A140E Automatic Transmission Service and Repair Manual

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BY
AX-1
AUTOMATIC TRANSAXLE - GENERAL DESCRIPTION
GENERAL DESCRIPTION AX0EP-02
The A140E automatic transaxle described in this AX section is a 4-speed lock-up automatic transaxle
developed exclusively for use with a transversely-mounted engine.
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AX-2
AUTOMATIC TRANSAXLE - GENERAL DESCRIPTION
General Specifications
Type of Transaxle A140E
Type of Engine 5S-FE
Torque Converter Clutch Stall Torque Ratio 2.0 : 1
Lock-up Mechanism Equipped
Gear Ratio 1st Gear 2.810
2nd Gear 1.549
3rd Gear 1.000
O/D Gear 0.706
Reverse Gear 2.296
Number of Discs and Plates O/D Direct Clutch (C0) 2/1
Forward Clutch (C1) 4/4
Direct Clutch (C2) 3/3
Second Brake (B2) 3/3
First and Reverse Brake (B3) 6/5
O/D Brake (B0) 2/3
B1 Band Width mm (in.) 25 mm (0.98 in.)
ATF Type ATF DEXRON ® II
Capacity liter (US qts, Imp. qts)
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Transaxle 5.6 (5.9, 4.9)

Differential 1.6 (1.7, 1.4)
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IN-1
INTRODUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL IN002-0W
To assist you in finding your way through the manual, the Section Title and major heading are given
at the top of every page.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM
(Special Service Materials) which should be prepared before beginning the operation and explains the
purpose of each one.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how
the parts fit together.
Example:
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IN-2
Theprocedures are presented in a step-by-step format:

The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
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This format provides the experienced technician with a FAST TRACK to the information needed. The
upper case task heading can be read at a glance when necessary, and the text below it provides de-
tailed information. Important specifications and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they are required you are given the page
to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave
the procedure to look up your specifications. They are also found at the back of AX section, for quick
reference.
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IN-3
CAUTIONS, NOTICES, HINTS:

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the compo-
nents being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information
to help you perform the repair efficiently.
SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System
of Unit), and alternately expressed in the metric system and in the English system.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
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IN-4
INTRODUCTION - GENERAL REPAIR INSTRUCTIONS
GENERAL REPAIR INSTRUCTIONS IN022-07
1. Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.
2. During disassembly, keep parts in the appropriate order
to facilitate reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative (-) terminal cable from the battery.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the ve-
hicle body.
(c) To prevent damage to the battery terminal post, loos-
en the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a clean shop rag. Do not scrape them with a file
or other abrasive objects.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
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not use a hammer to tap the terminal onto the post.

(f) Be sure the cover for the positive (+) terminal is prop-
erly in place.
4. Check hose and wiring connectors to make sure that they
are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the ”” symbol.
6. Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(b) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
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IN-5
INTRODUCTION - GENERAL REPAIR INSTRUCTIONS
the specified seal lock adhesive to the bolt, nut or

threads.
(c) Precoated parts are indicated in the component il-
lustrations by the ”” symbol.
7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9. Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found at the preparation of AX section.
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10. When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
11. To pull apart electrical connectors, pull on the connector

itself, not the wires.
12. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
a vehicle raised on a jack alone, even for a small job
that can be finished quickly.
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AX-3
AUTOMATIC TRANSAXLE - OPERATION
OPERATION AX0SW-01
OPERATION
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AX-4
1. FUNCTION OF COMPONENTS
FUNCTION OPERATION
O/D Direct Clutch (C0) Connects overdrive sun gear and overdrive carrier
Prevents overdrive sun gear from turning either clockwise or
O/D Brake (B0)
counterclockwise
When transmission is being driven by engine, connects overdrive sun
O/D One-way Clutch (F0)
gear and overdrive carrier.
Front Clutch (C1) Connects input shaft and intermediate shaft
Rear Clutch (C2) Connects input shaft and front and rear planetary sun gears
Prevents front and rear planetary sun gears from turning either clockwise
No.1 Brake (B1)
or counterclockwise
Prevents outer race of F1 from turning either clockwise or counterclockwise, thus
No.2 Brake (B2)
previnting front and rear planetary sun gears from turning counterclockwise
No.3 Brake (B3) Prevents front planetary carrier from turning either clockwise or counterclockwise
When B2 is operating prevents front and rear planetary sun gears from turning
No.1 One-way Clutch (F1)
counterclockwise
No.2 One-way Clutch (F2) Prevents front planetary carrier from turning counterclockwise
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AX-5
Power from the engine transmitted to the input shaft via the torque converter is then transmitted to the
planetary gears by the operation of the clutch.
By operation of the brake and one-way clutch, either the planetary carrier or the planetary sun gear
are immobilized, altering the speed of revolution of the planetary gear unit.
Shift change is carried out by altering the combination of clutch and brake operation.
Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle
opening angle and vehicle speed, and shift change automatically occurs.
The conditions of operation for each gear position are shown on the following illustrations:
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AX-6
2. HYDRAULIC CONTROL SYSTEM

The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu-
mulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect
all of these components.
Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hy-
draulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the ve-
hicle driving conditions.
There are three solenoid valves on the valve body.
The No.1 and No.2 solenoid valves are turned on and off by signals from the ECM to operate the shift
valves and change the gear shift position.
The No.3 solenoid valve is operated by signals from the ECM to engage or disengage the lock-up
clutch of the torque converter.
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AX-7
2. ELECTRONIC CONTROL SYSTEM

The electronic control system for controlling the shift timing and the operation of the lock-up clutch is
composed of the following 3 parts:
(a) Sensors: These sense the vehicle speed and throttle position and send this data to the ECM in the form
of electronic signals.
(b) ECM: This determines the shift and lock-up timing based upon the signals from the sensors.
(c) Actuators: Solenoid valves divert hydraulic pressure from one circuit of the hydraulic control unit to
another, thus controlling shifting and lock-up timing.
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IN-7
INTRODUCTION - GLOSSARY OF SAE AND TOYOTA TERMS
GLOSSARY OF SAE AND TOYOTA TERMS IN016-02
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE
recommendations, as well as their Toyota equivalents.
SAE TOYOTA TERMS
SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure -
CAC Charge Air Cooler Intercooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
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CTP Closed Throttle Position -

DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition -
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Toyota Diagnosis Communication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode -
ECL Engine Control Level -
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only
EEPROM (EEPROM),
Memory
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Toyota Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
Flash Electrically Erasable Programmable
FEEPROM -
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
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IAC Idle Air Control Idle Speed Control (ISC)

IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module -
IFI Indirect Fuel Injection Indirect Injection
IFS Inertia Fuel-Shutoff -
ISC Idle Speed Control -
KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure -
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface Temperature -
MVZ Manifold Vacuum Zone -
NVRAM Non-V olatile Random Access Memory -
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
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OBD On-Board Diagnostic On-Board Diagnostic (OBD)

OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module -
PNP Park/Neutral Position -
PROM Programmable Read Only Memory -
PSP Power Steering Pressure -
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module -
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass -
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter -
SRI Service Reminder Indicator -
SRT System Readiness Test -
ST Scan Tool -
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU (Electronic Control Unit)
TP Throttle Position Throttle Position
TR Transmission Range -
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Bimetallic Vacuum Switching Valve (BVSV)

TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three-W ay Catalyst (TWC)
TWC Three-W ay Catalytic Converter
CCRO
TWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCo
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type)
WOT Wide Open Throttle Full Throttle
WU-OC Warm Up Oxidation Catalytic Converter -
WU-TWC Warm Up Three-Way Catalytic Converter Manifold Converter
3GR Third Gear -
4GR Fourth Gear -
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AX-10
AUTOMATIC TRANSAXLE - PREPARATION
PREPARATION AX0EQ-02
SST (SPECIAL SERVICE TOOLS)

09240-00020 Wire Gauge Set
09330-00021 Companion Flange Holding Tool
09350-32014 TOYOTA Automatic Transmission

Tool Set
09308-10010 Oil Seal Puller
(09351-32020) Stator Stopper

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(09351-32032) Counter Driven Gear Holding Tool
(09351-32040) No.1 Piston Spring Compressor
(09351-32050) Snap Ring Expander
(09351-32061) Oil Pump Puller
(09351-32080) Lock Nut Wrench
(09351-32090) Oil Seal Remover & Replacer
(09351-32100) Drive Pinion Bearing Replacer

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(09351-321 11) Side Bearing Race Replacer
(09351-32120) Overdrive Bearing Replacer
(09351-32130) Handle
(09351-32140) Oil Seal Replacer
(09351-32150) Oil Seal Replacer
(09351-32190) Measure Terminal

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09502-10012 Differential Side Bearing Puller

09564-3201 1 Differential Preload Adaptor
09710-28020 Front Suspension Bushing Tool

Set
(09710-08040) Bushing Replacer
09950-00020 Bearing Remover
AX0ER-02
RECOMMENDED TOOL
09031-00030 Pin Punch .
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AX0ES-02
EQUIPMENT
Feeler gauge
Vernier calipers
Dial indicator or dial indicator with magnetic base
Straight edge
Torque wrench
AX0ET-02
LUBRICANT
Liters
Item Clacification
US qts Imp qts
Automatic Transaxle Fluid 5.6

(w/o Differential Fluid) Dry Fill 5.9 4.9 ATF DEXRON ® II
Drain and Refill 2.5
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2.6 2.2
1.6
Differential Fluid ATF DEXRON ® II
1.7 1.4
AX0EU-02
SSM (SPECIAL SERVICE MATERIALS)

08826-00090 Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
08833-00070 Adhesive 1324,

THREE BOND 1324 or equivalent
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AUTOMATIC TRANSAXLE - COMPONENT PARTS REMOVAL
COMPONENT PARTS REMOVAL AX0GS-02
COMPONENTS
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AX0EW-02
SEPARATE BASIC SUBASSEMBLY

1. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the manual shift lever.
(b) Pry off the lock washer and remove the manual valve
shaft nut.
(c) Remove the 2 bolts and pull out the park/neutral position
switch.
2. REMOVE UNION AND ELBOW

(a) Using the open end wrench, remove the union and elbow.
(b) Remove the O-rings from the union and elbow.
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3. REMOVE SL SOLENOID
(a) Disconnect the connector.
(b) Remove the 2 bolts and SL solenoid.
4. REMOVE THROTTLE CABLE RETAINING PLATE

5. REMOVE SOLENOID WIRE RETAINING BOLT
6. REMOVE COVER
(a) Remove the 2 bolts and cover bracket.
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(b) Remove the cover.
7. REMOVE OIL PAN AND GASKET

(a) Remove the 15 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE: Do not turn the transaxle over as this will contami-
nate the valve body with the foreign materials in the bottom
of the oil pan.
(c) Place the transaxle on wooden blocks to prevent damage
to the tube bracket.
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8. EXAMINE PARTICLES IN PAN

Remove the magnets and use them to collect any steel
chips. Look carefully at the chips and particles in the oil
pan and on the magnets to anticipate what type of wear
you will find in the transmission:
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bushing wear
9. DISCONNECT NO.1 AND NO.2 SOLENOID CONNEC-

TORS
10. REMOVE TUBE BRACKET AND OIL STRAINER

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11. REMOVE OIL TUBES

Pry up both tube ends with a large screwdriver and re-
move the 4 tubes.
12. REMOVE MANUAL DETENT SPRING

13. REMOVE MANUAL VALVE AND MANUAL VALVE
BODY
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14. REMOVE VALVE BODY

15. REMOVE THROTTLE CABLE AND SOLENOID WIR-

ING FROM CASE
16. REMOVE SECOND BRAKE APPLY GASKET

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17. REMOVE ACCUMULATOR PISTON AND SPRINGS

(a) Loosen the 5 bolts one turn at a time until the spring ten-
sion is released.
(b) Remove the cover and gasket.
(c) Remove the piston and spring for C1 and C2.

