all of their models that use the A5HF1 transaxle, and the location on valve body is shown in Figure 7. All of the Mitsubishi and pre-2006 Hyundai/Kia vehicles use only the pressure regulator valve in the valve body for line pressure control. Both versions have the capability of adjusting line pressure mechanically.

OEM Solenoid Part Numbers (At time of printing)

Mitsubishi Shift Solenoid ....................... MD758981

Hyundai & Kia Shift Solenoid ............. 46313-39051

Hyundai & Kia VFS Solenoid ............ 46313-3A060

VFS Solenoid (Line Pressure)

2007-Up Hyundai & 2006-Up Kia Only

6604

AIR OUT

HERE WITH

SOLENOID ON

SOLENOID RESISTANCE SHOULD BE

2.7 - 3.4 OHMS @ 20° C (68° F)

F4A5 K2E5B11

REDUCTION BRAKE

AIR OUT

HERE WITH

SOLENOID OFF

H

G

BAND SOLENOID

5

7 3

CLUTCH SOLENOID

AIR IN

HERE

UNDERDRIVE

CLUTCH SOLENOID

SECOND

CLUTCH SOLENOID

TCC

SOLENOID

OVERDRIVE

CLUTCH SOLENOID

LOW/REVERSE

SOLENOID RESISTANCE SHOULD BE

4.0 - 5.0 OHMS @ 20° C (68° F)

F4A K2 B151 E5

REDUCTION BRAKE

BAND SOLENOID

UNDERDRIVE

CLUTCH SOLENOID

H

SECOND

CLUTCH SOLENOID

5

7 3

TCC

SOLENOID

G

VFS SOLENOID (LINE PRESSURE)

"2007-UP HYUNDAI & 2006-UP KIA" ONLY

OVERDRIVE

CLUTCH SOLENOID

LOW/REVERSE

CLUTCH SOLENOID

Figure 6 Figure 7

8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Solenoid Operation

The F5A51 transaxle uses six solenoids for all of the upshifts, downshifts and apply & release of the TCC/DCC. All six of the shift solenoids are "Normally Applied" Pulse Width Modulated style and will interchange in any of their positions. The Low/Reverse solenoid is a double duty solenoid and will apply the Low/Reverse Clutch or will apply the Direct Clutch, depending on the position of the switch valve in the valve body. All shift solenoids can be air checked using the procedure shown in Figure 6, and solenoid resistance is checked across the 2 terminals. Solenoid locations on the valve body are also shown in Figure 6 and 7.

The Low/Reverse Solenoid, is used to apply and release the low/reverse clutch. When solenoid is deenergized (OFF), the low/reverse clutch is ON. When solenoid is energized (ON), low/reverse clutch is OFF. This function occurs with the switch valve in the valve body in the downshifted position. When the switch valve is upshifted, by overdrive clutch fluid, a different sequence of events occur still using the same solenoid. In this configuration, The Low/Reverse Solenoid, is used to apply and release the Direct Clutch. When the solenoid is de-energized (OFF), the direct clutch is ON. When the solenoid is energized (ON), the direct clutch is OFF.

Solenoid Function

The Underdrive Clutch Solenoid, is used to apply and release the underdrive clutch. When solenoid is deenergized (OFF), the underdrive clutch is ON. When solenoid is energized (ON), the underdrive clutch is OFF.

The Overdrive Clutch Solenoid, is used to apply and release the overdrive clutch. When solenoid is deenergized (OFF), the overdrive clutch is ON. When solenoid is energized (ON), the overdrive clutch is OFF.

The Second Clutch Solenoid, is used to apply and

release the second brake clutch. When solenoid is deenergized (OFF), the second brake clutch is ON. When solenoid is energized (ON), the second brake clutch is OFF.

The Reduction Solenoid, is used to apply and release the reduction brake band. When solenoid is deenergized (OFF), the reduction brake band is ON. When solenoid is energized (ON), the reduction brake band is OFF.

The VFS Solenoid, (7th solenoid) used on the 2007Up Hyundai and 2006-Up Kia models only, to more precisely control line pressure according to current vehicle driving conditions. It is a Variable Force Solenoid with duty control that uses a higher frequency of (600 Hz), instead of the existing PWM style that uses a lower frequency (60 Hz) to control all other solenoids. In PWM control, amount of oil flow is determined by the duration of ON signal with repeated ON/OFF pulses. In VFS control, amount of oil flow is determined by the width of the oil passage opening. 2007-Up Hyundai and 2006-Up Kia models are also equipped with an orificed tube that provides a constant stream of cooler fluid spraying on the VFS Solenoid for cooling the solenoid, which provides increased durability.

Electronic Components

Continued on Page 10

The TCC/DCC Solenoid, is used to apply and release the Torque Converter Clutch. When the solenoid is deenergized (OFF), the converter clutch is OFF, as it routes fluid to the spring side of the converter clutch control valve in the valve body. When solenoid is energized (ON), the converter clutch is ON, as it now exhausts fluid from the spring side of control valve, allowing it to stroke.

AUTOMATIC TRANSMISSION SERVICE GROUP

9

F4 K2 B1A51 E5

WWW.ALL-TRANS.BY

"O" RING

SEAL

G

TFT

SENSOR

Technical Service Information

H

5

7 3

View Looking Into Transaxle

Pass-Thru Case Connector

(Terminal ID, Page 12)

RETAINING

BOLT

MITSUBISHI F5A51 AND

EARLY HYUNDAI/KIA A5GF1

Internal Wire Harness And

10-Way Case Connector

Figure 8

Transaxle Fluid Temperature (TFT) Sensor

The Transaxle Fluid Temperature (TFT) sensor is located in the valve body, mounted into a fluid passage with a valve body to case bolt and requires an "O" ring seal, as shown in Figure 8.

The TFT is a negative temperature coefficient sensor, which means that as temperature increases the resistance decreases, as shown in Figure 9.

Electronic Components

Continued on Page 11

tft sensor resistance chart

Fluid Temp C° (F°)

Resistance

0° C (32° F) 16.7k - 20.5k

20° C (68° F)

40° C (104° F)

7.3k - 8.9k

3.4k - 4.2k

2007-UP HYUNDAI AND 2006-UP KIA a5HF1

Internal Wire Harness And

12-Way Case Connector

View Looking Into Transaxle

Pass-Thru Case Connector

(Terminal ID Page 14)

60° C (140° F)

80° C (176° F)

100° C (212° F)

10

1.9k - 2.2k

1.0k - 1.2k

0.57k - 0.69k

Added Connector

For VFS Solenoid

(Line Pressure Control)

Figure 9 Figure 10

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Internal Wire Harness (10-Way Mitsubishi) And (10-Way Early Hyundai/Kia)

The 10-way pass-thru case connector and internal wire harness assembly carries feed voltage to all solenoids and the switched ground signals from the Powertrain Control Module (PCM) to the appropriate solenoid to control all of the upshifts and downshifts, as well as the TCC apply and release (See Figure 10 and 11). The Internal wire harness is also used to feed 5 volts from the PCM to the TFT sensor and carries the fluid temperature signal back to the PCM. The 10-way pass-thru case connector and internal wire harness assembly, connector colors, and wire colors are shown in Figure 11. The pass-thru case connector terminal identification and terminal function along with a resistance chart are shown in Figure 13. Wire schematic for the Mitsubishi Eclipse is shown in Figure 14.

Note: This manual does not include "All" of the wire schematics for every model.

Internal Wire Harness (12-Way 2007-Up Hyundai) And (12-Way 2006-Up Kia)

The 12-way pass-thru case connector and internal wire harness assembly carries feed voltage to all solenoids and the switched ground signals from the Powertrain Control Module (PCM) to the appropriate solenoid to control all of the upshifts and downshifts, as well as the DCC apply and release (See Figure 10 and 12). The Internal wire harness is also used to feed 5 volts from the PCM to the TFT sensor and carries the fluid temperature signal back to the PCM. The 12-way pass-thru case connector and internal wire harness assembly, connector colors, and wire colors are shown in Figure 12. The pass-thru case connector terminal identification and terminal function along with a resistance chart are shown in Figure 15. Wire schematic for the 2007 Hyundai Azera is shown in Figure 16 and wire schematic for the 2006 Kia Sedona is shown in Figure 17.

4 K2 B1F A51 E5

TFT SENSOR

RED, WITH

BLACK GROUND

Wire colors may vary. Wire colors may vary.

H

5

7 3

G

“REDUCTION”

BLACK CONNECTOR

TWO YELLOW WITH

GREEN GROUND

10-Way Mitsubishi,

Early Hyundai/Kia

Pass-Thru Connector

“UNDERDRIVE”

BLACK CONNECTOR

TWO RED, WITH

WHITE GROUND

“SECOND”

WHITE CONNECTOR

TWO RED, WITH

GREEN GROUND

“TCC/DCC”

BLACK CONNECTOR

TWO YELLOW, WITH

BLUE GROUND

“OVERDRIVE”

BLACK CONNECTOR

ONE RED WITH

ORANGE GROUND

“LOW/REVERSE”

WHITE CONNECTOR

ONE YELLOW WITH

BROWN GROUND

K B1F4A51 2E5

TFT SENSOR

RED, WITH

BLACK GROUND

H

G

"VFS (LINE)"

BLACK CONNECTOR

ONE ORANGE WITH

BROWN GROUND

12-Way Hyundai/Kia

Pass-Thru Connector

5

7

3

WHITE CONNECTOR

ONE YELLOW WITH

BROWN GROUND

"REDUCTION"

BLACK CONNECTOR

TWO YELLOW WITH

GREEN GROUND

"UNDERDRIVE"

BLACK CONNECTOR

TWO RED, WITH

YELLOW GROUND

"SECOND"

WHITE CONNECTOR

TWO RED, WITH

GREEN GROUND

"DCC"

BLACK CONNECTOR

TWO YELLOW, WITH

BLUE GROUND

"OVERDRIVE"

BLACK CONNECTOR

ONE RED WITH

ORANGE GROUND

"LOW/REVERSE"

Figure 11 Figure 12

AUTOMATIC TRANSMISSION SERVICE GROUP

11

Technical Service Information

WWW.ALL-TRANS.BY

CASE CONNECTOR TERMINAL IDENTIFICATION AND INTERNAL COMPONENT RESISTANCE CHART

"Mitsubishi"

"Pre-2007 Hyundai" &

"Pre-2006 Kia" Only

(10-Way Connector)

10 9

6

View Looking Into Transaxle

COMPONENT TERMINALS

Underdrive Solenoid

2nd Solenoid

Overdrive Solenoid

Low/Rev Solenoid

TCC Solenoid

Reduction Solenoid

4

5

Case Connector

7

8

2

3

1

INTERNAL COMPONENT RESISTANCE CHART

Terminals 9 and 3

Terminals 9 and 4

Terminals 9 and 5

Terminals 10 and 6

Terminals 10 and 7

Terminals 10 and 8

7

8

1

View Looking Into Transaxle

Harness Connector

RESISTANCE

2.7 - 3.4 Ohms @ 20°C (68°F)

3

2

9

10

5

4

6

TFT Sensor

TERMINAL

NUMBER

1

2

3

4

5

6

7

8

9

10

Terminals 1 and 2

INTERNAL

WIRE COLOR

Red

Black

White

Green

Orange

Brown

Blue

Green

Red

Yellow

See Chart in Figure 9

CIRCUIT

DESCRIPTION

5 Volt Power to TFT Sensor

Ground to TFT Sensor

Ground for Underdrive Solenoid control

Ground for Second Clutch Solenoid control

Ground for Overdrive Solenoid control

Ground for Low/Reverse Solenoid control

Ground for TCC Solenoid control

Ground for Reduction Solenoid control

Power to Underdrive, Second, and Overdrive Solenoids

Power to TCC, Low/Reverse, and Reduction Solenoids

NOTE: Wire colors may vary.

Figure 13

12

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

WIRE SCHEMATIC MITSUBISHI ECLIPSE "ONLY"

"Mitsubishi Eclipse Only"

IGN FUSE

NO. 3

7.5A

BATT FUSE

NO. 15

20A

1

TRANSMISSION

CONTROL RELAY

RELAY BOX LOCATED

LEFT REAR ENGINE

COMPARTMENT

Black/White

3 3

OSS

Sensor

ISS

Sensor

2 21 1

Brown

White/Violet

Green/Yellow

Brown Brown

Green/Yellow

Brown

Black/White

White/Violet

Conn.

Black/White

See PCM Connector

Views on Page 20

PCM

B-21

111

112

5 V

113

To Park/Neut

Position Switch

See Page 19

B-20

Conn.

65

66

55

54

53

56

Red/Blue

White/Red

Orange

Blue

Yellow/Red

Green/White

Red/White

Red/Blue

White/Blue

Case

B-111 Conn.

10

9

3

4

5

7

8

6

Yellow

Red

White

Green

Orange

Blue

4

3 2

White/Blue

TRANSAXLE

Underdrive

Solenoid

2nd Clutch

Solenoid

Overdrive

Solenoid

Black

Red

RedRed

YellowYellowYellow

Red/Blue

White/Blue

Black

B-21

Conn.

B-20

Conn.

5 V

74

Conn.

B-20

Green

70

Brown

57

82

69

B-20

Conn.

PCM

Black/Pink

Black

Case

B-111 Conn.

1

2

Red

Black

NOTE: Wire colors may vary.

Figure 14

AUTOMATIC TRANSMISSION SERVICE GROUP

TCC Control

Solenoid

Reduction

Solenoid

Low/Rev Solenoid

TFT

Sensor

TRANSAXLE

13

Technical Service Information

WWW.ALL-TRANS.BY

CASE CONNECTOR TERMINAL IDENTIFICATION AND INTERNAL COMPONENT RESISTANCE CHART

9

101112

"2007-Up Hyundai" &

"2006-Up Kia" Only

(12-Way Connector)

4

3 2

1

8

7

4

View Looking Into Transaxle

Pass-Thru Case Connector

COMPONENT TERMINALS

Underdrive Solenoid

2nd Solenoid

Overdrive Solenoid

Low/Rev Solenoid

DCC Solenoid

Reduction Solenoid

VFS Solenoid

TFT Sensor

TERMINAL

NUMBER

3

INTERNAL

WIRE COLOR

5

6

2

1

INTERNAL COMPONENT RESISTANCE CHART

Terminals 5 and 3

Terminals 5 and 4

Terminals 5 and 12

Terminals 6 and 11

Terminals 6 and 9

Terminals 6 and 10

Terminals 7 and 8

Terminals 1 and 2

CIRCUIT

DESCRIPTION

2.7 - 3.4 Ohms @ 20°C (68°F)

4.0 - 5.0 Ohms @ 20°C (68°F)

See Chart in Figure 9

8

7

C-110 Harness Connector (Hyundai)

C-03 Harness Connector (Kia)

RESISTANCE

101112

9

View Looking Into Transaxle

5

6

1

2

3

4

5

6

7

8

9

10

11

12

14

Red

Black

Yellow

Green

Red

Yellow

Orange

Brown

Blue

Green

Brown

Orange

NOTE: Wire colors may vary.

AUTOMATIC TRANSMISSION SERVICE GROUP

5 Volt Power to TFT Sensor

Ground to TFT Sensor

Ground for Underdrive Solenoid control

Ground for 2nd Clutch Solenoid control

Power to Underdrive, Second, and Overdrive Solenoids

Power to DCC, Low/Reverse, and Reduction Solenoids

Power to VFS (Line Pressure) Solenoid

Ground for VFS (Line Pressure) Solenoid control

Ground for DCC Solenoid control

Ground for Reduction Solenoid control

Ground for Low/Reverse Solenoid control

Ground for Overdrive Solenoid control

Figure 15

Technical Service Information

WWW.ALL-TRANS.BY

WIRE SCHEMATIC "2007-UP HYUNDAI AZERA ONLY"

"2007-Up Hyundai Azera Only" ATM FUSE

To Transaxle

Range Switch

See Page 23

Purple

Blue

3 3

Pulse

Generator

"B"

(OSS)

2 21 1

Green

Black Black

Blue

Pulse

Generator

"A"

(ISS)

Black

Gray

Green

Blue

See PCM Connector

Views on Page 24

PCM

Gray

C-144B

Conn.

ISS Sig

10

OSS Sig

9

UD

2ND

OD

DCC

RED

L/R

B/UP FUSE

C-144B

Conn.

45

42

44

22

10A

3

43

20A

Orange

Green/Black

Yellow

Black

White

Black

Yellow

Red/White

Brown

Orange

Brown

C-110

Case

Conn.

6

5

3

4

12

9

10

11

1

Yellow

Red

Yellow

TRANSMISSION

CONTROL RELAY

4

3 2

Brown

TRANSAXLE

Underdrive

Solenoid

Green

2nd Clutch

Solenoid

Orange

Overdrive

Solenoid

ENGINE COMPARTMENT

JUNCTION BLOCK

Black

Red

RedRed

YellowYellowYellow

NOTE: Wire colors may vary.

C-144B

Orange

Brown

Conn.

C-144A

Conn.

50

20

C-144A

Conn.

BATT

AT

Relay

VFS

PCM

TFT

Snsr

Grnd

{

+

Blue

6

Black Black

33

59

75

C-144B

Conn.

1

2

Blue BrownBlue

8

Orange OrangeOrange

7

C-110

Case

Conn.

Figure 16

AUTOMATIC TRANSMISSION SERVICE GROUP

RedBlue

Black

Blue

Green

Brown

Sensor

TFT

DCC Control

Solenoid

Reduction

Solenoid

Low/Rev Solenoid

VFS (Line)

Solenoid

TRANSAXLE

15

Technical Service Information

WWW.ALL-TRANS.BY

WIRE SCHEMATIC "2006-UP KIA SEDONA ONLY"

"2006-Up Kia Sedona Only" ATM FUSE

To Transaxle

Range Switch

See Page 27

Purple

Blue

3 3

Pulse

Generator

"B"

(OSS)

Pulse

Generator

"A"

(ISS)

2 21 1

Black

White

Brown

Orange

Black Black

Green

Gray

Green

White

Blue

See PCM Connector

Views on Page 28

Gray

C01-2 Conn.

ISS Sig

10

OSS Sig

9

On/Start

12

Input

C01-2

Conn.

PCM

UD

2ND

OD

DCC

RED

L/R

TFT

ENG FUSE

C01-2 Conn.

7.5A

INTEGRATED POWER

3

Green/Black

45

42

43

44

22

Blue

6

15A

Red/White

MODULE

(ENG. COMP.)

Orange

Brown

Orange

Yellow

Black

White

Black

Yellow

C-03 Case

Conn.

6

5

3

4

12

9

10

11

1

Yellow

Red

Yellow

TRANSMISSION

CONTROL RELAY

4

3 2

Brown

TRANSAXLE

Underdrive

Solenoid

Green

2nd Clutch

Solenoid

Orange

Overdrive

Solenoid

Blue

DCC Control

Solenoid

Black

Red

RedRed

YellowYellowYellow

NOTE: Wire colors may vary.

16

C01-1 Conn.

Orange

Brown

60

20

C01-1 Conn.

BATT

AT

Relay

VFS +

PCM

Snsr

Grnd

VFS -

Black Black

33

59

75

C01-2 Conn.

Blue BrownBlue

Orange OrangeOrange

C-03 Case

Conn.

RedBlue

1

2

8

7

Figure 17

AUTOMATIC TRANSMISSION SERVICE GROUP

Black

Green

Brown

Sensor

TFT

Reduction

Solenoid

Low/Rev Solenoid

VFS (Line)

Solenoid

TRANSAXLE

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Mitsubishi Transaxle Range Switch (TRS)

The Transaxle Range Switch (TRS) is located on top of the transaxle, as shown in Figure 18. The TRS is a mechanical multi-position switch with four selector positions, one reverse switch and one switch for positions P/N, for starting control. Refer to the TRS wire schematic in Figure 22. The appearance of the selector lever, as shown in Figure 19, will vary between the different vehicle applications. However, they all have four detent positions and the operation and function remains the same.

Selector Lever Positions

When the "Park" position is selected, there is no

P

powerflow through the transmission. 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.

Transaxle Range

Switch Assembly

When the "Reverse" position is selected, the vehicle

R

can be operated in a rearward direction at a reduced gear ratio.

When the "Neutral" position is selected, there is no

N

powerflow through the transmission. 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 restart the engine if that becomes necessary.

The "Drive" position is the normal position for most

D

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 transmission to operate in each of the five forward gear ratios. Downshifts are available for safe passing, by depressing the accelerator. With the shift lever in the "D" position and moved into the right hand selector gate, 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.

Continued on Page 18

5F5A5 K E B1

1 2

TYPICAL SHIFT QUADRANT

"MITSUBISHI"

Lock Button

P

R

N

D

Figure 18 Figure 19

+

AUTOMATIC TRANSMISSION SERVICE GROUP

17

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Mitsubishi Transaxle Range Switch Check Transaxle Range Switch Adjustment

The only voltage sent to the TRS goes in at terminal 8 and 10 as shown in Figure 22. In Reverse, voltage exits through terminal 7 to the reverse lamps and to the PCM. Ignition start voltage is sent to terminal 10 and out thru terminal 9 to the starter relay. Diagnosis here is easily done using the DVOM set to DC volts. The TRS can also be checked with the connector removed and your DVOM set to Ohms. You should have continuity across the terminals shown in the chart in Figure 20 (Less than 2 ohms), related to the position of the gear selector lever. If these do not check properly, replace the transaxle range switch.

6

10

5

9

4

3

8

2

7

1

(In Vehicle "All Models")

1. Place the shift selector lever in the "N" position.

2. Loosen the control cable to the manual control lever on transaxle.

3. Place the manual control lever on transaxle in neutral position.

4. Loosen transaxle range switch mounting bolts and turn the TRS body so the hole in the end of the manual control lever and the hole in flange of the TRS body are aligned. Note: The TRS body can be aligned by inserting

a 5-mm diameter steel bar (3/16" bit) into the end hole of the manual control lever and the flange hole in TRS switch body, as shown in Figure 21.

5. Torque transaxle range switch mounting bolts to 11 N·m (97 in.lb.). Note: Ensure that the switch body does not

move during the torquing process.

6. Remove the alignment tool.

Electronic Components

Continued on Page 21

"Mitsubishi Only" Continuity Test

Terminal

1

*

3

4

*

7

8

9

10

P R N D

3/16 inch

D

N

R

P

Drill Bit

18

Figure 21Figure 20

AUTOMATIC TRANSMISSION SERVICE GROUP

MITSUBISHI TRANSAXLE RANGE SWITCH CONNECTOR AND TERMINAL IDENTIFICATION

WWW.ALL-TRANS.BY

C-17

1 2 3

4 5 6 7 8

Shift Switch

Assembly Connector

(LOCATED IN SHIFT LEVER ASSEMBLY)

Technical Service Information

"Mitsubishi Only"

Voltage From

Ignition Switch

Black/White

Power From

Fuse Block

See Page 13

IGN FUSE

NO. 3

7.5A

"Mitsubishi Eclipse Only"

View Looking Into Transaxle

Range Switch Connector

4

2

1

3

6

5

To Starter

Black/White

Relay

C-17

Conn.

2

UPSHIFT SWITCH

ONOFF ONOFF

DOWNSHIFT

SWITCH

7

C-17

Conn.

White/Red

Yellow

10 8

P

R

N

D

9 4 7 3

Red

Shift Switch

YellowRed/Blue

Yellow

Assembly

1

3

Red

MODE

SELECT

SWITCH

AUTO

6

SPORT MODE

Black/White

R

N

D

1

Yellow

Transaxle Range Switch

P

Brown

Red/Blue

7

8

Red/Blue

Black/Blue

109

Red/Blue

Back-up

Lamps

B-19

Conn.

PCM PCM

32

B-19

Conn.

B-20

Conn.

36

R

Input

See PCM Connector

Views In Figure 23

NOTE: Wire colors may vary.

D

Input

N

Input

Figure 22

AUTOMATIC TRANSMISSION SERVICE GROUP

B-20

Conn.

6761777339

P

Input

19

Technical Service Information

WWW.ALL-TRANS.BY

"MITSUBISHI ONLY" CONNECTOR VIEWS

The PCM is located in the engine compartment on the left fender panel just below the relay box.

B-18 B-19 B-21 B-22B-20

Powertrain Control Module (PCM)

B-18

B-19

B-20

B-21

B-22

1 2 3

4 5 6 7 8

Shift Switch Assembly

C-17 Connector

(LOCATED IN SHIFT LEVER ASSEMBLY)

10 9

4321

765

111098

141312

18171615

2524232221

29282726

3433323130

38373635

4342414039

565554535251

57

6261605958

63

696867666564

70

76

7574737271

83

8280797877

81

Powertrain Control Module (PCM) Connectors

See Page 29 For

Inout and Output

Speed Sensor

Connector Views

7

8

9594939291

99989796

104103102101100

108107106105

113112111110109

View Looking Into Transaxle

Range Switch Harness B-113 Connector

7

6

10

125 127124 126123122121

131 133130 132129128

138 140137 139136135134

144 146143 145142141

151 153150 152149148147

3

5

4

9

8

2

1

78

10

20

6

4

5

2

3

1

View Looking Into Transaxle

Case Connector

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 23

1

3

2

5

4

6

View Looking Into Transaxle

Harness B-111 Connector

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

"Hyundai Only" Transaxle Range Switch (TRS)

The Transaxle Range Switch (TRS) is located on top of the transaxle, as shown in Figure 24. The TRS is a mechanical multi-position switch with four selector positions on the "Tiptronic" version, seven selector positions on "Non-Tiptronic" versions, one reverse switch and one switch for positions P/N, for starting control. Refer to Figure 25 for the two versions of the Shift Lever assembly and the TRS wire schematic is shown in Figure 26.

"Hyundai Only" Selector Lever Positions

When the "Park" position is selected, there is no

P

powerflow through the transmission. 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

R

can be operated in a rearward direction at a reduced gear ratio.

When the "Neutral" position is selected, there is no

N

powerflow through the transmission. 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 restart the engine if that becomes necessary.

The "Drive" position is the normal position for most

D

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 transmission to operate in each of the five forward gear ratios. Downshifts are available for safe passing, by depressing the accelerator. On "Tiptronic" models with the shift lever in "D" position and moved into the right hand selector gate, 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. Refer to Figure 25.

When the "Third" position is selected, the transaxle

3

will take off in first gear and not allow any shifts above third gear. This position can also be used for engine braking as necessary.

0 1 813 3

6 G 2U K D

Transaxle Range

Switch Assembly

When the "Second" position is selected, the transaxle

2

will take off in first gear and not allow any shifts above second gear. This position can also be used for engine braking as necessary.

When the "Low" position is selected, the transaxle

L

will take off in first gear and not allow any shifts above first gear. This position can also be used for engine braking as necessary.

"Hyundai Only" Transaxle Range Switch Check

The only voltage sent to the TRS goes in at terminal 8 and 10 as shown in Figure 26. In Reverse, voltage exits through terminal 7 with a signal to the BCM & PCM. The BCM illuminates the Reverse lamps.. Ignition start voltage is sent to terminal 10 and out thru terminal 9 to the starter relay. Diagnosis here is easily done using the DVOM set to DC volts. The TRS can also be checked with the connector removed and your DVOM set to Ohms. You should have continuity across the terminals shown in the charts in Figure 25 (Less than 2 ohms), related to the position of the gear selector lever. If these do not check properly, replace the transaxle range switch.

Figure 24

AUTOMATIC TRANSMISSION SERVICE GROUP

21

Technical Service Information

WWW.ALL-TRANS.BY

HYUNDAI "NON-TIPTRONIC" MODELS HYUNDAI "TIPTRONIC" MODELS

P

R

N

D

3

2

L

Transaxle Range Switch

"Non-Tiptronic Models"

(Face View)

3

1

2

7 8

5

6

4

10

9

P

R

N

D

Transaxle Range Switch

"Tiptronic Models

(Face View)

3

1

*

7 8

+

*

4

*

10

9

"Non-Tiptronic" Continuity Test

Terminal

1

2

3

4

5

6

7

8

9

10

P R N D 3 2 L

Figure 25

Terminals not used are marked with an asterisk (*)

"Tiptronic" Continuity Test

Terminal

1

*

3

4

*

7

8

9

10

P R N D

22

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE RANGE SWITCH CONNECTOR AND TERMINAL IDENTIFICATION

"Hyundai Only"

Transaxle Range Switch

Harness Connector F-09

Shift Switch (Face View)

(LOCATED IN SHIFT LEVER ASSEMBLY)

67891011

**34

5

To Starter

Relay

Shift Switch

Assembly

UPSHIFT SWITCH

ONOFF ONOFF

DOWNSHIFT

SWITCH

From Ignition

Switch Thru

Start Fuse 10A

Green

10 8

P

R

N

D

9 4 7 3

Black

Engine Comp

Junction Block

F-09

Conn.

Yellow

9

MANUALNORMAL

SELECT

SWITCH

Power From

Fuse Block

See Page 15

B/UP FUSE

10A

Purple

R

N

D

1

Yellow

"Hyundai Only"

Refer To Page 24 For Transaxle

Range Switch Connector

As There Are Two Versions

Transaxle

P

Range Switch

RedRed

BCM

Reverse Lamps Illuminated By

BCM or PCM

F-09

Conn.

C-144A

Conn.

PCM PCM

NOTE: Wire colors may vary.

NOTE: Unused terminals are marked with asterisk (*).

7

Blue

8

Up

Shift

Blue

68

Gray

Select

Switch

F-09

Conn.

Yellow

6773

D

Input

Purple Brown

5

N

Input

Ground

Input

5

Green

9

Down

Shift

PWM Signal

}

C-144B

Conn.

37

Figure 26

AUTOMATIC TRANSMISSION SERVICE GROUP

38

39

See Page 24 For PCM Connector

Views

C-144A

Green Green

Conn.

Input

C-144B

Conn.

3

P

4

R

23

Technical Service Information

WWW.ALL-TRANS.BY

CONNECTOR VIEWS AND TERMINAL IDENTIFICATION

"HYUNDAI ONLY"

PCM Connector C-144A

16

17

18

*

20

37

38

39

40

60

80

*

56

57

58

59

79

78

*

Harness Connector C-108

Pulse Generator "A"

(Input Speed)

(Face View)

3

1

2

Harness Connector C-109

Transaxle Range Switch

"Tiptronic Models"

(Face View)

*

10

3

*

4

*

9

(Face View)

*

15

32

33

*

52

53

54

55

72

73

*

1

78

PCM Connector C-144B

(Face View)

*

51

71

26

25

27

28

29

*

45

46

47

48

49

*

66

68

69

70

*

1

23

21

*

42

43

44

41

62

63

64

61

*

17

18

19

*

37

38

39

40

57

58

59

60

79

*

78

77

12

13

14

15

16

32

33

34

35

36

52

53

54

55

56

72

73

74

75

76

7

8

9

10

11

*

28

29

30

31

*

48

49

51

50

68

69

70

71

67

2

3

4

5

6

*

25

45

*

1

22

23

24

21

42

43

44

41

62

63

64

61

*

2

3

4

5

6

7

8

9

*

PCM located left rear of engine compartment.

9

Harness Connector C-115

101112

Pulse Generator "B"

(Output Speed)

(Face View)

3

Harness Connector F-09

(LOCATED IN SHIFT LEVER ASSEMBLY)

1

2

Shift Switch (Face View)

8

7

4

2

1

3

5

6

View Looking Into Transaxle

Pass-Thru Case Connector

**34

5

67891011

4

3 2

1

Harness Connector C-109

Transaxle Range Switch

"Non-Tiptronic Models"

6

10

NOTE: Unused terminals are marked with asterisk (*).

24

(Face View)

3

5

4

9

See Page 22

8

}

1

2

78

Figure 27

AUTOMATIC TRANSMISSION SERVICE GROUP

7

101112

9

View Looking Into Transaxle

C-110 Harness Connector

5

6

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Kia Transaxle Range Switch (TRS)

The Transaxle Range Switch (TRS) is located on top of the transaxle, as shown in Figure 28. The TRS is a mechanical multi-position switch with four selector positions, one reverse switch and one switch for positions P/N, for starting control. Refer to the TRS wire schematic in Figure 32. The appearance of the selector lever, as shown in Figure 29, will vary between the different vehicle applications. However, they all have four detent positions and the operation and function remains the same.

Selector Lever Positions

When the "Park" position is selected, there is no

P

powerflow through the transmission. 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.

Transaxle Range

Switch Assembly

When the "Reverse" position is selected, the vehicle

R

can be operated in a rearward direction at a reduced gear ratio.

When the "Neutral" position is selected, there is no

N

powerflow through the transmission. 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 restart the engine if that becomes necessary.

The "Drive" position is the normal position for most

D

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 transmission to operate in each of the five forward gear ratios. Downshifts are available for safe passing, by depressing the accelerator. With the shift lever in the “D" position and moved into the right hand selector gate, 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.