(d) Remove the O-rings.
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(e) Pop out piston C1 into a rag, using low-pressure com-

pressed air 98 kPa (1 kgf/cm2, 14 psi).
(f) Remove the 2 O-rings from the B2 piston.
18. MEASURE PISTON STROKE OF SECOND COAST

BRAKE
(a) Apply a small amount of paint to the piston rod at the point
it meets the case.
(b) Using SST, measure the piston stroke while applying and
releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2,
57 - 114 psi).
SST 09240-00020
Piston stroke:
1.5 - 3.0 mm (0.059 - 0.118 in.)
If the piston stroke exceeds the limit, replace the piston
rod or brake band.
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19. REMOVE SECOND COAST BRAKE PISTON

(a) Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)
(b) Remove the cover.

(c) Remove the piston and outer return spring.
(d) Remove the O-ring from the cover.
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20. REMOVE OIL PUMP AND DIRECT CLUTCH

NOTICE: Before removing the oil pump, remove the se-
cond coast brake piston.
(b) Using SST, pull out the oil pump from the transaxle case.
SST 09350-32014 (09351-32061)
21. REMOVE OIL PUMP AND DIRECT CLUTCH

While holding the input shaft, grasp the pump stator shaft
and pull the oil pump and direct clutch together out of the
transaxle case.
NOTICE: Push the second coast brake band into the case,
being careful not to catch it on the direct clutch drum.
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22. REMOVE DIRECT CLUTCH FROM OIL PUMP

23. BE CAREFUL WHEN REMOVING RACE BEHIND OIL
PUMP
24. REMOVE CLUTCH DRUM THRUST WASHER

25. REMOVE FORWARD CLUTCH
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26. REMOVE BEARINGS AND RACES FROM FORWARD

CLUTCH
27. REMOVE SECOND COAST BRAKE BAND

(a) Push the pin with a small screwdriver and remove it from
the bolt hole of the oil pump mounting.
(b) Remove the brake band.
28. REMOVE FRONT PLANETARY RING GEAR

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29. REMOVE BEARING RACES FROM FRONT PLAN-

ETARY RING GEAR
30. REMOVE PLANETARY GEAR

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31. REMOVE RACES AND BEARINGS FROM PLAN-

ETARY GEAR
32. REMOVE SUN GEAR, SUN GEAR INPUT DRUM, SE-

COND BRAKE HUB AND NO.1 ONE-WAY CLUTCH
33. STAND TRANSMISSION CASE UP AND REMOVE SE-

COND COAST BRAKE BAND GUIDE
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34. REMOVE SNAP RING HOLDING SECOND BRAKE

DRUM TO CASE
35. REMOVE SECOND BRAKE DRUM

If the brake drum is difficult to remove, lightly tap it with a
wooden block.
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36. REMOVE SECOND BRAKE PISTON RETURN SPRING
37. REMOVE PLATES, DISCS AND FLANGE
38. REMOVE SECOND BRAKE DRUM GASKET

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39. REMOVE SNAP RING HOLDING NO.2 ONE- WAY

CLUTCH OUTER RACE TO CASE
40. REMOVE NO.2 ONE-WAY CLUTCH AND REAR PLAN-

ETARY GEAR
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41. BE CAREFUL WHEN REMOVING THRUST WASHERS

FROM BOTH SIDES OF PLANETARY CARRIER
42. REMOVE REAR PLANETARY RING GEAR
43. REMOVE BEARINGS AND RACES

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44. CHECK OPERATION OF FIRST AND REVERSE

BRAKE PISTON
Apply compressed air into the case passage and confirm
that the piston moves.
If the piston does not move, disassemble and inspect.
45. REMOVE SNAP RING HOLDING FLANGE TO CASE

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46. REMOVE FLANGES, PLATES AND DISCS
47. TURN TRANSAXLE CASE AROUND

48. REMOVE 11 BOLTS HOLDING OVERDRIVE UNIT TO
TRANSAXLE CASE
49. REMOVE OVERDRIVE UNIT WITH ALL PARTS

(a) Tap on the overdrive case circumference with a plastic
hammer to remove the unit from the transaxle case.
(b) Remove the overdrive planetary gear and counter gear if
they remained in the transaxle.
HINT: The overdrive unit is heavy, so be careful not to
drop it.
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AX-22
(c) Remove the overdrive brake drum from the transaxle

case.
(d) Remove the overdrive planetary gear and counter gear if

they remain in the transaxle.
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50. REMOVE OVERDRIVE CLUTCH APPLY GASKET AND

OVERDRIVE BRAKEAPPLY GASKET
51. REMOVE PISTON RETURN SPRING

(a) Place SST, and compress the return springs evenly by
tightening the bolt gradually.
SST 09350-32014 (09351-32040)
(b) Using snap ring pliers, remove the snap ring.

(c) Remove SST.
(d) Remove the return spring from the case.
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52. REMOVE FIRST AND REVERSE BRAKE PISTON

(a) Apply compressed air into the passage of the case to re-
move the piston.
HINT: Hold the piston so it is not slanted and blow with the
gun slightly away from the oil hole.
(b) If the piston does not pop out with compressed air, use
needle-nose pliers to remove it.
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(c) Remove the 2 O-rings from the piston.
53. REMOVE PARKING LOCK PAWL BRACKET
54. REMOVE PARKING LOCK ROD

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55. REMOVE PIN, SPRING AND PARKING LOCK PAWL
56. REMOVE MANUAL VALVE SHAFT

(a) Remove the retaining spring.
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(b) Using a hammer and chisel, pry and turn the collar.
(c) Using a hammer and punch, drive out the pin.
(d) Slide out the shaft and remove the manual valve lever
from the case.
57. REMOVE MANUAL SHAFT OIL SEAL

Remove the oil seal with a screwdriver.
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AX0EX-02
DISASSEMBLY OF DIFFERENTIAL
1. REMOVE CARRIER COVER
2. MEASURE TOTAL PRELOAD

Using a torque meter, measure the total preload, and note
the measurement value.
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3. MEASURE BACKLASH OF SIDE GEAR

Measure each side gear backlash while holding one pin-
ion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
4. REMOVE LH BEARING RETAINER

(b) Tap the retainer with a plastic hammer to remove it.
(c) Remove the O-ring from the retainer.
5. REMOVE RH SIDE BEARING CAP

Remove the 2 bolts and the side bearing cap.
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6. REMOVE DIFFERENTIAL CASE, OUTER RACE AND

ADJUSTING SHIM
Remove the differential case, the outer race and the ad-
justing shim from the case.
7. MEASURE DRIVE PINION PRELOAD

Using a torque meter, measure the drive pinion preload.
Preload (at starting):
Reused bearing
0.5 - 0.8 N·m (5 - 8 kgf·cm, 4.3 - 6.9 in.·lbf)
The total preload measured in step 2 minus the drive pin-
ion preload equals 0.1 - 0.2 N·m (1.5 - 2.0 kgf·cm, 1.3 -
1.7in.·lbf).
If the result is not within this specification, the side bearing
preload is bad.
ProCarManuals.com
8. REMOVE DRIVE PINION CAP

(a) Remove the drive pinion cap installation bolt.
(b) Using a screwdriver, push out the drive pinion cap.
9. REMOVE COUNTER DRIVEN GEAR

(a) Using a chisel, loosen the staked part of the nut.
WWW.ALL-TRANS.BY
AX-27
(b) Install SST onto the gear.

SST 09350-32014 (09351-32032)
(c) Using SST to hold the gear, remove the nut.
SST 09330-00021
(d) Using SST, remove the gear and bearing.

SST 09350-32014 (09351-32061)
ProCarManuals.com
10. REMOVE OUTER RACE FROM CASE

Using SST, remove the outer race.
SST 09350-32014 (09308-10010)
11. REMOVE OIL SLINGER
12. REMOVE SPACER

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AX-28
13. REMOVE ROTOR SENSOR
14. REMOVE DRIVE PINION

(a) Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)
ProCarManuals.com
(b) Install a brass bar into case hole to tap out the drive pin-
ion.
(c) Tap the drive pinion and remove the bearing cage from
the bore.
15. REMOVE BEARING CAGE FROM DRIVE PINION

16. REMOVE O-RING FROM BEARING CAGE
WWW.ALL-TRANS.BY
IN-13
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
IN008-02
ProCarManuals.com
WWW.ALL-TRANS.BY
IN-14
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
ProCarManuals.com
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AX-30
AUTOMATIC TRANSAXLE - SECOND COAST BRAKE
SECOND COAST BRAKE AX0EZ-02
COMPONENTS
ProCarManuals.com
AX0F0-02
SECOND COAST BRAKE PISTON

DISASSEMBLY
1. REMOVE OIL SEAL RING
Remove the oil seal ring from the piston.
2. REMOVE PISTON ROD

(a) Remove the E-ring while pushing the piston with needle-
nose pliers.
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AX-31
(b) Remove the spring, washer and piston rod.
AX0F1-02
SECOND COAST BRAKE INSPECTION

INSPECT BRAKE BAND
If the lining of the brake band is peeling off or discolored,
or even if a part of the printed numbers are defaced, re-
place the brake band.
ProCarManuals.com
AX0F2-02
SECOND COAST BRAKE PISTON

ASSEMBLY
1. SELECT PISTON ROD
If the band is OK, but the piston stroke is not within the
standard value, select a new piston rod.
Piston stroke:
1.5 - 3.0 mm (0.059 - 0.118 in.)
There are 2 lengths of piston rod.
Piston rod length:
72.9 mm (2.870 in.)
71.4 mm (2.811 in.)
2. INSTALL PISTON ROD
(a) Install the washer and spring to the piston rod.
(b) Install an E-ring while pushing the piston.

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AX-32
3. INSTALL OIL SEAL RING

(a) Apply ATF to the oil seal ring.
(b) Install the oil seal ring to the piston.
NOTICE: Do not spread the ring ends more than necessary.
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-33
AUTOMATIC TRANSAXLE - OIL PUMP
OIL PUMP AX0F3-02
COMPONENTS
ProCarManuals.com
AX0F4-02
OIL PUMP DISASSEMBLY

1. REMOVE OIL SEAL RINGS
Remove the 2 oil seal rings from the stator shaft back
side.
2. REMOVE THRUST WASHER FROM STATOR SHAFT

BACK SIDE
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AX-34
3. REMOVE STATOR SHAFT

Remove the 11 bolts and stator shaft.
Keep the gears in assembly order.
4. REMOVE FRONT OIL SEAL

Pry off the oil seal with a screwdriver.
ProCarManuals.com
AX0F5-02
OIL PUMP BUSHING INSPECTION

1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body.
Using a feeler gauge, measure the clearance.
Standard body clearance:
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Maximum body clearance:
0.3 mm (0.012 in.)
If the body clearance is greater than the maximum, re-
place the oil pump body subassembly.
2. CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure between the driven gear teeth and the cres-
cent-shaped part of the pump body.
Standard tip clearance:
0.11 - 0.14 mm (0.0043 - 0.0055 in.)
Maximum tip clearance:
0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, replace
the oil pump body subassembly.
3. CHECK SIDE CLEARANCE OF BOTH GEARS

Using a steel straightedge and a feeler gauge, measure
the side clearance of both gears.
Standard side clearance:
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Maximum side clearance:
0.1 mm (0.004 in.)
There are 3 different thicknesses for drive and driven
gears.
WWW.ALL-TRANS.BY
AX-35
Drive and driven gear thickness
Thickness
Mark
mm (in.)
A 9.440 - 9.456 (0.3717 - 0.3723)
B 9.456 - 9.474 (0.3723 - 0.3730)
C 9.474 - 9.490 (0.3730 - 0.3736)
If the thickest gear cannot make the side clearance within

standard specification, replace the oil pump body subas-
sembly.
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Maximum inside diameter:
38.18 mm (1.5031 in.)
If the inside diameter is greater than the maximum, re-
place the oil pump body subassembly.
ProCarManuals.com
5. CHECK STATOR SHAFT BUSHINGS

stator shaft bushings.
Front side
21.57 mm (0.8492 in.)
Rear side
27.07 mm (1.0657 in.)
place the stator shaft.
AX0F6-02
OIL PUMP ASSEMBLY

1. INSTALL FRONT OIL SEAL
Using SST and a hammer, install a new oil seal. The seal
end should be flush with the outer edge of the pump body.
SST 09350-32014 (09351-32140)
2. INSTALL DRIVEN GEAR AND DRIVE GEAR

Make sure the top of the gears are facing upward.
WWW.ALL-TRANS.BY
AX-36
3. INSTALL STATOR SHAFT ONTO PUMP BODY

Align the stator shaft with each bolt hole.
4. TIGHTEN 11 STATOR SHAFT BOLTS
5. INSTALL THRUST WASHER

(a) Coat the thrust washer with petroleum jelly.
(b) Align the tab of the washer with the hollow of the pump
body.
ProCarManuals.com
6. INSTALL 2 OIL SEAL RINGS ON OIL PUMP

Install 2 oil seal rings to the stator shaft groove, then snug
them down by squeezing their ends together.
NOTICE: Do not spread the ring ends too much.
HINT: After installing the oil seal rings, check that they
move smoothly.
7. CHECK PUMP DRIVE GEAR ROTATION

Turn the drive gear with screwdrivers and make sure that
it rotates smoothly.
NOTICE: Be careful not to damage the oil seal lip.
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AX-37
AUTOMATIC TRANSAXLE - DIRECT CLUTCH
DIRECT CLUTCH AX0GT-02
COMPONENTS
ProCarManuals.com
AX0F7-02
DIRECT CLUTCH DISASSEMBLY

1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, measure the direct clutch piston stroke while applying
and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/
cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)
Piston stroke:
1.11 - 1.44 mm (0.0437 - 0.0567 in.)
If the piston stroke is greater than the maximum inspect
each component.
WWW.ALL-TRANS.BY
AX-38
2. REMOVE SNAP RING FROM CLUTCH DRUM

3. REMOVE FLANGE, DISCS AND PLATES

(a) Place SST on the spring retainer and compress the
springs with a shop press.
SST 09350-32014 (09351-32070)
(b) Remove the snap ring with the snap ring pliers.
ProCarManuals.com
(c) Remove the piston return spring.
5. REMOVE CLUTCH PISTON

(a) Install the direct clutch onto the oil pump.
(b) Apply compressed air to the oil pump to remove the pis-
ton. (if the piston does not come out completely, use
needle-nose pliers to remove it).
(c) Remove the direct clutch from the oil pump.
(d) Remove the 2 O-rings from the piston.

WWW.ALL-TRANS.BY
AX-39
AX0F8-02
DIRECT CLUTCH INSPECTION

1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying lowpres-
sure compressed air.
2. INSPECT DISCS, PLATES AND FLANGE

Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:
If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
ProCarManuals.com
3. CHECK DIRECT CLUTCH BUSHING

direct clutch bushing.
47.07 mm (1.8531 in.)
place the direct clutch.
AX0F9-02
DIRECT CLUTCH ASSEMBLY

1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
(a) Install new O-rings to the piston. Coat the O-rings with
ATF.
(b) Being careful not to damage the O-rings, press the piston
into the drum with the cup side up.
2. INSTALL PISTON RETURN SPRING

(a) Place the return spring and snap ring onto the piston.
(b) Place SST on the spring retainer, and compress the re-
turn spring with a shop press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring with the snap ring pliers. Be sure the
end gap of snap ring is not aligned with the spring retainer
claw.
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AX-40
3. INSTALL PLATES, DISCS AND FLANGE

(a) Install plates and discs.
Install in order: P=Plate D=Disc
P - D - P - D - P - D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING

Check that the end gap of the snap ring is not aligned with
one of the cutouts.
ProCarManuals.com
5. RECHECK PISTON STROKE OF DIRECT CLUTCH

(a) Install the direct clutch on the oil pump.
(b) Set a dial indicator and measuring terminal (SST) togeth-
er, measure the direct clutch piston stroke while applying
and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/
cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)
Piston stroke:
1.11 - 1.44 mm (0.0437 - 0.0567 in.)
If the piston stroke is non- standard, select another
flange.
HINT: There are 2 different flange thickness.
Flange thickness:
2.60 mm (0.1024 in.)
3.00 mm (0.1181 in.)
WWW.ALL-TRANS.BY
AX-41
AUTOMATIC TRANSAXLE - FORWARD CLUTCH
FORWARD CLUTCH AX0FA-02
COMPONENTS
ProCarManuals.com
AX0FB-02
FORWARD CLUTCH DISASSEMBLY

1. CHECK PISTON STROKE OF FORWARD CLUTCH
Set a dial indicator and measuring terminal (SST) togeth-
er, measure the forward clutch piston stroke while apply-
ing and releasing compressed air (392 - 785 kPa, 4 - 8
kgf/cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)
Piston stroke:
1.41 - 1.82 mm (0.0555 - 0.0717 in.)
If the piston stroke is greater than the maximum inspect
the each component.
WWW.ALL-TRANS.BY
AX-42
2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES

ProCarManuals.com
4. REMOVE RETURN SPRINGS

(a) Place SST on the spring retainer and compress the
SST 09350-32014 (09351-32070)
(b) Remove the snap ring with the snap ring pliers.
5. REMOVE CLUTCH PISTON

(a) Apply compressed air into the oil passage to remove the
piston.
If the piston does not come out, use needle-nose pliers
to remove it.
WWW.ALL-TRANS.BY
AX-43
(b) Remove the 2 O-rings from the piston.
6. IF NECESSARY, REMOVE OIL SEAL RINGS

Remove the 2 oil seal rings from the shaft.
ProCarManuals.com
AX0FC-02
FORWARD CLUTCH INSPECTION

1. INSPECT CLUTCH PISTON
2. INSPECT DISCS, PLATES AND FLANGE

HINT:
place all discs.
AX0FD-02
FORWARD CLUTCH ASSEMBLY

1. INSTALL OIL SEAL RINGS
Install the 2 oil seal rings to the shaft.
NOTICE: Do not spread the ring ends more than necessary.
move smoothly.
WWW.ALL-TRANS.BY
AX-44
2. INSTALL CLUTCH PISTON TO CLUTCH DRUM

(a) Install the 2 new O-rings to the piston.
(b) Coat the O-rings with ATF.

(c) Press the piston into the drum with the cup side up, being
careful not to damage the O-rings.
ProCarManuals.com
3. INSTALL PISTON RETURN SPRINGS

(a) Place the piston return spring and snap ring onto the pis-
ton.
(b) Place SST on the piston return spring, and compress the
SST 09350-32014 (09351-32070)
(c) Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.

(a) Install the plates and discs.
P - D - P - D - P - D - P - D
(b) Install the flange with the flat end facing downward.

Check that the end gap of snap ring is not aligned with one
of the cutouts.
WWW.ALL-TRANS.BY
AX-45
6. RECHECK PISTON STROKE OF FORWARD CLUTCH

Set a dial indicator and measuring terminal (SST) togeth-
er, measure the forward clutch piston stroke while apply-
ing and releasing compressed air (392 - 785 kPa, 4 - 8
kgf/cm2, 57 - 114 psi).
SST 09350-32014 (09351-32190)
Piston stroke:
1.41 - 1.82 mm (0.0555 - 0.0717 in.)
If the piston stroke is less than the limit, parts may be mis-
assembled and reinstall them.
If the piston stroke is non- standard, select another
flange.
HINT: There are 5 different flange thickness.
Flange thickness:
2.8 mm (0.110 in.)
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
3.6 mm (0.142 in.)
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-46
AUTOMATIC TRANSAXLE - FRONT PLANETARY GEAR
FRONT PLANETARY GEAR AX0FE-02
COMPONENTS
ProCarManuals.com
AX0FF-02
ONE-W AY CLUTCH AND SUN GEAR

DISASSEMBLY
1. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the sun gear and turn the hub. The hub should turn
freely clockwise and should lock counterclockwise.
2. REMOVE SECOND BRAKE HUB AND ONE- WAY

CLUTCH FRONT SUN GEAR
While turning the hub clockwise, remove the one-way
clutch from the sun gear.
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AX-47
3. REMOVE THRUST WASHER FROM SUN GEAR INPUT

DRUM
4. REMOVE SUN GEAR FROM DRUM

(a) Using snap ring pliers, remove the snap ring from the
drum.
(b) Remove the sun gear from the drum.
ProCarManuals.com
5. REMOVE SHAFT SNAP RING

Using snap ring pliers, remove the shaft snap ring from
the sun gear.
AX0FG-02
ONE-W AY CLUTCH AND SUN GEAR

ASSEMBLY
1. INSTALL SHAFT SNAP RING TO SUN GEAR
2. INSTALL SUN GEAR TO DRUM
(a) Install the sun gear to the drum.
(b) Using snap ring pliers, install the snap ring to the drum.
3. INSTALL THRUST WASHER TO SUN GEAR INPUT

DRUM
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AX-48
4. INSTALL ONE-WAY CLUTCH AND SECOND BRAKE

HUB ON SUN GEAR
While turning the hub clockwise, slide the one-way clutch
onto the sun gear.
5. RECHECK OPERATION OF ONE-WAY CLUTCH
AX0FH-02
PLANETARY RING GEAR INSPECTION

1. INSPECT RING GEAR FLANGE BUSHING
flange bushing.
Standard inside diameter:
19.025 - 19.050 mm (0.7490 - 0.7500 in.)
place the flange.
ProCarManuals.com
2. REMOVE RING GEAR FLANGE

(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange from the ring gear.
3. INSTALL RING GEAR FLANGE

(a) Position the flange into the ring gear.
(b) Using a screwdriver, install the snap ring.

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AX-49
AX0FJ-02
FRONT PLANETARY GEAR INSPECTION

MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the planetary pinion gear
thrust clearance.
Standard clearance:
0.20 - 0.50 mm (0.0079 - 0.0197 in.)
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-50
AUTOMATIC TRANSAXLE - SECOND BRAKE
SECOND BRAKE AX0FK-02
COMPONENTS
ProCarManuals.com
AX0FL-02
SECOND BRAKE PISTON DISASSEMBLY

REMOVE SECOND BRAKE PISTON
(a) Apply compressed air to the oil hole to remove the piston.
(b) Remove the 2 O-rings from the piston.