Continued on Page 26

0 1 813 3

6 G 2U K D

TYPICAL SHIFT QUADRANT

"KIA"

Lock Button

P

R

N

D

Figure 28 Figure 29

+

AUTOMATIC TRANSMISSION SERVICE GROUP

25

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Kia Transaxle Range Switch Check Transaxle Range Switch Adjustment

The only voltage sent to the TRS goes in at terminal 8 and 10 as shown in Figure 32. In Reverse, voltage exits through terminal 7 to the BCM & PCM. The BCM/PCM illuminates the reverse lamps. Ignition start voltage is sent to terminal 10 and out thru terminal 9 to the starter relay. Diagnosis here is easily done using the DVOM set to DC volts. The TRS can also be checked with the connector removed and your DVOM set to Ohms. You should have continuity across the terminals shown in the chart in Figure 30 (Less than 2 ohms), related to the position of the gear selector lever. If these do not check properly, replace the transaxle range switch.

6

10

5

9

4

3

8

2

7

1

(In Vehicle "All Models")

1. Place the shift selector lever in the "N" position.

2. Loosen the control cable to the manual control lever on transaxle.

3. Place the manual control lever on transaxle in neutral position.

4. Loosen transaxle range switch mounting bolts and turn the TRS body so the hole in the end of the manual control lever and the hole in flange of the TRS body are aligned. Note: The TRS body can be aligned by inserting

a 5-mm diameter steel bar (3/16" bit) into the end hole of the manual control lever and the flange hole in TRS switch body, as shown in Figure 31.

5. Torque transaxle range switch mounting bolts to 11 N·m (97 in.lb.). Note: Ensure that the switch body does not

move during the torquing process.

6. Remove the alignment tool.

Electronic Components

Continued on Page 29

"Kia Only" Continuity Test

Terminal

1

*

3

4

*

7

8

9

10

P R N D

3/16 inch

D

N

R

P

Drill Bit

26

Figure 31Figure 30

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE RANGE SWITCH CONNECTOR AND TERMINAL IDENTIFICATION

"Kia Only"

Transaxle Range Switch

Harness Connector M-01

Shift Switch (Face View)

(LOCATED IN SHIFT LEVER ASSEMBLY)

To Starter

123456

891011121314 *

Relay

Switch Assembly

UPSHIFT SWITCH

ONOFF ONOFF

DOWNSHIFT

SWITCH

From Ignition

Switch Thru

Start Fuse 7.5A

Black

Sport Mode

SELECT

SWITCH

Power From

Fuse Block

See Page 16

ENG FUSE

7.5A

Green

Purple

10 8

Transaxle

Range Switch

RedRed

P

R

N

D

9 4 7 3

Pass. Comp.

Fuse Block

M-01

Conn.

Yellow

D

1

Yellow

P

R

N

5

SELECT NORMAL

"Kia Only"

Harness Connector C-21 Transaxle Range Switch

(Face View)

3

*

10

*

4

9

BCM

1

*

78

Reverse Lamps Illuminated By

BCM or PCM

M-01

Conn.

C01-1 Conn.

PCM PCM

NOTE: Wire colors may vary.

NOTE: Unused terminals are marked with asterisk (*).

12

Blue

8

Up

Shift

14

Green

9

Down

Shift

13 6

Blue

Select

Switch

Blue Gray

PWM

Signal

M-01

Conn.

Instrument

Panel

Yellow

67 73

D

Input

Purple Brown

5

N

Input

Ground

Input

}

C01-2 Conn.

37

Figure 32

AUTOMATIC TRANSMISSION SERVICE GROUP

38

39

See Page 28 For PCM Connector

Views

C01-1

Green Green

Conn.

Input

C01-2 Conn.

3

P

4

R

27

Technical Service Information

WWW.ALL-TRANS.BY

CONNECTOR VIEWS AND TERMINAL IDENTIFICATION

"KIA ONLY"

PCM Connector C01-1

(Face View)

20

37

38

39

40

57

58

59

60

*

78

*

32

33

*

51

52

53

54

55

56

*

71

72

73

*

15

16

17

18

*

Harness Connector C-13

Pulse Generator "A"

(Input Speed)

(Face View)

3

1

2

PCM Connector C01-2

(Face View)

10

26

25

27

28

29

*

45

*

47

48

49

*

66

*

69

70

*

1

23

21

*

42

43

44

41

62

63

64

61

*

40

60

*

15

16

17

18

19

37

38

39

35

36

55

56

57

58

59

79

78

75

76

77

10

11

12

13

14

32

33

30

31

34

51

52

53

54

50

70

71

72

73

74

2

3

4

5

6

7

8

9

PCM located on firewall, left rear of engine compartment, behind relay box.

Harness Connector C-15

Pulse Generator "B"

(Output Speed)

(Face View)

3

1

2

8

7

9

*

25

*

28

29

45

*

48

49

*

68

69

67

1

23

21

22

24

42

43

44

41

62

63

64

61

*

9

101112

5

6

2

3

4

*

6

7

8

Harness Connector C-21

Transaxle Range Switch

*

10

NOTE: Unused terminals are marked with asterisk (*).

(Face View)

3

*

4

9

Harness Connector M-01

Shift Switch (Face View)

(LOCATED IN SHIFT LEVER ASSEMBLY)

1

*

4

2

1

3

View Looking Into Transaxle

Pass-Thru Case Connector

123456

891011121314 *

78

8

7

4

3 2

101112

1

5

6

9

View Looking Into Transaxle

C-03 Harness Connector

28

Figure 33

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Input and Output Speed Sensors

The Input and Output Speed Sensors are located on top of the transaxle case, as shown in Figure 34, and retained with a bolt. Both speed sensors are equipped with an "O" ring seal to seal the case bore, as shown in Figure 35 and 36. Refer to Page 30 for speed sensor operation and diagnosis.

Continued on Page 30

Output Speed

Sensor

INPUT SPEED SENSOR

RETAINING

BOLT

INPUT SHAFT

SPEED SENSOR

"O" RING

Power

Signal

Ground

31221

Brown

Black/White

White/Violet

3

Input Speed

B1F5 5

1K2E5

A

Sensor

AT F

OUTPUT SPEED SENSOR

OUTPUT SHAFT

SPEED SENSOR

"O" RING

Figure 35

1

2

3

RETAINING

BOLT

3

2

1

Brown

Green/Yellow

Black/White

Ground

Signal Power

Figure 34

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 36

29

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Input Speed Sensor

When the key is turned on, you should see battery voltage at input speed sensor terminal 3. A coil built into the input shaft speed sensor generates a 0 - 5 volt pulse signal when the input shaft rotates. The pulse signal frequency increases with a rise in input shaft speed. The PCM interprets this pulse signal as input shaft speed. The input shaft speed sensor generates the pulse

signal as the teeth on the underdrive clutch housing pass the magnetic tip of the sensor. The input speed sensors all operate in the same manner but all of the PCM terminals are different. You must refer to the wiring schematic for the model you are working on. Mitsubishi wire schematic - See Page 13. Hyundai wire schematic - See Page 15. Kia wire schematic - See Page 16.

Output Speed Sensor

When the key is turned on, you should see battery voltage at output speed sensor terminal 3. A coil built into the output shaft speed sensor generates a 0 - 5 volt pulse signal when the output shaft rotates. The pulse signal frequency increases with a rise in output shaft speed. The PCM interprets this pulse signal as output shaft speed. The output shaft speed sensor generates the pulse signal as the teeth on the direct planetary carrier pass the magnetic tip of the sensor. The output speed sensors all operate in the same manner but all of the PCM terminals are different. You must refer to the wiring schematic for the model you are working on. Mitsubishi wire schematic - See Page 13. Hyundai wire schematic - See Page 15. Kia wire schematic - See Page 16.

Conditions To Set DTC

If no output pulse is detected from the input shaft speed sensor for one second or more, while driving in 3rd or 4th gear at a speed of 30 km/h (19 mph) or more, there is an open or short in the input shaft speed sensor circuit, and a DTC is set. When a DTC is output four times, the transaxle is locked into 3rd gear as a failsafe measure.

Conditions To Set DTC

If the output from the output speed sensor is continuously 50% lower than vehicle speed for one second or more, while driving in 3rd or 4th gear at a speed of 30 km/h (19 mph) or more, there is an open or short in the output speed sensor circuit, and a DTC is set. When a DTC is output four times, the transaxle is locked into 3rd as a failsafe measure.

Electronic Components

Continued on Page 31

30

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

ELECTRONIC COMPONENTS (CONT'D)

Powertrain Control Module (PCM)

The main function of the PCM is to electronically control a multitude of components including the transaxle upshifts and downshifts, and the torque converter clutch apply or release. The PCM learns the driving habits and the preferences of each individual driver by processing driving data on engine output, engine load, foot brake operation, etc. The PCM then uses this data to adjust shift timing to best suit the drivers style.

Reading And Erasing DTC's

The PCM monitors its input and output signals, some signals at all times and others only under specified conditions. When an irregular signal is initially monitored, the PCM decides that a malfunction has occured and records this as a diagnostic trouble code. The diagnostic results can be read with scan tool. Diagnostic trouble codes are kept in memory by direct battery feed. The codes are retained in memory even if the ignition switch is in the Off position. The DTC's are not erased even after the battery terminals and the PCM connector are disconnected. A compatable scan tool is

required to read and erase diagnostic trouble codes. Diagnostic Trouble Codes are described as follows: Mitsubishi Codes, Figure 38. Hyundai & Kia Codes, Figure 39 and 40.

Selector Lever Position Indicator Light (Mitsubishi Only)

The selector lever position indicator light located in the instrument cluster, as shown in Figure 37, will flash once per second (D1 thru D5) if there are any diagnostic trouble codes stored related to the transaxle system. Check for diagnostic trouble codes if the selector lever position indicator (D1 thru D5) is flashing once per second (Requires Scanner). This applies to Mitsubishi Only. Hyundai and Kia models use a Malfunction Indicator Lamp (MIL) that illuminates when there is a trouble code stored. Note: If the selector lever position indicator light

(D1 thru D5) is flashing "twice" per second, the transaxle fluid temperature is high. It flashes when the fluid temp is approximately 257°F or more, and quits flashing when fluid temp drops to approximately 239°F or less.

80

60

40

20

TCL

OFF

0

888888

100

MPH

ABS

888

ODO

CRUISE

km/h

A B

120

140

160

Reset

D1

2

1

0

3

-

X1000RPM

BRAKE

+

4

SERVICE

ENGINE

SOON

5

6

7

8

Powertrain Control Module (PCM) Locations

Mitsubishi - The PCM is located in the engine compartment on the left inner fender panel, just below the relay box. PCM connector views Page 20. Hyundai - The PCM is located in the left rear of the engine compartment. PCM connector views Page 24. Kia - The PCM is located on firewall, at the left rear of the engine compartment, behind the relay box. PCM connector views Page 28.

Selector Lever Position

Indicator Light

Mitsubishi Only

Figure 37

AUTOMATIC TRANSMISSION SERVICE GROUP

31

Technical Service Information

WWW.ALL-TRANS.BY

"MITSUBISHI" DIAGNOSTIC TROUBLE CODE DESCRIPTION

Code

P0500

P0603

P0606

P0630

P0642

P0705

P0712

P0713

P0715

P0720

P0731

P0732

P0733

P0734

P0735

P0736

Description

Vehicle Speed Sensor Malfunction

EEPROM Malfunction

PCM Malfunction

VIN Not Programmed or Incompatable PCM

Throttle Position Sensor, Power Supply

Transaxle Range Switch, Open Circuit

Transaxle Fluid Temperature Sensor, Short Circuit

Transaxle Fluid Temperature Sensor, Open Circuit

Input Speed Sensor, Open Circuit/Short Circuit

Output Speed Sensor, Open Circuit/Short Circuit

1st Gear Ratio Error

2nd Gear Ratio Error

3rd Gear Ratio Error

4th Gear Ratio Error

5th Gear Ratio Error

Reverse Gear Ratio Error

P0741

P0742

P0743

P0753

P0758 Underdrive Solenoid, Open Circuit/Short Circuit

P0763

P0768

P0773

P1751

P1771

Torque Converter Clutch, Performance or Stuck Off

Torque Converter Clutch, Performance or Stuck On

Torque Converter Clutch Solenoid, Open Circuit/Short Circuit

Low/Reverse Solenoid, Open Circuit/Short Circuit

Second Clutch Solenoid, Open Circuit/Short Circuit

Overdrive Solenoid, Open Circuit/Short Circuit

Reduction Brake Band Solenoid, Open Circuit/Short Circuit

Transaxle Control Relay, Open Circuit/Short To Ground

Transaxle Range Switch, Short Circuit

32

CODE RETRIEVAL REQUIRES CAPABLE SCANNER

Figure 38

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

"HYUNDAI & KIA" DIAGNOSTIC TROUBLE CODE DESCRIPTION

Code

P0500

P0501

P0560

P0600

P0601

P0602

P0604

P0605

P0630

P0700

P0703

P0705

P0707

P0708

P0712

P0713

Description

Vehicle Speed Sensor, Circuit Malfunction

Vehicle Speed Sensor, Range/Performance

System Voltage

CAN Communication Bus

EEPROM, Check Sum Error

EEPROM, Programming Error

Internal Control Module, RAM Error

EEPROM, Abnormal

VIN Not Programmed or Incompatable PCM

PCM Request For MIL On

Stop Lamp Switch, Short Circuit/Open Circuit

Transaxle Range Switch, Malfunction

Transaxle Range Switch, Open Circuit

Transaxle Range Switch, Short Circuit

Transaxle Fluid Temperature Sensor, Short Circuit

Transaxle Fluid Temperature Sensor, Open Circuit

P0715

P0717

P0720

P0722

P0725

P0731

P0732

P0733

P0734

P0735

P0736

P0740

P0741

P0742

P0743

P0746

P0748

P0750 Low/Reverse Solenoid, Open Circuit/Short Circuit

Input Speed Sensor, Open Circuit/Short Circuit

Input Speed Sensor Circuit, No Signal

Output Speed Sensor, Open Circuit/Short Circuit

Output Speed Sensor Circuit, No Signal

Crank Position Sensor, Open Circuit

1st Gear Ratio Error

2nd Gear Ratio Error

3rd Gear Ratio Error

4th Gear Ratio Error

5th Gear Ratio Error

Reverse Gear Ratio Error

Torque Converter Clutch, Defective System

Torque Converter Clutch, Stuck Off

Torque Converter Clutch, Stuck On

Torque Converter Clutch Solenoid, Open Circuit/Short Circuit

VFS Solenoid (Line Pressure), Performance

VFS Solenoid (Line Pressure), Electrical

Continued on Page 34

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 39

33

Technical Service Information

WWW.ALL-TRANS.BY

"HYUNDAI & KIA" DIAGNOSTIC TROUBLE CODE DESCRIPTION

Code Description

P0755 Underdrive Solenoid, Open Circuit/Short Circuit

P0760

P0765

P0770

P0885

P0890

P0891

P1500

P1529

P1602

P1603

P1604

P1630

P1631

P1701

P1702

P1703

P1704

Second Clutch Solenoid, Open Circuit/Short Circuit

Overdrive Solenoid, Open Circuit/Short Circuit

Reduction Brake Band Solenoid, Open Circuit/Short Circuit

A/T Relay Circuit, Circuit Malfunction

A/T Relay Circuit, Low Circuit

A/T Relay Circuit, Open Circuit

Vehicle Speed Sensor, Open Circuit/Short Circuit

Vehicle Speed Sensor, Open/Short

Serial Communication Line Problem With PCM

CAN Communication Bus, OFF

No ID From PCM to CAN

CAN-BUS OFF, TCM Failure Open/Short

CAN-TIME OUT ECU, ECM Failure Open/Short

Throttle Position Sensor, Malfunction

Throttle Position Sensor, Misadjusted

Throttle Position Sensor, Open Circuit

Throttle Position Sensor, Short Circuit

P1707

P1723

P1726

P1749

P1764

P1766

Cruise Control Brake Switch Malfunction

Transaxle Control Relay, Open Circuit/Short To Ground

Accelerator Pedal Position Sensor Signal

Serial Communication Error, ECM, TCM

CAN Controller Circuit Malfunction

CAN Communication BUS, OFF

CODE RETRIEVAL REQUIRES CAPABLE SCANNER

34

Figure 40

AUTOMATIC TRANSMISSION SERVICE GROUP

TO TCC

WWW.ALL-TRANS.BY

APPLY

TO REDUCTION

BAND

Technical Service Information

VALVE BODY TO CASE PASSAGE IDENTIFICATION

LOW/REVERSE

"FROM”

COOLER

CLUTCH

2ND CLUTCH

FEED PIPE

"TO"

COOLER

REVERSE

CLUTCH

PUMP

PRESSURE

TO TCC

RELEASE

UNDERDRIVE

CLUTCH

PUMP

SUCTION

UNDERDRIVE

LOW/REVERSE

ACCUM.