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AX-51
AUTOMATIC TRANSAXLE - SECOND BRAKE
AX0FM-02
SECOND BRAKE INSPECTION

INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surface of the discs, plates and flange
are worn or burnt. If necessary, replace them.
HINT:
place all discs.
ProCarManuals.com
AX0FN-02
SECOND BRAKE PISTON ASSEMBLY

INSTALL PISTON
(a) Coat a new O-ring with ATF.
(b) Install the 2 O-rings on the piston.
(c) Press the piston into the drum, being careful not to dam-
age the O-rings.
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AX-52
AUTOMATIC TRANSAXLE - REAR PLANETARY GEAR
REAR PLANETARY GEAR AX0FP-02
COMPONENTS
ProCarManuals.com
AX0FQ-02
ONE-W AY CLUTCH DISASSEMBLY

Hold the outer race and turn the hub. The hub should turn
freely counterclockwise and should lock clockwise.
2. SEPARATE ONE- WAY CLUTCH AND PLANETARY

GEAR
3. REMOVE THRUST WASHERS
Remove the 2 thrust washers from both sides of the plan-
etary gear.
WWW.ALL-TRANS.BY
AX-53
4. REMOVE ONE-WAY CLUTCH FROM OUTER RACE

(a) Remove the 2 snap rings and retainers from both sides.
(b) Remove the one-way clutch from the outer race.
AX0FR-02
REAR PLANETARY GEAR INSPECTION

CLEARANCE
thrust clearance.
Standard clearance:
0.20 - 0.50 mm (0.0079 - 0.0197 in.)
ProCarManuals.com
AX0FS-02
ONE-W AY CLUTCH ASSEMBLY

1. INSTALL ONE-WAY CLUTCH
(a) Install the one-way clutch into the outer race, facing the
flanged side of the one-way clutch toward the shiny side
of the outer race.
(b) Install the 2 retainers and snap rings to both sides.
2. INSTALL PLANETARY GEAR INTO ONE- WAY

CLUTCH
Install the planetary gear into the one-way clutch, facing
the inner race of the planetary gear toward the black side
of the one-way clutch outer race.
WWW.ALL-TRANS.BY
AX-54
4. INSTALL THRUST WASHERS

(a) Coat the 2 thrust washers with petroleum jelly.
(b) Align the tab of the washers with the hollow of the carrier.
ProCarManuals.com
AX0FT-02
RING GEAR FLANGE REPLACEMENT

1. REMOVE RING GEAR FLANGE
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange from the ring gear.
2. INSTALL RING GEAR FLANGE

(a) Position the flange into the ring gear.
(b) Using a screwdriver, install the snap ring.
WWW.ALL-TRANS.BY
AX-55
AUTOMATIC TRANSAXLE - FIRST AND REVERSE BRAKE
FIRST AND REVERSE BRAKE AX0FU-02
COMPONENTS
ProCarManuals.com
AX0FV-02
FIRST AND REVERSE BRAKE INSPECTION

INSPECT DISCS, PLATES AND FLANGES
flanges are worn or burnt. If necessary, replace them.
HINT:
place all discs.
Before assembly new discs, soak them in ATF for at
least 15 minutes.
WWW.ALL-TRANS.BY
AX-56
AUTOMATIC TRANSAXLE - OVERDRIVE UNIT
OVERDRIVE UNIT AX0FW-02
COMPONENTS
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-57
AX0FX-02
OVERDRIVE BRAKE DISASSEMBLY

(a) While pushing the return spring, remove the snap ring
with a screwdriver.
(b) Remove the piston return spring.
2. REMOVE CUSHION PLATE, PLATES, DISCS AND

FLANGE
ProCarManuals.com
3. REMOVE PISTON FROM DRUM

Apply compressed air to oil hole to remove the piston.
HINT: Blow with the gun slightly away from the oil hole,
and be careful that the piston does not tilt.
4. REMOVE O-RINGS
Remove the inner and outer O-rings from the piston.
WWW.ALL-TRANS.BY
AX-58
AX0FY-02
OVERDRIVE BRAKE INSPECTION

INSPECT DISCS, PLATES AND FLANGE
HINT:
place all discs.
ProCarManuals.com
AX0FZ-02
OVERDRIVE DIRECT CLUTCH

DISASSEMBLY
1. CHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while ap-
plying and releasing compressed air (392 - 785 kPa, 4 -
8 kgf/cm2, 57- 114 psi).
Piston stroke:
1.21 - 1.91 mm (0.0476 - 0.0752 in.)
If the piston stroke is greater than the maximum, inspect
the each component.
2. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE

WWW.ALL-TRANS.BY
AX-59
3. REMOVE BEARING AND RACE FROM CLUTCH

DRUM AND CASE
4. REMOVE SNAP RING WITH SCREWDRIVER

ProCarManuals.com
5. REMOVE FLANGES, DISCS AND PLATES

(a) Place SST on the spring retainer and compress the spring
with a shop press.
SST 09350-32014 (09351-32070, 09351-32200)
(b) Remove the snap ring.

WWW.ALL-TRANS.BY
AX-60
7. REMOVE PISTON FROM CLUTCH DRUM

(a) Install the clutch drum of the case.
(b) Apply compressed air to the pressure apply hole of the
case.
(c) Remove the piston from the clutch drum.
If the piston does not come out completely, use needle-
nose pliers to remove it.
(d) Remove the clutch drum from the case.
8. REMOVE O-RINGS
Remove the 2 O-rings from the piston.
ProCarManuals.com
AX0G0-02
OVERDRIVE DIRECT CLUTCH INSPECTION

1. INSPECT OVERDRIVE DIRECT CLUTCH
2. INSPECT DISCS, PLATES AND FLANGES

Check that the sliding surfaces of discs, plates and
flanges are worn or burnt. If necessary, replace them.
HINT:
place all discs.
3. CHECK DIRECT CLUTCH BUSHING

two direct clutch bushings.
22.09 mm (0.8697 in.)
place the direct clutch drum.
WWW.ALL-TRANS.BY
AX-61
AX0G1-02
OVERDRIVE DIRECT CLUTCH ASSEMBLY

1. INSTALL CLUTCH PISTON
(a) Install new O-rings to the piston. Coat the O-rings with
ATF.
(b) Press the piston into the drum with the cup side up, being
careful not to damage the O-ring.
ProCarManuals.com

(a) Install the return spring and set snap ring in place.
(b) Place SST on the spring retainer, and compress the

spring with a shop press.
SST 09350-32014 (09351-32070, 09351-32200)
(c) Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.

Flange - D - P - D - Flange
WWW.ALL-TRANS.BY
AX-62

Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.
5. INSTALL BEARING AND RACE

(a) Coat the bearing with petroleum jelly and install it facing
the race side downward to the clutch drum.
Bearing:
Outer diameter
46.3 mm (1.823 in.)
Inner diameter
26.2 mm (1.031 in.)
ProCarManuals.com
(b) Coat the race with petroleum jelly and install it to thecase.
Race:
Outer diameter
43.0 mm (1.693 in.)
Inner diameter
24.5 mm (0.965 in.)
6. INSTALL DIRECT CLUTCH ON CASE
7. RECHECK PISTON STROKE OF DIRECT CLUTCH

Using a dial indicator, measure the piston stroke while ap-
plying and releasing compressed air (392 - 785 kPa, 4 -
8 kgf/cm2, 57- 114 psi).
Piston stroke:
1.21 - 1.91 mm (0.0476 - 0.0752 in.)
WWW.ALL-TRANS.BY
AX-63
AX0G2-02
COUNTER DRIVE GEAR DISASSEMBLY

(a) While turning the overdrive gear clockwise, install the ov-
erdrive direct clutch into the one-way clutch.
(b) Hold the overdrive direct clutch and turn the intermediate
shaft. The shaft should turn freely clockwise and should
lock counterclockwise.
(c) Remove the overdrive direct clutch.
2. CHECK COUNTER DRIVE GEAR PRELOAD

(a) Hold the intermediate shaft in a vise with soft jaws.
(b) Using a tension gauge, measure the preload.
9 - 15 N (920 - 1,530 gf, 2.0 - 3.4 lbf)
HINT: Turn the counter drive gear right and left several
times before measuring the preload.
ProCarManuals.com
3. REMOVE RETAINING PLATE

(a) Remove the snap ring with a screwdriver.
(b) Remove the retaining plate.
4. REMOVE ONE-WAY CLUTCH AND OUTER RACE

WWW.ALL-TRANS.BY
AX-64
5. REMOVE NO.3 OVERDRIVE PLANETARY THRUST

WASHER
6. REMOVE ONE-WAY CLUTCH FROM OUTER RACE

Note the direction of the one-way clutch.
ProCarManuals.com
7. REMOVE PLUGS FROM PLANETARY GEAR

Remove the 4 plugs with a magnetic finger.
HINT: Be careful not to lose them.
8. REMOVE ADJUSTING NUT AND WASHER

(a) Pry off the locking washer with chisel.
(b) Using SST, loosen the adjusting nut.

SST 09350-32014 (09351-32080)
(c) Remove the adjusting nut and washer.
WWW.ALL-TRANS.BY
AX-65
9. REMOVE INTERMEDIATE SHAFT BEARING

Using SST, press out the bearing from the shaft.
SST 09950-00020
10. REMOVE COUNTER DRIVE GEAR AND FRONT

BEARING
Press out the gear and bearing together.
ProCarManuals.com
11. REMOVE REAR BEARING

Using SST, press out the bearing.
SST 09950-00020
12. REMOVE OVERDRIVE PLANETARY RING GEAR

FROM COUNTER DRIVEGEAR
(a) While pulling up the ring gear, compress the snap ring
with needle-nose pliers and remove it from the groove.
(b) Remove the ring gear from the counter drive gear.
13. REMOVE OUTER RACES FROM COUNTER DRIVE

GEAR
Drive out the 2 races with a brass bar and hammer.
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AX-66
14. REMOVE SNAP RING FROM COUNTER DRIVE GEAR

Using a screwdriver, remove the snap ring.
AX0G3-02
OVERDRIVE PLANETARY GEAR

INSPECTION
CLEARANCE
thrust clearance.
Standard clearance:
0.20 - 0.50 mm (0.0079 - 0.0197 in.)
ProCarManuals.com
AX0GU-02
COUNTER DRIVE GEAR ASSEMBLY

1. INSTALL SNAP RING INTO COUNTER GEAR
Install the snap ring with a screwdriver.
2. INSTALL OUTER RACES INTO COUNTER DRIVE

GEAR
Using SST, press in the 2 outer races to the gear both
side.
SST 09350-32014 (09351-32120, 09351-32150)
HINT: Press in the 2 outer races until they touch the snap
ring. Tap the races in straight, so that they do not tilt.
3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO

COUNTER DRIVEGEAR
While pushing down the ring gear, squeeze the snap ring
end with a needle-nose pliers, and install it into the
groove.
HINT: When the snap ring is fully seated, the end will be
free.
WWW.ALL-TRANS.BY
AX-67
4. INSTALL REAR BEARING

Using SST, press in the bearing onto the shaft.
SST 09350-32014 (09351-32120)
HINT: Press in the bearing until the side surface of the in-
ner race touches the shaft.
5. INSTALL COUNTER DRIVE GEAR AND FRONT BEAR-

ING
(a) Install the gear onto the shaft, and mesh the ring gear with
the planetary pinions.
(b) Place the front bearing onto the shaft.
HINT: Hold the ring gear to prevent it from falling.
ProCarManuals.com
(c) Using SST, press in the bearing until there is slight play
between the bearings.
SST 09350-32014 (09351-32120)
6. INSTALL INTERMEDIATE SHAFT BEARING

Using SST, press in the bearing until it slightly touches the
front bearing of the counter drive gear.
SST 09350-32014 (09351-32120)
HINT: The counter drive gear can be turned lightly.
7. PLACE NEW LOCKING WASHER AND ADJUSTING

NUT ONTO INTERMEDIATE SHAFT
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AX-68
8. ADJUST PRELOAD OF COUNTER DRIVE GEAR

(a) Place SST onto the adjusting nut and hold the shaft in a
vise with soft jaws.
SST 09350-32014 (09351-32080)
(b) Tighten the adjusting nut until the following gear starting
load occurs with a tension gauge.
9 - 15 N (920 - 1,530 gf, 2.0 - 3.4 lbf)
HINT: Turn the counter drive gear right and left several
times before measuring the preload.
(c) Lock the adjusting nut with one tab on locking washer.
Bend the locking washer tab until it is even with the adjust-
ing nut groove.
ProCarManuals.com
9. INSTALL PINION SHAFT PLUGS

Install the 4 plugs into the pinion shaft.
10. INSTALL NO.3 OVERDRIVE PLANETARY THRUST

WASHER
Install the thrust washer, facing the groove toward the ov-
erdrive case.
11. ASSEMBLE OVERDRIVE ONE-WAY CLUTCH

(a) Install the one-way clutch into the outer race.
(b) Install a retainer on both sides of the one-way clutch.
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AX-69
12. INSTALL OVERDRIVE ONE-WAY CLUTCH INTO HUB

Be sure that the one-way clutch is installed in the correct
direction.
ProCarManuals.com
13. INSTALL RETAINING PLATE

(a) Place the retaining plate into the hub.
(b) Install the snap ring with a screwdriver.

(a) While turning the overdrive gear clockwise, install the ov-
erdrive direct clutch into the one-way clutch.
(b) Hold the overdrive direct clutch and turn the intermediate
shaft. The shafts should turn freely clockwise and should
lock counterclockwise.
(c) Remove the overdrive direct clutch.
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AX-70
AX0G4-02
OVERDRIVE CASE DISASSEMBLY

1. REMOVE C0 ACCUMULATOR PISTON FROM OVER-
DRIVE CASE
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retaining plate and two springs.

(c) Remove the accumulator piston.
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(d) Remove the O-ring from the piston.
2. REMOVE OIL SEAL RINGS

Spread the 2 rings apart and remove them.
OVERDRIVE CASE INSPECTION

INSPECT OVERDRIVE CASE BEARING
Check that the bearing turns smoothly with your finger.
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AX-71
AX0G5-02
OVERDRIVE CASE ASSEMBLY

1. INSTALL OIL SEAL RINGS ON OVERDRIVE CASE
Install the oil seal rings to the O/D case groove, then snug
them down by squeezing their ends together.
move smoothly.
2. INSTALL C0 ACCUMULATOR PISTON OF OVER-

DRIVE CLUTCH
(a) Install a new O-ring to the accumulator piston. Coat the
O-ring with ATF.
(b) Install the accumulator piston, 2 springs and plate.
(c) Install the snap ring with snap ring pliers.
ProCarManuals.com
AX0G6-02
OVERDRIVE BRAKE ASSEMBLY

1. INSTALL PISTON INTO DRUM
(a) Install the new O-rings to the piston. Coat the O-rings
with ATF.
(b) Press the piston into the drum, being careful not to dam-
age the O-rings.
2. INSTALL FLANGE, DISCS AND PLATES

(a) Install the flange, facing the flat end upward.
WWW.ALL-TRANS.BY
AX-72
(b) Install the discs and plates.

Flange - D - P - P - D - P
HINT: There are 2 different thickness plates, as shown in
the illustration.
(c) Install the cushion plate facing the rounded end upward.
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4. INSTALL SNAP RING INTO CASE

one of the cutouts.
5. INSTALL OVERDRIVE GEAR ASSEMBLY ONTO

CASE
While turning the overdrive gear clockwise, install the ov-
erdrive gear assembly to the case.
If the overdrive gear assembly is properly installed to the
overdrive case, the clearance between them will be about
24 mm (0.94 in.).
WWW.ALL-TRANS.BY
AX-73
AUTOMATIC TRANSAXLE - VALVE BODY
VALVE BODY AX0G7-02
COMPONENTS
ProCarManuals.com
AX0G8-02
VALVE BODY DISASSEMBLY

1. NOTE THE NUMBERS OF ADJUSTING RINGS
HINT: Count the number of adjusting rings before disas-
sembly of the valve body because the throttle pressure is
changed according to the number. (Some of the valve bo-
dies do not have any adjusting rings).
2. REMOVE SOLENOIDS
(a) Remove the No.1 and No.2 solenoids.
(b) Remove the O-rings from the solenoids.
WWW.ALL-TRANS.BY
AX-74
3. REMOVE UPPER VALVE BODY COVER

Remove the 9 bolts and upper valve body cover.
4. REMOVE STRAINER GASKETS, PLATE AND SLEEVE

STOPPER FROM UPPER VALVE BODY
(a) Remove the strainer, 2 gaskets and plate.
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(b) Remove the sleeve stopper.
5. REMOVE BOLTS FROM UPPER VALVE BODY

Remove the 3 bolts from the upper valve body.
6. REMOVE LOWER VALVE BODY COVER

(b) Remove the lower valve body cover and gasket.
WWW.ALL-TRANS.BY
AX-75
7. REMOVE BOLTS FROM LOWER VALVE BODY

Remove the 3 bolts from lower valve body.
8. LIFT OFF LOWER VALVE BODY AND PLATE AS

SINGLE UNIT
Hold the plate to the lower valve body and lift off the lower
valve body.
HINT: Be careful that the check balls do not fall out.
9. REMOVE PLATE AND GASKETS
ProCarManuals.com
AX0G9-02
VALVE BODY ASSEMBLY

1. POSITION PLATE AND NEW GASKETS ON LOWER
VALVE BODY
Position the new No.2 gasket, the plate and then the new
No.1 gasket on the lower valve body.
HINT: Since No.1 gasket and No.2 gasket are similar use
the illustration below to discriminate between them.
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AX-76
2. PLACE LOWER VALVE BODY WITH PLATE AND GAS-

KETS ON UPPER VALVE BODY
HINT: Hold the lower valve body, gaskets and plate se-
curely so they do not separate.
Align each bolt hole in the valve bodies with the gaskets
and plate.
3. INSTALL AND FINGER TIGHTEN BOLTS IN LOWER

VALVE BODY TO SECURE UPPER VALVE BODY
Install and finger tighten the 3 bolts.
HINT: Each bolt length (mm, in.) is indicated in the illustra-
tion.
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4. INSTALL LOWER VALVE BODY COVER

(a) Install the lower valve body cover over the new gasket.
(b) Install and finger tighten the 10 bolts.
tion.
5. INSTALL AND FINGER TIGHTEN BOLTS IN UPPER

VALVE BODY
Install and finger tighten the 3 bolts.
tion.
6. INSTALL SLEEVE STOPPER

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AX-77
7. INSTALL UPPER VALVE BODY COVER GASKETS,

PLATE AND THROTTLE MODULATOR OIL STRAINER
(a) Position a new gasket and plate and then another new
gasket.
HINT: The gaskets are not identical, but can be installed
in any order.
(b) Install the oil strainer onto the gasket.
8. INSTALL UPPER VALVE BODY COVER

(a) Position the upper valve body cover.
(b) Install and finger tighten the 9 bolts.
tion.
ProCarManuals.com
9. INSTALL SOLENOIDS
(a) Install the new O-rings on the solenoids.
(b) Install the No.1 and No.2 solenoids.
(c) Install and finger tighten the 3 bolts.
tion.
10. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BO-

DIES
(a) Tighten the 16 bolts in the lower valve body.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Tighten the 12 bolts in the upper valve body.

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AX-78
AUTOMATIC TRANSAXLE - UPPER VALVE BODY
UPPER VALVE BODY AX0GA-02
COMPONENTS
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-79
AX0GB-02
VALVE BODY SPRINGS SPECIFICATIONS

HINT: During re-assembly please refer to the spring specifications below to help you to discriminate
between the different springs.
ProCarManuals.com
Free Length / Coil Outer Diameter

Spring (Color) Number of Coils
mm (in.)
(A) Throttle Modulator Spring (None) 21.70 / 9.50 (0.8543 / 0.3740) 9.5
(B) Accumulator Control Spring (Yellow) 28.06 / 10.60 (1.1047 / 0.4173) 13.0
(C) Low Coast Modulator Spring (None) 21.60 / 7.90 (0.8504 / 0.3110) 11.5
(D) Down Shift Valve Spring (Yellow) 29.76 / 8.73 (1.1717 / 0.3437) 13.5
(E) Throttle Valve Spring (None) 30.70 / 9.20 (1.2087 / 0.3622) 9.5
Second Coast Modulator Valve Spring
(F) 20.93 / 8.50 (0.8240 / 0.3364) 10.0
(Light Green)
(G) Lock-up Relay Valve spring (Green) 26.56 / 10.20 (1.0457 / 0.4016) 11.5
(H) Cut-back Valve Spring (None) 21.80 / 6.00 (0.8583 / 0.2362) 13.5
WWW.ALL-TRANS.BY
AX-80
AX0GC-02
RETAINERS, PINS, VIBRATING STOPPER AND CHECK BALLS LOCATION

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Height / Width / Thickness

Retainer
mm (in.)
(H) Throttle Modulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126)
(I) Accumulator Control Valve 11.5 / 5.0 / 3.2 (0.453 / 0.197 / 0.126)
(J) Cut-back Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126)
(K) Lock-up Relay Valve 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126)
(L) 2nd Coast Modulator Valve 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126)
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AX-81
AUTOMATIC TRANSAXLE - LOWER VALVE BODY
LOWER VALVE BODY AX0GV-02
COMPONENTS
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-82
AX0GD-02
VALVE BODY SPRINGS SPECIFICATIONS

HINT: During re-assembly please refer to the spring specifications below to help you to discriminate
between the different springs.
ProCarManuals.com
Free length / Outer diameter

Spring (Color) Number of Coils
mm (in.)
Secondary Regulator Valve Spring
(A) 43.60 / 10.90 (1.7165 / 0.4291) 11.5
(None)
(B) Lock-up Signal Valve Spring (None) 30.00 / 8.20 (1.1811 / 0.3228) 11.5
(C) 3-4 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5
(D) 1-2 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5
(E) 2-3 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5
(F) Primary Regulator Valve Spring (None) 66.65 / 18.60 (2.6240 / 0.7323) 12.5
(G) Cooler By-pass Valve Spring (None) 19.90 / 11.00 (0.7835 / 0.4331) 8.5
(H) Pressure Relief Valve Spring (None) 11.20 / 6.40 (0.4409 / 0.2520) 7.5
WWW.ALL-TRANS.BY
AX-83
AX0GE-02
RETAINER, STRAINER AND CHECK BALLS LOCATION

ProCarManuals.com
Height / Width / Thickness

Retainer
mm (in.)
(I) Primary Regulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.128)
(J) 2-3 Shift Valve 8.0 / 6.0 / 3.2 (0.315 / 0.236 / 0.126)
(K) 1-2 Shift Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126)
(L) 3-4 Shift Valve 8.0 / 6.0 / 3.2 (0.315 / 0.236 / 0.126)
(M) Secondary Regulator Valve 13.0 / 6.0 / 3.2 (0.512 / 0.236 / 0.126)
(N) Lock-up Signal Vave 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126)
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AX-84
AUTOMATIC TRANSAXLE - DIFFERENTIAL ASSEMBLY
DIFFERENTIAL ASSEMBLY AX0GF-02
COMPONENTS
ProCarManuals.com
WWW.ALL-TRANS.BY
AX-85
AX0GG-02
DIFFERENTIAL CASE DISASSEMBLY

1. REMOVE RING GEAR
(a) Loosen the staked part of the lock plate.
(b) Remove the 8 bolts and locking plates.

(c) Using a copper hammer, tap on the ring gear to remove
it from the case.
ProCarManuals.com
2. REMOVE SIDE BEARINGS

Fasten SST under the bearing above the cutouts on the
speedometer drive gear. Remove the bearing from the
case.
SST 09502-10012
3. CHECK SIDE GEAR BACKLASH

Using a dial gauge, measure the backlash of each side
gear while holding one pinion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
4. DISASSEMBLE DIFFERENTIAL CASE

(a) Drive out the pinion shaft lock pin from the side on which
the ring gear is installed.
WWW.ALL-TRANS.BY
AX-86
(b) Remove the pinion shaft from the case.

(c) Remove the 2 pinions and 2 side gears with the 4 thrust
washers.
5. REMOVE LH OIL SEAL

Using a hammer and screwdriver, remove the oil seal.
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6. REMOVE BEARING OUTER RACE FROM LH SIDE

BEARING RETAINER
Using SST, press out the outer race and shim.
SST 09350-32014 (09351-32090)
7. REMOVE RH OIL SEAL

Using a hammer and screwdriver, remove the oil seal.
AX0GH-02
DIFFERENTIAL CASE ASSEMBLY

1. INSTALL RH OIL SEAL
(a) Using SST, drive in a new oil seal until its surface is flush
with the surface of the case.
SST 09350-32014 (09351-32130, 09351-32150)
(b) Coat the oil seal lip with MP grease.
WWW.ALL-TRANS.BY
AX-87
2. INSTALL BEARING OUTER RACE TO LH SIDE BEAR-

ING RETAINER
(a) Place the shim onto the retainer.
(b) Using SST, press a new outer race into the retainer.
SST 09350-32014 (09351-32111, 09351-32130)
HINT: Use the 2.60 mm (0.1024 in.) thick thim.
3. INSTALL LH OIL SEAL

(a) Using SST, drive in a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)
Oil seal drive in depth:
2.7 mm (0.106 in.)
(b) Coat the oil seal lip with MP grease.
ProCarManuals.com
4. ASSEMBLE DIFFERENTIAL CASE

(a) Install the removed thrust washers to the side gears.
(b) Install the side gears with thrust washers, pinion thrust
washers and pinion gears.
(c) Install the pinion shaft.