"TO"

LUBE

OVERDRIVE

CLUTCH

DIRECT

CLUTCH

OVERDRIVE

ACCUM.

SECOND

ACCUM.

Figure 41

AUTOMATIC TRANSMISSION SERVICE GROUP

35

REDUCTION

WWW.ALL-TRANS.BY

BAND, VIA FEED

PIPE FROM PUMP

(SEE BELOW)

Technical Service Information

FRONT CASE PASSAGE IDENTIFICATION

"FROM"

COOLER

"TO"

LUBE

TCC/DCC

APPLY

REDUCTION

BAND

OUT TO TCC/DCCC APPLY

(DA) PRESSURE TAP

PUMP

PRESSURE

OUT TO TCC/DCC RELEASE

(DR) PRESSURE TAP

TCC/DCC

RELEASE

REDUCTION

BAND FEED PIPE

FROM PUMP

PUMP

SUCTION

FILTER

UNDERDRIVE

CLUTCH

FILTER BORE

36

Figure 42

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

REAR CASE PASSAGE IDENTIFICATION

4 H

REDUCTION BAND

ACCUMULATOR

REVERSE

CLUTCH

LUBE

OVERDRIVE

CLUTCH

DIRECT

CLUTCH

DI R

OUT TO LUBE TAP

OUT TO DIRECT

CLUTCH TAP

DIRECT CLUTCH

ACCUMULATOR TO

REAR COVER "O" RING SEAL

DIRECT CLUTCH

ACCUMULATOR PISTON

OUT TO LUBE TAP

OUT TO DIRECT

CLUTCH TAP

DIRECT CLUTCH ACCUMULATOR

REAR COVER PASSAGE IDENTIFICATION

Figure 43

AUTOMATIC TRANSMISSION SERVICE GROUP

REVERSE

CLUTCH

LUBE

OVERDRIVE

CLUTCH

DIRECT

CLUTCH

37

Technical Service Information

WWW.ALL-TRANS.BY

Reduction

Band

PRESSURE TAP LOCATIONS

51K2E5B1

5A

F

A T F

"To"

Cooler

"From"

Cooler

Reverse

Clutch

Overdrive

Clutch

Second Clutch

Underdrive Clutch

TCC/DCC

Apply

TCC/DCC

Release

Lube

Reduction

Band

Direct

RV

I RD

RDI

OD

Clutch

Low/Reverse Clutch

38

Drain Plug

Figure 44

AUTOMATIC TRANSMISSION SERVICE GROUP

Reverse

WWW.ALL-TRANS.BY

Clutch

Technical Service Information

PRESSURE TAP LOCATIONS

Reduction

Band

Lube

4 H

DI R

RV

Direct

Clutch

OD

Overdrive

Clutch

Reverse

Clutch

Low/Reverse

Clutch

AIR CHECK LOCATIONS

Second

Clutch

Overdrive

Clutch

Direct

Clutch

Test Plate Makes This

Task Much Easier.

Reduction

Band

Underdrive

Clutch

Figure 45

AUTOMATIC TRANSMISSION SERVICE GROUP

39

Technical Service Information

WWW.ALL-TRANS.BY

"MITSUBISHI, PRE-2007 HYUNDAI, AND PRE-2006 KIA"

LINE PRESSURE TEST SPECIFICATIONS

PRESSURES (PSI) MEASURED AT 2500 RPM

Gear

Park

Reverse

Neutral

"D"-1st

"D"-2nd

"D"-3rd

"D"-4th

"D"-5th

** TCC Apply (DA) pressures may vary between 0 and 50 psi, when OFF, depending on throttle opening and vehicle speed. With TCC fully applied pressure should be approximately 100 psi.

Underdrive

Clutch

137-153

113-131

* TCC Release (DR) pressures measured at 1500 RPM.

Second

Clutch

137-153

113-127

Overdrive

Clutch

113-131

Low/Rev

Clutch

44-56

185-256

44-56

137-153

Reverse

Clutch

185-256

Reduction

Band

44-56

185-256

44-56

137-153

113-128

Clutch

113-128

"2007-UPHYUNDAI & 2006-UP KIA"

LINE PRESSURE TEST SPECIFICATIONS

Direct

T.C.C.

Apply

**

T.C.C.

Release

* 32-52

* 73-106

* 32-52

* 73-106

* 65-104

0

Gear

Park

Reverse

Neutral

"D"-1st

"D"-2nd

"D"-3rd

"D"-4th

"D"-5th

** DCC Apply (DA) pressures may vary between 0 and 50 psi, when OFF, depending on throttle opening and vehicle speed. With DCC fully applied pressure should be approximately 100 psi.

Underdrive

Clutch

137-153

113-131

* DCC Release (DR) pressures measured at 1500 RPM.

Second

Clutch

137-153

113-127

PRESSURES (PSI) MEASURED AT 2500 RPM

Overdrive

Clutch

113-131

Low/Rev

Clutch

44-56

185-256

44-56

137-153

Reverse

Clutch

185-256

Reduction

Band

44-56

185-256

44-56

137-153

113-128

Direct

Clutch

113-128

D.C.C.

Apply

**

D.C.C.

Release

* 32-52

* 73-106

* 32-52

* 73-106

* 65-104

0

40

Figure 46

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

Service information provided in this manual by ATSG is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools and equipment could cause injury to you or others. The service procedures we recommend and describe in this manual are effective methods of performing service and repair on this unit. Some of the procedures require the use of special tools that are designed for specific purposes. This manual contains CAUTIONS that you must observe carefully in order to reduce the risk of injury to yourself or others. This manual also contains NOTES that must be carefully followed in order to avoid improper service that may damage the vehicle, tools and/or equipment.

TRANSAXLE DISASSEMBLYSAFETY PRECAUTIONS

EXTERNAL COMPONENTS

1. The transaxle should be steam cleaned on the outside, to remove any dirt or grease before disassembly begins.

2. This transaxle can be disassembled very easily on a work bench without the benefit of any holding fixture for rotation.

3. Remove the torque converter from transaxle, as shown in Figure 47. Caution: Use care when removing the torque

converter, to avoid personal injury and/or damage to converter, as it is heavy.

Continued on Page 42

TORQUE

CONVERTER

Figure 47

5B1

5A51K2E F

A T F

AUTOMATIC TRANSMISSION SERVICE GROUP

41

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

EXTERNAL COMPONENTS (Cont'd)

4. Remove the fluid level indicator from transaxle as shown in Figure 48.

5. Remove air breather assembly from transaxle, as shown in Figure 48.

6. Remove the input shaft speed sensor retaining bolt and the input shaft speed sensor, as shown in Figure 48.

7. Remove and discard the "O" ring.

8. Remove the output shaft speed sensor retaining bolt and the output shaft speed sensor, as shown in Figure 48.

OUTPUT SHAFT

SPEED SENSOR

RETAINING

BOLT

9. Remove and discard the "O" ring.

10. Remove the manual lever nut, washer, and the manual lever, as shown in Figure 48.

11. Remove the transaxle range switch retaining bolts and transaxle range switch, as shown in Figure 48.

Continued on Page 43

NUT

WASHER

RETAINING

BOLT

MANUAL

LEVER

"O" RING

INPUT SHAFT

SPEED SENSOR

"O" RING

TRANSAXLE

RANGE SWITCH

5B1

5A51K2E

F

RETAINING

BOLT

FLUID LEVEL INDICATOR

A T F

ADJUST AT HOT

HOT

AIR BREATHER

42

Figure 48

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

EXTERNAL COMPONENTS (Cont'd)

12. Remove the speedometer adapter, the vehicle speed sensor, or the sealing cap, depending on which the transaxle is equipped with. Refer to Figure 50.

13. As a diagnostic aid, install dial indicator, as shown in Figure 49, measure and record the input shaft end play.

Continued on Page 44

0

1010

2020

3030

4040

5050

0

Figure 49

SPEEDO

ADAPTER

VEHICLE SPEED

SENSOR (VSS)

"O" RING

RETAINING BOLT

SEALING CAP IF SEALING CAP IS USED THE

VEHICLE SPEED IS CALCULATED

"O" RING

ELECTRONICALLY BY PCM

5B1

5A51K2E F

Figure 50

AUTOMATIC TRANSMISSION SERVICE GROUP

43

Technical Service Information

WWW.ALL-TRANS.BY

4 K2 B1F A51 E5

PAN BOLT

(15 REQUIRED)

H

5

7

3

G

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS

1. Remove the 15 pan bolts and remove the oil pan, as shown in Figure 51.

2. Disconnect the shift solenoid connectors and the fluid temperature sensor connector, as

shown in Figure 52. Note: Some of the shift solenoids can be

cross-connected. We have provided you with color of the wires that we observed. If yours are different, label them now to prevent you from cross-connecting on re- assembly.

3. Remove the connectors and drape the wire harness up and over the top of pan rail. Note: The Mitsubishi and early Hyundai/Kia

version is illustrated in Figure 52. 2007-Up Hyundai and 2006-Up Kia versions have one extra line pressure solenoid and are illustrated in Figure 53.

Continued on Page 45

Figure 51

K B1F4A51 2E5

TFT SENSOR

RED, WITH

BLACK GROUND

H

5

7 3

G

“REDUCTION”

BLACK CONNECTOR

TWO YELLOW WITH

GREEN GROUND

10-Way Mitsubishi &

Early Hyundai/Kia

Pass-Thru Connector

“UNDERDRIVE”

BLACK CONNECTOR

TWO RED, WITH

WHITE GROUND

“SECOND”

WHITE CONNECTOR

TWO RED, WITH

GREEN GROUND

“TCC/DCC”

BLACK CONNECTOR

TWO YELLOW, WITH

BLUE GROUND

“OVERDRIVE”

BLACK CONNECTOR

ONE RED WITH

ORANGE GROUND

“LOW/REVERSE”

WHITE CONNECTOR

ONE YELLOW WITH

BROWN GROUND

44

Wire colors may vary.

Figure 52

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

4. If you have 2007-Up Hyundai or 2006-Up Kia version, remove the connectors, as shown in Figure 53, 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 53).

5. Remove the internal detent spring, as shown in Figure 54.

6. Remove the TFT sensor, as shown in Figure 54, remove and discard the "o" ring seal.

7. Remove the valve body to case mounting bolts as shown in Figure 55. Note: Remove all valve body bolts "Except"

the bolts that we labeled with "E", as shown in Figure 55. The bolts labeled with "E" are solenoid body to main valve body bolts.

Continued on Page 46

F4A K2 B151 E5

"O" RING

SEAL

G

TFT

SENSOR

H

5

7 3

Figure 54

DETENT SPRING

RETAINING

BOLT

RETAINING

BOLT

4 K2 B1F A51 E5

TFT SENSOR

RED, WITH

BLACK GROUND

Wire colors may vary.

BLACK CONNECTOR

ONE ORANGE WITH

G

"VFS (LINE)"

BROWN GROUND

H

5

7 3

BLACK CONNECTOR

TWO YELLOW WITH

GREEN GROUND

12-Way Hyundai/Kia

Pass-Thru Connector

"UNDERDRIVE"

BLACK CONNECTOR

TWO RED, WITH

YELLOW GROUND

"SECOND"

WHITE CONNECTOR

TWO RED, WITH

GREEN GROUND

"DCC"

BLACK CONNECTOR

TWO YELLOW, WITH

BLUE GROUND

"OVERDRIVE"

BLACK CONNECTOR

ONE RED WITH

ORANGE GROUND

"LOW/REVERSE"

WHITE CONNECTOR

ONE YELLOW WITH

BROWN GROUND

"REDUCTION"

A

E E E

A

B

H

B

C

F

G G G

E

G

GGG

G

B

1

7

9

2

D

B

5

B

7

3

8

B

Figure 53

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 55

45

Technical Service Information

WWW.ALL-TRANS.BY

BF4A51K2E5 1

HOLLOW

DOWEL

HOLLOW

DOWEL

.375" DIAMETER

STEEL CHECKBALLS

(2 REQUIRED)

REFER TO FIGURE 55

FOR VALVE BODY TO CASE

BOLTS AND LOCATIONS

VALVE BODY

TO CASE BOLTS

H

5

7 3

G

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

8. Remove 28 valve body to case bolts and the valve body assembly, as shown in Figure 56.

9. Notice the two steel balls in the top of valve body, as shown in Figure 56. Note: Place steel balls and hollow dowels in

a safe location for reassembly.

10. Set the valve body assembly aside for the component rebuild section.

11. Remove the manual shaft retaining pin from pan rail, as shown in Figure 57.

12. Remove and discard the 2nd clutch case seal, as shown in Figure 57.

13. Remove the case worm track oil screen, as shown in Figure 57. Note: Replace case screen as necessary.

Figure 56

4 K B1F A51 2E5

5

6

7

Continued on Page 47

5 MANUAL SHAFT RETAINING PIN. 6 2ND CLUTCH CASE SEAL ASSEMBLY. 7 CASE OIL SCREEN.

46

Figure 57

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

14. Remove each accumulator piston and springs, as shown in Figure 58. Note: The Mitsubishi accumulator springs

are identified with blue dye, as shown in Figure 60, and Hyundai/Kia accumulator springs are identified with White and Yellow paint, also shown in Figure 60. If your springs are not identified, label them now as you remove them, for re-assembly ID.

15. Remove and discard all accumulator piston seal rings, as shown in Figure 59.

ACCUMULATOR

PISTON SEAL (SCARF CUT)

ACCUMULATOR

PISTON

Continued on Page 48

A 1K2E5F4 5 B1

Figure 59

ACCUMULATOR SPRING IDENTIFICATION

Mitsubishi "Bluing"

1

2

Hyundia/Kia Paint "Color"

Yellow Paint

Full Surface

3

White Paint

Full Surface

4

1 LOW/REVERSE CLUTCH ACCUMULATOR PISTON AND SPRINGS. 2 UNDERDRIVE CLUTCH ACCUMULATOR PISTON AND SPRINGS. 3 SECOND CLUTCH ACCUMULATOR PISTON AND SPRINGS. 4 OVERDRIVE CLUTCH ACCUMULATOR PISTON AND SPRING.

Figure 58

AUTOMATIC TRANSMISSION SERVICE GROUP

4

3

2

1

2

NO. ACCUMULATOR

Low/Reverse Clutch

1

Underdrive Clutch

2

Second Clutch

3

Overdrive Clutch

4

3

Mitsubishi

"Bluing"

None None

One Half

Full Surface

None None

Figure 60

4

Hyun/Kia

"Color"

Yellow Paint Full Surface

White Paint Full Surface

47

Technical Service Information

WWW.ALL-TRANS.BY

SNAP

F4A5 K2E5B11

MITSUBISHI & EARLY

HYUNDAI/KIA 10-WAY

INTERNAL WIRE

HARNESS ASSEMBLY

SNAP RING

CASE

CONNECTOR

"O" RING

LATE HYUNDAI/KIA 12-WAY

INTERNAL WIRE

HARNESS ASSEMBLY

RING

CASE

CONNECTOR

"O" RING

Added Connector

For VFS Solenoid

(Line Pressure Control)

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

16. Remove the case connector snap ring and remove the internal wire harness through the inside of the case, as shown in Figure 61.

Note: Both the 10-way Mitsubishi and early

Hyundai/Kia, and the 12-way late Hyundai/Kia internal harness are shown in Figure 61.

17. Remove and discard the case connector "O" ring, as shown in Figure 61.

18. 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 62.

19. Remove and discard the two "O"ring seals on the manual shaft, as shown in Figure 62.

Figure 61

F4A5 K2E B11 5

"O" RING

SEALS

48

Continued on Page 49

AUTOMATIC TRANSMISSION SERVICE GROUP

INSIDE DETENT LEVER AND

PARK ROD ASSEMBLY

Figure 62

RETAINING PIN

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

20. Rotate the case on the work bench so that the converter housing is facing up, as shown in Figure 64.

21. Remove the 20 torque converter housing bolts, as shown in Figure 63 and 64. Note: Six of these bolts are inside of the

converter housing, as shown in Figure 63.

22. Remove and discard the two small "O" rings between the converter housing and the case, as shown in Figure 64. Note: The "O" rings may be stuck to the

torque converter housing.

Continued on Page 50

28

29

27

T I M

K

E

N

®

P 9

0 0

N

P 8

8 9

9

6 7

U S

A

B1A K 5

2F5 5

1 E

27 CONVERTER COVER TO CASE "O" RINGS (2 REQUIRED). 28 CONVERTER COVER TO CASE RETAINING BOLTS (20 REQ.). 29 TORQUE CONVERTER HOUSING.