WWW.ALL-TRANS.BY
AX-88
(d) Check the side gear backlash.

Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Referring to the table below, select thrust washers which
will ensure that the backlash is within specification. Try to
select washers of the same size for both sides.
Thrust washer thickness
mm (in.)
Thickness Thickness
0.95 (0.0374) 1.10 (0.0433)
1.00 (0.0394) 1.15 (0.0453)
1.05 (0.0413) 1.20 (0.0472)
If the backlash is not within specification, install a thrust

washer of a different thickness.
(e) Using a hammer and punch, drive the lock pin through the
case and hole in the pinion shaft.
ProCarManuals.com
(f) Stake the differential case.
5. INSTALL SIDE BEARINGS

(a) Install the speedometer drive gear onto the differential
case.
(b) Using SST and a press, press in the RH side bearing onto
the differential case.
SST 09350-32014 (09351-32090, 09351-32120)
WWW.ALL-TRANS.BY
AX-89
(c) Using SST and a press, press in the LH side bearing onto
the differential case.
SST 09710-28020 (09710-08040)
6. INSTALL RING GEAR

(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 100 °C (212 °F) in an oil bath.
(c) Carefully remove the ring gear from the water.
NOTICE: Do not heat the ring gear above 110 °C (230 °F).
(d) Clean the contact surface of the ring gear with cleaning
solvent.
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(e) Quickly install the ring gear on the differential case.

(f) Install new locking plates and set bolts. When the ring
gear has cooled sufficiently, tighten the set bolts uniformly
a little at a time. Torque the bolts.
(g) Using a hammer and drift punch, stake the locking plates.
HINT: Stake one claw flush with the flat surface of the nut.
For the claw contacting the protruding portion of the nut,
stake only the half on the tightening side.
AX0GJ-02
DRIVE PINION DISASSEMBLY

1. REMOVE DRIVE PINION SHAFT BEARING
SST 09950-00020
WWW.ALL-TRANS.BY
AX-90
2. REMOVE OIL SEALS FROM CAGE

Using SST, press out the two oil seals together.
SST 09350-32014 (09351-32090)
3. REMOVE SHAFT BEARING OUTER RACE FROM

CAGE
Using a hammer and brass bar, drive out the outer race
from the cage.
ProCarManuals.com
4. REMOVE COUNTER DRIVEN GEAR BEARING

SST 09950-00020
AX0GK-02
DRIVE PINION SHAFT ASSEMBLY

1. INSTALL COUNTER DRIVEN GEAR BEARING
Using SST, press in a new bearing.
SST 09350-32014 (09351-32090)
2. INSTALL OIL SEALS TO CAGE

(a) Using SST, press in a new oil seal with the lip facing down-
ward.
SST 09350-32014 (09351-32090)
Oil seal press in depth (from flat end):
9.5 mm (0.374 in.)
WWW.ALL-TRANS.BY
AX-91
(b) Measure the oil seal press in depth.

Oil seal press in depth:
4 mm (0.16 in.)
(c) With the oil seal lip facing upward, use SST to press in a
new oil seal until its end is flush with the surface of the
cage.
SST 09350-32014 (09351-32090)
(d) Coat the oil seal lip with MP grease.
ProCarManuals.com
3. INSTALL SHAFT BEARING OUTER RACE TO CAGE

Using SST, press a new outer race into the cage.
SST 09350-32014 (09351-32111, 09351-32130)
4. INSTALL DRIVE PINION SHAFT BEARING

Using SST, press in the bearing.
SST 09350-32014 (09351-32100)
5. PLACE BEARING CAGE ONTO DRIVE PINION SHAFT

Be careful not to damage the oil seal with the splines.
WWW.ALL-TRANS.BY
AX-92
AX0GL-02
DIFFERENTIAL SIDE BEARING PRELOAD

ADJUSTMENT
1. PLACE OUTER RACE AND ADJUSTING SHIM ONTO
RH SIDE BEARING
Use the adjusting shim which was removed or one 2.40
mm (0.0945 in.) thick.
2. PLACE DIFFERENTIAL CASE INTO TRANSAXLE

CASE
Be sure to install the adjusting shim.
ProCarManuals.com
3. INSTALL LH BEARING RETAINER

(a) Do not install the O-ring yet.
(b) Do not coat the bolt threads with sealant yet.
(c) Temporarily tighten the bolts evenly and gradually while
turning the ring gear.
4. INSTALL RH SIDE BEARING CAP

Tighten the bolts evenly and gradually while turning the
ring gear.
5. TIGHTEN LH BEARING RETAINER

WWW.ALL-TRANS.BY
AX-93
6. ADJUST SIDE BEARING PRELOAD

Using SST and a torque meter, measure the preload of
the ring gear.
SST 09564-3201 1
New bearing
1.0 - 1.6 N·m (10 - 16 kgf·cm, 8.7 - 13.9 in.·lbf)
Reused bearing
0.5 - 0.8 N·m (5 - 8 kgf·cm, 4.3 - 6.9 in.·lbf)
If the preload is not within specification, remove the differ-

ential case assembly.
Reselect the RH adjusting shim.
mm (in.)
Thickness Thickness
1.90 (0.0748) 2.40 (0.0945)
1.95 (0.0786) 2.45 (0.0965)
2.00 (0.0787) 2.50 (0.0984)
2.05 (0.0807) 2.55 (0.1004)
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2.10 (0.0827) 2.60 (0.1024)

2.15 (0.0846) 2.65 (0.1043)
2.20 (0.0866) 2.70 (0.1063)
2.25 (0.0886) 2.75 (0.1083)
2.30 (0.0906) 2.80 (0.1103)
HINT: The preload will change by about 0.3 - 0.4 N·m (3

- 4kgf·cm, 2.6 - 3.5 in.·lbf) with a change in shim thick-
ness of 0.05 mm (0.0020 in.).
7. REMOVE DIFFERENTIAL CASE AND COMPONENT

PARTS
If the preload is adjusted within specification, remove the
bearing retainer, differential case, RH side bearing and
shim.
Be careful not to lose the adjusting shim.
WWW.ALL-TRANS.BY
AX-94
AUTOMATIC TRANSAXLE - COMPONENT PARTS INSTALLATION
COMPONENT PARTS INSTALLATION AX0GW-02
COMPONENT PARTS INSTALLATION

Disassembly, inspection and assembly of each component group have been indicated in the preceding
chapter. Before assembly, make sure, again, that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this
group immediately.
Recommended ATF:
DEXRON ® II
GENERAL INSTALLATION NOTES:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspec-
tion before assembly because even a small nick could cause fluid leakage and affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air-never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.
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WWW.ALL-TRANS.BY
AX-95
BEARING AND RACE DIAMETERS

ProCarManuals.com
mm Front Bearing Race Thrust Bearing Race Rear Bearing Race

(in.) Outer / Inner Diameter Outer / Inner Diameter Outer / Inner Diameter
(A) 43.0 / 30.5 (1.693 / 1.201) 42.0 / 28.9 (1.654 / 1.138) 42.0 / 27.1 (1.654 / 1.067)
(B) 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.7 / 23.0 (1.406 / 0.906)
(C) 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.0 / 19.0 (1.378 / 0.748)
(D) 45.0 / 28.0 (1.772 / 1.102) 45.0 / 30.0 (1.772 / 1.181) -
(E) 37.3 / 24.1 (1.469 / 0.949) 37.6 / 24.0 (1.480 / 0.945) 37.6 / 22.2 (1.480 / 0.874)
(F) - 46.3 / 26.2 (1.823 / 1.031) 43.0 / 24.5 (1.693 / 0.965)
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AX-96
AX0GM-02
DRIVE PINION ASSEMBLY INSTALLATION

1. INSTALL NEW O-RING ONTO BEARING CAGE
2. INSTALL DRIVE PINION SHAFT INTO CASE

Slightly tap the cage into the case until the groove with the
bore can be see.
HINT: Drive in the bearing cage until the surface of the
bearing cage passes through the groove with the bore.
ProCarManuals.com
3. INSTALL SNAP RING INTO CASE

(a) Using SST, install the snap ring into the groove.
SST 09350-32014 (09351-32050)
(b) Slightly tap the drive pinion to fit the snap ring into the
groove.
4. INSTALL ROTOR SENSOR

Install the rotor sensor, facing the magnet outward.
WWW.ALL-TRANS.BY
AX-97
5. INSTALL OIL SLINGER

Install the oil slinger, facing the lip outward.
6. INSTALL OUTER RACE

Using SST, drive the outer race into the case.
SST 09350-32014 (09351-32100, 09351-32140)
ProCarManuals.com
7. INSTALL NEW SPACER

Always use new spacer.
Install the spacer with the small end first.
8. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT

(a) Place a bar at the drive pinion side and position the outer
end of the bar against a vise or similar.
(b) Using SST, driven in gear onto the shaft until the nut can
be installed on the threads of the shaft.
NOTICE: Be careful not to cause an impact to the transaxle
case.
SST 09350-32014 (09351-32140)
WWW.ALL-TRANS.BY
AX-98
9. ADJUST DRIVE PINION PRELOAD

(a) Coat the threads and surface of the nut with MP grease.
(b) Using SST to hold the gear, tighten the nut.
Torque: 172 N·m (1,750 kgf·cm, 127 ft·lbf)
SST 09330-00021, 09350-32014 (09351-32032)
(c) Turn the gear counterclockwise and clockwise several

times.
(d) Using a torque meter, measure the preload of the drive
pinion.
New bearing
1.0 - 1.6 N·m (10 - 16 kgf·cm, 8.7 - 13.9 in.·lbf)
Reused bearing
0.5 - 0.8 N·m (5 - 8 kgf·cm, 4.3 - 6.9 in.·lbf)
If the preload is greater than specified, replace the
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bearing spacer.
If the preload is less than specified, retighten the nut
13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the speci-
fied preload is reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure.
Do not back off the nut to reduce the preload.
Maximum torque:
289 N·m (2,950 kgf·cm, 213 ft·lbf)
(e) If the preload is adjusted within specification, make a note
of it.
AX0SX-01
DIFFERENTIAL INSTALLATION
1. PLACE OUTER RACE AND SELECTED ADJUSTING
SHIM ONTO RH SIDE BEARING
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AX-99
2. PLACE DIFFERENTIAL CASE INTO CASE

Be sure to install the adjusting shim into place.
3. INSTALL LH BEARING RETAINER

(a) Install a new O-ring.
(b) Position the retainer by tapping it while holding the differ-
ential case center with the retainer.
(c) Clean the threads of the bolts and case with white gaso-
line.
ProCarManuals.com
(d) Coat the threads of the bolts with sealer.

Sealer:
Part No.08833-00070, THREE BOND 1324 or equiva-
lent
(e) Temporarily tighten the bolts evenly and gradually while
turning the ring gear.
4. INSTALL RH SIDE BEARING CAP

Tighten the bolts evenly and gradually while turning the
ring gear.
5. TIGHTEN LH BEARING RETAINER

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AX-100
6. MEASURE TOTAL PRELOAD

Using a torque meter, measure the total preload of the
drive pinion shaft.
Total preload (at starting):
Add drive pinion preload (See page AX-xx)
New Bearing
0.3 - 0.4 N·m (2.9 - 4.0 kgf·cm, 2.5 - 3.5 in.·lbf)
Reused bearing
0.1 - 0.2 N·m (1.5 - 2.0 kgf·cm, 1.3 - 1.7 in.·lbf)
If the preload is not within specification, redisassemble
and readjust.
ProCarManuals.com
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AX-101
7. STAKE COUNTER DRIVEN GEAR NUT

8. INSTALL DRIVE PINION CAP
9. INSTALL CARRIER COVER

(a) Clean the threads of the bolts and case with white gaso-
line.
(b) Coat the threads of the bolts with sealer.
Sealer:
Part No.08833-00070, THREE BOND 1324 or equiva-
lent
(c) Install the carrier cover over the gasket.
ProCarManuals.com
AX0SY-01
4-SPEED GEAR UNIT INSTALLATION

1. INSTALL MANUAL VALVE SHAFT
(a) Coat the oil seal lip with MP grease.
(b) Using a socket wrench and hammer, drive in a new manu-
al valve shaft oil seal to the case.
(c) Assemble a new collar to the manual valve lever.
(d) Install the manual valve lever shaft to the transaxle case
through the manual valve lever.
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AX-102
(e) Using a pin punch, drive in the roll pin until its surface is
flush with the manual valve lever surface.
(f) Match the collar hole to the lever calking hollow and calk
the collar to the lever.
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(g) Install the retaining spring.
(h) Make sure that the lever moves smoothly.
2. INSTALL PARKING LOCK PAWL

(a) Place the parking lock pawl onto the case. Hook the
spring ends to the case and pawl.
(b) Install the pin into the hole of the case through the spring
and pawl.
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AX-103
3. INSTALL PARKING LOCK ROD
4. INSTALL PARKING LOCK PAWL BRACKET

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5. CHECK OPERATION OF PARKING LOCK PAWL

Make sure the counter driven gear is locked when the
manual valve lever is in the P position.
6. INSTALL FIRST AND REVERSE BRAKE PISTON TO

TRANSMISSION CASE
(a) Coat a new O-rings with ATF.
(b) Install the 2 O-rings on the piston.
(c) Push the piston into the bore of the case, facing the spring
seat upward.
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AX-104

(a) Place the return spring and snap ring on the piston.
(b) Place SST, and compress the return spring evenly by
tightening the bolt gradually.
SST 09350-32014 (09351-32040)
(c) Install snap ring. Visually check to make sure it is fully

seated and centered by the 3 lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the
spring retainer claw.
(d) Remove SST.
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8. INSTALL OVERDRIVE UNIT

(a) Install the overdrive brake apply gasket and overdrive
clutch apply gasket.
(b) Install the overdrive brake drum to the case.

(c) Install a new case gasket to the case.
(d) Make sure that the length from the top surface of the case
to the counter driven gear top surface should be about 24
mm (0.94 in.).
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AX-105
(e) Install the overdrive unit with overdrive case to the trans-
axle case.
(f) Install and tighten the bolts.
9. CHECK INTERMEDIATE SHAFT END PLAY

(a) Make sure that the intermediate shaft has thrust play.
Thrust play:
0.49 - 1.51 mm (0.0193 - 0.0594 in.)
If the thrust play is not within specification, check the
installation of intermediate shaft.
(b) Make sure that the intermediate shaft turns smoothly.
ProCarManuals.com
10. INSTALL FIRST AND REVERSE BRAKE IN CASE

(a) Install the inner flange facing the flat end toward the oil
pump side.
D - P - D - P - D - P - D - P - D - P - D
(c) Install the outer flange, facing the flat end toward the pis-
ton side.

one of the cutouts.
12. CHECK OPERATION OF FIRST AND REVERSE

BRAKE
Apply compressed air into the oil passage with the case
and be sure that the piston moves.
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AX-106
13. INSTALL RING GEAR INTO CASE

(a) Coat the races and bearing with petroleum jelly and install
them onto the ring gear.
Bearing and races
mm (in.)
Outer Diameter Inner Diameter
Front Race 37.3 (1.469) 24.1 (0.949)
Bearing 37.6 (1.480) 24.0 (0.945)
Rear Race 37.6 (1.480) 22.2 (0.874)
(b) Install the ring gear into the case.

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14. INSTALL REAR PLANETARY GEAR INTO CASE

(a) Align the flukes of the discs in the first and reverse brake.
(b) Coat the thrust washer with petroleum jelly.

Align the tab of the washer with the hollow of the carrier.
(c) Align the spline of the planetary carrier with either of the
flukes of the discs, and install the planetary gear into the
first and reverse brake discs.
15. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH

SHINY SIDE UPWARD
(a) Place the one-way clutch with the shiny side upward.
(b) Install the one-way clutch onto the inner race while turn-
ing the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
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AX-107
(c) Coat the thrust washer with petroleum jelly and install it
onto the planetary gear.
16. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH

Turn the planetary carrier. The carrier should turn freely
clockwise and lock counterclockwise.
ProCarManuals.com

one of cutouts.
18. INSTALL SECOND COAST BRAKE BAND GUIDE

Install the 2 band guides so that its tip touches the case.
19. INSTALL SECOND BRAKE INTO CASE

(a) Install the flange, facing the flat end toward the oil pump
side.
Flange - D - P - D - P - D - P
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AX-108

Each spring end is installed onto the protrusion with the
case.
21. INSTALL SECOND BRAKE DRUM INTO CASE

Align the groove of the drum with the bolt and place it into
the case.
ProCarManuals.com

(a) Place the snap ring into the case so that the end gap is
installed into the groove.
(b) While compressing the piston return springs over the
drum with hammer handles, install the snap ring into the
groove.
(c) Be sure the end gap of the snap ring is not aligned with
one of the cutouts.
23. INSTALL SECOND BRAKE DRUM GASKET

Install a new gasket until it makes contact with the second
brake drum.
24. CHECK OPERATION OF SECOND BRAKE

Blow compressed air into the oil passage with the case,
and be sure that the piston moves.
WWW.ALL-TRANS.BY
AX-109
25. INSTALL NO.1 ONE- WAY CLUTCH AND SECOND

BRAKE HUB
(a) Align the flukes of the discs in the second brake.
(b) Align the spline of the hub with the flukes of the discs and
install the hub to the second brake discs.
(c) Check the distance between the surfaces of the second

brake hub and rear planetary gear.
Distance:
Approx. 5 mm (0.20 in.)
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26. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM

While turning the sun gear clockwise, install it into the
one-way clutch.
27. INSTALL FRONT PLANETARY GEAR ONTO RING

GEAR
(a) Coat the races and bearing with petroleum jelly, and
install them onto the ring gear.
Bearing and race
mm (in.)
Front Race 37.9 (1.492) 22.0 (0.866)
Bearing 36.1 (1.421) 22.2 (0.874)
Rear Bearing 35.0 (1.378) 19.0 (1.102)
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AX-1 10
(b) Coat the race and bearing with petroleum jelly, and install
them onto the planetary gear.
Bearing and race
mm (in.)
Bearing 45.0 (1.772) 30.0 (1.181)
Race 45.0 (1.772) 28.0 (1.102)
(c) Install the planetary gear onto the ring gear.

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28. INSTALL FRONT PLANETARY GEAR ASSEMBLY

ONTO SUN GEAR
(a) If the planetary gear and other parts are installed correctly
into the case, the end of the bushing with the ring gear
flange will be flush with a shoulder of the intermediate
shaft or under.
(b) Coat the race with petroleum jelly and install it onto the tip
of ring gear flange.
Race:
Outer diameter
35.7 mm (1.406 in.)
Inner diameter
23.0 mm (0.906 in.)
29. INSTALL INTERMEDIATE SHAFT OIL SEAL RING

WWW.ALL-TRANS.BY
AX-1 11
30. INSTALL SECOND COAST BRAKE BAND

(a) Place the band into the case.
(b) Install the pin through the oil pump mounting bolt hole.
31. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH

(a) Coat the races and bearing with petroleum jelly, and
install them onto both sides of the clutch drum.
Bearing and race (Front side)
mm (in.)
Bearing 42.0 (1.645) 28.9 (1.138)
27.1 (1.067)
Race 42.0 (1.654)
ProCarManuals.com
AT2765:Bearing and race (Rear side)

mm (in.)
Bearing 36.1 (1.421) 22.2 (0.874)
Race 37.9 (1.492) 22.0 (0.866)
(b) Coat the clutch drum thrust washer with petroleum jelly
and install it with the oil groove facing upward onto the di-
rect clutch drum.
(c) Align the flukes of discs in the direct clutch.

WWW.ALL-TRANS.BY
AX-1 12
(d) Mesh the hub with the flukes of the direct clutch while turn-
ing the clutch drum or forward clutch.
(e) If the flukes of the discs are meshed with the hub correctly,
the end of the bushing with the direct clutch drum will be
flush with the surface of the forward clutch.
(f) Place the direct clutch and forward clutch into the case.
(g) Rotate the forward clutch to mesh the front planetary ring
gear and discs.
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(h) Check the distance between the A and B.

Distance:
Approx. 3 mm (0.118 in.)
32. INSTALL OIL PUMP INTO CASE

(a) Coat the race with petroleum jelly and install it onto stator
shaft.
(b) Coat a new O-ring with ATF and install it to oil pump.
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AX-1 13
(c) Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transaxle case.
(d) Hold the input shaft, and lightly press the oil pump body
to slide the oil seal rings on the stator shaft through the
direct clutch drum.
NOTICE: Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
(e) Install tighten the 7 bolts.

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AX-1 14
33. MEASURE THRUST PLAY OF INPUT SHAFT

Measure the thrust play with a dial gauge.
Thrust play:
0.3 - 0.9 mm (0.012 - 0.035 in.)
HINT: There are 2 thickness of races for the end of stator
shaft.
If the thrust play is in excess of standard, select one of
them.
Race thicknesses:
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
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34. CHECK INPUT SHAFT ROTATION

Make sure that the input shaft rotates smoothly.
35. INSTALL DRIVE PINION CAP
36. INSTALL SECOND COAST BRAKE PISTON

(a) Coat a new O-rings with ATF and install them on the cov-
er.
(b) Install the outer spring with the piston.
(c) Place the cover into the bore.
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AX-1 15
(d) Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351-32050)
(e) Check that the front end of the piston rod contacts the
center of the second brake band depression.
37. CHECK SECOND COAST BRAKE PISTON STROKE

(a) Apply a small amount of paint to the piston rod at the point
it meets the case.
(b) Using SST, measure the piston stroke while applying and
releasing compressed air (392 - 785 kPa, 4 - 8 kgf·cm,
57 - 114 psi).
SST 09240-00020
Piston stroke:
1.5 - 3.0 mm (0.059 - 0.118 in)
If the stroke is more than standard value, replace the pis-
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ton rod with a longer one.

Piston rod length:
72.9 mm (2.870 in)
71.4 mm (2.811 in)
38. INSTALL ACCUMULATOR PISTONS AND SPRINGS

(a) Install the springs and pistons into the bore.
Free length
Sprnig Color
mm (in.)
C1 57.64 (2.2693) Red, Purple
B2 69.39 (2.7323) Green, White
C2 70.21 (2.7641) Purple
(b) Place the cover with the gasket and tighten the bolts grad-
ually in sequence.
tion.
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AX-1 16
39. INSTALL NEW SECOND BRAKE APPLY GASKET
40. INSTALL THROTTLE CABLE IN CASE

Push the cable through the case, being careful not to
damage the O-ring. Check for full seating.
NOTICE: In subsequent work, to avoid breaking the cable
fitting do not roll the case over the cable.
ProCarManuals.com
41. INSTALL SOLENOID WIRING
42. PLACE VALVE BODY ON TRANSAXLE

(a) While holding the cam down by your hand, slip the cable
end into the slot.
(b) Lower the valve body into place.
NOTICE: Do not entangle the kick-down switch wire or so-
lenoid wire.
43. INSTALL BOLTS IN VALVE BODY

tion. Hand tighten the 12 bolts first, then torque with a
torque wrench.
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AX-1 17
44. INSTALL MANUAL VALVE BODY AND DETENT

SPRING
tion.
(a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Hand tighten the 4 bolts first. Then, tighten them with a
torque wrench.
(d) Place the detent spring on the manual valve body and
hand tighten the 2 bolts first.
Then, tighten them with a torque wrench.
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
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45. INSTALL OIL TUBES

Using a plastic hammer, install the 4 tubes into the posi-
tions indicated in the illustration.
NOTICE: Be careful not to bend or damage the tubes.
46. INSTALL TUBE BRACKET

47. INSTALL OIL STRAINER

Each bolt length (mm, in.) is indicated in the figure.
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AX-1 18
48. CONNECT SOLENOID WIRING

(a) Connect the No.1 solenoid connector. (white and shorter
wire)
(b) Connect the No.2 solenoid connector. (black and longer
wire)
49. INSTALL 3 MAGNETS IN PLACE

NOTICE: Make sure that the magnets do not interfere with
the oil tubes.
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50. INSTALL OIL PAN WITH NEW GASKET

51. INSTALL COVER
52. INSTALL COVER BRACKET

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AX-1 19
53. INSTALL SOLENOID WIRING RETAINING PLATE

54. INSTALL THROTTLE CABLE RETAINING PLATE
55. INSTALL FILLER TUBE AND BRACKET
56. INSTALL SL SOLENOID

(a) Coat the O-ring with ATF and push the tip of SL solenoid
into the hole.
(b) Tighten the 2 bolts evenly and gradually.
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57. INSTALL PARK/NEUTRAL POSITION SWITCH

(a) Install the park/neutral position switch to the manual valve
shaft.
(b) Install the seal gasket and locking plate.
(c) Tighten the nut and stake it with the locking plate.
58. ADJUST PARK/NEUTRAL POSITION SWITCH
(a) Align the groove and return neutral basic line.
(b) Lock the switch with 2 bolts.
59. INSTALL UNION AND ELBOW
(a) Coat a new O-rings with ATF.
(b) Install the O-rings to the union and elbow.
(c) Install the union and elbow to the transaxle case.
HINT: Install the elbow as shown in the illustration.