Figure 63 Figure 64

AUTOMATIC TRANSMISSION SERVICE GROUP

49

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

23. Remove and discard the oil filter and "O" ring, as shown in Figure 65.

24. Remove the differential assembly from case, as shown in Figure 65.

25. Set complete differential assembly aside for the component rebuild section.

26. Remove the two reduction band feed pipe retaining bolts, as shown in Figure 66, and remove feed pipe with brackets.

Continued on Page 51

DIFFERENTIAL

ASSEMBLY

OIL FILTER

"O" RING

A 5

5 K 1

F 512 E B

REDUCTION

BAND FEED PIPE

T

I M

K

E

N

®

P 9

0 0

N

P 8

8 9

9

6

7

U S A

BOLT

REDUCTION

BAND FEED PIPE

BOLT

50

Figure 65

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 66

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

27. Remove the six oil pump retaining bolts, as shown in Figure 67, and remove the oil pump assembly.

28. Set complete oil pump assembly aside for the component rebuild section.

OIL PUMP BOLTS

(6 REQUIRED)

28. Remove and discard the oil pump to case gasket, as shown in Figure 67. Note: Gasket may be stuck to oil pump.

29. Remove the underdrive clutch housing by lifting straight up, as shown in Figure 68.

30. Remove the number 1 selective thrust washer, as shown in Figure 68. Note: Number 1 selective thrust washer may

be stuck to oil pump.

31. Set the complete underdrive clutch housing aside for the component rebuild section.

Continued on Page 52

OIL PUMP ASSEMBLY

OIL PUMP TO

CASE GASKET

T

I M

K

E

N

®

P 9

0 0

N

P

8

8 9

9

6 7

U S A

NUMBER 1

THRUST WASHER

(SELECTIVE)

UNDERDRIVE

CLUTCH HOUSING

T

I M

K E

N

®

P 9

0 0

N

P 8

8 9

9

6 7

U S

A

1A 5

B1A K 5

2F5 5

1 E

B5 K

12 E

F 5

Figure 67 Figure 68

AUTOMATIC TRANSMISSION SERVICE GROUP

51

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

32. Remove underdrive clutch hub and number 2 thrust bearing, as shown in Figure 69.

33. Remove the reduction band servo cover snap ring and cover, as shown in Figure 70.

34. Remove and discard the servo cover "O" ring seal, as shown in Figure 70.

35. Remove reduction band servo piston snap ring and piston assembly, as shown in Figure 70.

36. Remove and discard the servo piston seal, as shown in Figure 70.

37. Remove the reduction band servo piston return spring, as shown in Figure 70.

Continued on Page 53

47

48

49

50

51

52

53

54

55

TRANSFER

DRIVE GEAR

F 512 E

NUMBER 2

THRUST BEARING

UNDERDRIVE CLUTCH HUB

T I M

K

E

N

®

P 9

0 0

N

P 8

8 9

9

6

7

U S A

1A 5

E

F 2 B5 51K

T I M

K E

N

® P 9

0 0

N

P 8

8

9

6 7

U S A

47 REDUCTION BAND SERVO COVER SNAP RING.

B15A K 5

48 REDUCTION BAND SERVO COVER. 49 REDUCTION BAND SERVO COVER "O" RING SEAL. 50 REDUCTION BAND SERVO PISTON SNAP RING. 51 REDUCTION BAND SERVO ADJUSTING NUT. 52 REDUCTION BAND SERVO PISTON. 53 REDUCTION BAND SERVO PISTON SEAL RING. 54 REDUCTION BAND SERVO APPLY PIN. 55 REDUCTION BAND SERVO PISTON RETURN SPRING.

52

Figure 69 Figure 70

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

38. Remove the two parking rod roller support pins, as shown in Figure 71, using needle nose pliers.

39. Remove the parking rod roller support from the inside of case, as shown in Figure 71.

40. Remove the parking pawl pivot pin, as shown in Figure 72.

41. Remove the parking pawl, and return spring as an assembly, as shown in Figure 72.

42. 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.

Continued on Page 54

PARKING PAWL

PIVOT PIN

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

PARKING PAWL AND

SPRING ASSEMBLY

ROLLER SUPPORT

RETAINING PINS

PARKING ROD

ROLLER

SUPPORT

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

Figure 72

11

3 4 51 2

01

9

8

7

6

T

I

M

K

E

5

4

N

®

P

9

0

N

P

8

9

6

7

U

S

A

Figure 71 Figure 73

AUTOMATIC TRANSMISSION SERVICE GROUP

53

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

43. Now you can remove the direct planetary carrier and driven transfer gear assembly, as shown in Figure 74, and set aside for component rebuild section.

44. Remove the direct clutch housing from case, as shown in Figure 75, and set aside for component rebuild section.

45. Remove the reduction band from the case, as shown in Figure 75. Note: May be necessary to remove the band

anchor plug and "O" ring to remove band, as shown in Figure 76.

Continued on Page 55

DIRECT CLUTCH

HOUSING ASSEMBLY

REDUCTION

BAND

DIRECT PLANETARY

CARRIER AND DRIVEN

TRANSFER GEAR

ASSEMBLY

A K

5 51 E B1

K E 1

A 5

5 5

F 12 B

T

I M

K

E

N

®

P 9

0 0

N

P 8

8 9

9

6

7

U S A

Figure 75

RV

D I R

OD

5

2F

54

BAND ANCHOR PLUG

AND "O" RING

Figure 74 Figure 76

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

46. Remove the number 11 thrust bearing, as shown in Figure 77. Note: Number 11 thrust bearing may be stuck to

back side of direct clutch housing.

47. Remove the number 12 thrust bearing race, as shown in Figure 77.

48. Remove the reduction sprag retaining snap ring from the case, as shown in Figure 77.

49. Remove the reduction (OWC-2) sprag assembly from case, as shown in Figure 77, and set aside for the component rebuild section.

NO. 11 THRUST

BEARING

NO. 12 THRUST

BEARING RACE

SNAP RING

50. Remove the reduction sprag race cushion spring, as shown in Figure 77. Note: Reduction sprag race cushion spring is

found in Hyundai and Kia models only.

51. Remove and discard the two direct clutch seal rings from the case, as shown in Figure 77.

52. Rotate transaxle case on bench so that rear cover is facing up, as shown in Figure 78.

53. Remove the reduction accumulator snap ring, cover, return spring and accumulator piston, as shown in Figure 78.

54. Remove and discard the cover "O" ring seal and the accumulator piston seal ring.

Continued on Page 56

REDUCTION (OWC-2)

SPRAG ASSEMBLY

REDUCTION SPRAG RACE

CUSHION SPRING

DIRECT CLUTCH

SEAL RINGS

HYUNDAI/KIA

ONLY

SNAP RING

REDUCTION ACCUMULATOR

COVER

REDUCTION ACCUMULATOR

COVER "O" RING SEAL

REDUCTION ACCUMULATOR

RETURN SPRING

REDUCTION ACCUMULATOR

PISTON AND SEAL RING

RV

OD

D I

R

1A 5

E

12 B5 K

F 5

Figure 77 Figure 78

AUTOMATIC TRANSMISSION SERVICE GROUP

55

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

55. Remove the fourteen rear cover retaining bolts, as shown in Figure 79.

56. Remove the transaxle rear cover, as shown in Figure 79, and set aside for component rebuild section.

57. Remove and discard the six rear cover to case "O" ring seals, as shown in Figure 79.

56

RV

58. Remove and discard the case cover to the direct clutch accumulator "O" ring seal, as shown in Figure 80.

59. Remove the direct clutch accumulator piston and return spring, as shown in Figure 80.

60. Remove and discard direct clutch accumulator piston seal ring (See Figure 80).

Continued on Page 57

OD

65

57

D I

D I R

R

64

61 62

63

D I R

56 REAR COVER RETAINING BOLTS (14 REQUIRED). 57 REAR COVER. 65 REAR COVER TO CASE "O" RING SEALS (6 REQUIRED).

56

61 DIRECT CLUTCH ACCUMULATOR PISTON. 62 DIRECT CLUTCH ACCUMULATOR PISTON SEAL RING. 63 DIRECT CLUTCH ACCUMULATOR PISTON RETURN SPRING. 64 DIRECT CLUTCH ACCUM. TO CASE COVER "O" RING SEAL.

Figure 79 Figure 80

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

61. Remove number 8 selective thrust race and the number 7 thrust bearing assembly, as shown in Figure 81. Note: Number 8 selective thrust race may be

stuck to rear cover.

62. Remove the reverse/overdrive clutch housing assembly, as shown in Figure 81.

63. Set the reverse/overdrive clutch housing aside for the component rebuild section.

64. Remove the number 6 thrust bearing and the overdrive clutch hub, as shown in Figure 82.

65. Set the overdrive clutch hub and the number 6 bearing aside for component rebuild section.

66. Remove the number 5 thrust bearing and the sun gear and shell assembly, as shown in Figure 83.

67. Set the number 5 thrust bearing and the sun gear and shell assembly aside for component rebuild section.

181

180

179

Continued on Page 58

182

183

D I

R

D I

R

179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY. 180 NUMBER 7 THRUST BEARING. 181 NUMBER 8 THRUST BEARING RACE (SELECTIVE).

182 NUMBER 6 THRUST BEARING. 183 OVERDRIVE CLUTCH HUB.

Figure 81 Figure 82

AUTOMATIC TRANSMISSION SERVICE GROUP

57

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

68. Remove 2nd clutch retainer snap ring, as shown in Figure 84.

69. Remove the 2nd clutch retainer/piston assembly and the return spring, as shown in Figure 84, and set aside for component rebuild section. CAUTION: Various 2nd clutch stack-ups in the

Hyundai and Kia models are in service. If you're working on Hyundai/Kia, remove 2nd clutch pack very carefully and tag the components for identification including which direction the stepped plates are installed. Refer to Page 59 for the various stack-ups observed, and there may be more than shown at this time.

70. If your working on Mitsubishi, remove the 2nd clutch plates as shown in Figure 84.

Continued on Page 60

149

148

144

CAUTION - CAUTION

REFER TO PAGE 59

143

184

200

C

141

140

D I R

3

142

D I R

184 NUMBER 5 THRUST BEARING. 200 REVERSE SUN GEAR AND SHELL ASSEMBLY.

58

140 2ND CLUTCH DOUBLE SIDED FRICTION PLATES (4 REQUIRED). 141 2ND CLUTCH STEEL PLATES, .119" THICK (2 REQUIRED). 142 2ND CLUTCH STEPPED PLATE. 143 2ND CLUTCH FLAT APPLY PLATE (SELECTIVE). 144 2ND CLUTCH APPLY PISTON RETURN SPRING. 148 2ND CLUTCH PISTON RETAINER. 149 2ND CLUTCH RETAINER RETAINING SNAP RING, .090" THICK.

Figure 83 Figure 84

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

A5HF1 2ND CLUTCH, PRE-2007 HYUNDAI

A5HF1 2ND CLUTCH, PRE-2006 KIA

S

C

B

A STEPPED APPLY PLATE, ID "J", = .059"/.118" THICK. B DOUBLE-SIDED FRICTIONS = .070" THICK (4 REQUIRED). C STEEL PLATES, ID "4", = .119" THICK (2 REQUIRED). D STEPPED PLATE, ID "S", = .039"/.118" THICK (1 REQUIRED).

3

F5A51 MITSUBISHI (ALL MODELS)

A

B

D

A FLAT APPLY PLATE, ID "B", = (SELECTIVE). B DOUBLE-SIDED FRICTIONS = .070" THICK (4 REQUIRED). C STEEL PLATES, ID "3", = .098" THICK (2 REQUIRED). D STEPPED PLATE, ID "NONE", = .059"/.098" THICK (1 REQUIRED).

B

3

A

C

D

Figure 85 Figure 87

A5GF1 2ND CLUTCH, PRE-2007 HYUNDAI

A5GF1 2ND CLUTCH, PRE-2006 KIA

B

A5GF1 2ND CLUTCH, 2007-UP HYUNDAI

A5GF1 2ND CLUTCH, 2006-UP KIA

A

B

S

3

C

E

S

F

A STEPPED APPLY PLATE, ID (NONE), = .041"/.098" THICK. B DOUBLE-SIDED FRICTIONS = .070" THICK (4 REQUIRED). C STEEL PLATES, ID "3", = .098" THICK (3 REQUIRED).

Figure 86

AUTOMATIC TRANSMISSION SERVICE GROUP

A STEPPED APPLY PLATE, ID (NONE), = .039"/.119" THICK. B DOUBLE-SIDED FRICTION = .070" THICK (1 REQUIRED). E SINGLE-SIDED, INT SPLINE FRICTION = .091" THICK (3 REQUIRED). F SINGLE-SIDED, EXT SPLINE FRICTION = .091" THICK (3 REQUIRED).

Figure 88

59

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

Note: Keep the 2nd clutches in the order you

removed them and set aside for reference during reassembly.

71. Remove the planetary gear set and low sprag assembly (OWC-1), as shown in Figure 89, and set aside for the component rebuild section.

72. Remove the L/R & 2nd clutch pressure plate selective snap ring (139) and the L/R & 2nd clutch pressure plate, as shown in Figure 90.

73. Remove the next snap ring (137) from the groove in the case, as shown in Figure 90.

74. Remove the low/reverse clutch friction and steel plates, as shown in Figure 90.

75. Remove the low/reverse clutch selective apply plate, as shown in Figure 90.

76. Remove the low/reverse clutch "Waved" plate, as shown in Figure 90.

136

139

138

137

135

Continued on Page 61

PLANETARY

GEAR SET ASSEMBLY

134

133

B

D

I R

D

I R

60

133 LOW/REVERSE CLUTCH "WAVED" CUSHION PLATE. 134 LOW/REVERSE CLUTCH APPLY PLATE (SELECTIVE). 135 LOW/REVERSE CLUTCH FRICTION PLATES (6 REQUIRED). 136 LOW/REVERSE CLUTCH STEEL PLATES, .040" THICK (5 REQ). 137 L/R & 2ND CLUTCH PRESSURE PLATE SNAP RING (.078" THICK). 138 L/R & 2ND CLUTCH STEPPED PRESSURE PLATE. 139 L/R & 2ND CLUTCH PRESSURE PLATE SNAP RING (SELECTIVE).

Figure 90Figure 89

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

77. Using the special tools shown in Figure 91, or a suitable substitute, compress low/reverse clutch piston return spring.

78. Remove the low sprag (OWC-1) inner race snap ring (132), as shown in Figure 92.

79. Slowly release compression tool and remove the tool from the case.

80. 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.

81. Remove the low/reverse clutch return spring retainer, as shown in Figure 92.

82. Remove the low/reverse clutch piston return spring, as shown in Figure 92.

83. Remove the low/reverse clutch piston, as shown in Figure 92.

84. Remove and discard the low/reverse clutch piston "D" ring seals.

132

131

130

129

128

Continued on Page 62

126

D I

R

MD999577

126 LOW/REVERSE CLUTCH APPLY PISTON AND "D" RING SEALS. 128 LOW/REVERSE CLUTCH PISTON RETURN SPRING. 129 LOW/REVERSE CLUTCH RETURN SPRING RETAINER. 130 LOW SPRAG (OWC-1) INNER RACE "LIP TYPE" LUBE SEAL.

MD998924

131 LOW SPRAG (OWC-1) INNER RACE. 132 LOW SPRAG (OWC-1) INNER RACE RETAINING SNAP RING.

Figure 91 Figure 92

AUTOMATIC TRANSMISSION SERVICE GROUP

61

Technical Service Information

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY

INTERNAL COMPONENTS (CONT'D)

85. Remove the transfer drive gear by accessing the retaining bolts through the access holes provided in gear, as shown in Figure 93. Note: Reference marks must be placed on

case and bearing housing (See Figure 93), as the housing bolts in case in 1 direction only. If bearing service is not necessary, the transfer drive gear does not need to be removed.

86. Rotate the transfer gear as necessary so the access holes are over the bolts for removal and remove four bolts.

87. Rotate the transfer gear 45 degrees and remove the remaining four bolts (Total of 8).

CENTER PUNCH OR PERMANENT MARKER

ON CASE AND BEARING HOUSING

88. Remove the transfer drive gear assembly, as shown in Figure 94.

SPECIAL NOTE:

The transfer drive gear and bearings are serviced only as a complete assembly. The exploded views provided in this manual of the transfer drive gear and bearings, as shown in Figure 95, are for reference only.