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AX-120
60. INSTALL MANUAL SHIFT LEVER

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AX-15
AUTOMATIC TRANSAXLE - SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS AT06P-0C
SERVICE DATE
Oil Pump
0.07 - 0.15 mm
Body clearance STD
0.0028 - 0.0059 in.
0.3 mm
Maximum
0.012 in.
0.11 - 0.14 mm
Tip clearance STD
0.0043 - 0.0055 in.
0.3 mm
Maximum
0.012 in.
0.02 - 0.05 mm
Side clearance STD
0.0008 - 0.0020 in.
0.1 mm
Maximum
0.004 in.
38.18 mm
Pump body bushing inside diameter Maximum
1.5031 in.
Stator shaft bushing inside diameter
Front side 21.57 mm
ProCarManuals.com
Maximum 0.8492 in.

Rear side 27.07 mm
Maximum 1.0657 in.
Direct Clutch
47.07 mm
Clutch drum bushing inside diameter Maximum
1.8531 in.
1.11 - 1.44 mm
Direct clutch piston stroke
0.0437 - 0.0567 in.
2.60 mm
0.1024 in.
Flange thickness
3.00 mm
0.1181 in.
Forward Clutch
1.41 - 1.82 mm
Piston stroke
0.0555 - 0.0717 in.
2.8 mm
0.110 in.
3.0 mm
Flange thickness 0.118 in.
3.2 mm
0.126 in.
3.4 mm
0.134 in.
3.6 mm
0.142 in.
Front Planetary Gear

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AX-16
19.025 - 19.050 mm
Ring gear bushing inside diameter Standard
0.7490 - 0.7500 in.
0.20 - 0.50 mm
Planetary pinion gear thrust clearance Standard
0.0079 - 0.0197 in.
Rear Planetary Gear

0.20 - 0.50 mm
0.0079 - 0.0197 in.
Overdrive Unit
1.21 - 1.91 mm
Overdrive direct clutch piston stroke
0.0476 - 0.0752 in.
22.09 mm
Overdrive direct clutch bushing inside diameter Maximam
0.8697 in.
9 - 15 N
Counter drive gear preload
920 - 1,530 gf 2.0 - 3.4 lbf
0.20 - 0.50 mm
0.0079 - 0.0197 in.
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AX-17
Valve Body Spring

Free length and Coil outer
Spring Total No. of coils and Color
diameter mm (in.)
Upper valve body
21.7 (0.854) 9.5
Throttle modulator valve
9.5 (0.374) None
28.1 (0.105) 13.0
Accumulator control valve
10.6 (0.417) Yellow
21.6 (0.850) 11.5
Low coast modulator valve
7.9 (0.311) None
29.8 (1.172) 13.5
Down shift plug
8.7 (0.344) Yellow
30.7 (1.209) 9.5
Throttle valve
9.2 (0.362) None
20.9 (0.824) 10.0
Second coast modulator valve
8.5 (0.336) Light Green
21.8 (0.858) 13.5
Cut-back valve
6.0 (0.236) None
26.6 (1.046) 11.5
Lock-up relay valve
ProCarManuals.com
10.2 (0.402) Green

Lower valve body
11.2 (0.441) 7.5
Pressure relief valve
6.4 (0.252) None
29.3 (1.152) 10.5
1 - 2 shift valve
9.7 (0.382) None
29.3 (1.152) 10.5
2 - 3 shift valve
9.7 (0.382) None
29.3 (1.152) 10.5
3 - 4 shift valve
9.7 (0.382) None
66.7 (2.453) 12.5
Primary regulator valve
18.6 (0.732) None
43.6 (1.717) 11.5
Secondary regulator valve
10.9 (0.429) None
30.0 (1.181) 11.5
Lock-up signal valve
8.2 (0.323) None
19.9 (0.784) 8.5
Cooler By-pass valve
11.0 (0.433) None
Valve Body Retainer

Height Width Thickness
Reteiner
mm (in.) mm (in.) mm (in.)
Upper valve body
Throttle Modulator valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126)
Accumulator control valve 11.5 (0.453) 5.0 (0.197) 3.2 (0.126)
Cut-back valve 9.2 (0.591) 5.0 (0.197) 3.2 (0.126)
Lock-up relay valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126)
Second coast modulator valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126)
Lower valve body
Primary regulator valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126)
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AX-18
1 - 2 shift valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126)

2 - 3 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126)
3 - 4 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126)
Lock-up signal valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126)
Accumulator Spring
Spring Free length mm (in.) Color
C1 57.64 (2.2693) Red, Purple
B2 69.39 (2.7323) Green, White
C2 70.21 (2.7641) Purple
ProCarManuals.com
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AX-19
Differential
1.0 - 1.6 N·m
Drive pinion preload (at starting) New bearing 10 - 16 kgf·cm 8.7 - 13.9 in.·lbf
Reused bearing 0.5 - 0.8 N·m
5 - 8 kgf·cm 4.3 - 6.9 in.·lbf
Add drive pinion preload
Total preload (at starting) 0.3 - 0.4 N·m
New bearing 2.9 - 4.0 kgf·cm 2.5 - 3.5 in.·lbf
Reused bearing 0.1 - 0.2 N·m
1.5 - 2.0 kgf·cm 1.3 - 1.7 in.·lbf
0.05 - 0.20 mm
Pinion to side gear backlash
0.0020 - 0.0079 in.
0.95 mm
0.0374 in.
1.00 mm
0.0394 in.
1.05 mm
Side gear thrust washer thickness
0.0413 in.
1.10 mm
ProCarManuals.com
0.0433 in.
1.20 mm
0.0427 in.
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AX-20
1.90 mm
0.0748 in.
1.95 mm
0.0768 in.
2.00 mm
0.0787 in.
2.05 mm
0.0807 in.
2.10 mm
0.0827 in.
2.15 mm
0.0846 in.
2.20 mm
0.0866 in.
2.25 mm
0.0886 in.
2.30 mm
0.0906 in.
2.35 mm
Side bearing adjusting shim thickness
0.0925 in.
ProCarManuals.com
2.40 mm
0.0945 in.
2.45 mm
0.0965 in.
2.50 mm
0.0984 in.
2.55 mm
0.1004 in.
2.60 mm
0.1024 in.
2.65 mm
0.1043 in.
2.70 mm
0.1063 in.
2.75 mm
0.1083 in.
2.80 mm
0.1103 in.
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AX-21
AT06Q-0C
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Stator shaft x Oil pump body 10 100 7
Upper valve body x Lower valve body 5.4 55 48 <in.lbf>
Ring gear x Differential case 97 985 71
Side bearing cap x Transaxle case 72 730 53
Bearing retainer x Transaxle case 19 195 14
Counter drive gear x Drive pinion 172 1,750 127
Carrier cover x Transaxle case 25 250 18
Parking lock pawl bracket 7.4 75 65 in.·lbf
Overdrive case x Transaxle case 25 260 19
Oil pump x Transaxle case 22 220 16
Valve body x Transaxle case 10 100 7
Manual valve body x Transaxle case 10 100 7
Detent spring x Valve body 10 100 7
Oil tube bracket x Transaxle case 10 100 7
Oil strainer x Valve body 10 100 7
Oil pan x Transaxle case 4.9 50 43 in.·lbf
Park/Neutral position switch 6.9 70 61 in.·lbf
ProCarManuals.com
Park/Neutral position switch adjusting bolt 5.4 55 48 in.·lbf

Union 27 275 20

A140E Automatic Transmission Service and Repair Manual

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A140E Automatic Transmission Service and Repair Manual

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A140E Automatic Transmission Service and Repair Manual

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GENERAL DESCRIPTION AX0EP-02

Transaxle 5.6 (5.9, 4.9)

HOW TO USE THIS MANUAL IN002-0W

Theprocedures are presented in a step-by-step format:

CAUTIONS, NOTICES, HINTS:

GENERAL REPAIR INSTRUCTIONS IN022-07

1. Use fender, seat and floor covers to keep the vehicle

not use a hammer to tap the terminal onto the post.

the specified seal lock adhesive to the bolt, nut or

11. To pull apart electrical connectors, pull on the connector

2. HYDRAULIC CONTROL SYSTEM

2. ELECTRONIC CONTROL SYSTEM

GLOSSARY OF SAE AND TOYOTA TERMS IN016-02

CTP Closed Throttle Position -

IAC Idle Air Control Idle Speed Control (ISC)

OBD On-Board Diagnostic On-Board Diagnostic (OBD)

Bimetallic Vacuum Switching Valve (BVSV)

SST (SPECIAL SERVICE TOOLS)

09330-00021 Companion Flange Holding Tool

09350-32014 TOYOTA Automatic Transmission

09308-10010 Oil Seal Puller

(09351-32020) Stator Stopper

(09351-32032) Counter Driven Gear Holding Tool

(09351-32040) No.1 Piston Spring Compressor

(09351-32050) Snap Ring Expander

(09351-32061) Oil Pump Puller

(09351-32070) No.2 Piston Spring Compressor

(09351-32080) Lock Nut Wrench

(09351-32090) Oil Seal Remover & Replacer

(09351-32100) Drive Pinion Bearing Replacer

(09351-321 11) Side Bearing Race Replacer

(09351-32120) Overdrive Bearing Replacer

(09351-32140) Oil Seal Replacer

(09351-32150) Oil Seal Replacer

(09351-32190) Measure Terminal

(09351-32200) No.3 Piston Spring Compressor

09502-10012 Differential Side Bearing Puller

09564-3201 1 Differential Preload Adaptor

09710-28020 Front Suspension Bushing Tool

(09710-08040) Bushing Replacer

09950-00020 Bearing Remover

Dial indicator or dial indicator with magnetic base

Automatic Transaxle Fluid 5.6

SSM (SPECIAL SERVICE MATERIALS)

08833-00070 Adhesive 1324,

COMPONENT PARTS REMOVAL AX0GS-02

SEPARATE BASIC SUBASSEMBLY

2. REMOVE UNION AND ELBOW

4. REMOVE THROTTLE CABLE RETAINING PLATE

(b) Remove the cover.

7. REMOVE OIL PAN AND GASKET

8. EXAMINE PARTICLES IN PAN

9. DISCONNECT NO.1 AND NO.2 SOLENOID CONNEC-

10. REMOVE TUBE BRACKET AND OIL STRAINER

11. REMOVE OIL TUBES

12. REMOVE MANUAL DETENT SPRING

14. REMOVE VALVE BODY

15. REMOVE THROTTLE CABLE AND SOLENOID WIR-