Continued on Page 63

RETAINING BOLTS

(8 REQUIRED)

F 512 B5 K E 1A 5

TRANSFER DRIVE

GEAR ASSEMBLY

K 5

F 512 E B15A

62

Figure 93 Figure 94

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

TRANSFER DRIVE GEAR AND

TAPERED ROLLER BEARING ASSEMBLY

221

217

218

219

220

COMPONENT REBUILD

Transaxle Case Assembly

1. Clean the transaxle case thoroughly and dry with compressed air.

2. Install alignment dowel MD998412, as shown in Figure 96, as a guide for proper alignment.

3. Align your reference marks from disassembly process and install transfer drive gear assembly, as shown in Figure 96.

4. Install three retaining bolts, remove alignment tool and install the fourth bolt.

5. Rotate the transfer drive gear 45 degrees and install the remaining four bolts.

6. Torque all transfer drive gear retaining bolts to 34 N·m (25 ft.lb.).

Continued on Page 64

RETAINING BOLTS

(8 REQUIRED)

216 TRANSFER DRIVE GEAR BEARING NUT. 217 TRANSFER DRIVE GEAR "TAPERED ROLLER" BEARING (2 REQ.). 218 TRANSFER DRIVE GEAR BEARING CUP (2 REQUIRED). 219 TRANSFER DRIVE GEAR BEARING HOUSING. 220 TRANSFER DRIVE GEAR. 221 TRANSFER DRIVE GEAR RETAINING BOLTS (8 REQUIRED).

Illustration For Reference Only

Serviced Only As Assembly

218

217

216

ALIGNMENT DOWEL

MD998412

1A 5

E

12 B5 5 K

F

Figure 95

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 96

63

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD

Transaxle Case Assembly (Cont'd)

7. Install new differential bearing cup as necessary using the proper driver, as shown in Figure 97. Note: We will cover the differential pre-load

adjustment during the final assembly process.

8. 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

0.5 - 1.5 mm (.020" - .059") below number 12 thrust bearing race case surface, as shown in Figure 99.

9. Install new direct clutch seal rings into the case grooves, as shown in Figure 98, and lube with small amount of Trans-Jel®.

Continued on Page 65

CAGED NEEDLE

BEARING

580 DIFFERENTIAL BEARING CUP (2 REQUIRED).

F 51 E B15A K 5

580

DIRECT CLUTCH OIL SEAL RINGS

Figure 98

Caged Needle Bearing Must Be

0.5 - 1.5 mm (.020" - .059")

Below No. 12 thrust Bearing Race

CAGED NEEDLE

BEARING

2

Surface, As Shown Below

TRANSAXLE

CASE

64

Figure 97 Figure 99

AUTOMATIC TRANSMISSION SERVICE GROUP

560

WWW.ALL-TRANS.BY

Technical Service Information

REDUCTION SPRAG (OWC-2) EXPLODED VIEW

561 561

562 562563

564

565

HYUNDAI AND

KIA ONLY

566

560 REDUCTION SPRAG (OWC-2) ASSEMBLY RETAINING SNAP RING. 561 REDUCTION SPRAG (OWC-2) RETAINERS (2 REQUIRED). 562 REDUCTION SPRAG (OWC-2) END BEARINGS (2 REQUIRED). 563 REDUCTION SPRAG (OWC-2) ASSEMBLY.

COMPONENT REBUILD

Transaxle Case Assembly (Cont'd) Reduction Sprag (OWC-2) Assembly

10. Disassemble reduction sprag (OWC-2) assembly using Figure 100 as a guide.

11. Clean and inspect reduction sprag parts thoroughly and dry with compressed air.

12. Install one reduction sprag retainer on bottom of

reduction sprag outer race, as shown in Figure 101. Note: ID groove on outer race must face up.

ID GROOVE

FACING UP

564

564 REDUCTION SPRAG (OWC-2) OUTER RACE. 565 REDUCTION SPRAG RACE CUSHION PLATE (HYUNDAI & KIA ONLY). 566 DIRECT CLUTCH "STEP-CUT" SEALING RINGS.

Figure 100

13. Install one reduction sprag end bearing, as shown in Figure 102, into the reduction sprag outer race. Note: ID groove on outer race must face up.

562

Continued on Page 66

PREVIOUSLY

INSTALLED

RETAINER

561

561 REDUCTION SPRAG RETAINERS (2 REQUIRED). 564 REDUCTION SPRAG OUTER RACE.

564

562 REDUCTION SPRAG END BEARINGS (2 REQUIRED). 564 REDUCTION SPRAG OUTER RACE.

Figure 101 Figure 102

AUTOMATIC TRANSMISSION SERVICE GROUP

ID GROOVE

FACING UP

65

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD

Transaxle Case Assembly (Cont'd) Reduction Sprag (OWC-2) Assembly (Cont'd)

14. Install the reduction sprag assembly into the outer race, as shown in Figure 103, with the "lip" on sprag cage facing up. Note: The reduction sprag cage has no arrows

on it to help with direction of installation. The "lip" must face up and the "windows" to the left, with the ID groove on the outer race also facing up, as shown in Figure 103.

15. Install the second reduction sprag end bearing, as shown in Figure 103, with the smooth side facing up.

16. Install the second reduction sprag retainer by snapping it over the lip on the outer race, as shown in Figure 103.

17. Install reduction sprag race cushion plate into the case, as shown in Figure 104. Note: Cushion plate is used on Hyundai & Kia

only and 2 wider lugs go toward area of case with no lug cavities.

18. Install the completed reduction sprag (OWC-2) assembly, as shown in Figure 104, into transaxle case with the ID groove facing up.

19. Install the reduction sprag assembly retaining snap ring, as shown in Figure 104, and ensure that it is fully seated (See Figure 105).

Continued on Page 67

560

564

561

562

563

"WINDOWS"

FACE LEFT

564

"LIP" ON SPRAG

FACES UP

ID GROOVE

FACING UP

2 WIDER

LUGS

565

HYUNDAI AND

KIA ONLY

1A 5

E

12 B5 5 K

F

561 REDUCTION SPRAG RETAINERS (2 REQUIRED). 562 REDUCTION SPRAG END BEARINGS (2 REQUIRED). 563 REDUCTION SPRAG (OWC-2) ASSEMBLY. 564 REDUCTION SPRAG OUTER RACE.

66

560 REDUCTION SPRAG ASSEMBLY RETAINING SNAP RING. 564 COMPLETED REDUCTION SPRAG (OWC-2) ASSEMBLY. 565 REDUCTION SPRAG RACE CUSHION PLATE (HYUNDAI & KIA ONLY).

Figure 103 Figure 104

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD

Transaxle Case Assembly (Cont'd) Reduction Sprag (OWC-2) Assembly

20. Ensure that reduction sprag retaining snap ring is fully seated in groove, as shown in Figure 105.

21. Temporarily install the direct clutch housing, as shown in Figure 106, to check proper operation of the reduction sprag (OWC-2). Note: Direct clutch housing should freewheel

counter-clockwise and lock in the clockwise direction, as shown in Figure 106.

22. Remove the direct clutch housing and set the completed case aside for final assembly.

DIRECT CLUTCH HOUSING SHOULD

FREEWHEEL COUNTER-CLOCKWISE

AND LOCK CLOCKWISE

ENSURE SNAP RING

IS FULLY SEATED

F

R

E

H

E

W

Figure 106

L

Figure 105

AUTOMATIC TRANSMISSION SERVICE GROUP

67

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Rear Cover Assembly

1. Remove and discard the overdrive clutch seal rings and the reverse clutch seal rings.

2. Inspect end cover journal and sealing ring area for any wear and/or damage and check seal ring groove clearance with a feeler gage, as described in Figure 107.

3. Install new input shaft caged needle bearing, as necessary, using the proper driver, as shown in Figure 108.

4. Install new reverse clutch seal rings into their grooves, as shown in Figure 109, and ensure they are properly hooked and seated.

5. Install new overdrive clutch seal rings into their grooves, as shown in Figure 109, and ensure they are properly hooked and seated.

6. Install selective number 8 thrust bearing race, as shown in Figure 109, and retain with a small amount of Trans-Jel®.

7. Set the completed rear cover assembly aside for the final assembly process (See Figure 110)

Continued on Page 69

MITSUBISHI MB990938

58

57

57 REAR COVER. 58 INPUT SHAFT CAGED NEEDLE BEARING.

MAXIMUM SEALING RING CLEARANCE

OVERDRIVE

SEALING RINGS

REVERSE

SEALING RINGS

USE FEELER GAGE BETWEEN SEALING

IS APPROXIMATELY

.004"-.005"

RING AND RING LAND

Figure 108

181

59

Ensure That Seal Rings

60

57

57 REAR COVER. 59 OVERDRIVE CLUTCH SEAL RINGS (2 REQUIRED). 60 REVERSE CLUTCH SEAL RINGS (2 REQUIRED). 181 NUMBER 8 THRUST BEARING RACE.

Are Properly Hooked

As Shown

68

Figure 107 Figure 109

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPLETED REAR COVER ASSEMBLY

Figure 110

COMPONENT REBUILD SECTION

Reduction Servo Assembly

1. Install new "O" ring seal into the groove on the reduction servo cover, as shown in Figure 111, and lube with a small amount of Trans-Jel®.

2. Install new scarf-cut sealing ring into the groove on the reduction servo piston, as shown in Figure 111.

3. Set the completed reduction servo piston and cover aside for the final assembly process, as shown in Figure 112.

Component Rebuild

Continued on Page 70

47

48

49

50

52

53

47 REDUCTION BAND SERVO COVER SNAP RING. 48 REDUCTION BAND SERVO COVER. 49 REDUCTION BAND SERVO COVER "O" RING SEAL. 50 REDUCTION BAND SERVO PISTON SNAP RING. 52 REDUCTION BAND SERVO PISTON ASSEMBLY. 53 REDUCTION BAND SERVO PISTON SEAL RING.

Figure 111

COMPLETED REDUCTION SERVO

COVER AND PISTON ASSEMBLY

Figure 112

AUTOMATIC TRANSMISSION SERVICE GROUP

69

160

WWW.ALL-TRANS.BY

Technical Service Information

REVERSE/OVERDRIVE CLUTCH HOUSING EXPLODED VIEW, "MITSUBISHI" MODELS ONLY

161

162

164

165

166

168

171

169

170

5F A1

5

W

163

173

172

174

P

175

167

176

177

70

178

179

160 REVERSE CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 161 REVERSE CLUTCH BACKING PLATE (.160" THICK). 162 REVERSE CLUTCH FRICTION PLATES (.070" THK) (QTY VARIES). 163 REVERSE CLUTCH STEEL PLATES (.070" THICK) (QTY VARIES). 164 OD CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 165 OD CLUTCH BACKING PLATE (.158" THICK). 166 OD CLUTCH FRICTION PLATES (.072" THK) (QTY VARIES). 167 OD CLUTCH STEEL PLATES (.119" THICK) (QTY VARIES). 168 OD CLUTCH APPLY PLATE (.158" THICK). 169 OD BALANCE PISTON RETAINING SNAP RING. 170 OD CLUTCH BALANCE PISTON. 171 OD CLUTCH BALANCE PISTON "D" RING SEAL. 172 OD CLUTCH APPLY PISTON RETURN SPRING. 173 OD CLUTCH APPLY PISTON. 174 OD CLUTCH APPLY PISTON OUTER "D" RING SEAL. 175 REVERSE CLUTCH APPLY PISTON. 176 REVERSE CLUTCH APPLY PISTON OUTER "D" RING SEAL. 177 OVERDRIVE CLUTCH PISTON INNER "D" RING SEAL. 178 REVERSE CLUTCH APPLY PISTON INNER "D" RING SEAL. 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY.

Figure 113

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive Clutch Housing

1. Disassemble reverse/overdrive clutch housing using Figure 113 as a guide.

Note: It is "Mandatory" that you check the clutch pack as it is removed. The amount and thickness of plates will vary, as well as the diameter. The bottom apply plate is not used in all models.

Note: Beginning in 2006 for Kia and 2007 for

Hyundai, the overdrive clutch pack changed to a "partial"single-sided friction stack-up. Refer to Figure 114 and 115 for the different versions of the overdrive clutch pack.

OVERDRIVE CLUTCH PACK WITH

DOUBLE-SIDED FRICTION PLATES

All Mitsubishi

Pre-2007 Hyundai

Pre-2006 Kia

2. Clean all reverse/overdrive parts thoroughly with a good cleaning solution and dry with compressed air.

3. Inspect all reverse/overdrive parts thoroughly for any wear and/or damage.

Continued on Page 72

OVERDRIVE CLUTCH PACK WITH

SINGLE-SIDED FRICTION PLATES

2007-Up Hyundai

2006-Up Kia

164

165

B

167

168

166

185

187

166

188

B

186

164 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 165 OVERDRIVE CLUTCH BACKING PLATE (.158" THICK). 166 OVERDRIVE CLUTCH FRICTION PLATES (.072" THICK). 167 OVERDRIVE CLUTCH STEEL PLATES (.119" THICK). 168 OVERDRIVE CLUTCH APPLY PLATE (.158" THICK).

164 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 166 OD DOUBLE-SIDED FRICTION PLATE (.072" THICK) (1 REQ.). 185 OD CLUTCH "STEPPED" BACKING PLATE (.159"/.238" THICK). 186 OD CLUTCH SINGLE-SIDED, INT SPLINE PLATES (.099" THICK). 187 OD CLUTCH SINGLE-SIDED, EXT SPLINE PLATES (.099" THICK). 188 OD CLUTCH APPLY PLATE (.158" THICK).

Figure 114 Figure 115

AUTOMATIC TRANSMISSION SERVICE GROUP

71

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd)

4. Install new inner piston "D" ring seal into lower groove in reverse/overdrive clutch retainer, as shown in Figure 116, and lube with small amount of Trans-Jel®.

5. Install new inner piston "D" ring seal into upper groove in reverse/overdrive clutch retainer, as shown in Figure 116, and lube with small amount of Trans-Jel®.

6. Install new outer "D" ring seal onto the reverse clutch apply piston, as shown in Figure 117, and lube with a small amount of Trans-Jel®.

7. Install new outer "D" ring seal onto overdrive clutch apply piston, as shown in Figure 118, and lube with a small amount of Trans-Jel®.

Continued on Page 73

175

176

177

175 REVERSE CLUTCH APPLY PISTON/OVERDRIVE CLUTCH RETAINER. 176 REVERSE CLUTCH APPLY PISTON OUTER "D" RING SEAL.

Figure 117

178

174

179

173

177 OVERDRIVE CLUTCH PISTON INNER "D" RING SEAL. 178 REVERSE CLUTCH APPLY PISTON INNER "D" RING SEAL. 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY.

72

173 OVERDRIVE CLUTCH APPLY PISTON. 174 OVERDRIVE CLUTCH APPLY PISTON OUTER "D" RING SEAL.

Figure 116 Figure 118

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd)

8. Install new "D" ring seal onto overdrive clutch balance piston, as shown in Figure 119, and lube with a small amount of Trans-Jel®.

9. Install the completed reverse apply piston into the retainer, aligning the lube holes, as shown in Figure 120, and ensure that it is fully seated.

10. Install the completed overdrive apply piston into the reverse apply piston, as shown in Figure 120, and ensure that it is fully seated.

11. Install the overdrive clutch piston return spring as shown in Figure 120. Note: Ensure alignment holes are seated

over the dowels on piston (See Figure 120).

12. Install the overdrive clutch balance piston over return spring assembly, as shown in Figure 120, and lay snap ring on top of piston.

13. Compress the return spring assembly with a spring compressor, install the snap ring into groove with snap ring pliers, and remove the spring compressor.

172

F 5

169

5

A

1

170

ALIGN HOLE

AND DOWEL

173

175

170 OVERDRIVE CLUTCH BALANCE PISTON. 171 OVERDRIVE CLUTCH BALANCE PISTON "D" RING SEAL.

Continued on Page 74

171

170

ALIGN

LUBE HOLES

169 OVERDRIVE BALANCE PISTON RETAINING SNAP RING. 170 OVERDRIVE CLUTCH BALANCE PISTON AND SEAL ASSEMBLY. 172 OVERDRIVE CLUTCH APPLY PISTON RETURN SPRING. 173 OVERDRIVE CLUTCH APPLY PISTON AND SEAL ASSEMBLY. 175 REVERSE CLUTCH APPLY PISTON AND SEAL ASSEMBLY. 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY.

179

Figure 119 Figure 120

AUTOMATIC TRANSMISSION SERVICE GROUP

73

Technical Service Information

WWW.ALL-TRANS.BY

OVERDRIVE CLUTCH PACK WITH

DOUBLE-SIDED FRICTION PLATES

All Mitsubishi

Pre-2007 Hyundai

Pre-2006 Kia

164

165

167

B

166

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd) "Double-Sided" Overdrive Clutch

14. Install the overdrive apply plate inside reverse apply piston, as shown in Figure 121. Note: Install apply plate with the rounded edge

facing up and the area with no teeth must be aligned with the lube holes in the retainer, as shown in Figure 122.

15. Alternate with double-sided frictions and steel plates, as shown in Figure 121, until you have installed 4 frictions and 3 steel plates. Note: Align steel plates so the area with no

teeth are aligned with the lube holes in the retainer, as shown in Figure 122. Friction plates should be soaked in proper ATF for 1 hour before assembly.

16. Install the overdrive clutch backing plate, as shown in Figure 121. Note: Install backing plate with the rounded

edge facing the friction and the area with no teeth must be aligned with the lube holes in the retainer, as shown in Figure 122.

17. Install the selective overdrive clutch backing plate snap ring, as shown in Figure 121.

168

164 OD CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 165 OD CLUTCH BACKING PLATE (.158" THICK). 166 OD CLUTCH FRICTION PLATES (.072" THK) (QTY VARIES). 167 OD CLUTCH STEEL PLATES (.119" THICK) (QTY VARIES). 168 OD CLUTCH APPLY PLATE (.158" THICK). 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY.

Continued on Page 75

LUBE

APPLY

PLATE

HOLE

SPACE BETWEEN

TEETH ON STEEL PLATE

ROUNDED EDGE

TOWARDS FRICTION

179

1F 5A5

LUBE

HOLE

BACKING

PLATE

F5A51 UNIT

74

Figure 121 Figure 122

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd) Partial "Single-Sided" Overdrive Clutch

18. Install the overdrive apply plate inside reverse apply piston, as shown in Figure 124. Note: Install apply plate with the rounded edge

facing up and the area with no teeth must be aligned with the lube holes in the retainer, as shown in Figure 123.

19. Next, install a normal "double-sided" friction plate, as shown in Figure 124. Note: All friction plates should be soaked in

proper ATF for 1 hour before assembly.

20. Next, install the "single-sided" plates beginning with an external spline plate with lining facing up and alternate with internal spline plates until you have installed three of each, as shown in Figure 124. Note: The area on the external-spline plates

with no teeth must be aligned with lube holes in the retainer, as shown in Figure 123.

21. Install the overdrive clutch backing plate, as shown in Figure 124, with the step facing up. Note: The area on backing plate with no teeth

must be aligned with the lube holes in retainer, as shown in Figure 123.

22. Install the selective overdrive clutch backing plate snap ring, as shown in Figure 124.

OVERDRIVE CLUTCH PACK WITH

SINGLE-SIDED FRICTION PLATES

2007-Up Hyundai

2006-Up Kia

164

185

187

166

B

186

LUBE

HOLE

APPLY PLATE

Continued on Page 76

SPACE BETWEEN

TEETH ON STEEL PLATE

ROUNDED EDGE

TOWARDS FRICTION

Figure 123 Figure 124

LUBE

HOLE

BACKING

PLATE

A5HF1 UNIT

188

179

F 15A5

164 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 166 OD CLUTCH DOUBLE-SIDED FRICTION (.072" THICK) (1 REQ.). 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY. 185 OD CLUTCH "STEPPED" BACKING PLATE (.159"/.238" THICK). 186 OD CLUTCH SINGLE-SIDED, INT SPLINE PLATE (.099" THICK) (3). 187 OD CLUTCH SINGLE-SIDED, EXT SPLINE PLATE (.099" THICK) (3). 188 OD CLUTCH APPLY PLATE (.158" THICK).

AUTOMATIC TRANSMISSION SERVICE GROUP

75

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd)

23. Install the clutch compressing tools as shown in Figure125 and 127. Note: The overdrive lined plates are "Waved"

and must be compressed as shown to achieve the proper clutch clearance reading.

24. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 127.

25. With the plates compressed clutch clearance should be 1.5-1.7 mm (.059"-.066").

26. Change the selective snap ring as necessary, using the chart in Figure 126, to obtain proper overdrive clutch clearance.

Continued on Page 77

UNDERDRIVE AND OVERDRIVE

SELECTIVE SNAP RING CHART

Thickness

1.6 mm (.063")

1.7 mm (.067")

1.8 mm (.071")

1.9 mm (.075")

2.0 mm (.079")

2.1 mm (.083")

2.2 mm (.087")

2.3 mm (.091")

2.4 mm (.094")

2.5 mm (.098")

2.6 mm (.102")

2.7 mm (.106")

2.8 mm (.110")

2.9 mm (.114")

3.0 mm (.118")

F5A51 SERIES

I.D. Color

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Figure 126

Part Number

MD759960

MD759961 MD759962 MD759963 MD750841

MD750842 MD750843 MD750844

MD750845 MD750846 MD750847

MD750848 MD750849 MD750850 MD750851

F5A51 = MB991629

MD998924

Figure 125

OVERDRIVE CLUTCH CLEARANCE

1.5-1.7 MM (.059"-.066")

F

5 1

A

B

5

Figure 127

76

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd)

27. Install the reverse clutch plates beginning with a steel plate and alternating with friction plates until you have installed two of each, as shown in Figure 128.

160

161

Note: Quantity of friction & steels will vary by

model. Friction plates should be soaked in ATF for 1 hour, prior to installation.

28. Install the reverse clutch backing plate with the rounded edge towards friction plate, as shown in Figure 128 and 129.

29. Install the reverse clutch backing plate snap ring, as shown in Figure 128.

W

162

B

F 5

Continued on Page 78

163

179

ROUNDED EDGE

TOWARDS FRICTION

5

A

1

BACKING

PLATE

160 REVERSE CLUTCH BACKING PLATE SNAP RING (SELECTIVE). 161 REVERSE CLUTCH BACKING PLATE (.160" THICK). 162 REVERSE CLUTCH FRICTION PLATES (.070" THK) (QTY VARIES). 163 REVERSE CLUTCH STEEL PLATES (.070" THICK) (QTY VARIES). 179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY.

{

Most Use 2 Frictions & 2 Steels

(Some Use 3 of Each)

Figure 128 Figure 129

AUTOMATIC TRANSMISSION SERVICE GROUP

77

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd)

30. Install the clutch compressing tools that are shown in Figure 132. Note: The reverse lined plates are "Waved"

and must be compressed as shown to check for the proper clutch clearance reading.

31. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 130. Note: Proper compression can at times be

achieved by hand, as shown in Figure 130, as most have only 2 friction plates.

32. With the plates compressed clutch clearance should be 1.6-1.8 mm (.063"-.070").

33. Change the selective snap ring as necessary using the chart in Figure 131, to obtain proper reverse clutch clearance.

Continued on Page 79

SELECTIVE SNAP RING CHART

Thickness

1.6 mm (.063")

1.7 mm (.067")

1.8 mm (.071")

1.9 mm (.075")

2.0 mm (.079")

2.1 mm (.083")

2.2 mm (.087")

2.3 mm (.091")

2.4 mm (.094")

2.5 mm (.098")

2.6 mm (.102")

2.7 mm (.106")

2.8 mm (.110")

REVERSE CLUTCH

F5A51 SERIES

I.D. Color

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Figure 131

Part Number

MD761088

MD761089 MD761090 MD758947 MD756690

MD756691 MD756692 MD756693

MD756694 MD756695 MD756696

MD756697 MD756698

REVERSE CLUTCH CLEARANCE

1.6-1.8 MM (.063"-.070")

W

B

F 5

5

A

1

REVERSE CLUTCH COMPRESSION TOOL

F5A51 = MB991789

MD998924

78

Figure 130 Figure 132

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Reverse/Overdrive clutch Housing (Cont'd) Overdrive Clutch Hub

34. Turn the reverse/overdrive clutch housing over as shown in Figure 133.

35. Install the number 7 thrust bearing in direction shown in Figure 133, and retain with a small amount of Trans-Jel®.

36. Set the completed overdrive/reverse clutch housing aside for the final assembly process.

NUMBER 7

THRUST BEARING

1. Clean the overdrive clutch hub thoroughly in cleaning solution and dry with compressed air.

2. Inspect the overdrive clutch hub thoroughly for any wear and/or damage.

3. Install the number 6 thrust bearing in direction shown in Figure 134, and retain with a small amount of Trans-Jel®.

4. Set the completed overdrive clutch hub aside for final assembly process (See Figure 135).

COMPLETED OVERDRIVE CLUTCH HUB

NUMBER 6

THRUST BEARING

Figure 133

Figure 134

OVERDRIVE

CLUTCH HUB

Figure 135

Component Rebuild

Continued on Page 80

AUTOMATIC TRANSMISSION SERVICE GROUP

79

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Planetary Gear Train Assembly

1. Disassemble the planetary gear train by first removing the snap ring, and using Figure 136 and 137 as a guide.

2. Clean all of the planetary gear train parts using a suitable cleaning solution and dry with compressed air.

GEAR TRAIN EXPLODED VIEW

179

3. Inspect all planetary gear train parts for any wear and/or damage, replace as necessary. Note: Mitsubishi, Hyundai, and Kia all have

different planetary gear ratios and will not interchange. Inspect any replacement parts very carefully.

Continued on Page 81

200

183

180

181

201

202

203

182

204

184

206

205

207

80

179 REVERSE/OVERDRIVE CLUTCH RETAINER ASSEMBLY. 180 NUMBER 7 THRUST BEARING. 181 NUMBER 8 THRUST BEARING RACE (SELECTIVE). 182 NUMBER 6 THRUST BEARING. 183 OVERDRIVE CLUTCH HUB. 184 NUMBER 5 THRUST BEARING. 200 REVERSE SUN GEAR AND SHELL ASSEMBLY. 201 PLANETARY RETAINING SNAP RING. 202 OVERDRIVE PLANETARY CARRIER ASSEMBLY. 203 NUMBER 4 THRUST BEARING. 204 UNDERDRIVE SUN GEAR. 205 NUMBER 3 THRUST BEARING. 206 OUTPUT PLANETARY CARRIER ASSEMBLY. 207 OUTPUT INTERNAL RING GEAR.

Figure 136

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

207 OUTPUT INTERNAL RING GEAR. 208 LOW SPRAG END BEARINGS (2 REQUIRED).

209

LOW SPRAG ASSEMBLY (OWC-1) EXPLODED VIEW

210

208 208

209

209 LOW SPRAG AND CAGE ASSEMBLY (OWC-1). 210 LOW SPRAG ASSEMBLY RETAINER PLATE.

Figure 137

COMPONENT REBUILD SECTION

Planetary Gear Train Assembly (Cont'd)

4. Place output internal ring gear on a flat work surface, as shown in Figure 138.

5. Install one low sprag end bearing in direction shown in Figure 138, until fully seated.

210

208

6. Install the low sprag assembly (OWC-1) into the ring gear so that the arrows are pointing down, as shown in Figure 138.

7. Install the second low sprag end bearing in the direction shown in Figure 138, until fully seated.

8. Install the low sprag assembly retainer by snapping it over the lip on the ring gear, as shown in Figure 138.

207

207 OUTPUT INTERNAL RING GEAR. 208 LOW SPRAG END BEARINGS (2 REQUIRED). 209 LOW SPRAG AND CAGE ASSEMBLY (OWC-1). 210 LOW SPRAG ASSEMBLY RETAINER PLATE.

Figure 138

AUTOMATIC TRANSMISSION SERVICE GROUP

208

207

Continued on Page 82

81

ENSURE THAT RETAINER

WWW.ALL-TRANS.BY

IS FULLY SEATED

Technical Service Information

COMPONENT REBUILD SECTION

Planetary Gear Train Assembly (Cont'd)

9. Ensure that low sprag retainer is fully seated, as shown in Figure 139, and check it the full 360 degrees.

10. Turn the ring gear assembly over and set on blocks or similar device to raise it off of the work surface, as shown in Figure 140.

11. Install the output planetary carrier into output ring gear, as shown in Figure 140, and rotate to engage planetary gears.

12. Install the number 4 thrust bearing onto the overdrive carrier, as shown in Figure 141, with needles facing up and retain with Trans-Jel®.

Continued on Page 83

Figure 139

OUTPUT

PLANETARY

CARRIER

NUMBER 4

THRUST BEARING

OVERDRIVE

PLANETARY

CARRIER

OUTPUT

RING GEAR

ASSEMBLY

NUMBER 4

THRUST BEARING

82

BLOCKS

Figure 140 Figure 141

AUTOMATIC TRANSMISSION SERVICE GROUP

201

WWW.ALL-TRANS.BY

202

203

204

Technical Service Information

COMPONENT REBUILD SECTION

Planetary Gear Train Assembly (Cont'd)

13. Install the number 3 thrust bearing into the output planetary carrier in the direction shown in Figure 142.

14. Install the underdrive sun gear into the output planetary carrier in the direction shown in Figure 142, and rotate into position to engage into planetary gears.

15. Ensure the number 4 thrust bearing (203) is still in place in the overdrive carrier (202). Refer to Figure 142.

16. Install the overdrive carrier and the number 4 thrust bearing as an assembly, by rotating into position, as shown in Figure 142.

17. Install the overdrive carrier retaining snap ring, as shown in Figure 142, and ensure that it is fully seated.

18. Set completed planetary gear train assembly aside for the final assembly process, as shown in Figure 143.

205

OUTPUT CARRIER AND RING GEAR

ASSEMBLY

201 PLANETARY RETAINING SNAP RING. 202 OVERDRIVE PLANETARY CARRIER ASSEMBLY. 203 NUMBER 4 THRUST BEARING. 204 UNDERDRIVE SUN GEAR. 205 NUMBER 3 THRUST BEARING.

Component Rebuild

Continued on Page 84

COMPLETED PLANETARY

GEAR TRAIN ASSEMBLY

Figure 142 Figure 143

AUTOMATIC TRANSMISSION SERVICE GROUP

83

117

WWW.ALL-TRANS.BY

Technical Service Information

UNDERDRIVE CLUTCH HOUSING EXPLODED VIEW

115

116

114

113

112

110

111

103

102

109

108

107

101

106

105

104

100

100 TURBINE SHAFT SEALING RINGS. 101 TURBINE SHAFT. 102 NUMBER 1 SELECTIVE THRUST WASHER. 103 UNDERDRIVE CLUTCH HOUSING. 104 TURBINE SHAFT RETAINING SNAP RING. 105 UNDERDRIVE CLUTCH HOUSING INNER "D" RING SEAL. 106 UNDERDRIVE CLUTCH PISTON OUTER "D" RING SEAL. 107 UNDERDRIVE CLUTCH APPLY PISTON. 108 UNDERDRIVE CLUTCH PISTON RETURN SPRING ASSEMBLY.

84

109 UNDERDRIVE CLUTCH BALANCE PISTON "D" RING SEAL. 110 UNDERDRIVE CLUTCH BALANCE PISTON. 111 UNDERDRIVE CLUTCH BALANCE PISTON SNAP RING. 112 UNDERDRIVE CLUTCH STEEL PLATES. 113 UNDERDRIVE CLUTCH FRICTION PLATES. 114 UNDERDRIVE CLUTCH BACKING PLATE. 115 UNDERDRIVE CLUTCH BACKING PLATE SELECTIVE SNAP RING. 116 NUMBER 2 THRUST BEARING. 117 UNDERDRIVE CLUTCH HUB.

Figure 144

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Underdrive Clutch Housing

1. Disassemble the underdrive clutch housing using Figure 144 as a guide. Note: It is "Mandatory" that you check the

clutch pack as it is removed. The amount and thickness of plates will vary, as well as the diameter. The bottom apply plate is not used in all models.

2. Clean all underdrive clutch housing parts with cleaning solution and dry with compressed air.

3. Inspect all underdrive clutch housing parts for any wear and/or damage. Replace as necessary.

4. Install new underdrive clutch inner "D" ring seal in underdrive clutch housing, as shown in Figure 145, and lube with a small amount of Trans-Jel®.

5. Install new underdrive clutch outer "D" ring seal onto underdrive clutch apply piston, as shown in Figure 146, and lube with a small amount of Trans-Jel®.

6. Install new "D" ring seal onto the underdrive clutch balance piston, as shown in Figure 147, and lube with a small amount of Trans-Jel®.

107

106

106 UNDERDRIVE CLUTCH PISTON OUTER "D" RING SEAL. 107 UNDERDRIVE CLUTCH APPLY PISTON.

Figure 146

103 UNDERDRIVE CLUTCH HOUSING. 105 UNDERDRIVE CLUTCH HOUSING INNER "D" RING SEAL.

Continued on Page 86

105

110

103

109

109 UNDERDRIVE CLUTCH BALANCE PISTON "D" RING SEAL. 110 UNDERDRIVE CLUTCH BALANCE PISTON.

Figure 145 Figure 147

AUTOMATIC TRANSMISSION SERVICE GROUP

85

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Underdrive Clutch Housing (Cont'd)

7. Install the underdrive clutch piston assembly into the underdrive housing with a twisting

111

110

108

motion, as shown in Figure 148.

8. Install the return spring assembly in direction shown in Figure 148, and ensure that holes in retainer are engaged over dowels on piston.

9. Install the underdrive clutch balance piston over the return spring assembly, as shown in Figure 148.

10. Compress the balance piston and return spring using the proper adapters and compressor.

11. Install the snap ring, as shown in Figure 148, and slowly remove the compression tool.

Continued on Page 87

107

ALIGN HOLE AND DOWEL

103

103 UNDERDRIVE CLUTCH HOUSING. 107 UNDERDRIVE CLUTCH APPLY PISTON. 108 UNDERDRIVE CLUTCH PISTON RETURN SPRING ASSEMBLY. 110 UNDERDRIVE CLUTCH BALANCE PISTON ASSEMBLY. 111 UNDERDRIVE CLUTCH BALANCE PISTON SNAP RING.

86

Figure 148

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Underdrive Clutch Housing (Cont'd)

12. Install the underdrive clutch plates beginning with a steel plate and alternating with friction plates, as shown in Figure 150, until you have installed four of each (Quantity Varies). Note: When installing the steel plates, align

them so that the places with no teeth will be aligned with the lube holes in the housing, as shown in Figure 149.

Note: Friction plates should be soaked in

ATF for 1 hour before installation.

13. Install the underdrive clutch backing plate, as shown in Figure 149 and 150, with the rounded edge towards the friction.

14. Install the underdrive backing plate selective snap ring, as shown in Figure 150.

Continued on Page 88

115

114

LUBE

HOLE

SPACE BETWEEN

TEETH ON STEEL PLATE

ROUNDED EDGE

TOWARDS FRICTION

113

112

LUBE HOLE

103

BACKING

PLATE

ALL MODELS

103 UNDERDRIVE CLUTCH HOUSING ASSEMBLY. 112 UNDERDRIVE CLUTCH STEEL PLATES (QUANTITY VARIES). 113 UNDERDRIVE CLUTCH FRICTION PLATES (QUANTITY VARIES). 114 UNDERDRIVE CLUTCH BACKING PLATE. 115 UNDERDRIVE CLUTCH BACKING PLATE SELECTIVE SNAP RING.

Figure 149 Figure 150

AUTOMATIC TRANSMISSION SERVICE GROUP

87

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Underdrive Clutch Housing (Cont'd)

15. Install the clutch compressing tools, as shown in Figure 151 and 153. Note: Underdrive lined plates are "Waved"

on all models and must be compressed as shown in Figure 153 to achieve the proper clutch clearance reading. The underdrive friction plates were changed in May, 2000 to a friction with a less perceptable wave, but must still be compressed.

16. Compress the plates and measure with feeler gage between snap ring and backing plate, as shown in Figure 153.

17. With the plates compressed clutch clearance should be 1.6-1.8 mm (.063"-.071").

18. Change the selective snap ring as necessary, using the chart in Figure 152, to obtain proper underdrive clutch clearance.

Continued on Page 89

UNDERDRIVE AND OVERDRIVE

SELECTIVE SNAP RING CHART

Thickness

1.6 mm (.063")

1.7 mm (.067")

1.8 mm (.071")

1.9 mm (.075")

2.0 mm (.079")

2.1 mm (.083")

2.2 mm (.087")

2.3 mm (.091")

2.4 mm (.094")

2.5 mm (.098")

2.6 mm (.102")

2.7 mm (.106")

2.8 mm (.110")

2.9 mm (.114")

3.0 mm (.118")

F5A51 SERIES

I.D. Color

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Brown

None

Blue

Figure 152

Part Number

MD759960

MD759961 MD759962 MD759963 MD750841

MD750842 MD750843 MD750844

MD750845 MD750846 MD750847

MD750848 MD750849 MD750850 MD750851

UNDERDRIVE CLUTCH COMPRESSION TOOL

F5A51 = MB991629

UNDERDRIVE CLUTCH CLEARANCE

1.6 - 1.8 MM (.063" - .071")

MD998924

Figure 151 Figure 153

88

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Underdrive Clutch Housing (Cont'd)

19. Install the turbine shaft through the underdrive clutch housing, as shown in Figure 154, install snap ring and ensure that it is fully seated.

20. Install the number 1 thrust washer, as shown in Figure 155, and retain with Trans-Jel®.

21. Install two new turbine shaft "butt-cut" sealing rings, as shown in Figure 155, and ensure rotation.

22. Set the completed underdrive clutch housing aside for the final assembly process.

Component Rebuild

Continued on Page 90

100

102

101

103

Install Snap Ring And

Ensure Fully Seated

100 TURBINE SHAFT SEALING RINGS. 101 TURBINE SHAFT. 102 NUMBER 1 SELECTIVE THRUST WASHER. 103 UNDERDRIVE CLUTCH HOUSING.

Figure 154 Figure 155

AUTOMATIC TRANSMISSION SERVICE GROUP

89

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION COMPONENT REBUILD SECTION

Underdrive Clutch Hub Differential Assembly

1. Clean and inspect the underdrive clutch hub thoroughly.

2. Install the number 2 thrust bearing onto the underdrive clutch hub, in the direction shown in Figure 156, and retain with a small amount of Trans-Jel®.

3. Set the completed underdrive clutch hub aside for the final assembly process, as shown in Figure 157.

116

117

1. Disassemble the differential assembly using Figure 159 as a guide.

2. Clean and inspect all of the differential parts thoroughly. Replace as necessary.

3. If bearing service is required, the tools shown in Figure 158, or their equivalant, and suitable hydraulic shop press will be necessary.

Continued on Page 91

DIFFERENTIAL REQUIRED SPECIAL

TOOLS FOR BEARING SERVICE

116 NUMBER 2 THRUST BEARING. 117 UNDERDRIVE CLUTCH HUB.

COMPLETED UNDERDRIVE CLUTCH HUB

MD998917

MD998812

MD998820

Figure 156

MD998814

Figure 157

MD998823

90

Figure 158

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

DIFFERENTIAL EXPLODED VIEW

587

591

580

581

586

590

589

588

587

588

585

584

589

590

583

582

581

580 DIFFERENTIAL BEARING CUP (2 REQUIRED). 581 DIFFERENTIAL TAPERED ROLLER BEARING (2 REQUIRED). 582 DIFFERENTIAL RING GEAR TO CARRIER BOLTS (10 REQUIRED). 583 DIFFERENTIAL RING GEAR. 584 DIFFERENTIAL PINION SHAFT. 585 DIFFERENTIAL CARRIER ASSEMBLY. 586 DIFFERENTIAL PINION SHAFT RETAINING PIN. 587 DIFFERENTIAL SIDE GEAR SPACER (SELECTIVE). 588 DIFFERENTIAL SIDE GEAR. 589 DIFFERENTIAL PINION GEAR. 590 DIFFERENTIAL PINION GEAR WASHER. 591 SELECTIVE SPACER TO SET PRE-LOAD (CONV HOUSING SIDE)

Figure 159

AUTOMATIC TRANSMISSION SERVICE GROUP

580

91

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Differential Assembly

4. Remove the bearings using the split puller and the appropriate size general service gear puller as shown in Figure 160.

5. Install the tapered roller bearings using the special tools, shown in Figure 161, and using a suitable hydraulic shop press.

6. Assemble the differential side gears and pinion gears, as shown in Figure 159.

Continued on Page 93

MD998812

MD998820

TAPERED

ROLLER

BEARING

REMOVER

MD998812

MD998820

TAPERED

ROLLER

BEARING

92

Figure 160 Figure 161

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

DIFFERENTIAL ASSEMBLY (CONT'D)

7. Measure the backlash between the side gears and pinion gears, as shown in Figure 162.

8. If backlash is out of specification, as shown in Figure 162, select a spacer from the chart and re-measure the backlash. Note: Adjust until the backlash is equal at

both side gears.

9. If gear service was necessary, torque the ring gear bolts to 135 N·m (100 ft.lb.), as shown in Figure 163, using a criss-cross pattern.

10. Set completed differential assembly aside for the final assembly process (See Figure 164).

Component Rebuild

Continued on Page 94

TORQUE TO

135 NM (100 FT.LB.)

DIFFERENTIAL SIDE GEAR SPACERS

Thickness

.75-.82 mm (.029"-.032")

.83-.92 mm (.033"-.036")

.93-1.00 mm (.037"-.040")

1.01-1.08 mm (.040"-.043")

1.09-1.16 mm (.043"-.046")

SIDE GEAR BACKLASH

.025-.150 MM (.001"-.006")

Part No.

MD722986

MD722985

MD722984

MD722982

MD722983

Figure 163

COMPLETED DIFFERENTIAL ASSEMBLY

0

1010

2020

3030

4040

5050

0

Figure 162 Figure 164

AUTOMATIC TRANSMISSION SERVICE GROUP

93

Technical Service Information

WWW.ALL-TRANS.BY

DIRECT PLANETARY CARRIER EXPLODED VIEW

225

226

227 228

233

229

230

231

232

231

N

P

0

8

0

9

P

9

6

7

®

N

E

U

K

S

A

M

I

T

225 DIRECT PLANETARY CARRIER LOCK NUT. 226 DIRECT PLANETARY CARRIER ROLLER BEARING. 227 NUMBER 9 THRUST BEARING. 228 NUMBER 10 THRUST BEARING RACE. 229 OUTPUT PINION GEAR. 230 PARKING GEAR. 231 TAPERED ROLLER BEARINGS (2 REQUIRED). 232 TRANSFER DRIVEN GEAR & DIRECT PLANETARY RING GEAR. 233 DIRECT PLANETARY CARRIER ASSEMBLY.

Figure 165

COMPONENT REBUILD SECTION

Direct Planetary Gearset

1. Unstake the locking nut with a punch, as shown in Figure 166.

2. Using the special spanner wrench, remove the locking nut, as shown in Figure 167.

Continued on Page 95

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

MD998834

SPANNER WRENCH

94

Figure 166 Figure 167

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Planetary Gearset (Cont'd)

3. Remove the lock nut and direct planetary carrier roller bearing, as shown in Figure 168.

4. Remove the number 9 thrust bearing and the number 10 thrust bearing race (See Figure 168).

5. Install universal bearing remover under parking gear, as shown in Figure 169, with the assembly in hydraulic press.

6. Remove the parking gear and output pinion gear by pressing out the planetary carrier shaft, as shown in Figure 170.

Continued on Page 96

MD998917

PRESS RAM

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

Figure 169

225

226

229

227

228

230

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

225 DIRECT PLANETARY CARRIER LOCK NUT. 226 DIRECT PLANETARY CARRIER ROLLER BEARING. 227 NUMBER 9 THRUST BEARING. 228 NUMBER 10 THRUST BEARING RACE.

229 OUTPUT PINION GEAR. 230 PARKING GEAR.

Figure 168 Figure 170

AUTOMATIC TRANSMISSION SERVICE GROUP

95

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Planetary Gearset (Cont'd)

7. With the assembly still in the press, place suitable supports under the driven transfer gear, as shown in Figure 171.

8. Again press the direct planetary carrier shaft out and remove the tapered roller bearing and driven transfer gear, as shown in Figure 172.

9. Now install the universal split puller under the remaining tapered roller bearing, as shown in Figure 173, and press it off of the shaft.

Continued on Page 97

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

231

232

231 TAPERED ROLLER BEARINGS (2 REQUIRED). 232 TRANSFER DRIVEN GEAR & DIRECT PLANETARY RING GEAR. 233 DIRECT PLANETARY CARRIER ASSEMBLY.

Figure 172

PRESS RAM PRESS RAM

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

MD998917

233

96

Figure 171

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 173

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Planetary Gearset (Cont'd)

10. Press a new tapered roller bearing onto direct planetary carrier, as shown in Figure 174, using the proper adapters.

11. Install new bearing cups into the driven transfer gear, as shown in Figure 175, using the proper adapters.

12. Install the transfer driven gear/direct ring gear onto the direct planetary carrier, as shown in Figure 176, and rotate into position to engage planetary pinions.

13. Install the second tapered roller bearing onto the direct planetary carrier, as shown in Figure 176.

Continued on Page 98

BEARING CUP

Figure 175

MD998812

MD998813

MD998824

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

231

232

233

231 TAPERED ROLLER BEARINGS (2 REQUIRED). 232 TRANSFER DRIVEN GEAR & DIRECT PLANETARY RING GEAR. 233 DIRECT PLANETARY CARRIER ASSEMBLY.

Figure 174 Figure 176

AUTOMATIC TRANSMISSION SERVICE GROUP

97

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Planetary Gearset (Cont'd)

14. Press the tapered roller bearing into position, as shown in Figure 177.

15. Install the parking gear and output pinion gear onto direct planetary carrier shaft, as shown in Figure 178.

16. Press the output pinion gear into position, as shown in Figure 179.

Continued on Page 99

229

230

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

MD998812

MD998813

MD998824

229 OUTPUT PINION GEAR. 230 PARKING GEAR.

Figure 178

MD998812

MD998824

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

98

Figure 177

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 179

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Planetary Gearset (Cont'd)

17. Install the number 10 thrust bearing race and the number 9 thrust bearing, as shown in Figure 180.

18. Install the direct planetary carrier roller bearing, as shown in Figure 180.

19. Install the locking nut as shown in Figure 180.

20. Tighten the locking nut to the specified torque using the special spanner wrench, as shown in Figure 181. Loosen the locking nut 1 complete turn and once again torque the locking nut to 170 N·m (125 ft.lb.).

21. Stake the locking nut in place and set completed direct planetary gearset aside for final assembly, as shown in Figure 182.

Component Rebuild

Continued on Page 100

TORQUE TO 170 N·M (125 FT.LB.)

MD998834

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

225

226

227

228

Figure 181

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

T

I

M

K

E

N

®

P

9

0

N

P

8

9

6

7

U

S

A

225 DIRECT PLANETARY CARRIER LOCK NUT. 226 DIRECT PLANETARY CARRIER ROLLER BEARING. 227 NUMBER 9 THRUST BEARING. 228 NUMBER 10 THRUST BEARING RACE.

Figure 180 Figure 182

AUTOMATIC TRANSMISSION SERVICE GROUP

99

Technical Service Information

WWW.ALL-TRANS.BY

COMPONENT REBUILD SECTION

Direct Clutch Housing Assembly

1. Disassemble the direct clutch housing using Figure 183 as a guide. Note: It is "Mandatory" that you check the

clutch pack as it is removed. The amount and thickness of plates will vary, as well as the diameter. The bottom apply plate is not used in all models. Refer to Page 103.

DIRECT CLUTCH HOUSING exploded view

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. Install new bushings as necessary using the proper driver.

Continued on Page 101

540

541

550 551

549

542

543

552

544

553 553

545

547

546

554

548

REAR VIEW

555

556

540 DIRECT CLUTCH BACKING PLATE SELECTIVE SNAP RING. 541 DIRECT CLUTCH BACKING PLATE. 542 DIRECT CLUTCH FRICTION PLATES (QTY VARIES). 543 DIRECT CLUTCH STEEL PLATES (QTY. VARIES). 544 DIRECT CLUTCH WAVE PLATE. 545 DIRECT CLUTCH APPLY PLATE (NOT USED ALL MODELS). 546 DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING. 547 DIRECT CLUTCH RETURN SPRING RETAINER.

100

548 DIRECT CLUTCH RETURN SPRING RETAINER "D" RING SEAL. 549 DIRECT CLUTCH APPLY PISTON RETURN SPRING. 550 DIRECT CLUTCH APPLY PISTON. 551 DIRECT CLUTCH APPLY PISTON OUTER "D" RING SEAL. 552 DIRECT CLUTCH HOUSING INNER "D" RING SEAL.. 553 DIRECT CLUTCH HOUSING BUSHINGS (2 REQUIRED). 554 DIRECT CLUTCH HOUSING. 555 NUMBER 11 THRUST BEARING. 556 NUMBER 12 THRUST BEARING RACE.

Figure 183

AUTOMATIC TRANSMISSION SERVICE GROUP

Mitsubishi F5A5A F5A51 A5GF1 A5HF1 Transmission Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual