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UIHT5E T e c hn i c a l S e r v i c eI n fo r m a t i o n
AND OPERATION
DESCRIPTION
ElectricalComponentFunction
I BulkheadConnectors and Wiring Assemblies:
Provideselectricalcurrentflow pathfrom vehicle
harnessto internaltransaxleelectricalcomponents
and providesoil sealing.
The TurbineSpeedffSS) is a variablereluctance
sensorusedwith the vehicleelectroniccontrol
system.The sensor,afongwith a rotatingexciter
wheelon the drivensprocket,sendsa signalto the
EEGIV'The EEG{v readsthis signalandrgacts to the
speedinforrnationit transmitsby controllingthe clutch
application.
The ShiftControlsolenoidsprovideProperoperating
gear selectionand are controlledby the EEGIV.There
are three shift control solenoidsin the AXOD'E.They
usea threeport, normallyopenfeed to controltheflow
of oilto a hydraulicspoolvalve.
The ConverterBy-passClutchSolenoidis part of thE
torqueconverter.Whenenergizedby the EEGIV,it
sealstransmissionfluidunderpressureand causes
the converterclutchto engage.
TheTransmission OitTemperatureSensorC[OT)
informsthe EEG{Vof transmissionoiltemperature.lt
is a thermisterwhoseresistancevariesaccordingto
temperature.
The VariableForceSolenoidCVFS)is an analog
pressureregulatorthat variestransmissionline
pressureas directed by the EEG-iVprocessor.
The ModulgtedLock'up Solenoid(MLUS)is part of the
systemthat control converterclutch slip. The solenoid
receivesan alectronicsignaltromthe EEC-IV
processorand usesthis informationto vary pressure
whichsets the slip in the converterclutch.
Downshifts
Undercertainconditionsthe transexlewilldownshift
automaticatlyto a lower gear range withoutmovingthe
shift selector lever.There are three suchcategoriesot
automaticdownshifts:coastdown,torquedemandand
lorced or kickdownshifts.
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
4
--t
Coastdown
Thecoastdowndownshiftoccursas the name
indicates,whenthe vehicleis coastingdownto a stop'
TorqueDemand
The secondtype of downshittis torquedemand.The
torquedemanddownshiftoccurs(automatically). -
duri'ngpart throttleaccelerationwhenthe demandfor
torqul'is greater than the en-gbecan provideat that
gaai ratio-.The transaxlewilldisengaqethe-converter
Autcn to provideaddedacceleration,if applied.
Kickdown
The thirdtyPeof downshiftis the kickdown.For
paximumacceleration,the drivercan force a
downshiftby depressingthe acceleratorpedaltothe
floor.Aforced downshiftintosecondgear ls posslote
below88 km /h (55 mph)-Belowapproximately4o
km/h (25 mph)a forcbdkickdownto firstgear will
occlrr. A[ shift speedsspecificationsare subiectto
variationdue to hre sizeandenginecalibration
requirements.
ldentification Tag
Whenservicingthe automatictransaxle,refer to the
identificationtag located on top of the converter
housing.
TFANSN(LE ]9PDEL NUMBER
oescHarpxis srowx lNA MlRRofi
IMAGE. TH€ tvlODEL NUMBERSIIO{H
rs TNDIGATINGMODEL Pi{ iJ'!c-r
TFANS^)(LE
EI{GIN€ SIZE
DESlGNATOF
3.81
t r l t l
FZ.HrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n
T'TE DC'CTPTEX
t. TM,E cglII'ERTB
L coia\GirEn curllor (asrsr FrJrE cLwel
AilO DATpERASSEn|'rl
t c(lfirEFtEnco\rEn
.. rrrRaiG
a IIPCIJ€F
a FEA TOT
?- C,|LFI,TP DETT'ESI{AFT
a FOFur noCLUTCII
t. Lo$r orJErv Y c|-uTcr{
r0. orGRDEUE 6^TTD
tt. OIRECTSLUTCH
ta ornEcr d'Gw Y clt lcr{
tt, €LUTCH
ta REr'ER8ECLU'A{
rt, n ilErAnYGeAFS
ta. PAF{T{GGETN
17. IOWANTE*JEDATEI^'t'D
l L FN^L ONIVE$'T{ GEAR
tt FI'{AI. DB|VEPLATET
to. clrFCiErfiAL asscxglY
tt. oRtrrEsPnoo(Et
XI oRwt uiH lsgEr4Y (ClrAF{l
ta OR\IEH SFNOCXET
2{. vALvE EooY Fr rit corfFor AssEuELn
rs. OL FUI'P

AND TESTING
DIAGNOSIS

The followingdiagnosissequenceis a proven method r FlotundaDigitalVolt-Ohmmeter014'O0407or

for troubleshootingtne AXOD-Etransaxle. DO NOT equivalent.
attempt short cuts or assume someoneelse has done . GearPositionSensorAdjusterTg 1P-70010-A or
the critical checks and adjustments. equivalent.
Required Equipment:
AXOD-EDiagnosticSeguence
o Engine/EmissionsDiagnosis'manual.
1. Determinecustomerconcernrelativeto vehicle
r RotundaSUPERSTAR ll Tester OO7-OOO41-A
or usage.
equivalent.
o Hotor coldvehicleoperatingtemperature
o Servicejumperwire.
o Hotor coldambienttemPeratures

SERVICE
TRANSMISSION
AUTOMATIC UP
GRO
,

[|RrsG T e c h n i c a lS e r v i c e l n f o r m a t i o n
I Typeol terrain
o Vehicleloaded/unloaded
I Cityor highwaydriving
2. Fluidlevelcheck.Checkfor contamination
or
burntsmell.
3. Roadtest vehicleto confirmcustomerconcern.
4. Inspectvehiclefor non-Fordapprovedadd-on
devicessuchas engineturbo's,car telepfrcnes,
cruisecontrols,CB radio,linearboosters,back
up alarmsignals,computerselc., that if not
installedproperlywill affect EEGIV system or
transaxlefunction.Pay particularattentionto
add-onwiringsplices.
5, After road test with vehicleat normaloperating
temperatureperforma EEC-IVQuickTest using
SUPERSTARllTesterOO7-OOO41-A
or
equivalentas outlinedin Section14 of the
Engine/ EmissionsDiagnosis'manual.
Transaxle Fluid Level Check
CAUTION: Vehicles should not be driven if fluid
level is below DO NOT DRIVE hole.
Tran sax le - Operatin g Ternperature
The automatic transaxle fluid levd can only be
established at an operating temperature of
66oC-77"C (150oF.17O"F) (dipstickis hot to the
touch). The operating temperature may be obtained
by driving 24-32km (15-20 miles) of city-type driving
with the outside temperature above lOoC (5OoF).
Transaxle - Room Temperature
NOTE: The AXOD-E transaxle cannot have fluid level
established at room temperature.
Fluid levelcan only be checked at room temperature
21 oC-3S"C(20.F-9S"F) (dipstickcool to the touch)
to verify that the level is above the DO NOT DRTVE
mark. lf fluid level is below, then add only enough
MERCON@E4AZ-19582-B or equivalent to bring the
level above the DO NOT DRIVE mark. Operating
temperature must be obtained as ouflined to establish
correct fluid level if any ftuid is added during room
temperature check.
D ips t ic k Readin g
The fluid level on the dipstick should be within the
cross-hatched area at operating temperature. The
fluid levelon the dipstick shoufd read above the DO
NOT DRTVEmark (bonom hote on dipstick) at room
temperature.
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
6
't
Checkthe fluidas follows:
1. With the transaxlein PARK,engineat idlerpm,
foot brakesappliedandvehicleon levelsurface,
movethe transaxleselectorleverthrougheach
range,allowingtimein eachrangeto engage
transaxle.Returnto PARK,applyingparking
brakelullyandbfockthe wheels.Do not turnotf
the engineduringthe fluidlevelcheck.
2. Cleanalldirtfromthe transaxlefluiddipstickcap
beloreremovingthe dipstickfromthe fillertube.
3. Pullthedipstickout of the tube,wipeit cleanand
pushit allthe way back intothe tube.Ensureit is
fullyseated.
4. Pullthe dipstickout of thefillertubeagainand
checkthe fluidlevel.
NOTE:Thefluidlevelindication on the dipstick
willbedifferentat operatingtemperature and
roomlemperature.For the correctfluldlevel
readingon the dipstick,followthe appropriate
instructions statedpreviously.
CAUTION:lf vehiclehas been operatedfor an
extended period at high speed, or in city
traffic in hot weather, or vehicle is being
used to pull a trailer, the fluid must cool
approximately3O minutesafter enginehas
been turned off for an accuratereadingto be
obtained.
CAUTION:Use of a fluid other than specified
could result in transaxlemalfunction?fidr or
failure.
lf necessary,addenoughfluidthroughthefiller
tubeto raisethe levelto the correctheight.
CAUTION:Do not overfill the transaxle. This
wilf result in foaming,loss of fluid through the
vent and possible transaxle malfunction.lf
overfill occurs, excess fluid must be
removed.
5. Installthedipstick,makingsureit is fulryseatedin
the tube.
Overfillcancausethe fluidto foamandspillout
throughthe vent,resultingin a transaxle
malfunction.
Underfillcan resuftintransaxlelossof
enEagernent or slipping.Thisconditionis most
evidentin coldweatheror whenthe vehicleis
parkedor beingdrivenon a hill.
t|Rrsc T e c h ni c a l S e r v i c e I n fo r m a t i o n
lf the transaxle tluid levelis checked when the
fluid is at room temperature, the dipstick could be
misread to indicate that fluid should be added. lf
fluid is added at this time, an overfill condition
could result when the fluid reaches operating
temperaturesof 66"C-77"C (150"F- 170oF)
(dipstick hot to touch).
FLUID LEVEL A?
^oo Nor oRrvE" HoLE OPERATING TEMPEBATUFIE
66 "c-7l.C (150"F-170"Fl
Transaxle Fluid Condition Check
1. Makenormalfluidcheckas outlined.
2. Observecolorandodor of fluid.lt shouldbe red,
not brownor black.Odorcan sometimesindicate
an overheatingconditionor clutchdisc or band
failure.
3. Usean absorbentwhitefacialtissueto wipe
dipstick.Examinestainfor evidenceof solids
(specksof any kind)andlor antifreezesigns(gum
or varnishon dipstick).
lf specksare presentin the oil or thereis
evidenceof antifreeze. the transaxleoilpanmust
be removedfor furtherinspection.lf fluid
contamination or transaxlefailureis confirmedby
furtherevidenceof coolantor excessivesolidsin
the cil pan,the transaxlemustbe disassembled
andcompletelycleanedandserviced.This
includescleaningthe torqueconverter.and
transaxlecoolingsystem.lt wouldbe a wasteof
timeto performany furtherchecksbefore
cleaningandservicingthetransaxle.During
disassemblyand assembly,all overhaulchEcks
andadiustmentsof clearancesandend play must
be made-After the transaxlehas beenserviced,
all diagnosistests andadjustmentslistedin the
Diagnosischarts mustbe completedto ensure
that the conditionhas beencorrscted.
Highor Low FluidLevel
A fluidlevelthatis too highwillcausethefluidto
becomeaerated.Aeratedfluidwillcauselow control
pressureandthe aeratedtluidmay be forcedout the
vent.
A fluidlevelthatis too low can affectthe operationof
the transaxle.Low levelmayindicatefluidleaksthat
couldcauseiransaxledamage.
TRANSMISSION
AUTOMATIC GROUP
SERVICE
7
Shift Point Test
Thistest verifiesthat shiftcontrolvalvesare operating
properly.
Road Test
1. Bringengineandtransaxleupto normaloperating
temperature,
2. Operatevehiclewithtransmission selectorin
Orange.
3. Applyminimurn throttlepressureandobserve
upshiftspeedsand speedat whichconverter
clutchapplies.Referto TechnicalServiceBulletin
SpecialSpecificationsissue.
4. Stop vehicleand movetransaxleselectorto D
range.RepeatStep3. Transaxlewillmakeall
upshiftsexcept3-4 andconverterclutchapply
shouldoccurabove46 km lh(27 mph).
5. Depressacceleratorpedaltofloor(WOT).
Transaxleshouldshiftfromthirdto second,or
thirdto first dependingon vehiclespeed,and
converterclutchshouldrelease.
6. Withvehiclespeedabove48 km/ h (30 mph),
movetransaxleselectorfrom D rangeto 1 range
ftOW) and removefoot from acceleratorpedal.
Transaxleshouldimmediatelydownshiftto
secondgear.Whenvehiclespeeddrops below
32 km lh(2O mph),transaxleshoulddownshift
intofirstgear.
lf transaxlefailsto upshiftand/or downshiftas
7.
outlined,referto QuickT€st.
In-ShopTest
Thefollowingitemscan be checkedduringan in-shop
shift test:
r Shiftsolenoids
r Valves
o Converterclutch
1. Raisefrontof vehicleso thatfrontwheelsare
clearof floor.
CAUTION:Do not exceed 97 km/h (60 mph)
indicated speedometer speed. Indicated
speed is one-halfof actualtire sPeed. Do not
exceed recommendedtire speed rating.
CAUTION:The susPensionshould not be
allowed to hang free. When the constant
velocity ioint is run at a very high angle, extra
vlbrationsand damage to the seals and joints
can occur.
2. To checkshiftvalvesand shift solenoids,place
selectorleverin O range.Applyminimum throttle
pressureand observeupshiftspeedsand speeds
at whichconverterlocksup.
Thetransaxleshouldshiftin the followingorder:
 'l

!Z'HrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n

o 1-z Ouick Test 2

c 2-3
r Converter lockup
r 3-4
NOTE: Converter may remain locked up when
transaxle shifts into tourth.
At the shift points, the speedometer needle will
make a momentary surge, a slight drivelinebump
may be felt and engine speed will drop without
releasing accelerator pedal. ff shift speeds are
not within specification, refer to Diagnosis for
Electrical systern in this section.
Quick Teet
The Qur,:kTests are in the Engine/Emissions
Diagnosis'manualand must be used to diagnose
AXOD-Etransaxle conditions.
Observe the EquipmentHookup procedures outlined
Engine/ ErnissionsDiagnosis' manual.
Use the Self-Test Automatic Readout STAR Tester,
Model OO7-OOOO 17, or the SUPERSTAR ll Tester,
ModelOOT-OOO41-A or an equivalentto access
self-test service codes.
NOTE: Refer to the illustrationfor Self-Testconnector
pin orientationand STAR hookup. Afier the equipment
is properly hooked up, proceed to Quick Test Step
3.O.
Vehicle Preparation
1. Perform ALL safety steps requiredto start and
run vehicle tests - apply parking brake place shift
lever firmly into PARK position,block drive
wheels, etc.
2. Turn off ALL electricalloads-radios, lights,
AIC-heater blower fans, etc.

The following is a guide to using the Quick Tests with Using The Star Tester (OO7-OOO
17)
some special considerations to remember.
1. Turnthb ignitionkey off.
Quick Test 1 2. Connect the color coded adapter cable to the
Perform the visual check and vehicle preparation STAR tester.
outlinedin the Engine/ EmissionsDiagnosis' m3nual. 3. Connectthe adapter cable leads to the proper
NOTE: lt is possible to unknowingly correct some Self-Test connectors.
symptoms when performing the necessary visual
check- By moving or wiggling a wiring harness to 4. Connect the timing light.
insure proper connections some symptoms may be
eorrected. lt is important to the diagnostics to know STAF HOOKUFfWrH
what actions have corrected the symptom. Therefore, AOAPTERCABLEASSETBLY}
it may be a good idea to connect your tester prior to
performing the visual check. VEHICLE
SELFTEST
Correct results of the Quick Test are dependent on the CONNECTORS
proper operation of related non-EEGIV components.
STAF
It may be necessary to disconnect or disassemble SERVICE
harness connector assemblies to do some of the CONNECTORS
inspections, Pin locations should be noted before
disassembly.

V is ual G hec k
1. lnspect the air cleaner and inlet ducting.
2, Check allengine vacuum hoses for damage
leaks, cracks, blockage, proper roufing,etc.
3. Check EEC-IVsystem wiring harness for proper
connections, bent or broken pins, corrosion, trtrD
loose wires, proper routing, etc. frl I

4. Checf the processor, sensors and actuators for tr

physicaldamage.
rt
5. Check the engine coolant for proper level.
6. Check the transmissionfluid levelquality and for
external leakage. Ouick Test 3 (Key On EngineOff)
7. Make all necessary repairs hfore continuingwith
Followthe proceduresas outlinedin EngineI
Emissions Diagnosis'manualfor the K.eyOnEngine
Quick Test.
Off Self-Test.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
E
UiHrsc T e c h ni c a f S e r v i c e I n fo r m a t i o n
NOTE:As indicatedin the test procedure,treat engine
idleas a separatefaultand serviceit lirst.
TheKey On EngineOff test providesboth "hard"
failures(presentat the timeof lesting)and continuous
memorycodes.Alwaysservicethe hardfailuresfirst.
Theseare displayedfirst on the tester.For AX@€
taultsmostcodesare storedin memory.The pinpoint
testsfor thesecodesare coveredin this Section.
How to Runthe Key On EngineOff Sell-Test
DO
r Verifythat the vehiclehas beenproperlyprepared
accordinsto QUICKTEST STEPS1.Oand 2.O
I Startengineandrununtilatoperatingtemperature.
r Turnengineoff andwait 10 seconds.
r ActivateSelf-Test.
-STAR Tester:Latchthe centerbuttonin the down
position.
-Andog VOM:JumperSTIto SIGRTNat the
Self-Testconnectors.
-GHECK ENGINEor SERVTGE ENGINESOON
Light(MlL):JumperSTlto SIGRTNat the Self-Test
connectors.ServiceGodeswillbe flashedon the
CHECKENGINEor SERVICEENGINESOONUght.
- Message Center(Continental ApplicationsOnly):
Referto Appendix:Self-Test.
I Placeignitionkey in the ON position.
r Recordall servicecodesdisplayed.
DON'T
TRANSMISSION
AUTOMATIC GROUP
SERVICE
9
r DepressthrottleduringKey on EngineOff Self-Test
on gasolineengineapplications.
TheSUPERSTARllTester can readfast codes as well
as slow codes,andcan be usedon Ford EEC-IVas
wellas MCUand MEGSsystems.A built-inSelf-Test
memorywill retainthe codesas they are received.
Th€SUPERSTARllTester alsocontainsa beeperfor
runningthe wiggletests.
After hookingup the SUPERSTARll tester and turning
it on, the SUPERSTARll will brieflydisplav888- lt will
also lightallthe promptson the left side of the display
andthe speakerwill beep.Whenthe tester is ready,
boththe STFLOandSTGLOwillbe on, butthe
readoutwillbe blankif the vehiclekey is off.
Key On EngineOff (KOEO)Self-Test
1. Plugin bothconnectorsof the testerto the mating
connectorsof the vehicle.
2. Determinethe type of systemyou have(EEC-IV
or MECS)and set the switchto the propertype-
3. Selectfast code modeor dow code modewith
the rnodeselectorswitch.
4. TurnON the powerto tester.
5. Depressthe test buttonon the testerto the test
position.
6. TurnON the vehicleignitionkey.
The tester will now read any Self'Testcodes in this
mode.
Ul,srsG T e c h n i c a lS e r v i c eI n f o r m a t i o n

ACTIONTO TAKE
PERFORM
KOEOSELF.TEST

. Start engrn€and idb until whicle is at operatirlg If ..CHECKENGINE"

tamPerature. or "SERVICE
ENGINESOON" light
i-fOTE:lf ergiru does not start or stalls after starting, is on: GO to
continueto perforrn KOEO Self-Test. ContinuousMemory
coda charls, Quick
r l(ay off, wait t0 secgnds. Test Step E.0, before
addressingany other
o Actirrateself.Test. symptorfls.
r Key on, engine off. lf engineruns rough
or idles rough:GO to
NOTE: lf additionalinformation is required for KOEO PinpointTestStep 52,
Self-Test,refer to eubk TestAppendix. exceptDIS/EDIS
vehicles.GO to Quick
r Record all KOEO and ContinuousMernoryCodes TestStep 3.1.
receiwd.
lf engineis a no start:
o ls a PASScode "ll" presentin KOEO? GO to Pinpint Test
(11,ll-lGarry code). StepA1, exceptEDIS
whicles, GO to
NfiE: The first two '11's" arg PASScodes frqn PinpointTestStep
KOEO. The "10^ is consfuleredthe seoarator AA1.
code beturo€nKOEO ard Continuous'Menrory.
lf th€s€ symptomsare
not pres€nt: GO to
Quick TestStep 4.0.

lf KOEO servbe
codes are received:
GO to KOEOcode
charts, Ouick Test
Step 6.0.

lf no servicecodes
are received:GO to
PinpointTestStep
oA1.

QuickTcst 4.0 (ComputedTimingCheck, Gas

EnglneOnty)
ThisQuickTestis usedto diagnoseengineidle
concernsonly.Keepin mindhowever,that any engine
concernsor codes shouldbe servicedBEFOREthe
transaxleconcernsare senriced.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
10
U|RrsG T e c hn i c a l S e r v i c e l n f o r m a t i o n

TEST STEP RESTJLT ) ACTIONTO TAKE

4.0 | cotupurEDTrMrNc
cHEcK

o l(ey otf, wait 10seconds. Yes GO to Quick Test5-0.

o ActivateEngineRunnirg Self-Test. No GO to PinpointTest

Slep P2.
o Start engine.

informationis requiredfor Engine

NOfE: lf additircnal
Runnirg Self-Test,refer to Ouick Test Appendix

ll enginestarts but stalls or stalls durirg

Self-Test,GO to PinpointTestStep S1.

Ergine RunningServiceCode 98 indicates

whicle is in Failure Mode Etfects Managment
(FMEM)arrdDID NCIf PASSKOEO
On-Dernand/Continuous MemorySdf-Test.
Engine Runnirg Self-Testcannol be perforrned
while in FMEM. Go to ContinuousMernorycode
charts, Qubk TestStep 8.0,

I Check computedtimiqg atter the last service code

has been displayed.The timing will rEmainfixed for
two minutes, unless Self-Testis deactivaled.

NOTE:Computedtiming is equal to bass timing plug

20 clegreesBTDC !,vith3 degresstobrarrce.
See vehicledecal lor correcl base timing.

I ls computedtimingwithinspecs?

Quic k T es t 5 ( E n g i n e R u n n i n g ) o TheDynamicResponsecodeis a singlepulse(or a

The EngineRunningSelf-Testprovides "hard" failures
only. lf the Key On EngineOtt test indicates no hard
failures,the EngineRunningtest should always be
performed next it should be noted that transaxle fault
codes will appear in continuousmemory since the
system remainson duringdrive cycles. Special
considerationsfor the EngineRunningSelf-Testinclude
the following:
o lf a code other than 1 1 appears on the "Engine
Running"display, a fault is present; look up the fault
on the Service Code Chart to find the corresponding
PinpointTest.
r lf the enginestarts but stalls, or stalls during
Self-Test, Go to PinpointTest Step S 1.
r On vehiclesequippedwith the Brake On/Off Switch
(BOO), the brake pedal MUST be depressed and
released AFTER the lD code.
r On vehicles equippedwith the Power Steering
Pressure Switch (PSPS), within 1 to 2 seconds after
the lD code. the steering wheel must be turned at
least one-half turn and released.
10 code on the STAFTester)that occurs6'20
code.
secondsafterthe enginerunningidentification
(SeeAPPENDIX: CodeOutputFormat')
o Whenthe DynamicResponsecodeoccurs'perform
a briefwide-openthrottle.
How to Runthe EngineRunningSelf-Test
DO
o DeactivateSelf-Test.
r Startandrunengineat 2,O00rpmfor two minutes.
Thisactionwarmsup the EGOsensor.
r Turnengineotf, wait 1Oseconds.
o ActivateSelf-Test.
o Start engine.
r After the tD code, depressandrelaasethe brake
pedalif appropriate.See SpecialNote above-
I After the lD code,within 1 to 2 seconds,turnthe
steeringwheelat leastone'halftum andthen
releaseit. if appropriate.SeeSpecialNoteabove.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
u
V,RrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n
o I ? QVnamicResponseCodeoccurs, performa DON'T
briefwide-openthrottte (WOT).
o Depressthe throttleunlessa DynamicResponse
r Recordallservicecodesdisplayed. Godeis displayed.

PERFoRMENGTNE
RUNNTNG
selr_resr

r Deactivate Self-Test.
ll any Continuous
r Activate Engine Running Setf-Test. Memoryservice codes
were rec€ivedin
. Start engirr and idle until vehicle is at operating Oulck TestStep 3.0.
tsmpeEture.
GO to Continuous
MemoryCode charts
iIOTE: lf additionalinlormationis required tor Engine
QuickTestStep 8.0.
Running Self-Test,refer to euick TestApftndix.
o Record all service codes displapd. ll a Gontinuous
Memory PASSCode
(11)was receivedin
NOTE: Engine Flunning Servbe Code 99 indicates
OuickTestStep 3.0
whicle is in Failura Mode Eflects Managrnent and no symplomsare
(FMEM) and DtD NgI PASSKOEO present:EEC-lV
On-Dernand/Continrrcus Menrory Self-Test. diagnostictestlngis
Engine Running Setf-Teslcannot be perfornnd complete.
while in FMEM. Go u ContirnrousMennry code
charts, Quick Test Step E.0,. lf a Continuous
Memory PASSCode
. ls a PASS Code (fl) recaived durlng Ergire
(11)was receivedin
FlunnirB Setf-TEst?
Quick TestStep 3.0
and symptomsare
present:GO to
DiagnosisBy
Symptomchart Qurck
TestStep 9.0.

lf EngineFlunning
servicg codes are
received:GO to
EngirreFlunningcode
charts,Ouick Test
Step 7.0.

lf no servicecodes
are received:GO to
PinpointTest Step
CTA1.

Ouick Test 8 (Continuous) Somespecialconsiderationsfor Continuoustesting:

After.servicinQ any Key On EngineOff or Engine I Thecauseof someContinuousMernoryCodesmay
Runninghard failuresanda pais code(1 1) G received havebeeneliminatedif Key On EngineOff and/or
on.both,yorlcFnthen servicethe ContinuousMemory EngineRunningcodeswereserviced.Alwaysretest
(intermittent)iodes onlyif they are intermittentcodes
andserviceonlythe codesthatstillremain.
whichis truefor mostengineproblems,but not lor
AXOO-Etransrnissions.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
LZ
FZRrsE TechnicaS
f e r v i c eI n f o r m a t i o n
r lf one or more of the following codes are present, go
to the PinpointTest indicated in the Quick Test
service code charl first: The corresponding Pinpoint
Tests tor the above codes check the processor and
wiring harnesses to the solenoids. lf these tests fail
to locate a fault, go to the "Drive Cycle Test" for
codes or the Electrical Diagnosis Chart Index in this
Section. REPEAT the Quick Test atter completing
servhe on these codes.
I lf the Continuoustest passes (code 1 1) and a fault
is still present, reler to the "Diagnostic By
Symptom" Charts (Quick Test 7.O).
r lt should be noted that fault codes in continuous
memory willbe erased while disconnecting the
battery, exit Self-Test while the codes are being
displayed, or by disconnecting the processor. lt is
advisable to record allcodes displayed on paper so
one will not lose sight of effectively diagnosing the
customer's concern.
Continuous Monitor Mode (Wiggle Test)
r lt may be necessary to service non-EEC-lVfaults
before runningQuick Test. Refer to
Engine,'EmissionsDiagnosis' manualSection 2.
. ContinuousMemory Codes recorded in this step will
be used for diagnosis in Step 5.0 after PASS gode
1 1 is received in both the Key On EngineOff and the
EngineRunningSelf-Tests.
r Deviationtrom this procedure may cause the output
of false codes.
e Refer to Quick Test Appendix for further information
on how to read code output.
r The ContinuousMonitor Modes allow the technician
to ATTEMPT to re-create arf intermittent fault.
Ke y O n E ngine O ff W i g g l e T e s t Prrc e d u re
1. Hook up a STAR Tester as shown in Quick Test
Step 2"O.
2. Turnthe ignitionkey to the ON position.
3. Activate, wait 1Oseconds, deactivate and
rbactivale Self-Test.
4. You are now in the ContinuousMonitor Mode.
5. Tap. move, and wiggle the suspect sensor
and/ or harness. When a fault is detected, a
ContinuousMemory Gode willbe stored in
memory.This will be indicatedas tollows
dependingon the type of equipmentbeing used:
o STAR Tester: Red LED lights and/or
continuoustone.
. CI-{EGKENGINEoTSERVIGEENGINESOON
lndicator Lights
En gine Running W i g g l e T e s t Pro c e d u re
1. Hook up a STAR Tester as shown in Quick Test
Step 2.O.
2. Key off . wait 1Oseconds.
AUTOMATIC GROUP
SERVICE
TRANSMISSION
l3
3. Start the engine.
4. Activate Self-Test,wait 1Oseconds, deaclivate
and reactivate Self-Test.DO NOT shut the engine
otf-
5. You are now in the EngineRunningContinuous
Monitor Mode.
6. Tap, move, and wiggle the suspect sensor
andlor harness. When a fault is detected, a
ContinuousMemory Code willbe stored in
memory. This will be indicated as follows
depending on the type of equipment being used:
r STAR Tester: Red LED lights and /or
continuoustone.
. CHECK ENGINEor SERVICEENGINESOON
Light (MlL): Lights
ElectricalSystem
testsareto beperformed
Pinpoint
Thelollowing if a
concernis foundwith the transav.le.Beforethesetests
are'performed, the ElectronicEngineControl(EEC{V)
Quick-Test the Engine/EmissionsDiagnosis'rnanual
in
shouldbe performedto determineif any servicecodes
for the transaxleappear.lf any of the lollowingservice
codesappearduringthe Quick'Testthe AXOD-Edrive
cycle test for continuouscodesshouldbe performed,
ServiceCodes
r 645, 646, 647, and 648: Referto DiagnosisChart
and PinpointTestSummaryfor definitionof code.
r 629: Transaxleconverterbypassclutchsolenoid
circuitfaitedalwaysopenor alwaysclosed.
The fotlowingservicecodes are not transaxle-related
but can affectconverterbypassclutchoperation.
Servicethesecomponentsbeforeservicingthe
transaxlecodes:
. 112:-54oFindicatedair chargetemperature(ATC)
circuitgrounded.
| 113: -4O"Findicated ACTcircuitopen.
' 114: Air chargetemperature(AGT)sensorout of
range.
o 116: Enginecoolanttemperature (ECT)senorout of
range.
. 117: ECTshortcircuit.
o 118: ECTopencircuit.
. 1212ThrottlePosition(TP)sensorout of range-
t 122: TP sensorbelowminimumvoltage'
o 123: TP sensoraboveminimum voltage.
r 452: Vehiclespeedsensor(VSS)'notfunctioning.
r 519: Powersteeringpressureswitchcircuit'
o 521: Powersteeringpressureswitchdid not
changestates.
Ui,RrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

o 535: Brake On / Otf (BOO) switch always open or

brake not applied during EngineRunning
On-Demand Self Test.

AXOD-E Drive Cycle Test r lf one of the followingcodes appears during the
After performingthe EEC-IVQuick Test, the following
EEC-Nguickt6$t,$€rvice
it firstbcforc
Drive Cycle for checking AXOD-E continuouscodes
withthetransmission
continuing diagnosis.
should be performed.
1. Record and erase EEC-IVQuick Test codes.
2. Verity transaxle ffuid level is correct. Servhe Plnpoint
EECIV OuickTeetSectbn Est
Codc
3. Warm engineto operating temperature. 452 M
Continuors
4. With transaxle in D range, lightly accelerate from 6A Keyon EngneOfl B
a stop to 64 km i h (40 mph) to allow transaxle to
shift into third gear. Hold speed and throttle 622 KOEO c
opening steady for a minimumof 15 seconds. 624 KOEO
Continuous, E

5. Accelerate from 65 km I h (4O mph) to 8O km / h 625 KOEO E

(50 mph) to allow transaxle to shift to fourth gear. 628 Contiruous J
Hold speed and throttle position steady for a
minirnumof 15 seconds. 629 KOEO I

634 Continuous A
6. With transaxle in fourth gear and maintaining
steady speed and throttle opening,lightly apply 636 KOEO,KayOn Engirr running N
and release brakes (to operate brakelamps).You 637 KOEO,
Continuors N
may feelthe converter locking and unlockirig.
Then, hofd speed and throttle opening steady for 638 KOEO.
Continorrs N
an additionalfive seconds minimum. 639 KOER,
Contiruou I

7. Brake to a stop and remain stopped for a 641 KOEO D

minimumof 20 seconds wilh transaxle in D range. 545 Continuous F
8. Repeat steps 4 through 6 at least five times. 646 Continuous
9. Perform EEC-V Quick-Testand record ffiI Continuous H
continuouscodes. 648 Contirnrous I
r Service any non-transmissionerror codes first 649 Continuous E
as they can directly affect the operation of the 651 Continrcus
transmission.Repeat the quick test and road
test to verify correction. 6s2 KOEO J

C OD E :634-P IN P OIN T
SE RV IC E
TESTA
TESTSTEP RESULT ACTIONTO TAKE
A1 | nolus r MA N U L E v E Rp o s tl o N s E Nson
AL
r Apply the parking brake. Toolfits GOto 42.
e Place transmissionin NEUTRALposition. Tool does not A D J U S Ts e n s o r
r Verify that Manual Lever Position Sensor Tool fit a c c o i d i n gt o a d j u s t m e n t
T 8 9 T - 7 O O 1 O f-iJt s i n a p p r o p r i a t es l o t s . p r o c e d u r e si n t h i s m a n u a l
a n d R E P E A TO u i c k T e s t i n
t h e E n g i n e/ E r n i s s i o n s
D i a g n o s i s 'm a n u a l -

AUTOMATIC
TRANSMISSION
SERVICE P
GROU
l{
UlHrsG TechnicaS
l e r v i c eI n fo r m a t i o n

SERVICEGODE: 634-PINPOIHT
TEST A (Continued)
TEST STEP FESULT ACTIONTO TAKE
A2 CHECK OPERATIONOF MANUAL LEVERPOSITION
SENSOR
r Disconnectvehicle harness trom MLPS. Resistance FIEPEATQUICK TEST in
within the Engine/ Emissions
r I n s e r tM a n u a l L e v e rP o s i t i o nS e n s o r T e s t e rh a r n e s s
specification Diagnosis' manual
(DSST-1OOlO-A) or equivalentinto the Manual Lever
Position Sensor Connector. Resistance not REPLACEManual Lever
in specilication Position Sensor and
r Plug VOM into Manual Lever Position Sensor Tester.
REPEATOUICK TEST in
r Verity continuity ONLY occurs in the 3 continuily the EnginelEmissions
positions.For example: with the tester in the NIP Diagnosis' manual.
position. continuityshould occur ONLY when the
ManualLever is in N or P posilions, and not R @ 2 or
1 positions,with the tester in "R" position, continuity
should occur only when the manuallever is in "R"
position, and not P N O 2 1 positions. (Start and
backupcircuit.)
I PositionTester on the ohms position. Verify thal the
resistance readings lor each position of the manual
lever,P, R, N. O, D. 1, are within specificationsas
shown on the front of MLPS tester.

SERVICECODE:621 - PINPOINT
TEST B
TESTSTEP RESULT ACTION TO TAKE
B1 CHECKHARNESSCONNECTIONS
a Check that the vehicle harness connector is fully Yes GOto 82.
engaged on the lransaxle side bulkhead connector. No SERVICEas required.
a Check thai the vehicle harness connector lerminals REPEATQuickTest.
are fully engaged in the connector.
82 GHECKSOLENOIDAND HARNESSFOR RESISTANCE
GROUND
I Disconnect vehicle harness at transaxle side Yes GO to 83.
bulkhead connector. No GO to 85.
. lnstall test harness to the side bulkhead conneclor,
r C o n n e c to h m m e t e rn e g a t i v el e a d t o t e s t h a r n e s s
Blue wire and positive to Green wire.
r R e s i s i a n c es h o u l db e 1 2 - 3 0o h m s f o r s o l e n o i d .
I Leave ohrnmeterpositive wire connected to green
lead and louch ohmmeter negative lead to engine
ground.
r No ground (infiniteresistance) is alfowed.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
l5
U|RrsE l e r v i c eI n f o r m a t i o n
TechnicaS
SERVICE CODE: 621 - PINPOINT
TEST B (Continued)
TESTSTEP RESULT ACTIONTO TAKE
B3 CHECK SOLENOIDMECHANICSPOWER APPLTEDFOR
CLICK
. Connect Green wire of tesl harness to + 12 volts Yes GO to 84.
using a fused jumper wire.
tio GO to 85.
o Momentarilytouch Blue negative test harness wire lo
engine ground.
r Listen for solenoid click when ground is touchecl.A
stethoscope may be reguired to hear ctick through
pan.
I Click denotes solenoid is electrically OK.

CAUTIOH: Do not connect a power Supply with

reverse polarity to these wires or colenoid diode
will fait.

84 CHECKVEHICLEHARNESSFORCONTINUTW
AND
G RO U N D
NOTE:Refer to lhe AXOD-Etransarlc wlring harness
terminal locations and color codas precedlng theee
pinpoint tests.

Disconnect vehicle harness from processor and side Yes GO to 85.

bulkhead connector.
No SERVICEas required.
Check for continuity between Pin 51 on the 60 pin REPEATquick test.
conneclor and the 51 shift solenoid pin. See diagram
below. Must have continuity. Check from pin Sl to
ground. No ground is allowed.
Reconnect EEC-IVprocessor connector, turn the
ignition key to run position. Check all three solenoid
bulkhead connector pins marked in diagram below.
Must have banery voltage to actuate solenoids.

VE}IICLE HARilESS TO TRANSAXLE SIDE SJLI fiErD COaT|NECTOR '+

WtFtE 37.57

*1R8,. wtREssz wfRE st SSt

{ ,
LOOI'
wtREss3 55 + wlRE 37.57
ECC-|VPROCESSOA
coNNEC?Oe '+ WIFE37.57
HOTIN KEY.RJil" POSITION VCHELE TRAIISAXLE
S|DE AULX}IEAD COflNECTOF
Loorflxc ritTo YEH.coritirEcron

TRANSMISSION
AUTOMATIC GROUP
SERVICE
t6
7RrsE l e r v i c eI n f o r m a t i o n
TechnicaS

SERVfCECODE:621 - PlllPOlt{T
TEST B (Continucd)
TEST STEP RESULT ACTIOT{TO TAKE
B5 CHECK INTERNALCONNECTIONSCHECK INTERNAL
WIRING
r Remove transaxle side oil pan. Yes REPLACE EEC.IV
processorand rePeat
r Check that internalsolenoid connectorwith the while quicklest.
(+) and green (-) wires is firmly connected to the
solenoid connector and does not pull otf easily or fil No REPAIRoTREPLACE
loosely. bulkheadconnsctor
harnessor solenoidas
r Remove connector trom solenoid by lifting on the end
required.REPEATquick
of reiainingtab while pullingon wire end of the
test.
conneclor.
r Check both wires in the solenoid connEctorto the
bulkhead connector terminals by measuring the
resistance of each wire.
o R e s i s t a n c es h o u l db e l e s s t h a n 2 . 0 o h m s .
o Check resislance ol the solenoid.Resistance should
be 12-3oohms,

SEFVICECODE:822 - PIHPOINT
TEST C
TEST STEP RESULT ACTIONTO TAKE
c1 CHECK HARNESS CONNECTIONS
o Gheck that the vehicle hamess connector is fully Yes GO lo C2.
engaged on the transaxle side bulkhead conneclor. No SERVICEas required.
a Check that lhe vehicle harness connector tBrminals REPEATQuick TESI.
are fully engaged in the connector.
c2 ANDHARNESSFORRESISTANCE
CHECKSOLENOID
ANDGROUND
r Disconnect vehicle harness at transsxle side Yes GOto C3.
bulkhead conneelor. No GO to C5.
. Install lest harness to lhe side bulkhead connector,
r Connect ohmmeter negative lead to test harness red
wire and positive to yellow wire.
I Resistance should be 12-3Oohms for solenoid.
r Leave ohmmeter positive wire connected to yellow
lead and touch ohmmeter negative lead to engine
ground.
No ground (infinite resistance) is aflowed-
c3 CI.IECKSOLENOID MECHANICSPOWER APPLIEDFOR
CLICK
r Connect yellow wire of test harness to + 12 volts Yes GOto C4,
using a fused iumper wire. No GOlo C5.
. Momentarily touch red negative test harness wire to
engine ground
. Listen for solenoid click when ground is touched. A
stethoscope may be requiredto hear click through
pan-
r Click denotes solenoid is electrically OX.

CAUTION: Do not connect ! power supply with

reyersG polarity lo theee wirss or rolenoid dlode
will fail.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
t7
lZRrsE T e c hn i c a l S e r v i c e I n fo r m a t i o n
SERVICE GODE: 622 - P|I{POINT
TEST C (Continued)
ACTION TO TAKE
CHECKVEHICLEHAFNESSFOR CONTINUITYAND
GFIOUND
NOTE: Beferto the AXOD-E transaxle wiring harness
tcrminallocation and color codes preceding theee
pinpoint tests.

r Disconnect vehicle harness from processor and side Yes GO to C5.

bulkhead connector.
No SERVICEas required-
e Check for continuitybetween Pin 52 on the go pin REPEATQUiCKTest,
conneclor and the 52 shift solenoid pin- See diagrarn
below. Must have continuity.Check from Pin 52 to
ground.No ground is allowed. Reconnect EEC-IV
processor connector.
I Turnthe ignationkey to run position- Check all three
solenoid bulkhead connector pins marked '* in
diagram below. Must have battery voltage to
activate solenoids.
VEHICLE HAFNESS TO TRANSAXLE SIOE EULKHEAD COTJNECTON '+
wlFlE 37.57

\tlFlE SS.,_ wlFlE 5r ssr

wtRE

LooM ' +
wlgE ss3 55d WIRE 37-52
ECC.TVPHOCESSOn
' + WIFIE
CO'{HECTOF 37-57
.BUN' VETIICLEITARHESSTRANSAXLE
HOT IN XEY POSITION SIDE BULXHEAD COI,{NECTOR
LOOKING IN?O VEX. CONNECTOF

CHECK INTERNALCONNECTIONSCHECK INTEFINAL

WIRING
e Rerhovetransaxle side oil pan. R E P L A C EE E C . I V
. Check that internalsolenoid connector with the red processor and repeat
(+) and blue wires is tirmly connected to the solenoid Quick Test.
connector and does not pull of easily or fit loosely. No SERVICEor REPLACE
e Bemove connector from solenoid by litting on the end b u l k h e a dc o n n e c t o r
of relaininglab while pullingon wire end ol the harness or solenoid as
connector. required.REPEATOuick
Test.
. Check both wires in the connector to the bulkhe-ad
conneclor lerminals by measuringthe resistance of
each wire.
o Flesistanceshould be less than 2.Oohms.
r Check resistance of the solenoid.The resistance
s h o u l db e 1 2 - 3 Oo h m s .

SERVICECODE:641 - PIHPOINT
TESTD
TEST STEP RESULT ACTION TO TAKE
D1 I cxecx HARNESS
coNNEcTIoNS
. Gheck that the vehicle harness connector is fully Yes GOl o D 2.
engaged on the transaxle side bulkhead connector.
r Gheck that the vehicle harness connector terminals
No E req uir ed.
S E R V IC as
are fully engaged in the connector. FIEPEAT OuickTest.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
r8
Ul,HrsE T e c hn i c a l S e r v i c e l n fo r m a t i o n

SERVICECODE:641 - PlilPOlt'lT
TESTD (Continued!
TESTSTEP RESULT ACTIONTO TAKE
o2 CHECKSOLENOIDAND HARNESSFOR RESISTANCE
A N DG R O U N D
r Disconnectvehicle harness ai transaxle side Yes GOto D3.
bulkhead connector.
r lnstall test harness to the bulkhead connector. No GOto D5.
r Connect ohmrneter negative lead to test harness
white wire and positive lo black wire.
r Flesistanceshould be 12-3Oohms for solenoid.
. Leave ohmmeter positive wire connected to black
lead and touch ohmmeter negative lead to engine
ground.No ground (infiniteresistance) is allowed.
D3 CHECK SOLENOID MECHANICSPOWER APPLIED FOR
CLIGK
r Connect black wire of test harness to * 12 volts using Yes GOto D4.
a fused iumper wire. No GO to D5.
o Momentarily touch white negative test harness wire
to engine ground.
o Listen for solenoid click when ground is touched. A
stethoscope may be required to hear click through
pan.
r Click denotes solenoid in electrically OK:

CAUTION: Do not connecl. pout.r aupply with

reyer3e polarity to thecc wirer or rolsnoid diodc
will fail.

FORCONTINUITY AND
04 | cxecx vEHlcLEHARNESS
I GROUND
I *Org, Reler to the AXOO-Etransarlc wirine harnllt
prccoding thcso
I tcrminatiocationr and color codcr
I pinpoint tests.
V", GO to D5.
bulkhead conneclor SERVICEas required.
lNo
o Check for continuitybetween pin 55 on the 60 pin I REPEATQuick Test.
conneclor and 55 shift solenoid pin- See diagram I
below. Must have continuity. Check frorn pin 55 to I
ground.No ground is allowed. Reconnect EEG{V I
processor conneclor. I
r Turnthe igniiionkey lo run position. Check allthree I
'* in
solenoid bulkhead connector pins marked I
diagram below. Must have battary voltage lo acluale I
solenoids. I
VEHICLEHARNESSTO TRANSAXLESIOEBULK}IEADCONilEC'OR -t'+ WfRE 37-57

-D tl
wtREssz 6ili w r R E5 1 S S 1
v F a t t

wrREss3 55 4y7i.+ wrRE

37-5?
-1/
ECC-IVPRCTC€ssoR '+ WIRE 37.57 5
COI{NEGTOR VEHICLEHARNSSSlRAltlSAXLt
+ }IOTIN KEY"RUN'FOS]TION SI.r EULKHElp col{ilEcToF
tool${G ll'lro vEr{. co0lilEcroR

TRANSMISSION
AUTOMATIC GROUP
SERVICE
t9
UI,RrsE T e c h n i c aS
l e r v i c eI n fo r m a t i o n

SERVICECODE:641 - PlNpOtt{T
TESTD (Continucd)
TEST STEP RESULT ACTIONTO TAKE
D5 CHECK INTERNALCONNECTIONSCHECK INTERNAL
WIFING
e Rernovetransaxle side oilpan- Yas R E P L A C EE E C i V
r Check that internal solenoid connector with the processor and REPEAT
yellow (*) and black wires is firmly connected to the Q u i c kT e s t .
solenoid connector and does not pull off easily or fit No SERVICEor REPLACE
loosely. bulkhead connector
I Rernove connactor from solenoid by ilfting on the end h a r n e s so r s o l e n o i da s
of retainingtab while putlingon wire end of the required.REPEATQuick
connector. Test.
r Check both wires in the conn€ctor to the bulkhead
connector terminals by measuring the resistance of
each wire.
I Resistance should be less than 2.O ohms.
e Check resistance of the solenoid. Resistance shoutd
b e 1 2 - 3 0o h m s .

SERVICE CODES: 624, 625, G49. 55'l

- PINPOINTTEST E

TESTSTEP RESULT ACTIOHTO TAKE

E1 CHECK HARNESS CONNECTIONS
r Checkthet the vehicleharnassconnscloris fully Yes GO to E2.
engagedonthe transaxlsbulkheadconnector.
No SERVICEas required.
r Cheekthat the vehicleharnsssconnectorterminals REPEATQuick Test.
are tullyangagedin the connector.
E2 CHECKSOLENOID ANDHARNESSFORHESISTANCE
ANDGROUND
o Disconnect vehicle harness at transaxle upper Yes GO to E3.
bulkhead connector.
No GO to E5.
r Install test harness to the upper bulkhead connector.
. Connect ohmmeter negative lead to test harness blue
wire and positive to yellow wire.
o Rssistance should be 2.5-6.5 ohms for solenoid.
o Leave ohmmeler posilive wire connected to yellow
lead and touch ohmmeternegativc lead to engine
ground. No ground (infinite resistance) is altowecl.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
20
fInrsE T e c h n i c a lS e r v i c eI n fo r r n a t i o n

SERVICE CODES:G24,625,6f9, 651

- PlllPOlltlTTEST E (Continued)
TESTSTEP RESULT ACTIOHTO TAKE
E3 CHECKSOLENOIDMECHANICSPOWERAPPLTEDFOR
cLrcS -. _
I Connecl yellow wire of test harness lo + 12 volts Yes GO to E4.
using a tused jumper wire.
No )t GO to E5.
o Momentarilytouch blue negativetest harness wire to
engine ground.
r Listen for solenoid click when ground is touched. A
stethoscope may be required to hear click through
pan.
r Click denoles sotenoid is etectricailyOf.

CAUTION: Do nol connccl a powcr rupply wlth

reyct8o eolarity to thcre wlrer or rolenold diode
will fail. (EPC solsnoid dorr not have a diode,)
ALTERNATEFUNCTIONALECP TEST
r Connect 0- tOOpsigauge to transaxle TV port. Tesl
as above by momentarilytouching the blue negative
test harness wire to ground- This energizes EpC
solenoid.EPC energized = 1O-2Opsi. EpC
deenergized = 75.85 psi.
E4 CHECK VEHICLEHARNESS FOR CONTINUTTYAND
GROUND
NOTE: Reler to the AXOO-E tranraxle wiring harnclr
tcrminal locationg and color coder prcccdlng thcce
pinpoint tcsts.

Disconnectvehicle harness from processor and Yes tl uotoEs.

upper bulkhead connector.
No )l SenvlCEas required.
Gheck for continuity between pin 36 on the 6O pin REPEAT
ouickresr=
connoctor and the EPC g8 sotenoidpin. See diagram
below. Must have continuity.Gheck from pin 3g to
ground-No ground (infiniteresistance) is allowed. I
Reconnect EEC-lVprocessor conneclor.
I
II
Turn the ignition key to run position. Check the
bulkhead pin marked . * tor EpC, must have battery
v o l t a g et o a c t u a t e s o l e n o i d .

vEHtcLE HAFI|ESSTOTnAitsnxLg ul 'PEF SULKHEAD '+ W]RE

ffi
COT.INEgrDR Tgr wRE {9 WNE38 Erc
WIRE wlFEa5.
WIRE 53 MLUS
too"-- '+ WIFIE
ECC.IV PFOCESSOR 3?-57
CONNESTDR '-
VEHICTE HASi{ESS TRAIISAXLE
HOT I1.{KEY .RUN'' POS'TION UPPERBULKHEADCONNECTOR

AUTOMAIIC
TRANSMISSION GROUP
SERVICE
2l
UiRrsE T e c h n i c aS
l e r v i c el n fo r m a t i o n
SERVICE CODES: 624, 625, 649, 65 1
- PINPOINT TEST E (Continued)

TESTSTEP RESULT AcfloNro raxe

E5 CHECK INTERNALCONNECTIONSCHECK INTERNAL
WIRING
t Remove transaxle side oilpan- Yes R E P L A C EE E C . I V
processor and REPEAT
r Check that internalsolenoid connector with the white
Q u i c kT e s t .
(*) and green wires is firmly connected to the
solenoid connector and does not pull olf eesily or fit No SERVICEor REPLACE
loosely. bulkhead connector
harness or solenoid as
r Remove connector from solenoid by lifting on the end
required.REPEATOuick
of retaining tab while pulfing on wire end of the Test,
connector.
r Check both wires in the connector to the bulkhead
connectorterminalsby measuringthe resistance of
each wire.
r Besistance should be less than 2.Oohms.
e Check resistance of the solenoid. Flesistsncgshould
be 2.5-6.5 ohrns.

SERVICE CODE: 645 - PINPOINT

TEST F

TESTSTEP HESULT ACTIONTO TAKE

F1 GHECKFORSOLENOID
CODE(S)
o lf code(s) 645 is present, go to pinpoint test Cl Code present GO to appropriate
p i n p o i n lt e s t .
No code GO to F2.
present
F2 CHECK WIRING
Gheck that vehicle hamess connector is tully Connectorfully HEPLACEEEC-IV
engaged on the transaxle bulkhead sido connector engaged processor. REPEATQuick
and that the vehicle harness terminals are fully Test.
engaged in connector, Connector SERVICEas required.
loose or R E P E A TO u i c k T e s t .
terminalsnot
ful l yengaged

SERVICE CODE:646 - PINPOINT

TESTG
TESTSTEP RESULT ACTIONTO TAKE
G1 CHECKFOR SOLENOIDCODES
e lf code present. go to pinpointtest B 1 and C1 Gode presenl GO to appropriate
p i n p o i n tt e s t .

No code GOto G2.

present
G2 CHECKWIRING
Check that vehicle harness connector is fully Connectorfully R E P L A C EE E C . I V
engaged on the transaxle bulkhead side connector engaged p r o c e s s o r .R E P E A TO u i c k
and that the vehicle harness terminals are fully Test.
engaged in connector. Connector S E R V I C Ea s r e q u i r e d .
loose or REPEATQuick Test.
lerminals not
fully engaged

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
22
ARrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

SEBVICECODE:647 - P|i{POINT
TEST H
TEST STEP RESULT ACTIOHTO TAKE
H1 I cxecx FoRsoLENotDcoDEs
o lf code 647 is present, go to pinpointtest D I Gode present Go to the appropriate
pinpointtest.
No code GO to H2.
present
H2 I CHECK WTRING
Check that vehicle hamess conn€ctor is fulty Connector fully REPLACEEEC.IV
engaged on the tranxaxle bulkhead side connector engaged processor. REPEATQuick
and that the vehicle harness terminals are fully Test.
engaged in conneclor.

Connector SERVICEas required.

loose or REPEATQuick Test.
terminalsnot
fully engaged

CODE:648- PINPOINT
SERVICE
TE S TJ
TEST STEP RESULT ACTIOI{TO TAKE
J1 CHECKFORSOLENOID CODES
o ll code(s)621.622, or641 is present,go'topinpoint Code(s) GO to appropriate
t e s t8 1 , C 1 ,o r D 1 . present pinpoint test.
No code(s) GO to J2.
present
J2 CHECKWIRING
Check that vehicle harness connector is fully Connector fully REPLACEEEC.IV
engaged on the transaxle bulkhead side connector Engaged processor. REPEATQuicl
and that the vehicle herness terminals ara fully Test.
engaged in connector. SERVICEas required.
Connector
loose or REPEATquick test.
terminalsnot
fully engaged

S E R V I C EC O D E : 6 2 9 , 6 5 2 , 6 2 8 -
PIXPOINT TEST K
TESTSTEP RESULT ACTIONTO TAKE
K1 CHECKHARNESSCONNECTIONS
a Gheck that the vehicle harness connactor is fully Yes GO to K2.
engaged on the transaxle upper bulkheEd connector.
No SERVICEas required.
a Chcck that ihe vehicle herness connector terminals REPEATQuick Test.
are fully angaged in the connector.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
27
[|srsG l e r v i c eI n f o r m a t i o n
TechnicaS
SERVICECODE:629,652,628 -
Plt{POll{TTESTK (Gontinued)
TEST STEP RESULT ACTIONTO TAKE
K2 CHECK SOLENOID ANO HARNESS FOR RESISTANCE
AND GROUND
I Disconnectvehicle harness at transaxle upper Yes GO to K3.
bulkhead connector. No GO to K5.
r Installf est harness to the upper bulkhead connector,
o Connect ohmmeter negative lead to test harness
green wire and positive to black wire.
o Resistance should be:
MLUS = 0.75 - 2.0 ohms
LUS = 16 - 40 ohms.
r Leave ohmmeter positive wirg connected to black
lead and touch ohmmeter negative lead to engine
ground. No ground (infinite resistance) is allowed.

NOTE: MLUS is modulatsd lock-up clutch

solenoid. LUS is lock-up clutch tolenoid. Either
one may bs used, depending upon modcl.

K3 CHECK SOLENOIDMECHANICSPOWER APPLIED FOR

CLICK
e Connect black wire of test harness to * 12 volts using Yes GO to K4.
'
a fused jumper wire. No GO to K5.
r Momentarily touch green negative test harness wire
to engine ground.
e Listen for solenoid click when ground is touched. A
stethoscope may be required to hear click through
Pan.
r Click denotes solenoid is electrically OK.

CAUTlOl,l: Do not connect a power supply wilh

roycrse polarity to thcec wircr or rolcnoid diode
will tail. HLUS solenold do6s nol contaln a diodc.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
24
[/lrsE l e r v i c el n f o r m a t i o n
TechnicaS

SERYICE CODE:629,652,628 -
PlilPOltlT TEST K (Continuedl
TESTSTEP RESULT ACTIOHTO TAKE
K4 CHECKVEHICLEHARNESSFORCONTINUITY
AND
G HO UND
NOTE:Refer to thc AXOD-Etranrarle wiring harnesr
torminallocatlons ald color codec Arecedlngthese
pinpoint teclr.

Disconnect vehicle harness from processor and Yes GOto K5.

upper bulkhead connector. No SERVICEas required.
Gheck for continuity belween pin 53 on the 80 pin REPEATQuickTest.
conneclor and the converter clufch solenoid 53 pin.
See diagram below.
Must have continuity. Check hom pin 53 to ground.
No ground (infinite resistance) is allowed.
Reconnect EEC-lVprocessor connector. Turn the
ignitionkey to run position. Check the bulkhead
conneclor pin marked 'f for MLUS, must have
battery voltagef o ectivate solenoid.

VEHICLE '{ARNESS II' TNATSAXLE ,PPER A'LKHEAD

,'+ WIRE
coNNECrOfi TOTWIRE49
J.:'+ wrRE36EPc
I
wrBE.6
WIRE I
wrREs3MLUS
=;il '+ W|FE37-57
l-
ECGTV PROCESSOR
CONNEGIOR
VEHFLE HART{ESS TF/ \NSATLE
HOT IN KEY.FUN- POSITION UPFER BT'LKHEAP COI txEgtoB

K5 CHECK INTERNALCONNECTIONSCHECK INTERNAL

WIRING
o Remova transexleside oil pan. Yee REPLACEEEC.IV
proce3sorandREPEAT
o Check that internal solencid connector with the red
(+) and black wires is firmly connected to the QuickTest.
solenoid connector and does not pull of easily or fit No SERVICEor REPLACE
loosely. bulkheadconnector
o Remove connector from solenoid by liftingon the end
harnessor solenoidas
required.REPEATQuick
of retainingtab while pullingon wire end of the
Test.
connector.
r Gheck both wires in the conneclor to the bulkhead
connector terminals by measuring the resistance of
each wire.
I Resistance should be less than 2.O ohms.
o Check resistance of the solenoid.
MLUS = O.75- 2.0 ohrns
LUS = 16- 40 ohms.

AUTOMATIC
IRANSMISSION GROUP
SERVICE
2'
ff rsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

SEFVICE CODE:639 - PINPOINT

TEST L
TESTSTEP RESULT ACTIOH TO TAKE
L1 CHECK HARNESS CONNECTIONS
o Check lhat vehicle harness connector is futly Connectorfully GO to L2.
engaged on lhe turbine speed sensor and that the engaged
vehicle harness terminals are fully e,ngagedin
Cdnnecior SERVIGEas required.
connector.
loose or REPEATQuick Test.
terminals not
fully engaged
L2 CHECK RESISTANCE
r Rsmove vehicle harness connector from EEC-IV Resistance in GO to L6.
processor-
r Connect an ohmmeter negative lead to pin 46 of the
specification
J
I
Resistance out GO to L3.
processor connector and the positive lead to pin 5. of specification
I
o Record resistance: Resistance should be :
approxima lely 8O-22Oohms.
L3 CHECKHARNESSFORCONTINUITY
Remove vehicle harness connector frorn turbine Continuity Go ro L4.
speed sensor.
No continuity SERVICE or REPLACE
Remove vehicle harness for EEC-IVprocessor. harness.REPEAT Quick
Check lor continuity between the positive terminalof Tesl.
the TSS connector and pin 5 of processor connector.
Check for continuity betrveen the negative lerminal of
the TSS connector and pin 46 of the processor
conneclor.

40

L4 | ,CHECKTSS RESTSTANCE -. .
I Connect an ohmm€ter negative lead to the negative Resistance in GOl o L5.
terminal of ths TSS an the positive lead to the specification
posilive terminal of the TSS. Th.epolarity is denoted
Flesislance out REPLACE TSS.REPEAT
on the back side of the TSS terminats.
of specification QuickTesl.
o Rccord resistance: Resistance should be
approximatetyeO-220ohms-
L5 CHECKTSSMAGNETISM
I RemoveTSS. TSS GO to L6.
I Place TSS against a metal surface to which a magnet magnetized
would stick. The TSS should be rnagnetized. TSS is not REPLACETSS. REPEAT
magnetized O u i c kT e s t .

AUTOMAIIC
TRANSMISSION GROUP
SERVICE
26
UlnrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

SERVICECODE:639 - PIHPOINT
TEST L (Continucdl
TESTSTEP RESULT } ACTIONTO TAKE
L6 CHECK EXCITERWHEEL
Remove turbinespeed sensor. Depth within MARK tooth wilh a marke
With remote starter, starl and stop vehicle until a specification and BEPEATuntil all four
teeth are measured.lf all
tooth of the exciter wheel is visible through the TSS
hole. teeth are within
specification,REPLACE
HOTE: Ensure a tooth is visible. The ercitcr wheel EEC-lVprocessor.
will always be vicible through the TSS hole. FEPEATQUiCKTESI.
Depth not in SERVICEor REPLACEas
specification required.

Measureth€ depthof the exciterwheeltooth trom

the outeredge ol the chaincover.Distanceshould
not exceed2o.62mm(.81inch).

SERVICECODE:452 - PINPOINT
TESTM
TESTSTEP RESULT } ACTIOI{TO TAKE
M1 DRIVECYCLEFORCHECKING
VEHICLESPEED
SENSOR(VSS)
r Record and clear EEC-IV continuous memory codes. Yas GOto M2.
r warm engine to operating temperature. No Unablelo duplicatef ault
r Perform the drive cycle bElow as appropriate lor the at thistime.lt anyother
vehicle being terted.
codesars present,
RETURNto QuickTest for
r Place the gear selestor in LOW and moderately direction.lf codes are nol
accelerate to 25 mph, then coagt down to an idle and present,test is
stop the vehicle. Shut engine off, compl6lad.
M2 CHECK VEHICLESPEED SENSOR
r Key off, wait l0 seconds Yes GOto 1t13.
r Locate and disconnect vehicle speed sensor. No REPLACEsensor,
o DVOM on 2OO,OOO test step M 1
REPEAT
ohm scale.
o Measure resistance across vehicle speed sensor.
r ls resislance between 19Oand 240 ohms?

TRANSMISSION
AUTOMATIC GROUP
SERVICE
27
UZ,FrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n
SERVICECODE:452 - PINPOI|IT
TEST H (ConUnscdl
TEST STEP RESULT ACTIONTO TAKE
lt3 CHECK CONTINUITYOF VEHICLESPEED SENSOR
(vss) HARNESS
. Key off, wait 1Oseconds. Yes GO to M4,
r Disconnect processor 5O pin connector_lnrpect for No SERVICEopen circuit.
damaged pins, corrosion, loose wires, etc. Sswice FEPEATTest Step Ml.
as necessary. REMOVEbreakout box.
I Inslall breakout box. RECONNECTprocessor
and VSS.
I Processor and VSS disconnected
o DVOM on 200 ohm scale.
o Measure resigtance between Test pin 3 at the
breakoul box and the VSS vehicle hamsss.connector
as shown below-

TEST PIN 6 O--ySS OF -

TEST ptN 3 O-YSS txF

+

I Are both resistances less than 5 ohms?

lt4 CI'IECKVSS HARNESSFORSHORTSTO POWEROR
GROUND
r Key off. Yes REMOVEbreakoutbox.
o Processordisconnectad. RECONNECT processor.
GOto t{5.
r VSSdisconnected.
NO REMOVEbreakoutbox.
r DVOMon 2O0,O0O ohm scale. processor
RECONNECT
I MeasureresistancgbetwqenTest pin 3 and Test pins end VSS.SERVICEas
37,4 and6 at the breakoutbox. required.REPEATTeSt
r MegsureresistancebetweenTest Pin6 and Test pin StepM 1.
37 et the breakoutbox.
o Are all recistencesgr"aterthan 1O,OOO
ohms?
t5 REPEATDHIVECYCLE WITHA KNOWNGOODVSS
INSTALLED
I SubstitutcVSSwith knowngood ssnsor. Yes REMOVE breakout box.
r Processorand VSS connected. REINSTALLori ginal VSS.
REPLACE processor.
r Performdrivecycle outlinedin test step Ml, then
REPEATstep Ml.
rcturnto this step.
No The original continuous
r ls code 452 preeentin contlnuousmemory?
memory code 452 was
the result of the original
VSS. REPEATquick tesl.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
2E
Ei,RrsE T e c hn i c a l S e r v i c e I n fo r m a t i o n

SERVICECODE:636, 637, 638 -

PINPOII{TTEST il
TESTSTEP RESULT ACT]ONTO TAKE
N1 CHECK HARNESS CONNECTIONSTOT SENSOR
r Check that the vehicle harness connector is tully Yes GOto t{2.
engaged on the transaxle upPer bulkhcad connector. No SERVICE as
oTREPLAGE
r Check that the vehicle harness connector terminals required.
are fully engaged in the conneclor,
N2 CHECKTOTSENSORRESISTANCE
NOTE:Refrr to thc AXOD€ Trantcrlr Wirlng
Herncu Tcrminal locatlonr and Color Coder
preccding thcse Pinpoint Tortr

Install test harness to the uPPertransaxle bulkhead Resistancein GOto il3.

connector. rang€
Carefully touch the transarle oil pan on the driver's Resistance REPLACETOTsensor
side. away from the exhausl syelem, to approximate grealerthan andREPEATQuickTest in
the temperalurs. After running tha Quick Test, the 1O7Kohms the Engine/Emiesions
transaxte oil pan should be warm to the touch. (As a Diagnosis'nanual.
guide,warm to the touch is about 41'7OoC Resistanceout PERFOBMeecondtest
(105-158'F)). of range listedin this step.
Connect ohmrneter negative lead to the white wire REPEAT QulckTsst in the
and the positive lead to the rod wire on the service Engine/ Emissions
harness. Diagnosis'manual.
Rscord lhe resistance.
Resistance should be approximately in the following
ran9es-

FU'IOTETPERJ\ruNE
TR/TI{SAXLE
furEtlmr
Dcgrrc!'C Dcgrccl'F Olilttr
$20 32-s8 107K-gl.5K
a4 5904 3:t.5lct4.sK
41.71) xl$r58 14.5K5.0K
71-90 15$pl 5.0fc2.5K
9t1il €s?30 2.5161.5K
11F130 231266 1.5tQ.8K

lf the resistance was not the apPropriate temperature

rang€ but was between O.8K and lOfK ohms, Perform
the following test. lf the transaxle is cold, run lhe
transaxle to heat it up. lf the transaxle is watln, allow
the transaxle to cool. Gheck TOT sensor rssistance
again. Compare the resistance with the.initiaf
resistance. Resistance ehould decrease if transaxle
was heated anclshould increase if transexle wes
allowed to cool. lf the correct change in resistance
occurs, REPEATQuick Test.

AUIOMATIC
TRANSMISSION
SERVICE
GROUP
29
UlHrsE T e c h n i c a l S e r v i c e l n fo r m a t i o n

SERYICECODE;636, 637, 53S -

PFfPOlllT TEST ll (Contlnucd)
TEST STEP RESULT ACTIONTO TAKE
x3 CHECKTOTSENSORFOR SE|oRTTO GROUND
I Install tast jumper harness to lrensaxla upper Continuily REPLACETOT sensor
bulkhead connector. and REPEATQuick Test.
r Checlt for continuity batween enginc around and No continuity lf code was e continuous
white wire wilh an ohmmetsr or othsr low currenl code, INSPECTtransaxfe
tester(less than 2O0 mitliampe). lluid to determine if fluid is
r Repeat the continuity cheelc wlth thc red wire. burned. lf burnt, TEAR
r Connection should show no conlinuity (infinlte DOWN trapsaxle.and
INSPECTfor damage.
rasistancG).
SEHVICEas required and
REPEATQuick Test in the
Engine/Emissions
Diagnosis'manual. I

Usethe followingdiagnosischarts to diagnose

problemsin the transaxle.

TRANSM
AUTOMATIC ISSION P
GROU
SERVICE
'o
ganrsET e c hn i c a l S e r v i c e l n fo r m a t i o n
AUTOIIATIGTRANSAXLEDIAGNOSIS_

CONDITIOH POSSIBLESOURCE ACTION

. OilLeak 1. Side pen orboltom pan. 1. Service as required
. Loybolt torque.
. Damaged gasket or pan rail.
. Distorted pan.
. Engine or power
steering fluid leaks may
app€ar on transaxle.
2. Fill lube or electrical bulkhead 2. Service as required
connectors.
. Loose fit/damaged case.
o Externalseal
damage/missing.
3. Manualshatt. 3, Replace seal.
o Damaged seal.
4. Speedometer cover and servo 4. R e p l a c e O - r i n gs e a l .
cover$.
o Damaged O-ring seal.
5. Cooler fitlings or pressure taps. 5 . Service as required.
. Lowtorque, damaged thraads-

. Cooler line not fully snapped

OilVenting or Foaming
High or Low Oil Pressure (Verity
With Gauge)
into fttting-
6. Convertar or converter seal. 6. Service as required.
o Damaged sealagsembly, or
garter spring missing.
. Converter hub scored.
o Weld seam leaking.
7. Hallshaft seals. 7. Replace seal.
o Damaged sealassambly, or . Inspect CV joint journal for
ganet spring missing. damage.
8. Speedometer cable or speed 8. Rgplace O-ring seal.
s9nsor.
. Darnaged O-ring seal.
9. Turbine speed sensor. 9. Replace O-ring seal.
. Damaoed O-rino seal.
t. Oillevel (venting). 1.Drainandfill transaxleto proper
. Transaxleoverfilled. level.
2. Transrnissionlluid. ?. DetFrminesourceof leak.Service
. Contaminated with antifreeze or as r:equired.
engine overheating.
3. Bi-rnetallicelement stuck open. 3. Replaceelement.
4. Oil filter plugged/damaged. 4. Replacefiliersealandfilter.
. Damaged/missingseal.
1.Oillevel. 1. Fill transaxle as necessary.
o Oilleyeltoo low
2.EPC solenoid. 2. Refer to Electrical Systgrn
o Inqperative/damaged. Diagnosisin this section.
3. Pressure regulatorvalve or spring. 3. Determinesource of damage.
. Nicked scored bore or valve. Service as required.
o Damagad spring.
4. Throttlc Position Sensor 4. Service as required.
misadiusted.

SERVICE
TRANSMISSION
AUTOMATIC GROUP
3r
FjlsrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

AUTOMATICTRANSAXLEDIAGilOSIS-
AXOD-E(Conffnued)
CONDITIOH POSSIBLESOURCE
High or Low OilPresgure (Verity 5. Oilpumpassembly.
With Gauge) - Continued o Ringstuck,sealsdamaged,
Yanesdamaged.
. Pumpdriveshaftbrokenor
damaged.
No 1-2 Shift (Firsl GearOnly)
J 1.EEC-IVprocessor.
I r Damaged.
I z. Snit sotenoid1.
I r Wiringshort/open.
| 3. Mainregulatorvalve.
| . Stuck.nickedor damaged.
| 4. 1-2ghiftvalve.
I r Stuck.nickedor damaged-
| 5. Intermediateclulch shuttlevatve.
| . Stuck,nickador damaged.
6. 1-2capacitymodulatorvalve.
. Stuck.nickedor damaged.
7. No. 10checkball.
. Missingor damaged-
9. Controlassembly.
. Boltstoo looseor too tight.
9. Intennediateclulchtap plug
loose/mi3sing.
10.Drivensprocketsupport.
o Sealsdamaged/missing or holes
bloclted.
1 1.Intermediateclutchassembly.
o Clutchplatesdamaged/missing.
t lYave spring
darnagedlmissing.
t Pistonor sealsdamaged-
. Ball checkassembly
stuck/damagedor
missing.
o
Clutchcylinder
darnaged.
12. Direct/ intermediate
clutchhub.
. Sealsdamaged/mlssing orholes
blocked.
13, Frontcarrierdamaged.
ACTION
5. Determinesource of damage.
Service as required.
L Refer to Electrical System
Diagnosis in this section.
2. REterto Electrical System
Diagnosisin this section.
3. Determinesource of contamination
ordamage. Service as required.
4. Determinesource of contamination
or damage. Service as required.
5. Determinesource of contamination
or damage. Service as required,
6. Determinesource of contamination
or damage. Service as required.
7 . R e p l a c ec h e c k b a l l .
8. Tightenbolts to specification.
9. Service as required.
10. Determinesource of
contaminationor damage. Service as
required.
1 1 . D e t e r m i n es o u r c e o f
contamanationordamage. Service as
required.
12.Determine
sourceof
contamination
or damage.Serviceas
required.
13.Inspectwelds.Serviceas
requirecl.

TRANSMISSION
AUTOMATIC SERVICE
GROUP
,2
f,|RrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n
AUTOI|AT|C TRAIrSAXLED|ASilOSTS-
AXOD.E (ConUnucd!
cor{DtTlol{ POSSIBLESOURCE
1-A Shift Feels Hgrsh or Soft 1.EPCsolenold.
. lnoperative/damsged,
2. EEC-IVprocessor.
. Inoperative.
3. Oilpressurs.
o Highor low oil pressure.
4. Accumulatorregulatorvalveand
plungor.
. Stuck,nickedor damaged.
5. No. 12check ball.
. Missingball.
6. 1-2capacftymoduletorvalve.
. Velvestuck. nicked or damaged.
. Springmisring or dameged.
7. 1-ZAccunulatorassembly.
a Pistonstuck or damaged.
o Seeldemagedor mlsslng.
o SPringsdarnagedor
missing.
1-2ShiftSpeedHighor Low 1.Vohiclc cpeerl 3ensor.
t Inoperatlve.
2. Spcedometsrgea.r.
o Wrongormlsslng g€er.
3. Controlaaacmbly:1-2shift valve
and lntermediateclstch shuttlc vafve.
. Vatve(c)stuck,nickedor
damagad.
. Spring(s)micsingor damaged.
ACTION
1. Refer to Electrical System
Diagnosisin this section.
2. Refer to Electrical Systern
Diagnosisin this section.
3. Perform controlpressure test.
Service ae reguired.
4. Determine source of contamination
or damage. Service as requlred.
5. Replace check ball,
8. Determing source of contamination
or damage. Service as required.
7. Determine source of contamination
or damage. Service as rEquired.
1. Referto ElectricalSystem
Disgnoeisin this eection.
2. Installcorrectspeedometerdriven
9e3r.
3. Determinsaourceof contamination
or damage.Serviceas required.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
,,
VaRrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

AUTOMATrcTRANSAXLEDIAGNOSIS-
AXOD-E (Gontinued)
COtrfDlTlON POSSIBLESOURCE ACTION
No 2-3 Shifi (1-a Shift OK) 1. Shift solenoid No. 2 1 . R e l e r t o E l e c t r i c a lS y s t e m
. lnoperative. D i a g n o s i si n t h i s s e c t i o n .
2- EEC-IV processor- 2. Refer to Electrical System
. lnoperative. Diagnosis in this section.
3. Low/ intermediateservo. 3. Installcorrect aPPIYrod, if
. Wrong apply rod (too long). r e q u i r e d .D e t e r m i n es o u r c e o f
c o n t a m i n a t i o nS . e r v i c ea s r e q u i r e d .
I Servo bore or piston
damaged.
. Piston seals
damaged / missing.
o Missing/broken return
spring or retainingclip.
4. Direct/ intermediateclutch hub. 4 . D e t e r m i n es o u r c e o f
. Seals damaged or missing or . e r v i c ea s r e q u i r e d .
c o n t a m i n a t i o nS
holes blocked.
5- Driven sprocket support- 5. Determinesource of
. Seals damaged or missing or contamination.Service as requirecl.
holes blocked.
6. Direct one-way clutch,assembly. 6. Disassemble and inspect. Service
. Darnagedcage/rollers springs. as required.
o Missing rollers.
o Misassembled on inner
rece.
7- Controlassembly. 7- Tighten to specification.
o Bolts too loose or too tight.
8. 2-3 shift valve. 8- Determinesource of
a Valve stuck, nicked or damaged. contamination.Service as required.
9. No. 3 or No. 8 check ball(s) 9 . R e p l a c ec h e c k b a l l .
missing.
1O.Gase servo reiease passage. 1O.Determinesource of blockage.
. Blocked. Service as required.
't 1. Servo release tube. 1 1 . S e r v i c ea s r e q u i r e d .
. Leaking.
. lmproperlyinstalled.
12. Direct clulch assembly. 1 2 . D e t e r m i n es o u r c e o f
o Clutch plates damaged/missing. contaminationor damage. Service as
required.
. Piston or seats damaged.
o Ballcheck assembly stuck
or missing.
o Cylinderdamage.
13. 1-Z shift valve 1 3 .D e t e r m i n es o u r c e o f
o Stuck, nickgd or damaged. contamination.Service as required

TRANSMISSION
AUTOMATIC GROUP
SERVICE
34
s|'HrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n
AUTOT'ATICTRAI{SAXLEDIAGNOSIS-
CONDITION
2-3 Shift Feels Harsh of Soft
2-3 ShaftSpeed High or Low.
AXOD-E(Continued)
POSSIBLESOUBCE ACTION
1. EPC solenoid. 1. Reler to Electrical System
. lnoperative/ damaged. DiaEnosisin this section.
2. EEC-IVprocessor. 2. Refer to Electrical Systdrn
. Inoperative. Diagnosis in this section.
3. Low or high oil pressure. 3. Perform controlpressure test.
Service as required.
4. Low / intermediate servo. 4.Installcorrect apply rod, if
. Wrong apply rod length- required.Determinesource of
damage. Service as required.
aPiston.seal, springs rod or
spring.
5. 2-3 servo regulatorvalve. 5. Determinesource of contamination
. Stuck, nicked or damaged. or darnage.Service as required.
. Spring damaged.
6 . M i s s i n gN o - 9 , N o - 1 Oo r N o . 1 2 Replace ball
t Check Ball.
1. Vehicle spead sensor. 1 . R e f e rt o E l e c t r i c a lS y s t e m
o Inoperative. D i a g n o s i si n t h i s s e c t i o n .
2. Speedomet€r gear. 2. Inslall correct speedometer gear.
o Wrong ormissing.
3. Controlassembly: 1-2 shift valvs 3. Determinesource of contamination
2-3 shift valve VFS erratic pressure or damage. Service as required.
o Valves stuck, nicked or damaged.

. Shift solenoid damaged.

No 3-4 Shift(1-2 and 2-3 0K) 1. Shift solenoid No.3 1. Refer to Electrical System
o Wiring ehortlopen. D i a g n o s i si n t h i s s e c t i o n .
2. EEC-IVF.'ocessor 2. Refer to Electrical System
. Inoperative. Diagnosis in this section,
3. Overdrive band assembly not 3. Perform air pressure test. Service
holding. as required.
4. Overdrive servo assembly. 4. Install correct apply rod, if
. Wrong apply rod (loo long ). required. Determinesource of
contaminationor damage. Service as
o Servo bore or piston
required.
damaged.
o Piston seals damaged or
missing.
o
Missing or broken
return spring or
retainingclip.
5. Forward clutch assembfy. 5. Deterrninesource of damage.
o Damaged return springs/piston. Service as required.
6. Controlassembly bolts too loose 6- Tighten bolts to specification.
or too tighl.
7 .3-4 shift valve. 7. Determinesource of contaminalion
. Valve stuck, nicked or damaged. o r d a m a g e .S e r v i c ea s r e q u i r e d .
. S p r i n gd a m a g e d .
8. 1-? shift valve. E. Determinesource of contamination
o Valve stuck. nicked or damaged. or damage. Service as required.
. Spring rnissing.
9. Forward clutch controlvalve. 9. Determinesource of
o Valve stuck, nicked or damaged. . e r v i c ea s r e q u i r e d .
c o n l a m i n a i i o nS
. Spring missing.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
35
[I'srsE T e c hn i c a l S e r v i c e I n fo r m a t i o n

AUTOI'ATIC TRANSAXLE DIAGHOSIS -

CONDITION
3-4 Shift Feels Harsh or Sofl
3-4 Shift Speed High or Low
No ConverterCtutchApply
Converter Clutch Doss Not
Reloase
AXOD{ (Contlnuad)
POSSIELESOURCE ACTION
1 .E P C s o l e n o i d . 1 . R e f e rt o E l e c t r i c a lS y s t e m
. Inoperativerdamaged. D i a g n o s i si n t h i s s e c t i o n .
2. EEC-IVprocossor. 2- Refer to Electrical System
. Inoperative. D i a g n o s i si n t h i s s e c t i o n .
3. Oil pressur€ too high or too low. 3. Performcontrol pressure test.
4. 3-4 Accumulator assembly. 4- Determinesource of damage or
. Accumulator piston stuck or contamination.Service as required.
damaged.
I Piston seal missing or
damaged.
.
Springs missing or
damaged.
5. No.4 and/orNo. 12 check ball. 5. Replace ball.
. Ballmissing/damaged.
6. Accumulator regulator valve. 6. Determine source of
o Stuck, nicked or damaged. contamination.Service as required.
1. Vehicle speed sonsor. 1. Refer to Electrical System
o Damaged. Diagnosis in this section.
2. Speedometer goar. 2. Instaflcorrect speedometer gear.
. l{rongr'missinggear.
3. Controlaseembly: t'2 shift valvs 3. Deterrninesource of contamination
andl or 3-4 shitt valve. or damage, Service as required.
. Valves stuclc,nicked or damaged.
1. Traneaxle electrical system or 1. Refer to Electrical System
efectronic en gine conlrol. Diagnosis in this section.
o No lock-up signal.
. By-pass sofenoid damaged or
inoperative.
. Bulkhead connector
damaged.
. Pinched wires.
2. Turbine shaft. 2. Service as required.
. Damaged or missing seals.
3. Bypass clutch controlvalve. 3. Determinesource of
. Bypass clutch controlvalve contamination.Service as required.
stuck-
. Bypass plunger stuck.
4- Pump ehaft. 4. Determinesource of contamination
. Missing or damaged seats. or damage. Service as required.
o Missing or damaged cup plug.
5. Velve body pilot sleeve. 5- Determinesouree of damage.
. Damaged/misaligned. Service as required.
1. Eleclronic engine control or 1. Refer to Electrical System
transmission electrical systam. Diagnosis in this section.
. No unlock signal.
. Bypecs solenoid damaged or
inopcrative-
.
Bulkhcad conneclor wires
damaged.
2. Bypass clutch conlrolvalve or 2. Determine source of
plungarvalve. contamination. Service as required.
t Valve stuck, nicked or damaged.
3. Solenoid filter plug (in main 3. Solenoidfilter plug (in rnain
control). control).

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
,6
VTRTsE T e c h n i c aS
AUTOTATICTRAT{SAXLEDIAGIIOSIS _
coHDrTroil
4-3 Downshifts Harsh
3-2 Downshifl Harsh
3-1.2-1 DownshitlHarsh
No Drive in Drive Range and No
Reverse In Reverse Range
AUTOMATIC
TRANSMISSION
l e r v i c eI n fo r m a t i o n
AXOD€ (Gontlnuedl
FOSSIELESOURCE ACTtOll
1. Overdrive servo essembly- 1. Inslall correct apply rod, il
. Incorecl sewo apply rod length. required.Dererminesource of
contaminalion or damage. Ssrvice as
o Damaged servo piston or saal.
required.
o
Damaged ormissing
springs.
2. No convsrtgr clutch release. 2- Refer to Electrical System
Diagnosis in this seclion.
1.Trangaxlcelec-trical
system. 1- Feterto Electrical system
Diagnosis in this section.
2. Highorlow presaur€. 2. Refer to control pressure test.
3. Lowl intarmediateseruoassemDly. 3.Installconect apply rod, if
o Darnagedor missingsprings. required. Determine sourca of
contaminationor damaqe. Service as
e Incorect servo aPplyrod requlred.
fength.
4.3-2 Shiftttming. 4. Determine source of
t Vafvcstuck,nickedor damaged. conlamination.Servica as required.
5. No.5 checkball. 5. Replace check ball.
o Ba l lmi ssi ng.
6. Intermediate clutchreturnspring 6. Seruice as required,
retainingringout of position.
7. Backoutvalve 7. Service as required.
I Valvegtuck.nickedor damaged.
1. Low / intsrmediate EErvoaesembly. 1. Install correct apply rod, if
o Damaged sefrvopiston or sgal. required. Determine source of
damage. Service as required.
. Damaged or missing springs.
.fncorrect soryo appfy rod
length.
2. High or low pre8sure. 2. Refer to control pressure test.
3. No. 9 check ball. 3. Replace chech ball.
. Ball missing (3-t only).
l. Oillevel low. 1.Serviceas required.
2. Oilprossure. 2. Performcontrolpressuretest.
o Pregsure too low. Serviceas required.
3. Manuallinkage. 3- Serviceas reguired.Referto
a Misadjusted, disconnected, Section17-O2.
damtged, broken, bent.
GROUP
SERVICE
,7
U|'srsE T e c h n i c a lS e r v i c e l n f o r m a t i o n

AUTOTATTCTRANSAXLEDIAGNOSIS-
AXOD-E (Conffnucd|
coxDrTroil POSSIBLESOURCE ACTION
No Drive in Drive Range and No | 4. Halfshaft. 4. Refer to Section 15-22.
Reverse in Revsrse Range - I r Damaged splines.
(Gontinued) I
I I Disengagedfromtransaxte.
I 5. Oilfilter. 5. Service or replace as required.
i . DamagedimissingO-rings.
I
I o Plugged.
| 6. Oalpump assembly. 6. Determinesource of clamage.
r Oitpumpvvornor damaged. Service as required.
I
I
I I Oilpump drive shaft damaged.
I 7. Drive chain assembly. 7. Determinesource of damage.
. Damaged / broken. Service as required.
8. Drive sprocket. 8. Determinesource of damage.
. Sprocket shaft to convert€r Service as required.
turbine spline dameged.
9. Driven sprocket. 9. Determinesource of damage.
. Sprocket shaftlo Service as required.
direct / iritermediate clutch hub
damagad.
1O.Forward clutch assembly- 1O.Determinesource of
o Burned or missing clutch plates. contaminationor damage. Service a s
required.
o Damaged piston ssals or
pistons.
. Fonvard clutch ballcheck
assembly missingor
damaged.
o Driven sprockel
support seals
damaged/missing or
holes blocked.
. Direct intermediate
clutch hub seals
damaged/missing
or holes blocked.
1 1 .G e a r s e t . 1 1. Service as required.
. Front sun.
o Front / rear carriers
. Ring gear.
. Final drive assembly.
12- Low one-wayclutch. 12. Service as required-
o Clulch as two way rotation.
13. Output shaft- 1 3 . D e t e r m i n es o u r c e o f d a m a g e .
. Darnagedsplines/misassembled Service as required.
with axles.
No Drive - Reverse OK 1. 2-3 $ervo regulatorvalve stuck. L Service as required.
2. Lowl intermediateband assembly. 2 . D e t e r m i n es o u r c eo f d a m a g e .
. Burned. Service as required.
a Broken ends-
3. Low I intermediateservo assembly. 3 . l n s t a l t c o r r e c ta p p l y r o d , i f
o Wrong apply rod (too short). required.Determinesource of
contamination.Service as required.
. Piston/sealtroddamaged.
4. Low / intarmedialeservo oil iubes. 4. Service as required.
. Darnaged(leaking oil).
a Darnaged case bores.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
38
!5|HrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n
AUTOMATICTRANSAXLEDIAGNOSIS_
AXOD-E(Continued)
CONDITION POSSIBLESOURCE ACTION
No Fleverse - Drive OK 1. Revsrsa clutch. t. Determinesource of damage.
I Burned or missing plales. Service as required.
2. Reverse apply tube. 2. Service as required.
. Leaking.
. lmproperlyinstalled.
No Park Range 1. Damaged park mechanism. 1. Determine source of damage.
. Chipped or broken perking pawl Service as required.
orpark g€ar.
a Br<iken park pawl return
sPring.
o Bent or broken actuating
rod.
. Manuallinkage
misadjusted.
Harsh Neutralto Reverse or Harsh 1. Oilpressure too high ortoo low. 1. Performcontrolpressuretest.
Neutralto Drive 2. Engagemenl control valve. 2. Deterrninesourceon
a Valve stuck, nicked or damaged. contamination. Serviceas required.
3. No. 3 check ball. 3. R epl acecheckbal l .
o Ballmissing.
4. No. 1 check ball. f . Rcplacecheckball.
o Ball missinE/damaged(harsh
reverse).
5. Neutral-drive accumulator 5. Determlfiesourceof
assembly. conlamination. Sefvioeas required.
. Accumulatorpiston stuck.
. Accumulatorsealdamaged or
missing.
.Accumulator spflngs
ctamagedor missing.
6. Low / intermediate servo assembly. I n s t e l l c o r l € o tr P p l y r o d , i f r e q u i r e d .
. Damaged or missing spring. Determinesource of ecntaminationor
damage. Service as requiretl.
. Incorrect lorvo apply rod
length.
TransaxleOvarheats 1. Excessive tow loads 1. Check Owner's Manualfor tow
rettrlctlon.
2. lmproper fluid level. 2. Perform flulcllrvelcheck.
3. Incorrectengine idle or 3. Refer to EngineDiagnorir.
pefformanca.
4. Rsstriction in cooler or llnes. 4. Service restriction.
5. Dirty or sticking valve body. 5. Clean, sorvice or rePlace valve
body.
6. Seized converter one-way clutch. 6. Rcplace converter.
7. lmproper clutch or band 7. PGrtorrnconlrol pressure test.
applicalion, or oil prassure control
system.
T r a n s a x l eF l u i dL e e k e 1. lmproper fluid levef. 1. Perform fluid lcvrlchcch.
2. Lcekege at grekets. seals, ctc. 2. Ramove alltraces of lubrloetionon
exposed surlaces of transaxle.
Check the venl for free'breathing.
Opcrate transaxle et normal
temperaturesand insPectfor
ieakage. Service as required.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
,9
VZRrsc T e c h ni c a l S e r v i c eI n fo r m a t i o n
Transaxle Fluid Leakage Checks Oil Cooler and Steel Lines
Check the vehicle speed sensor and speedometer When fluidleakage is foundat the oil cooler (in
cable connectionat the transaxle. Replace the rubber radiator),the cooler must be replaced.Refer to
sealif necessary. Section27-O3for oilcooler repiacementprocedures.
Leakage at the oil pan gasket often can be stopped by When oilcooler steel linesneed reptacing,each
'
tighteningthe attaching bolts to specification.if replacementlinemust be fabricatedfrom the same
necessary,replace the gasket. size steel lineas the original.Usingthe oil lineas a
Check the speedo gear cover seal. guide,bend the new lineas required.Add the
Check the chain cover-to-casegasket. necessary tittings and installthe line.Afterthe fittings
have been tightenedto specification,add fluid as
Check the bulkheadconnectors to chain cover. necessary and check for leaks.
Replacebulkheadassembly, if necessary.
NOTE: The cooler linesthat are attached to the
check the fluid filler tube connectionat the transaxle transaxle are a push connect design and must be
case. lf leakage is found here, installa new grommet. removed with a speciaf tool. The coofer lines attached
check the fluid lines and fittings between the transaxle to the radiatoruse the conventionalnut and ffare
and the cooler in the radiator tank for looseness,wear, fittings.
ordgmage. lf leakage cannot be stopped by tightening
a fluid line tube nut, reprace the damafed pi.ti. Refei S ervi ce P rocedures
to oilcooler and steer Lines. when oir is tbund to be OilCooler SteelLinesUsingpush Connect
leaking between the case and the cooler line fitting, Fi tti ngs
tighten the fitting to_maximumspecification. oo noi try
to stop the oil leak-by increasing the torque 1. lf leakageis noted at the cooler finefittingon the
beyond.specificatfon. This maytause dirmage to transaxle, remove the cooler linefitting retaining
tne casE threads. lf the leak contintjes,replace the clip. Using Cooler Line DisconnectToof
cooler linefitting and tighten to specification.The T86P-77265-AH or equivalent,remove the cooler
same procedure should be followed for oil leaks l i ne"
between the radiator cooler and cooler line fittingg.
check the engine coolant in the radiator. ff transaxre SP^CER
fluid is present in the coolant, the cooler in the radiator
is probably leaking.
The cooler can be further checked for leaks by
disconnecting the lines from the cooler fittings and
applying_34s-S17kPa (S0-7SFsi) air pressire to the
fittings.Remove the radiator cap to relievethe
pressure buildupat the exterior of the oil cooler tank. lf
the cooler is leaking and / or will not hold pressure, the
cooler must be replaced.
ORIi.JG
lf leakage is found at either the throttle control cable 2 FEO'O
grommet or the manual lever shaft, replace either or
both seals.
Oil-solubleaniline or fluorescent dyes premixed at the
rate of 2-Sml(t t Z teaspoon) of dye powder to O.23L SECONDAFY RETAINER
(1 / 2 pint)of transaxtgfluidhaveiroven helptutin-
focatingthe sourceoJfluidleakage.Suchdyes may be
usedlo determinewhetheran engineoil or fransaxie
fluidleakis present,or if the fluidin the oilcoolerleaks
intothe enginecoolantsystem.A blacklightmustbe
usedwith the fluorescentdye solution.
Checfrthe powersteeringgear system.Thepower
steeringgear systemis positionedover the rLar of the
transaxleand is filledwith transmissionfluid.Leaks NOTE: For descriptionon how to use Cooler Line
from the power steeringgear may poolon the
DisconnectToot T86P-77p6S-AHor equivalent
transaxlebeforedrippingontothe ground,thusgiving refer to Cooler Line DisconnectTool Usage.
the appearanceof a transaxlefluidleak.
lnspectboth componentscarefuilybefore 2. fnstallangledflare fittingE2SZ-7D223.Aor
equivalentin the transaxle. Tightenfitting to
disassembling either.tf the poweisteeringgear 24-31 N.m ( 18-23 lb-tt).
(system)is foundto be leaking,referto Secition13-46.
A.fter.an e.ngine oilfilterchangL,someresidualoilmay 3. Cut approximately7G-102mrn(3-4 inches)from
blowbackon the transaxlegivingthe appearanceof the existing cooler line.
transaxlefluidleakage.Theareashould'becleaned
andcheckedafterrunningthe engine.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
40
Ul'HrsG T e c h n i c a lS e r v i c eI n f o r m a t i o n

Connectpressuregaugeto linepressuretap. Start engineandcheck linepressure.Referto the

followingchart to determineif linepressureis
withinspecification.
lf linepressureis not withinspecification,perlorm
air pressurechecksand servicemaincontrol
system.

tdb WOTStaU
Rartge psl
kPa psi kPa
P N 331-531 48-77
Ft 421-683 €,1-99 a27.2089 265.303
(D;D 33r-53r 48-77 122Sr393 177-202

L 331-531 48:77 1443-1641 208-238

tf the lirr€pressureis not withinspecificationatter CAUTION:Do not maintainWOT in any gear

mechanicalchecks andthereare no electrical range lor more than five seconds.
codes,the EPCsolenoidmay be mechanrcally Pressacceleratorto floor (WOT)in each range.
malfunctioning. Connecta pressuregaugeto EPC Recordrpmreachedin eachrange.Stallspeeds
pressuretap. Start engineand check EPC rprn(3.8L),18732 183
pressure.For idlecondition,pressureshouldbe shouldbe 1796-2O96
rpm(3.OLr,225A-26O3 rpm (2.5L).
69 137kPa( 10-2Opsi).For WOTstallcondition,
pressureshouldbe 518-586kPa(73-87psi).lf CAUTION:.lfengine rprr recorded by
pressuresare not correct,replaceEPCsolenoid. tachometer exceeds maxlmum specified
rpffi, release accelerator immediately.Clutch
or band slippage is indicated.
lf the stall speedswere too high,rgfer to the
Stall Test foltowingStallSpeedDiagnosischart.lf the stall
The stalltest checks the operation of thefollowing
speedswere too low,first check enginetune-up.
items: lf engineis OK, removetorgueconverterand
checktorqueconverterreactoroneway clutch
a Converter one'way clutch for slippage.
r Forward clutch
. Lsw one-way clutch srA[ SPEEDHcH(SIJP]
r Reverse clutch Rrrec PorrlblcSourrr
o Low-intermediate band @.0,r r Fqrard CluEn
I LOwilrilerrrediate
oreway outdr
r Engineperformance r LowArfermedials Bandor Ssflo
NOTE: The stalltest should only be perforrned with the R r Forrard Outdr
engineand transaxle at normaloperating r Lm/hermediateOne.WavClutdr
temperatures. r RcvercsChlch

WARNING: APPLY THE SERVICE AND PARKING

BRAKES FIRMLY WHILE PERFOHMINGEACH
STALL TEST.
1. Connect tachometer to engine.
Transaxle Fluid Cooler Flow Test
2'. After testing each of the followingranges (O,D,
1, R), move selector lever to N (NEUTRAL)and NOTE: The transaxle linkageadjuslment,fluid level
run enginefor about 15 seconds to allow and controlpressure must be within specification
converterto coolbefore testingnext range- betore performingthis test. Refer to Section 17-O2tor
transaxle linkageadjustment.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
4l
FZRrsc T e c hn i c a l S e r v i c eI n fo r m a t i o n

Transaxle
Disassembly
1. InstallTorqueC"onverter HandlesT81P-7902-Q
or
Removeconverterfrom transaxle.
equivalent-
CAUTION:The torque converter is heavy. Be
carcful not to drop it.

TOFOUECOTTIVERTER

2. Mount lransaxle in Bench Mounted Holding

Fixture T57L-5OGB or equivalent. REMOVE SHIPPING
PLUG AND DRAIN FLUID

4. Return transaxle to horizontalposition.

5. Flemovetwo 8mm governor cover bolts, cover
and seal. Discard seal. A new one must be
installedduring assembly.

T57L€GB

3. Turntransaxlein verticalposition.
Remove
shippingplugsanddrainfluid.

6. Lift speedo cover, speedometer drive gear

assembly, and bearingout of case.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
42
l5|HrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

NOTE; Bearing sits on top of speedometer gear. 8. Remove three 8mm low-intermediateservo cover
bolts, cover, piston assembly and spring.
9. Removeand discard gasket.
NOTE: Pistonassemblyand springmay remainin
cover.

PISTON ANO ROO LOil.INTERMEDIATE

ASSY SERVO COVEF

7. Removethree8mmoverdriveservocover bolts,
cover,pistonassemblyand spring. 10. Removeservospringpositionretainerfromcase.
NOTE:DiscardO-ringsealoncover.
NOTE: Pistonassemblyand springmay remainin
cover.

SEFIVO SPRING
POSITION FIETAINEFI

1 1. Inspect and replace if damaged. Remove RH

output shaft seal as follows:

IN NOTE: Output shaft sealis a two-piece

construction,outer metalprotector and inner
\ \ i rubber seal.
\J.,)r
J-Z [r

N\

TRANSMISSION
AUTOMATIC GROUP
SERVICE
4t
f|HrsE T e c hn i c a l S e r v i c eI n fo r m a t i o n

a. lnstallShaft Protec'torDSOL€2$A or e. Tightenscrew on the end of tool untilseal is

equivalentintooutputshaftop€ning. removed.

SEAL REMOVER
r74P6700A

q' =,

\ SHAFT
PROT€CTOR

lPr DSOL.oil$A
I
I

Screw OutputShaft Seal Rernover

T74P€7OO-Aor equivalent,intometalseal METAL
PROTECTOR
protector.
Trghtenscrew on end of tool untilmetalseal
protector is removed.

1 2 . Removetwo 8mmneutralsafety switchretaining

bolts andremoveswitch.

RETAINING
BOLTS

1 3 . Remove one 8mm fluid leveldipstick tube

retaining bolt and pull tube from case.

Emm
BOLT

d. Removemetalsealprotectorfrom tool, and

installtoolinto
seal.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
u
l5lnrsG T e c h n i c a lS e r v i c eI n f o r m a t i o n

14. Remove five 8mm and tour 6mm chain cover bolts 16. Remove12 lomm gumpandvalvebodycover
from inside torque converter housing. (upperreservoir)bolts.Removecoverand
discardgasket.
trnm CHdt{
covER 30rYs ( : @
4 REO'O \r/--

tl
I
(
I

1on'rn CllAlN
COVER BOLTS
5 REO'O
&r'th
15. Removeconverteroil sealusingSealRemover
TOOL-1175-ACandlmpactSlideHammer
T5EL-1O1-Bor equivalent.

17. Disconnectelectricalconnectorsfrom Pressure

switchesandsolenoid.
CAUTION:Use both hands. Do not pull on
wire.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
4J
tlnrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

UPPEF BULI(HEAO
CONNECTOR NEUTRAL SAFETY
ELECTRICAL SWITCH ASSY
CONNEGTORS SID€ BULKHEAD
CONNECIBB

TUBBINE SPEEO
ELECTRICAL SENSOR
CONNECTORS

18. Compressingtabs on both sides of bulkhead

conneetorsfrom insideof chain cover, remove
connectors and wiringfrom chain cover.
CAUTION: Do not pull on wiring- pull on
connector.

ROTATE
cLoa{wlsE

20. Remove22 8mm oilpump and valve body

1 9 . Usinga 9mm wrench on flats on end of manual
shaft, rotate shaft clockwise to positionmanual
linkagein LOW detent (valve positionedaflthe
way in).
assembly retainingbolts. lrlotelength and location
of bolts.
CAUTION: Do not remoye the two bolts that
retain the oilpump and valve body assembly
together.
CAUT:)N: Do not remove orl pump cover
bolts.

IRANSMISSION
AUTOMATIC GROUP
SERVICE
46
!5lRrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

DOiror
REIO/E TTIIS BOLT REKIVE UTYE
BOOYBOLTS
IilDtcATED'I
DO NgT ARROWE
R€MOVE THIS
BOLT

DO iror REMO!/E
SD( OIL PUMP
ccn/EH BO|-TS

2 1 . Flotate valve body clockwise and remove manual

valve link from manualvalve. DISCONNEgT
MANIAL VALVE
2 2 . Disconnect manual valve link from detent lever LINX
and remove pump and valve body assembly.

23. Pulloil Pumpdriveshaft out of case. Remove and

discard foui Tetlono seals from pump shaft'

TRANSMISSION
AUTOMATIC GROUP
SERVICE
47
fZHTsc T e c h n i c a lS e r v i c eI n fo r m a t i o n

FORWARO UPPER
LINE CLUTCH BULKHEAD
PRESSURE CONNESIDR

SIOE SULKHEAD
Tv PRESSURE CONNE TOR

TUFBINE
SPEEDSENSOR

OIL PUMPDFIIVESHAFT
DISCAFOFOURTEFLON"
SEALSAFTERFEMOI/AL

24. Rotbtetransaxleintoverticalposition. c. Removemetalsealprotectorfromtooland

25. Removeand discardoutputshaftcirclip. installtoolintoseal.
d . Tightenscrewon endof tooluntilsealis
removed.

ea ,/*/i
4
@
_0 ".1
26. RemoveLH outputshaltsealasfollows:
a. Screw OutputShaftSealRemover 27. Remove13 1omm,one 13mmandone8mm
T74P-670O-A or equivalent
intometalseal chaincoverbolts.Notelengthandlocationof
protector. bolts.
b. lighten screw on the end of tool untilmetal
seal protectoris removed.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
#
UZHrsE T e c hn i c a l S e r v i c el n fo r m a t i o n

t - 8mm EOLT
I . tOmmBOLTS
O . l3rnmEOLTS

28. Removechaincoverandtag accumulator springs 30. RemoveNo. 1 andNo.3 thrustwashersfrom

to be suretheyare installedin theircorrect chaincover.
positionsduringassembly.
29. Bemoveanddiscardchaincovergasket. NO, 3 METAL ttO I PUSTIC
THRUST WASHER
THRUST wASt{ER

TAG
sPnrLos FoR
GASKET LOCATTOI{

V rlffii.ffir.eion
I i \l-sPntxes
\ I \ tl l/'\

TRANSMISSION
AUTOMATIC GROUP
SERVICE
49
EIRrsG T e c h n i c a lS e r v i c eI n fo r m a t i o n

31. Simultaneously,|lft out both sprockets with chain 33. Inspectdrivesprocketsupportbearingto

assembly. determineif it needsto be replaced.

lf bearing is OK, remove six T-30 Torxo bolts

attaching support to case.

slx
T-30
TORX
BOLTS

32. RemoveNo.2 thrustwasherfromdrivesprocket

supportandNo. 4 thrustwashertromdriven
sprocketsupport.
NOTE:No.4 thrustwashermay remainon driven
sprocket.
34. Remove and discard lockpin and two roll-pins
from manualshaft using Locknut Pin Flemover
DA 1P-3504-N or equivalent.
CAUTION: Use care not to damage anY
machined surfaces.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
50
[lHrsc T e c h n i c a lS e r v i c eI n f o r m a t i o n

YIEIT A

35. Slide manual linkage shaft out of case.Then, pry

seal out of case.

IIVEN MAC}IINED JIN'

ROCKET EoLT HOLE EDGE

IPPORT SURF^CE

3 7 . Removedrivensprocketsupportassemblyand
rerpve fiveTeflon@sealsfrom support.
RemoveNo. 5 selectivethrustwasher.
36. Determinewith a straightedgeor a llat bbck
whetherthe machinedboltholesurfaceson the
support are above or below the case machilred
surfacefor reassernbly.

TRANSMISSION
AUTOMAIIC GROUP
SERVICE
5l
UZRrsE TechnicaS
l e r v i c eI n f o r m a t i o n

NOTE:Thrustwashermay remainon sprocket 44. Remove magnet from oil pan.

supportassembly.

NOTE: lf support is bindingit may be necessary

to back out reverse clutch anchor bolt.

39. Remove17 8mmoitpancover bolts.Remove

@ver anddiscardgasket.

41. Usinga wire hook,removeNo. 8 selectivethrust

washerand No. 9 needlebearingfrom bottornof
cylinder.

olL PAr,tgoLTs
17REO'D

AUTOMATIC
TRANSMISSION
SERVICE
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52
UlFrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n
NOTE:Thrustwasher and negdlebearingmay 43. Rennveoverdriveband.
remainon drivensprocket supportassembly
whenit is removed.

N O 8
ThRUST
WASHER
{FTBER)

I,p|$rlJRE FREECOilPREIISIED^IF

44. Using Front Clutch LoadingToolTS6P-70389'A

or eguivalent, install hook end of tool into one of
the six lube holes in front sun and shell assembly.
Position notched block over edge of assembly
and tighten haldle. Do not over'tighten handle.
Lift assembly out of case.

42. Remove plastic overdrive band retainer.

o|'ERDRI'/E

FRONT SUN AND

[{AS

TRANSMISSION
AUTOMATIC GROUP
SERVICE
5,
fi|HrsG T e c h n i c a lS e r v i c eI n fo r m a t i o n

45. Remove8mm reverseapply tube/oilfilter 47. Remove8mmtubebracketboltsandbrackets.

bracket bolt and bracket.
NOTE:For completetransaxledisassembly,the
reverseapplytubemust be removedprior to
removingthe reverseclutch,or the ditferential.

46. Removeoil tilter screen and discard lip seal.

NOTE: Lip seal may stick insidecase. 48. tf necessary,removelubetubesusingLubeTube
RemoverT86P-7OOO 1-AandlmpactSlide
HammerT59L-1OO-B or equivalent.

AUTOMATIC
TRANSMISSION GROUP
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54
t|RrsE T e c h n i c a lS e r v i c el n f o r m a t i o n

49. Removetwo 8mm park rod abutmentbolts. 52. Loosen19mmreverseclutchanchorpinnut and

Removepark rod by liftingrod to clearabutment remove6mmAllenheadbolt.
andlowerfromcase.

PAFK

53. Rotatetransaxleto the horizontalposition.

50. Removepark pawlshafirollpin.
5 1 . Usemagnetto removepark pawlshaft,and
rernovepark pawland returnspring.
54. Locatehookportionof FrontClutchLoadingTool
T86P-7O389-A or equivalenton innerdiameterol
reverseclutchcylinder.Graspouterdiameterof
cylinderwithfingefiipsand slideclutchassembly
out of case.

PARK PATA'L
PAFK
SFIAFT
PAWL
SHAFT

TRANSMISSION
AUTOMATIC GROUP
SERVICE
J5
F5|srsE T e c h ni c a l S e r v i c eI n fo r m a t i o n

55. Rotate transaxle to verticalposition. Holdingthe

front planetary shaft, lift out both front and rear
planetary assembly.

PIJT.JETARY
ASSEMELI€S'

-Ft\Y;
9 G+Y*:

56. Liftout low-intermediate

drumandsungear 57. Remove low-intermediateband.
assembly.

W
IN
EANDANCHOF
PIN TOWARD
SERVO
06l 55-8

AUTOMATIC SERVICE
TRANSMISSION P
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56
[5|HrsE T e c h n i c a lS e r v i c eI n fo r r n a t i o n

58. Remove tinal drive gear assembly snap ring from

case using a screwdriver inserted through side of
case.
FINAT ORIVE
FIIHGGEAR

))\t

62. RemoveNo. 18 thrust washer and No. 19 needle

bearing.
NOTE: No. 18 thrust washer may remain on the
finaldrive assembly next to speedometerdrive
gear.
59. Lift out finaldrive assemblyusingoutputshaft-

60. Drive out rear lube tube sealusingRear Lube

Tube Seal InstallerT9 1P-76o85-4. Assembly
1. Positioncase in horizontalposition.
61. Removefinaldrive ring gear from case'
2. lf removed, installdrive sprocket support' Install
six (T'30) Torxo bolts and tighten to 9-12 N'm
(7-9lb-ft).

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57
IZRrsc T e c h n i c a lS e r v i c el n f o r m a t i o n

4. lnstallRH output shaft seal using Output Shaft

NOTE:Boltholesare offset.Sprocketsupport
Seal ReplacerT86P-1177-B or equivalent.
can onlybe alignedoneway.
NOTE: After installation,verify presence of garter
spring on seal.

*t*-r.r."N
OFFSE.T Ar{t} C'ilLY
ALtOtl OltE IYAY.

\ l
H P
$
GA8TER I
SPBING \ OUTPUT
/ our'pur SHAFT
/ saarr SEAL
sear REPTACEFI
I T86P-1r77-B
I
I

5. tnstallAXoD-EEndPlayToolTETP-7OO14-AH
andStepPlateAdapterDSOL-63O-3 or equivalent
and two boltsover RHoutputshaftopening-Tool
3. Installconverter oil seal using Front Pump Seal will treusedlater to performselectivethrust
Installer T ATL-7O4O1-A or equivalent. washerchecks.
NOTE: ,{fter installation,verify presence of garter
spring on seal.

6. Placecase in verticalposition.lnstallNo. 19
needlebearingover case boss with flat side
facingup, outerlip facingdown.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
'E
UlHrsE T e c hn i c a l S e r v i c eI n fo r m a t i o n

8. Assemble the following components:

I Speedo drive gear
r Differential assembly
r Finaldrive sun gear
Installfinaldrive ring gear with external splines r Parking gear
up. Using a hammer handle if necessary, tap
gently to fully seat into case splines. r No. 16 needle bearing
r Rear planetary support
r No. 15 needle bearing
r No. lSthrustwasher

NEEDL€
BEARING

\
I
v[ DIFFEFENTIAL
ASSY

AUTOMATIC
TRANSMISSION GROUP
SERVICE
VZ,RrsE T e c h ni c a l S e r v i c e I n fo r m a t i o n

9. Lowerfinaldriveassemblyintocase. 1 1 .Installanew rear lubetube usingRearLubeTube

InstallerTg 1P-76O85-A.
1 2 . Driveseal intopositionuntilseal makessolid
contactwith rear support.

t..^.(€t-.,
wrrxarto )-
rrrytzl
10. Installsnapringandalignendof snapringwith
low-intermediatebandanchorpin.

REAFLUBETUBE
SEAI INSTALLER
TsrP-?6085A

CASESURFACE
SEALFIRST
MAXESCONTAST

IrOTE: THIS CASESUFFICE WHERETHE

STEELS}IOIJLDEf,OF THE SEAL
RRST IAXES COilTrcT W|Lt
GIYE SOXE FES}SruCE OURI{G
INrTr,lL rlrarALulTtot{.
@ilT[tT'E DHYD.IGUiITIL THE
SEAL ]S FULLYSEATTI .

13. Usinga feelergauge(-OOS) check betweencase

andrear supportthroughopeningin snapring.lf
gaugepassesbetweensealand rear supportthe
sealis not fullyseated.Repeatstep 12.

AUTO
MATICTRANSMISSION GROUP.
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60
ffnrsE T e c h ni c a l S e r v i c eI n fo r m a t i o n

SUPPOHT

1 4 . Performendclearancecheckfor No. 18 selective Thecfearanceshouldbe 0.1€.65mm(0.004{.025

thrustwasheras follows: inch).lf the clearanceis not withinspecification,
I Placescrewdriverunderditferentialcase and selectivethrustwashersare availablein the following
pry up. thicknesses:
r MountDialIndicatorTOOL-42O1€or . 1.25-1. 1Smm(0.049-0.045 inch)Orange
equivalentwith styluson endof outputshaft. o 1.5o'1.gomm(0.OSg-O.oS5 inch)Purple
r Backout screwon toolinstalledin Step5 untilit . 1.75-1.65mm (0.069-0.055 inch)Yellow
no longertouchesshaft.
15. Afterinstallingthe correctthrustwasher,check
t Terodialindicator. the clearance.
I T'ightenscrewto 4-5 N.m(gS-+4lb-in). NOTE:After completingendclearancecheck,
I Observereadingon dialindicator. back off screw on tooland leavetool in position
for No. 5 and No.I selectivethrustwasher
cleararce check to be per{ormedlater.
16, Instanpark pawl,returnspring,park pawlshaft
DIAL INDICATOR
TOOL{201C
andlocatorpin.

OUTPUT
SHAFT

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
6l
l5l,RrsE T e c h n i c a lS e r v i c el n f o r m a t i o n

NOTE:Ensurethat the park pawlengagesthe

park gearand returnsfreely.

LOCATOR
PI'.I HOLE

17- Installpark rod actuatingleverand park rod in

case. Installparkrod abutmentandstart drumandsungear.
19. lnstalllow-intermediate
abutmentbolts. Pushin parlcpawland locate rod
betweenpawl and abutment.

ORUM AND SUN

GEAF ASSY

18. lnstalllow-irrtermediate
bandintocase andalpn
anchorpin pocket with anchorpin.

20.. Assemblethe followingcomponents:

o Ringgear ard shellassembly
o Rear planetary

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62
I?lnrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

o No. 13 needlebearing 23. Align clutch cylinder anchor pin pocket with
o Frontplanetary anchor pin case hole.
r Snapring

NEEOLE
BEARING

\u
i l l
BING GEAFI
ANO SHELL v//
ASSY
REAR
ANCHOR
PIJqNETARY
PIN
POCKET

2 1 . After assemblingcomponents,carefullyslide
assemblyover outputshaft.

NOTE: To seat reverse clutch, the intermediate

Pl.Af.tE?AFY
ASSEMALIES clutch hub can be used as a toolto complete
clutch plate engagement.Rotating planet with hub
will allow clutch splinesto engage.

INT€RM€OIATE
CLUTCH HU8

EI'IGAGE
SPUNES WITH
PIJNETARY
SHAFT

22. Lower reverseclutchintocase and start clutch

plateengagement.

AUTOMAIIC
TRANSMISSION
SERVICE
GROUP
6'
VaRrsG T e c h n i c a lS e r v i c e l n f o r m a t i o n

24. Start roverseanchor pin bolt hrt do not tighten. 26. Lowerassemblyintocase,aligningshellandsun
gear splinesintoforwardplanqtary.
CAUTION:Ensurethe assembly is fully
seated before removing the tool.

FRONT SUN AND

SHELL ASSY

- ) J
( t
f J
'
HOLES
i-t

25. Assembleforward,directand intermediateclutch

assembly.AttachFrontClutchLoadingTool
jl -1122
T86P-70389-Aor equivalentto assembly.

G
bandintocase.
27. Installoverdrive

\
'€[Jz -.<- nelfia scn-EElt'fif,clf,N wttit''
FFEE@r/IPRES3ED
rJrotsfuR€ AIR

SERVICE
TRANSMISSION
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GROUP
64
UiRrsG T e c h n i c a lS e r v i c eI n f o r m a t i o n

28. Installplasticretainerwith cross hairsfacingup.

NOTE:PertormSteps 26 through32 to check the

drivesprocketendclearanc€for No. S and No. g lf machinedbolt holesurfacesare below case
selectivethrustwashers. machinedsurface,placedepthmicrometeron
case machinedsurfaceand measuredistanceto
29. Tightenscrewon endplaytoofpreviously drivensprocketsupportmachinedbolt hole
installed. surfaces.Measureat bothsupportbolt hole
30. lf not alreadyremoved,rernoveallfive Teflono machinedsurfacesanddetermineaveragefrom
sealsfrom drivensprocketsupportassembly. bothreadings.lfreadingexceedsO.46mm(0.018
inch),referto No. I ThrustWasherSelection
31. InstallNo. 9 needlebearingoveroutputshaft, chart to determinecorrectthrustwasherto
withouterliplacingup.Then,installNo.8 install.Installcorrectthrustwasher,repeat
selectivethrustwasher. measurement andrecordreading.Go to Step 32.
32. RemoveNo. 5 thrusl washer,if stillattachedto
sprocketsupport.
33. Installdriven
sprocketsupportanddriven
sprocket.
34. To measureNo. 8 thrustwasherclearance,it first
mustbe determinedif machinedbolt hote
surfaceson drivensprocketsupporlare aboveor
belowcase machinedsurface.
lf machinedbolt holesurfacesare above case
machinedsurface,placedepthmicroneteron
machinedbolt holesurfaceon drivensprocket
support.Measuredistanceto case machined
surface.Measureat both support bolt hde
machinedsurfacesand determineaveragefrom
bothreadings.ff readingexceeds0.21mm(0.008
inch),refer to No. 8 ThrustWasher.
Use selectionchart to determinecorrectthrust
washerto install.Installcorrectthrustwasher,
repeatmeasurement and recordreading.Go to
Step32.

AUTOMATIC
IRANSMISSION
SERVICE
GROUP
65
Ui'RrsE TechnicalService Information

t€. t n{nusrwlsr{ERsELEcnoil Average reading for No. 5 thrust washer

Thrud ttlrlrr Thidtnar measurementO.O18-inch
Color
mrn Inclr.i Difference O.024-inch
t.5$t.€ 0.060{.056 Naturd NOTE: Readingfrom No. 8 thrust washer would
r.7&r.68 0.070{.065 Dark Green be added to determinetotal.
202-1.9 0.079{-075 Lrght Blue When driven sprocket support surface is below
case surface.
227-2.17 0,089{.085 Red
Average readingfor No. 8 thrust washer
measurement0.0 1S-inch
35. Removedrivensprocket,drivensprocket Average readingfor No. 5 thrust washer
support,No.I selectivethrustwasherandNo. 9 measurement.O.045-inch Diff erence 0.030-inch
needlebearing. NOTE: Readingfrom No. 8 thrust washer would
36. InstallNo.5 thrustwasheron drivensprocket be subtracted to determinetotal.
support,aligningtab on washerwith slot in driven
sprocketsupport.Applygreaseto thrustwasher
to helpholdit in position.

DRIVE SPROCKET
SUPPOFIT ASSY

No.5
THRUST WASHER

ALIGN TAg
wrtH sLoY

BOLT HOLE
SURFACE

sprocketsupportwithoutNo. I
3 7 . Installdriven
thrustwasherandNo. 9 needlebearing.
3€1.Positiondepthmicrometeron machinedcase
surfaceandmeasuredistancebetweendriven
sprocketsupportmachinedbolt holesurfaceand lp, 5 rHRusTw SHERs€LECTlOtl
case surface.Measureat both bolt hole Tfrud Wrrhcr llil*rcrr
machinedsurfacesanddetermineaveragetrom Color
rm hdr.r
both readings.Thedifferencebetweenthis
readingandthe readingfor No. I thrustwasher 2.2*?-18 0.0900.086 Green
recordedin Step31 mustbe greaterthanzero 2.5$2.{l 0.099{.005 Elaak
but lessthanO.85mm(0.033inch).lf 2.n-2..67 0.100-0.105 Nabnl
measurement exceedsspecification,referto No. Red
5 thrustWasherSelectionchartto determinethe 3.022,.92 0.1184.115
correctthrustwasherto install.
Example:
39. Remove driven sprocket support and install No- 9
Whendrivensprocketsupportsurfaceis above needle bearing and correct No. I thrust washer.
casesurface.
40. InstallTeflonb seals on driven sprocket support-
Averagereadingfor No.I thrustwasher
mbasurement O.OO6-inch

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l5|RrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

41. Installcorrect No.5 thrustwasheron driven
sprocketsupportand installdrivensprocket
support.Applygreaseto thrustwasherto help
holdit in position.
45. Installnew manualshaft lock pin through case
hole, aligningwith groove in shaft.
46. Installnew roll pins in detent lever and park rod
actuating lever.

47. InstallNo.2 andNo.4 tabbedthrustwashers

ontodriveanddrivensprocketsupports.Align
tabs on thrustwasherswith holesin sprocket
supports.Applygreaseto washersto helpholdin
position.
42. Install manual shaft seal by tapping into case.
43. Start manualshaft through seal and slide manual
detent lever onto shaft.
44. Slide manualshaft through park rod actuating
lever and tap into case hole.

PARK ROO
ACTUATOR

SERVICE
TRANSMISSION
AUTOMATIC GROUP
67
EIHTEE ServiceInformation
Technical
48. Lubricoteond instollcostironseolingringond scorf 50- lnstatlNo. 1 end No. B thrustwasherson chain
cutTeflonseolingringontothe inputshoft. ctrver. Use petroleumielly to hold in place-Make
sure tabs alignwith slots in chajncover.

No. 3 iTETAL hrQ. 1 Pt-{5TtC

THRU$T WASHER TI{fiUST WASHEff

5 1 - lnstallnewchainEovergasket.
52. lnstallaccumulatorspringsin correct position.

49. Installchainon driveanddrivensprockets.Lower

assernblyintosprochetsupports,rotating hKITE;3.0LAFFL|offIQH
sprocketsto efisurethat they are fullyseated- HASTSFEIHES.T'3L
HAfi 3 SFFINGS

53. InspectchainGoverallgnmentpinson cEse.

54. fiarefullyalignchaincovsr inputshatt bsre with
inputshaft. ApFlygentledownwardpressureon
chaincovertDovercomescsurflulator$pring
Fressureandstart two chaincover holts.

ISSION
TRANSM
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68
fiiHrsG T e c h n i c a fS e r v i c e I n f o r m a t i o n

CAUTION:Be ertremely caretul lo prevent 55. 9!"rt remainingchaincoverboltsandtighten

damage to the input shaft cast iron sealing 10mmboltsto 27-33 N.m(pG26 tbft). ?rghten
ring. 8mmbotrto 9-12N.m(7_9tb_ft).Tightentgmm
bolt to 34-48 N.m(25-gSfb.ft).Tightenboltsin
sequenceshown.
NOTE:After instaflingchaincover, inputshaft
shouldhavesomeend play and shouidrotate
freely.tf it willnot rotate freely,removechain
cover and inspectcast ironsealfor damage.

o.
@.

@o @
1DFCXJESPECIFEAT|oil
*. 912 N.rn(-/-9LeFrl
)' 2v33 N.m (2$,26L&r1
O. 3r-rt x.rr, (e+SSlB.Ff) @' @'

56. lighten park rod abutmentbolts to 27-30 N.m 58. lnstalltubes

(2cl2 tb-ft).
57. Tghten reversedrum6mmAilenheadanchorbolt
to lG 12 N.m(Z.S-9lb-ft)and tgmm tocknutto
34-47 N.m(25-gs tb-ft).
inpositionandtaptighilyuntilfully
seated.ApplyThreadtock 262,Ezrz_lgssa-Bcr
equivalcntaroundtube-tocasesurtace.

AUTOMATIC
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69
lj|qrsE T e c hn i c a l S e r v i c el n fo r m a t i o n

59. Installtuberetainingbrackets. 01. Installreverseapplytube/oilfilterbracket.

60. lnstalllip sealontooilfilterandpressoilfilterinto

case. 62. .lnstallmagnetin oilPan.

63. lnstall new oil pan gasket on case and installoil

pan. Tightenbolts to 14-16 N-m (1S12]bfl).

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70
U|RrsE T e c hn i c a l S e r v i c e I n fo r m a t i o n

64. Installfour new Teflono seals on pump driveshaft

and installshaft.

65. lnstallTV bracket with TV link through hole in

case. Tightenbolts to 9-12 N.m (7-9 lb-ft).
Connect manualvalve link to detent lever.

OIL PAN BOLTS

I7 REO'D

Start oilpumpandvalvebodyover pumpshaft 67. lnstall22valvebodyboltsandtightenin

andconnectmanualvalvelinkto manualvalve. sequenceto 9-12N.m(7-9lb-ft).
NOTE:Installthreeshortboltswhereindicated.

AUTOMATIC
TRANSMISSION
SERVICE
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7l
UZ,RrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

68. lnstallbulkheadconnectorintocase,makingsure
lockingtabs on bulkheadassemblyare secure.
Installfour electricalconnectorson proper
switchesand solenoidsuntila slightclick is felt.

UPPEFEULKHEAD
ccf.lNECloF NEUTRALSAFETY
sl flTCH a.SSY

TUFBINESPEED
SENSOF

69. Placegear shiftselectorin the neutralposition. 7'1. AlignMLPSslots usingGearPositionSensor

AdjusterT9 1P-7OO10"A or equivalent.
70. InstallManualLeverPositionSensor(MLPS)and
looselyinstalltwo retainingbohs. 72. Tightenretainingboltsto 9-12 N.m(7-9 lbft).

TRANSMISSION
AUTOMATIC GROUP.
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72

:.J.i,b..,-.-.-2..,,.-i.r:.. . " r
!5iRrsE T e c hn i c a l S e r v i c eI n fo r m a t i o n
73. Place gear shift selector in the neutral position. OVEFDRIVE
SEFVO PISTON
ANO SPRING
T85P-700238
GEARPOSITION
SENSORAD.'USTER
TOIF.TDOOA

RFTAININ6 EOLT
2 FIEO'D TIGHTEN TO
9"12 N'm
(7.e LSFT)

74. Installnew self-adhesive

oil pumpand valvebody LO$'/INTE
SERVO PISTON ANO SPRING
covergasketontocover. T8€P-7002$A

VALVEEOOY 79. Installlow/intermediate servo spring retainer.

ANOruUP
COVEB

SELF.
AOHESIVE
GlTSXET
ffi SEF1IO SPRING
POSITION RETATNEF
7 5 . Installcoverandtightento 9-12 N.rn(7-9lb-ft).
76. Rotatetransaxleto horizontalposition.
7 7 . Performservotravelcheckas follows: 80. Installservopistonand rod in case.
NOTE:This procedureappliesto both the NOTE:On low/intermediateservo,installwithout
overdriveservoand the low-intermediateservo. pistonseal.
NOTE:Thefollowingprocedureshouldbe 8 1 . InstallOverdriveServoRodTool
performedonly if oneol the componentslisted T86P-70023-BorLow / lntermediateServoRod
belowis beingreplacedduringassemblyof the ToolTS6P-7OO2SA andsecurein
or equivalent,
transaxle: cese usingservo coverbolts.Tightenboltsto
I Transaxlecase +12 N.m(7-9lb-ft).
'lighten
o Bandassembly 82. gaugediscscrewto 1.13N.m(10lbin)
for overdriveservo.Tlghtento 3.4 N.m(30lb-in)
I Drumand sungearassembly for low/ intermediateservo.
o Servopistonrod
83. MountDialIndicatorTOOL-42A1-Cor equivalent
r Servopiston andpositionstylusthroughholein gaugedisc.
7 8 . Installspringin case fromOverdriveServoRod Makecertainindicatorstylushas Contacted
or Low/ IntermediateServo
ToolT86P-7OO23-B servopistonon a flat surface.Do not contact
RodToolT86P-70023'Aor equivalent. , stepon piston.Zerodialindicator.

CA N S M I S S I O N ' S EGRRVOl C
A U T O M A TTIR UEP
73 1
FlRrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

84. Back off gauge disc screw untilpiston movement
stops and read dial indicator.The amountof
piston travel as indicatedon dialindicator will
determine the rod length to be installed. For
overdrive seruo, reading should be 1.8-3.8mm
(0.O7$O. 149 inch). For low/intermediate servo,
readingshouldbe 5.5-6.Smm(0.216'0.255 inch).
NOTE: lf a new low/intermediate band is
installed,reading should be 5-6mm (0. 196{.236
inch).
Overdrive Servo Travel Check
85. Select a new piston rod usingthe measurement
obtained in St'ep75. Installnew piston rod and -
repeat Steps 71 through 75 to verify amount of
piston travel.
86. Installseals on low / intermediateservo piston'
87. Installservo pistons and springs- Make sure they
are fully seated.

\lt@)-d \

iF
+
$
/^'
\\
+a\
LOWiINTERMEDIATE

J\ SERVO PTSTONAND SPRING

88. lnstallservocoversfor overdriveand

Low-lntermediate Servo Travel Check
low/intermediateservousingnewsealsfor
overdriveservoor gasketfor low/intermediate
sErvo.Tightencoverboltsto 9-12N'm(7-9lb-ft)'
CAUTION:Be sure to align tab on
low/intermediate servo cover with port on
case. Tlghten bolts two to three turns at a
time to prevent cocking servo coven

SEFVO PISTON
SELECTOR
N
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74
f,|RrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

Ov er dr iv e S er v o C o v e r

T@ffi
2_ Usingflat nose pliers,removethree accumulator
pi stons,
CAUTION: Do not use any objects in piston
shaft bore for removal.

L o w- lnt er m ediat e S e rv o C o v e r

3. Usingside cutters,carefullyremovebimetal
retainingpin collars and removebimetaland
89. Installdipstick tube grommet and dipstick tube in plate.
case- lighten retainingbolt to g-12 N.m (7-g lb-ft).
CAUTION: Use care not to damage machined
case surfaces or birnetallic strips.
4. Pull retainingpins from cover.
Subassemblies
Ch a in Cov er
Di sas s em bly
1, Removethree accumulatorpistonshafts.

ffieD
----:

AUTOMAIICTRANSMISSION
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73
f,|HTsc T e c h n i c a lS e r v i c e l n f o r m a t i o n

Remove8mmmanualvalvedetentspringbolt
andspring.

6. Removequick-connectoilcoolerfittings.

OUICK
DIS@I{NEgT
FTTTNGS

7. Rernovedrive sprocket supportneedlebearing

usingStator and DrivenSprocket Bearing
RemovErT86P-7OO4SAand lmpactSlkte
HammerT58L-101-Bor equivalent.

AUTOMAIIC
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[f|RrsE T e c h n i c a lS e r v i c eI n f o r r n a t i o n

STATOR AND ORIVEN

SPFOO( T BEAFIFIG RET'OVER
T86P-70O.$A

Assembly Installquick-connectoil cooler fittings.

1. Usingan arborpress,anstall
drivesprocket
supportneedlebearingusingStatorandDriven
SprocketBearingReplacerT86P-70043-B or
equivalent.

AUTOMATIC
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U|RrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

3. lnstallmanualvalve detent spring and position 6. Pface Bimetal Height Gauge T86P-7O422'A or
tab in locator hole.Trghtenbolt to 9-12 N'm (7-9 equivalentagainst retainingpin and under bimetal'
tb-ft) 7. Gently tap retainingcollar onto pin untilit seats
againsttooledge.
I,{ANUAL vALVE - ,/rc,'T
oErEirsPRrNG
Wt^t

O
-G>- RETA'NING PlN

SIUETAL
}IEIGHT
GAUGE
Tt6P-70,.22.A

4. Startbimetalretainingpinsin cover.Gentlytap
centerpinto bottomof hole.
8. Engageslottedendof bimetalunderrear
rEtiiningpin andretainingcotlarandthen iepeat
Steps6-and7 for slottedendof bimetal-
9. Removeslottedendof bimetalfromits pin.
Positionplateslottedendsonlo rear andmiddle
F€GHT 6.5mm (O-ZF|NCH)
Installslotiedendof bimetalunder
retaining'pins.
retainingcollar.

5. Place end of bimetal with hole over front retaining

pin. lnstallbimetal retainingcollars.

sealsandO-ringson accumulator
1O. lnstatlnew
pistons.

ACCUMULATOF

SERVICE
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GROU
78
fi|RTsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

1 1 . Installaccumulatorpistonsinto their proper A ssembl y

cylinder.
1. Positionvalve body on oil pump using a new
gasket.
2. Insert Pump Body Guide Pins T86P-7O37O-Aand
Valve Body Guide Pin T86P-701OO-Gor
equivalent,as shorvn.Installtwo valve body-to-oil
\ pump retainingbolts and tightento g-12 N.m (7-9
tb-ft).

@-
t

^ n@
ACCUMULATOF
PISTON
NOTE: N€W SEALS ,009^no
MUST BE INSTALLED 0 o oo' oOOc 0
SEFOHE INSTALLING
PISTONS o 3
I o fVALVE BODY
n ;GUIOE PIN
oo0 LrE6P.Torooc

n
j 0
12. lnstallthree accumulator piston shafts. o 0 o
0
0 n
ful 0 0 oooo !
ACCUMUI-ATOR PISTON ooo [!
t?
. t

o
Ll o0
a 0,/
u
U a
o @o
to o
n P

a@fi
O a

Oil Pump and Valve Body Assembfy
Disassembly
Removetwo 8mm bolts retainingoil pumpto valve
bodyandseparatevalvebodytromoilpirmp.Remove
gasketanddiscard.
Oil Pump Shaft, Bearing and Seal
Removal
1. Fromrotor sideof pump,usinga pressanda
correctsizesocket,pressbearingandseaf
assemblyout.
NOTE:lnspectbearingborein pumpbodyfor
damage.lf boreis damagedthe pumpassembly
mustbe replaced.

AUTOMATIC
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UZRrsc T e c h n i c a lS e r v i c e I n f o r r n a t i o n

f nstallation TOf,xt
OOLT
1. From maincontrol side of pumpbody, usinga q --o
press and Oil Shaft Seal InstaflationTool n o ; - -9o o
T89P-l 177-AHor equivalent,inan inverted "UO oO Gr o
position,press in nerr bearinginto pumpbody. r' S€FAn/rTOn
The bearingmust be flush with purnpbody 'o
3 oo :o-
io
c PTATE
surface. sF O--=n
!*{OTE:Do rpt use any rnEthodof instalhfionthat o o 0 ' . o
U . F r
wouldcause bearingto be below surfaceof purp o - t O
oo
body. A t^- o

2. Placenew sealon Oil Shaft Seal InstallatlonTool

T89P-1177-AHor eguivalent,wllh step in eaal
n o o i . ; i' ' lt 'i os lo '
matchingslep on tool(metal skte up). hstal by J- o_- 33
placingtool and seal into pumpboclykom the 6 o o o
rotor sid€.
3. Usinga press, installsealintopumpboclyuntil
tool F ffr.rshagainstpumpbody.
l,lOTE:The tod is designedwith a step where it 3. Flemoresevenball checks, h{vorelief valves and
contscts seal to ensur€correct instalhtion bypasssolenoidfilter.Gleanfilter.
position.
RETEF CHECK
IALVE

l**"
rTtT,E BALTS
30p/gffi

clrEcK
EAILs
R€LI€F
THIS CIIECKBALL HAS BEEN VALVE
DELETED BEGINhTINGIN THE 1993
qE^|'HshuXrrf,{ MODEL YEAR
lloclrTfFrmrfi
4. The individualvalvesand springsare removedby
remwing retainingclips and bore plugs. Refer to
the lollowingillustrationsfor valve and spring
locations.Cleanvalves,springsand vafvebody
as fttcessary.
CAUTION:Most valves are aluminum and
eannot bs rcmoved using a magnct. Remove
valvcg by tapping valve body on palm of
Valvc Body hand to elide valves out ol bore8. lt may be
Dlsesrnbly nocccgary to romovc valvee and sprlngs
wlng a piclt, fl lt ie necegsary to uso a pick,
1. Place valve body on bench with separator plate use extreme eaution to prevenl damaging
up, and r€movqtwo Torxo bolts retaining valves or valvc bores.
separator plate to valvebocly.
CAUTION:Do not turn the throttle valve
2, Removaseparatorplate and gasket. adjurting Bcraw.

TRANSMISSION
AUTOMATIC GROUP
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80
 TechnicalServiceInformation
AXOD-E
199I PUMP PLATE IDENTIFICATION
AND PUMP CHECKBALL LOCATION

o.oO o ol
o o o O l o.o0 o ol
Q o o o o l
o/- oo i
€ I
o u o o o
- oo o oo : o l o \ r o 6 c )
o .o 6 o "A O
F l
, n
v E e O .O Ol. . G
o [l o o o e=
fl.,, . o 0
o
' l o o 0 o o o o
:- -. ro oo ' o O,=o
e <) O
- 'F oo n- o
1^\ // -t ,F OO
e) o c / /
o 0(/ o c ) o
oc L-i o 0 0 ( o
/l o o oo \-.-i ,///) o
o o
0- . ..o UJ o - ^ o o ;o
o o O o o 0 %o < : " O O
o :q o
o
O
o o o o
^ ^ o
!
0
o J o o o oo
lo
g ooO o o 9
q
oOO o o O-
O
rwo HoLES oNE HOLE, DOES
USESNIJMBNR 12 NOT USE NTIMBER
CTIECKBALL 12 CTIECXDALL
EARLY 1991ONLY LATE 1991ONLY

NIIMBER12CHESI(BALL NI'MBER 12 CHECKBALL

ItrRE ELIMINATED
EARLY 1991ONLY LATE T99TONLY

AUTOMATIC
TRANSMISSION
SERVICEGROUP
8l
 T e c h ni c a lS e r v i c eIn f o r m a t i o n

BT3 CIIECKBAIT ELIMINATED ALLOWING FOR\trARI' CLUTCII

OIL TO EXIIAUST T'NORIT'ICED ON THE 3 - 4 IIPSHITT
o.o0 o ol
o o o |
=t - l-
o/-\ OO
o tl o o. =
u - r
.
oo o o o
[)o ' o O o.,o
-, rl o

fe
=, o oo
o / / o o
n
u - 0 (r i r oo
o0 \J o o
I .
;- J o o
^ l l o o e
s o 0
o ' ;
:v ov .
o o o o o
o
Q.o - o.-.o o99_
"_o 9
'TAIT
82 CHECI(BALL ArlDED, FORCTNG HOLE
IIATI IS .030" IT TAKES TTIE ON - OFF ( LUS
FORWARD CLUTCH OIL THROUGH IF HOLE AT
tt11tt Qf,lf'l$f,, SOLENOID
THE
IF HOLE AT ItA'' IS .2I5* IT TAKES TTTEMODTILATED ( MLUS
SOLENOID
1992- rJP

oN - oF'F'( LUS ) LOCK UP SOLENOID MODULATED ( MIUS ) LOCK UP

1991SABLE AND TAURUSONLY! SOLENOII)
1991CONTINENTAL I T&L L992- UP
TIIIS SOLENOID IS TO BE USED WITH A
PTTMPSPACERPLATE WITII A.O3O''HOLE TIIIS SOLENOID IS TO BE USED WITII A
T THE r?A'rPOSrrroN, As sHowIY ABOYE. PUMP SPACNRPLATE WITH A.2I5 HOLE
TrrE 'A'r POSTTION,
AS SHOWNABO\IE

SERVICEGROUP
TRANSMISSION
AUTOMATIC
EZ
fi|HrsE T e c h ni c a l S e r v i c eI n fo r m a t i o n

3. Flemovesix bofts retaining pump cover to pump

housing and remove cover.

-
ep
\-rl
;ti

a-.1i

6. Remove metalO-ring retainer and O-ringfrom

outer vane support. Discard Sring.
4. Removebore springby pryingspringout ot
METAL OFIT.IG
housing. RETAINEFI
CAUTION:Place a piece of cardboard or
sultable materiat under screwdriver to
prevent damage to housing Easket surface.
WARNING:USEEXTREMECAUTIONWHEN
REMOVINGSPRINGTO PREVENTPEBSONAL
IHJURY.

7. Removeanddiscardside seaf.

5. Remove outside vane support retaining pin.

8. Removesidesealsupport.

AUTOMATIC
TRANSMISSION
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83
Ul,RrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

9. Removetop vanepositioningring. 12. Removeinnervanesupport.

K}P \ANE
POSItFftlhlG BItCi INNERVANE
SUPFORIT

10. Removeoutervanesupport. 1 3 . Remove bttom vane positioning ring.

BOTTOMVANE
POSITIONII{G
BII.G

11. Remove$evenvanesfrom rotor. Aseembly

NOTE:Theonlyserviceableparts in the oilpumpare
SH'NYEOGEMUSTFACE
tN otRECnOr{OF AFFwl/
the seals.'lfany otherparts of the oilpumpare
damagedor worn,the entirepurnpassemblymustbe
replaced.

PUilP NNES

AUTOMATIC
TRANSMISSION
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84
VZ.Rrsc T e c h n i c a lS e r v i c e I n fo r m a t i o n

1 . Install bottom vane positioning ring. SHINY EDGE MUST FACE

IN OIFECTIOT{ OF ARROW
Bonroil sNE
Flilc
POSlTONlr.lG

ruMP \ANES

Installouter vanesupport.

2. Installinnervanesupportwith smallinslde
diametercounterbore tacing up.

INNERIANE
SUPPc' T

5. lnstalltopvanepositioningring.

TOF Uf{E
Hl}{G
FOSlTrCtr{lNG
lnstallsevenvenesin innervanesupport.
NOTE:Shinyportionof vane blade is installed
toward outar vane support.

AUTOMATIC
TRANSMISSION
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85
f,|RrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

6. Installnewsidesealsupport.

1 0 . lnstallnew O-ringin groove in outer vane support.

Then, installmetal O-ring retainer.
7. lnstallnewsideseal.
8. lnstalloutervanesupportretainingpin.

9. Installbore springbetweencase and tab on outer

vanesupport.
1 1 .lnstalloilpumpcoveron oil pumphousingand
installsix retainingbolts.Tightenboltsto 9-12
N.m(7-9 lb-ft).

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SERVICE
86
 --1

l7lnrsE T e c h n i c a lS e r v i c el n fo r m a t i o n

12- Installball checks and relief valve. 13. Positionseparator plate on pump housingusing a
new gasket. InsertValve Body Guide Pin Set
T86P-7O1OO-Aand Valve Body Guide Pin
CHECK BALLS T86P-7O1OGBor equivalent.Then, installtwo
Torxo bolts. Tightenbolts to 9-12 N.m (7-9
lb-ft).Remove guide pins.

VALVE BODY
GUIOE PIN
sEr r86P-7otOO-A TORX'
HERE EOLTS

o ^o € a/ /^O
u

fe fo '
o -/= du
l o e ffi-.7- ts-/,
J::
II a";f
lao
o (^'i, '
o "; tJ \/ '|J
/) t o
go o o
lLJc
7I'
c ?sn\-,'
ooo o^oo.,oP
._". o : O
-- - l- ? eo ?t' Cn
g o u c ;
0 - 0 o -E=
,-- - Co
o^\ co
o* o o
V^LVE BOOY
GUIDE PIN
sET T86P-7010G8
HER€

Shell Assembly, Forward, Direct and

In t er m ediat e Clu tc h e s

LOW
OVEROfiTVE DFUM ONE.WAY
ANO ONE.WAY CLUTCH
CLUTCH ISSY

No. r0 CLUTCH
NEEDLE
HUB
BEAFING

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
E7
VZRTsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

Dlsassembly 5. Remove No. 10 needlebearing.

1. Setassemblyon overdrivedrum.
2. Removesungear and shellassembly. IrlO. 1O NEEDLE BEARIT{G

OVERDR'VE
DRUM

3. FlemoveNo. 1I needlebearing.
6. Turnassemblyonto intermediatecylinderhub.
7. Removeoverdrivedrumandone-wayclutch
N O .r r assembly.
NEEDLE
EEAR|ttlG
OUTERUP NOTE:ONE-WAYCLUTCHOUTERRACE
FACINGDOWN GM\,E UUST BE VISIBLE.F PFOPERLY
INSTAIIED. CTUTCHMUST
ruRN

OVERDRIVE DRUM
ANO OI{E.WAY CLUTCH
ASSY

FOf,W^RD
CLUTGII

4. Remove intermediate clutch hub. OIRECT

CLUTCH

tNT€RMEDI,ATE
CLUTCH

TRANSMISSION
AUTOMATIC GROUP
SERVICE
8E
 -t

UZ,RrsE T e c hn i c a l S e r v i c e f n f o r m a t i o n

8. RemoveNo. 6 thrustwasher.

OIRECT OT.I€.WAY CLUTCH

ilO. 7 THRUST
WA^sHER
SLOTTEO
TAAS

Assembly
1. Set on intermediate
clutchcylinder.
9. Removeforwardclutchassemblyby pryingup on 2. InstalfNo. 7 thrustwasherintodirectclutchbeing
eachsidewithtwo screwdrivers. sure tabs are alignedwith slots in directclutch.
NOTE:DirectclutchhubO-ringsealsretain 3. lnstalldirectone-wayclutchandalignontoclutch
torwardclutchon hub.Pry evenlyanddo not pack splines.
locatescrewdriverendson br nearforward
clutchcheckball.

FOFWAFIO CLUTCH

OIRECTOltlE-tYAYCLUTCT{

PRY UP GENTLY WITH IN. 7 THRUST

TWO SCREWDFIIVERS WAS}IER
SLOTTED
TAaS
10. Removedirectone-wayclutchandNo. Z thrust
washer.

AUIOMATIC
IRANSMISSION
SERVICE
GROUP
E9
UIHrsE T e c h n i c a lS e r v i c el n fo r m a t i o n

4. lnstalltwo O-ring seals. NOTE: ONE-WAY CLUTCH OUTER RACE

GROOVE MUST 8E VISIBLE. IF PFIOPERLY
INSTALLEO, CLUTCH MUST
TURN COUNTERCLOCKWISE
otR€cr oa{E-
WAY CLUTCH

5. lnstallforwardclutchassembly.Usecaution not
to damage the &ring seals on direct clutch FOfIwARO
CLUTCH
hub.
6. InstallNo.6 thrustwasher.

L Turn assembly over and set on overdrive drum.

9. InstallNo. 1Oneedlebearingusinggrease to hold
in place.
1 0 . Installintermediateclutch hub with No. 1Oneedle
bearing.

7. Installoverdrive drum and one-way clutch

assembly.

1 1 . Install.No.
1 1 needlebearingwith outerlipfacing
down.

AUTOMAIIC
TRANSMISSION GROUP
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 -l

IZHrsc T e c h n i c a lS e r v i c eI n f o r m a t i o n

12. lnstallsungear and shellassembly.

No. rt
NEEOLE
8€ARING
OUTERLtP
FACIHGOOWN

ForwardClutch

Disassembly PRESSURE
1. Removesnapring,pressureplate,clutchpack PI.^TE
andwave spring. SilAP RING

CTUTCH PACK
ASSY

SERVICE
TRANSMISSION
AUTOMATIC P
GROU
9l
glnrsE T e c h n i c a lS e r v i c e I n fo r r n a t i o n
2. RemovesnapringandreturnspringusingClutch 4. Flemovepiston innerand outer seals.
SpringCompressorT65L-77515-Aor equivalent.
lnner Piston Seal

CLUTCII SFBlllG
COUPRESSOR
T65L.775tSA
INN€R PISTON
SE^L

OuterPistonSeal

3. Removepistonassemblyfrom hub.

TRANSMISSION
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92
 -t

E|RrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n
Assembly 3. lnstallwavespring,clutchpack.pressureplate
1. Inslallinnerandouterpistonseals(lipsealfacing andsnapring.
toward bottomof cylinder)andinstallpiston
assemblyusingForwardClutchSealLip
ProtectorT86P-7O548-A or equivalent.
SNAP RING

CLUICH PACK
ASSY

WAVE SPRING

4. CheckclutchpackclearanceusingDiallndicator
TOOL-4201-C oqequivalent. Pushdownwardon
the clutchpack withat least 135N(30 tbs)of
PISTON ASSY force. Releasepressureandzero dial indicator.
Litt pressureplateto the bottomof the snapring.
Notedialindicatorreading.Taketwo readings,
180degreesapart, and determinethe averageof
the two readings.Theclearanceshouldbe
1.89-1.40mm(0.O75-0.055 inch).lf the
clearanceis not withinspecifiCation, selective
snapringsare availablein the following
thicknesses:
1.24-1.34mm(0.049-0.053 inch)
lnstallreturnspringandsnapringusingClutch 1.6+ 1.70mm(0,063-0.O67 inch)
SpringCompressorT65L-77515.Aor equivalent. 1.95-2.05mm (0.077-O.OB 1 inch)
2.3+2.40mm(0.09 1-0.094inch)
2.65-2.7Smm(0.104-0.1O8inch)
After installingthe correct snapring,check the
clearance.

DI,AL INOICATOR
TOOL{201C

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VaRrsE T e c h n i c a lS e r v i c e I n fo r m a t i o n

Dlract Clutch

CLUTCH
CVLIND€R

PRESSUHE
PTITE

GHINGS

AffiA'3L'[O^

Disascembly
1. Remove snap ring, pressure plate and clutch
pack.

Removesnap ring and refurnspringusingGlutch

SpringCompressorT65L-T75 15-Aor equivalent.

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!/nrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

3. Remove two-piece piston assembly. Outer Piston Seal

CHECK BALL
TWOPIECE
PISTOGI ASSY

Assembly
andouterpistonlip seals(lipseals
1. Installinner
facingtoward bottomof cylinder)and installinto
hubusingDirectClutchLip SealProtector
T86P-70234-Aor equivalent.
4. Disassemble two-piece piston.

5. Removepistoninnerand outerlip seals.

Inner PistonSeal

2. Installpistonouterring.
3. Verityfree movementof check ball.

TRANSMISSION
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UlRrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n

4. Installreturn spring in cylinder aligningreturn 6. Installclutchpack,pressureplateandsnapring

spring notch with check ballin piston. intocylinder.

SNAP RING
FEruRN SPFING

NOrE: B€ SUFE TO AI|GN

RETURNSIPRINGHOTCH
clrEct( 8^ll tN
HSTOT.J

7. Check clutch pack clearance using Diallndicator

TOOL-4201-Cor eguivalent.Push downward on
the clutch pack with 135N (30lbs) ol
force.Release pressure and zero dial indicator.
Lift pressure plate to the bottom of the snap ring.
Note dial indicator reading.Take two readings,
180 degrees apart, and determinethe average of
5. InstallsnapringusingClutchSpringCompressor the two readings.The clearance should be:
T65L-77515-A or equivalent. (3-plate)(4-Plate)0.78- 1.29mm (O.031-O.O51
inch). ff the clearance is not within specification,
selective snap rings are availablein the following
thicknesses:
1-24-1.34mm (0.049€.O53 inch)
1.67-1.76mm (O.065-0.O69inch)
2. 14-2.24mm (O.O84-O.O88 inch)
2.61-2.71mm(O.102-O.106 i nch)
3.04-3.14mm(O.t t 9-O.123 inch)
After installinglhe correct snap ring, check the
clearance.

BENCH VISE

TRANSMISSION
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 -t

UiRrsG l e r v i c eI n f o r m a t i o n
T e c h n i c aS
Intermediate Clutch

OUTEF RETURN
PISTON SPRING
SEAt

CLUTCH
CYLINDEF

Disassembly
1. Removesnapring,pressureplateand clutch
pack assembly.

PFESSURE
PLATE

DIRECT|INTEFMEDIATE 11y4VESpRtHG
SYLIHOER ASSY

2, Hemovesnapringand returnspring,usingOutch
SpringCompressorT65L-77515-A or equivalent.

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SERVICE
97
tIRrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

3. Remove piston assembly.

4. Remove piston innerand outer seals.

O ut er P is t on S e a l

2. InstallsnapringandreturnspringusingClutch
SpringCompressorT65L-77515-Aor eguivalent.

SPRTIS COMPRESSO€
T65L-775r$A

lnner Piston Seal

INNEFI PISTON
SEAL

Assembly
1. Checkfor free movementof check ballin cylinder.
Installinnerlipsealon cylinderhubandouter
pistonlip seal(lipsfacingtowardbottomof
cylinder)on pistonand installpiston
using
ForwardClutchSealLip Protector
T86P-7O548-A or equivalent.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
9E
UIRTSE l e r v i c eI n f o r m a t i o n
T e c h n i c aS
3. Installclutchpack, pressureplateand snapring. 1.2S'1.3omm(0.O47€.O51 inch)
1.67-1.77mm(0.066-0.07O inch)
PRESSURE 2. 14-2.24mm(0.084-0.088inch)
PLATE (0.103€.1O7inch)
2.A1-2.71mm
SNAP RING 3.04-3.14mm(0.12O-O.124inch)

CLUTCH PACK DIAI INOICATOR

DIRECT/INTERMEDIATE ASSY TOOL4201€
wAvE SPRING
CYLTNDERAssY D73?TB
-------/

4. Check clutch pack clearance using Dial Indicator INTEHIIED|ATE

CLUTCHPACK CLEAEANCE
TOOL-4201-Cor equivalent.Push downward on CHECX
the clutch pack with 135N (30lbs) of force.
Release pressure and zero the dial indicator. Lift
pressure plate to the bottom of the snap ring.
Note dialindicator reading. Take two readings,
18Odegrees apart, and determine the average of
the two readings. The clearance should be:
(4-Plate) 1.O2-1.51mm(0.04G'0.059 inch). lf the
clearance is not within specification, selective
snap rings are availablein the following
thicknesses:

Feverse Clutch

OUTER
PISTON RETUFN
SEAL SPFING

CLUTCH INNER
CYLINDEF PISTON
SE^L
I
\ PHESSUHE

\s
PLATE
\

\
SilAP \
RING WAVE
SPRING

GROUP
SERVICE
AUIOMATICTRANSMISSION
99
!5i.FrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

Disassembly Piston lnner Seal

1. Removesnapring,pressureplate,clutchpack
andwavespring.

SNAP RING

CLUTCHPACK
ASSY

Piston Outer Seal

2. UsingClutchSpringCompressorT65L.77515-A
or equivafent,
removesnapringandreturnspring. PISTON
OLJTEH SEAL

Assembly
1. Installinnerandouterpistonlipseals(lipsfacing
toward bottomof cylinder)andinstallpistonusing
ReverseClutchOuterLip SealProtector
T86P-7040SAor equivalent.

FEVEFSE CLUTCH OUTER

LlP SEAL PHOTECTOR
T86P-70{t$A

3. Liftout pistonandremovepistoninnerandouler
seals.

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
t00
Ui'RrsE T e c h n i c a fS e r v i c eI n fo r m a t i o n
2. lnstallslap ringand returnspringusingClutch 1.52-1.62mm(0.05$0.064inch)
Spring Compressor T65L-TTSt S-n or-equivalent.
1.98-2.08mm (0.078€.081inch)
2.45-2.55mm(O.096€.jOOinch)
292$.A2m* (O.115{.1 18inch)
After installingthe correct snapring,checkthe
clearance.

3. Installwavespring,clutchpack,pressureplate Planetary Assembly

and snapring.
Dieassemblyand Assembly
1. Removesnapring.
2. Removefront planetary.
PACK 3. RemoveNo. 13 needlebearing.
4. Removerear planetaryfrom shellandringgear
assembly.
5. To assemble,reverseSteps 1 through4.

Frcrt|T
PLAI.IETARY

4. $ggf ctutchpack clearanceusingDialtndicator RING GE^R

TOOL-42O 1-C or equivalent.push Eownwaia;; FEAR

the clutchpack with lOSN(30 tbs)of force. PTINETARY
Releasepressureand zero dial inclicator.Lift o59a7_A

p.ress{t9plq!€ to the Eottomof the snap ring.

Notedialindicatorreading.,Take trro rdadinls,
.18O.degreeg.apart, and determinethe averige
' of
the two readings.The clearanceshouldbe:
0-97-1.63mm(0.03&0.064inch).tf rhe
cfearanceis not withinspecification,selective
glap ringsare availablein the following
thicknesses:

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
rot
FZRrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

rt, Slide out piniongears and thrust washers-

Differential and Gearset
Disassembly 4. Inspect needle bearings and pinionshafts.
Replace, it necessary.
1. Removeplanetarypinionshaft retainingsnap
ring.

5. Remove No. 17 needle bearing frorn top of

Usinga magnet,work planetarypinionshafts out differential planetary assembly.
of ditferentialcase housing.

}.IO, 17 NEEDI-E BEARING

P|.TETARY PII{ION
slufl

cAsE l{ot slNG

TRANSMISSION
AUTOMATIC GROUP
SERVICE
l02
Ui.FrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n
Using a drift, drive out differentialpinionshaft roll 9. Remove RH side gear and thrust washer.
pin.

HH SIOE GE R

1 0 . Pushoutputshafttowardcenterof housing,and
slideLH side gear upwardto gainaccessto
retainingring.
DIFFEREh'TIAL PINION
ST{AFT 1 1 .Removeretainingringand slideoutputshaftout of
differentialcase.
Removepiniongearandthrust
washer.

7. Tapout pinionshaftusinga drift. THRUST WASFIER

TAP OUT PINDN

S'{AFT USI}.IG A ORIFT

PINION g{AFT

RETAINING RING

Assembly
1. Withoutputshaftinsideof differentialcase,
slide
Removepiniongearsandthrustwashersby thrustwasherand LH sidegearonto outputshaft.
rotatingoutputshaft.
2. Installretainingringandslidegeardownover
retaaningring.

THRUST I'VASHER

rcTATE OTJTPI'T TAFT

FETAINII.IG RING

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
r03
E|srsG T e c h n i c a lS e r v i c e I n fo r m a t i o n

lnstallthrustwasherand RHside gearinto

differentialcase.

RH S'OE GEAF

4. Installtbrustwasherson piniongearsbeingsure
innerlipson washersare seatedin recessin
piniongears.
WHX-E FOTATING
OUTruT SHAFT
WALX P]NION GEARS
INTO POSITIC'N

AN|oN GEARRECESS

5. Positionpiniongears on side gears beingsure 7. Tappinionshaftthroughdifferentialcaseand

pin'iongears,makingsure-!-o alignretainingpin
teethon allgearsare engagedandrotate output
shaft. hob in shaftwith holein ditferentialcase'

P[.|IO}I GEAR PS.llOl'l SHAFf

ATGN RETA||i8}IGPIN
}TOI.EIN SHAFTWITH
lrorf lN cAsE.
FOT^TE OUrRtr gi^Fr

Whilerotatingthe outputshaft,walk piniongears

into position.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
r04
Ui,HrsE T e c h n i c a lS e r v i c e I n f o r m a t i o n
8. Usinga drift, tap in differentialpinionshaft roll pin. 1 0 . Installupperand lowerpiniongear thrustwashers
ontopiniongear.
NOTE:lt may be necessaryto usea littlegrease
to holdthrustwashers,needlebearingsand
spacerin position.Installandalignfinaldrive
piniongearswithdifferentialcase holes.

NEEDLE BEAFI|NGS
PINION GEAF

UPPER THRUST
WASH€R
LOA'ER THRUST

NOTE:Makesureallneedlebearings,thrust
washersand spacer are in position.
9. lnstallNo. 17 needlebearingover outputshaft
and seat on planetaryhousingwith positioning
tabsfacingup.

OUTPUT$TAFT

1 1 . Pushlinaldrivepinionshaftsthroughdifferential
case andgearsuntillowerstep on shaftis level
with ditferentialcase.

AUTOMATIC
TRANSMISSION GROUP
SERVICE
r05
[/lrsE TechnicalService Information

NOTE: Use care when installingpinionshafts to 4- Remove piston rod retainingclips and remove rod
prevent disturbingneedlebearings. and cushionspring.
5. Remove servo piston seal.
6. Remove seal and gasket from cover.

Assembly
1. Installfront pistonrod retainingclip on pistonrod-
2. Installcushionspringand piston.
3. Compress assembly and installrear piston rod
retainingclip.
4. Instaflservo piston seal.
5. Installcoversealand gasket.
6. Lubricate piston seals with petroleumjelly.
7. Installassembledpiston componentsinto servo
cover.
8. lnstall piston return spring into cover.
NOTE: uxG S{JFE LOIA/ER
STEF IS I€VEL WITH 9. Installassembledservo componentsinto case.
DIFFEREiITUL CASE AT.ID
FAC|NG IIIIU'AFID. NOTE: Make sure return spring is correctly
positionedin case.

12. lnstallfinaldrivepinionshaft retainingring in s E F v OC ER GASKET

differential case grooves.

C U S H I O N____+
sPRtNG

SNAP EING

10. Installthree to 9'12 N'm

8mmcoverbolts.'l'ighten
(7-9lb-ft).

Overdrive Servo
D i sassembl y
Low-lntermediate Servo 1. Removethree 8mm cover bolts,and remove
Disassembly return spring and rod.
1. Removethree8mmcoverbolts. 2. Remove servo piston from cover.
2. Removepistonreturnspring. 3. Remove rear piston rod retainingclip and remove
washer.
3. Removeservopistonand rodfromcover.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
106
ARrsE T e c h n i c a lS e r v i c eI n fo r m a t i o n

4. Remove servo piston and seal.

5. Flemovecushion spring-
6. Flemovefront piston rod retaining clip.
7. Rernovecover seal.

Assembly
1. Install front piston rod retaining clip on piston rod.
2. Instalfcushion spring, piston and washer.
3, Compress assembly and install rear piston rod SPEEDOMSTEB
retainingclip. OFIIVEGEAB

4. Lubricate piston sealwith petroleum jelly.

5. Installcover seal.
6. Installassembledservo components into case
and installcover. Assembly
NOTE: Make sure return spring is correcfly 1. Pushspeedometerdrivegear onto governor
positionedin case. shaftaligningslots in gear with shattroll pin.
7. lnstallthree 8mm cover botts. Tightento g-12 N.m
(7-erbft). 2. Installspeedometerdrivegear bearingon
speedorneterdrivegear with outerrace (black
side)facingup.
3. Instaltnewsealandcover.
REAR
CLIP 4. lnstalltwo8mmcoverbolts.lighten to 9-12 N.m
SERVO PISTON
(7-e rb-ft).

CUSHION
SPRING
COVER SEAL Driven Sprocket Support
REAR GFTOOVE
Dlsassembly
WASHER
Removsdrivensprocketsupportneedlebearingusing
SERVO ROO
Statorand DrivenSprocketBearingRemover
FRONT FETAINING T86P-7O043-A and lmpactSlideHammerT58L-101-B
CLIP
or equivalent.
FFONT GROOVE

PISTON RETURN SPRTNG

SPRING RETAINEF
STATORATE)
OBII/EN SPROCXET
SE Fr\|G
FErlOVEf,
159'-7fl).il'A

SpeedometerDriveGearAssembly
Disassembly
1. Removetwo 8mmcover boltsand removecover.
2. Removesealanddiscard.
3. Removethe followingcomponentsas an
assembly:
r Speedometerdrivegear bearing
r Speedometerdrivegear assembly
4. Removespeedorneterdrivebearingandgear
fromgovernorshaft.

AUTOMATIC SERVICE
TRANSMISSION GROUP
l 07
fZRrsE T e c h n i c a lS e r v i c eI n f o r m a t i o n

Assembly 3. Inspect all springs for distortion.Check all valves

Pressdrivensprocketsupportneedlebearingusing and plugs for free movementin their respective
StatorandDrivenSprocketBearingReplacer bores. Valves and plugs, when dry, must fall from
T86P-7OO43-B or equivalent. their own weight in their respective bores.
4. Roll manualvalve on a flat surface to check f or
AFBOR PFESS bent condition.

Servo
STATOR AT.ID
DRIvEN 1. lnspectservobodyfor cracksandpistonboretor
SPR@KET scores.
BEARING
REPI-AC€R
T65P-7004+8
2. Checkfluidpassagesfor obstructions.
3. lnspectbandandstrutsfor distortion.Inspect
bandendsfor cracks.
4. Inspectservospringfor distortion.
5. Inspectbandliningfor excessivewear and
bondingto metalband.
6. Replacedamagedseals.

DRIVEN SPFOCXET
SUPPORT Forward, Direct, lntermediate and Reverse
Clutches
1. Inspectciutchcylinderthrustsurfaces,piston
bore,andclutchplateserrationsfor scoresor
CLEANINGAND INSPECTION burrs.Minorscoresor burrsmay be removed
withcrocuscloth.Replacethe clutchcylinderif it
is badlyscoredor damaged.
Transaxle 2. Checkfluidpassagein clutchcylinderfor
Cleanthe parts with suitablesolventand use obstructions.Cleanout allfluidpassages.Inspect
moisture-treeair to dry off all parts andcleanout fluid clutchpistonfor scoresand replaceif necessary.
Passages. Inspectcheck ballsfor freedomof movementand
properseating.
The composition clutch plates, controlvalve
body-to-screen gasket, bands and synthetic 3. Checkclutchreleasespringfor distortionand
reels should not be cleaned in a vapor degreaser cracks.Replacespring(including wavesPring)if
or wlth any type of deterEent solution.To clean it is distortedor cracked.
theseparts,wipe themotf with a lint-treecloth.New
clutchplatesor bandsshouldbe soakedin the 4. Inspectcomposition clutchplates,steelclutch
specifiedtransmissionfluidfor 15 minutesbefore plates,andclutchpressureplatefor wornor
beingassembled. scoredbearingsurfaces.Fleplaceall partsthat
are deeplyscoredor burned.
5. Checkclutchplatesfor flatnessandfit on clutch
hubserrations.Discardany platethat does not
Valve Body slidefreelyon the serrationsor that is notflat.
1. Thoroughly cleanallparts,exceptcheckbalfs,in 6. Checkclutchhubthrustsurfacesfor scoresand
cleansolventand blowdry with moisture-free clutchhubsplinesfor wear.
compressedair.
2. Inspectall valveand plugboresfor scores.Check
allfluidpassges for obstructions.Inspectall
matingsurfacesfor burrsandscores.lf needed, OutputShaft
use crocus cloth to polish valves and plugs. outputshaftbearing
1. Inspeut forscores.
surfaces
Avoid roundingthe sharp edges of the valves lf excessive clearance or scores are found,
and plugs with the crocus cloth. replace shaft and inspect components.
2. Check splineson output shaft for wear and
replace shaft il splinesare excessively worn.
Inspectall bushings.

TRANSMISSION
AUTOMATIC GROUP
SERVICE
l0E
!5|Hrsc T e c h n i c a lS e r v i c eI n f o r m a t i o n
One-Way Clutches
1. Inspectouter and inner races for scores or
damaged surface areas where rollers or sprags
contact races.
2. Inspect rollers, sprags and springs for excessive
wear or damage.
3. Inspect spring and case for bent or damaged
spring retainers.
Speedometer Drive Assembly
1. Inspectdriveanddrivengears.Replaceif teeth
are broken,chippedor excessivelyworn.
Case
Inspectthe case for cracks andstrippedthreads.
Inspectthe gasketsurfacesand matingsurfacesfor
burrs.Checkthe ventfor obstructionsandcheck atl
fluidpassagesfor obstructionsandleakage.
flspect the case bushingtor scores.Checkall parking
linkageparts for wear or damage.
lf the transaxlecase threadis damaged,servicekits
maybe purchasedformlocaljobbers.To servicea
damagedthread,the followingproceduresshouldbe
caretullyfollowed.
1. Drilloutdamagedthreads,using the same drill
size as the thread O.D.For eximple, usea
5 / 16-inchdrillfor a 5 / 16 x 1gthread.
2. Selectproperspecialtapandtap the drilledhole.
Igp i* markedfor sizeof threadbeingrepaired.
Thus,the specialtap markedSl 16 x tg willnot
cut the samethreadas a standardS/ 16 x 1g tap.
It doescut a threadlargeenoughto
accOmmodate the insert,and after the insertis
installedthe originalthreadsize(S/ 16 x 1g) is
restored.
3. Placeinserton tool andadjustsleeveto lengthof
insertbeingused.Pressinsertagainsttace-of
tappedhole.Turntoolclockwiseandwindinsert
intoholeuntilinsertis one-halfturnbelowface.
4. Workingthroughinsert,bendinserttang straight
up and downuntilit breaksoff at notch.
5. lmproperlyinstalledinsertscan be removedwith
exlractor tool. Placeextractor tool in insertso
that bladerests againsttop coil one-quarterto
on*half turnaway lrom endof coil.Taptool
sharplywitha hammerso that bladecutsinto
insert.Exert downwardpressureon tooland turn
it counterclockwiseuntilinsertis removed.
AUTOMATIC
TRANSMISSION GROUP
SERVICE
109
Planetary Carriers
Individual parts of the planet carriers are not
serviceable except for the differential
components.
1. Checkpinsandshaftsin planetassembliesfor
loosefit and/or completedisengagement. Usea
new planet assemblyif eitherconditionexists.
Beforeinstallinga planetassembly,check shaft
welds.
2. lnspectpiniongearsfor damagedor excessively
wornteeth.
3. Checkfor freerotationof piniongears.
Thrust Bearings
Washthrustbearingsthoroughlyin cleaningsolvent.
Blowbearingsdry with compressedair.
Ensurethat bearingsare cleanand thenlubricatewith
transrnission
fluid.Replaceany bearingsand races
whichshow signsof pittingor roughness.
Stator to lmpeller Interference Check
1. Positionstator supportassemblyon a benchwith
splineendpointingup.
2. Mounta conveneron statorsupportwithsplines
on onaway clutchinnerrace engagingmating
splinesof stator support.
3. Holdstator supportstationary,and try to rotate
torqueconverterbothclockwiseand
counterclockwise. Convertershouldrotatefreely
withoutany signsof interferenceor scraping
withinconverterassembly.
4. lf thereis an indication
of scraping,trailingedges
of stator bladesmay be interferingwith leading
edgesof impellerblades.Insuchcases,replace
converter.
Converter and Oil Cooler
Wheninternalwear or damagehas occurredin the
transaxle,metalparticfes,clutchplatematerial,or
bandmaterialmayhavebeencarriedintothe
converterand oilcooler.Thesecontaminantsare a
majorcauseof recurringtransaxletroublesand MUST
be removedfrom the system beforethe transaxleis
put back intoservice.
Whenevera transaxlehas beendisassembted to
replacewornor damagedparts or becausethe valve
body sticks dueto foreignmaterial,the converterand
oilcooler MUSTbe cleanedby usinga mechanicalty
agitatedcleaner,suchas RotundaTorqueGonverter
andOilCoolerCleaner014-00028or equivalent.
U|RrsE T e c hn i c a l S e r v i c e I n fo r m a t i o n

The lack of a drain plug in the AXOD€ converter 1. Raisevehicleon a hoistor jackstands-Referto
increasesthe amountof residualflushing solvent Section1S04.
retainedin the converterafter cleaning.This reteined 2. Placea drainpanundertransaxle.
solventis not acceptableand a methodof dilutingit is
required.The followingprocedureis to be used after 3. LoosenpumPandvalvebodycoverboltsand
removalof the AXOD€ torque converterfrom the drain.
cleanirlgequipment.
4. Loosenlower panretainingbolts anddrainfluid
1. Tboroughly drainremainingsolventthroughhub- from transaxle.
2. Add 1.9liters(2.0 quarts)of cleantransmission 5. Whenfluidhasdrainedto levelofpanflange,
fluidto converter.Agitateby hand. removerest of pan bolts workingfrom the RH
3. Thoroughly drain solutionthroughconverter side and allow it to drop and drain skrwly-
hub. 6. Whenallfluidhas drainedfrom transaxle,remove
andthoroughlycleanpan.Discardgasltet-
7. Hace a new gasket on Panand installpan on
transaxb.
Transaxle Fluid Drain and Refill
Nonnalmaintenanceand lubricationrequirementsdo 8. Filltransaxleto correcl level.
not necessitateperiodicautornatictransa:tlelluid 9. Lower vehicle.
changes.lf a rnajorservice,suchas a clutch band,
bearing,etc., is requiredin the transaxle,it will haveto
be removedfor service.At this timo the converter,
transaxle cooler and cooler'lines must be
thoroughly flushed to removc any dirt. Oil Cooler Tube Leakage
Whenused undercontinuousor severeconditionsthe Whenfluid leakageis loundat the oil cooler,the cooler
transaxh and torqueconvertershouldbe drainedand mustbe replaced.Referto Section27'03.
refilledwith fluid as specified. Whenone or moreof the fluidcoolersteeltubesmust
CAIffiON: Usc of a fluid other than specilied be replaced,each replacementtube must be
could rcsult in transaxle malfunction and/ or fabriiated from the samesize steeltubingas the
failure. or[inal line.
Referto VehicleCertificationLabelaffixedto left hont Usingthe old tube as a guide,bendthe newtube as
door lock face panelor door pillarfor transa:tlecode. required.Add the necessaryfittingsand installthe
tube.
Whenfillinga dry transaxleand converter,refer to
Specilicationsfor capacity.Check the fluid bvel. Afterth fittingshavebeentightened,add fluidas
neededandcheck for fluidleaks-
Proceduresfor partialdrainand refill,due to in-vehicle
serviceoperation,are as follows:

TRANSMISSION
AUTOMATIC GROUP
SERVICE
ll0
 --l

ganrsE T e c hn i c a lS e r v i c eI n f o r ma t i on

Thrust Washer and Needle Bearing Location

14 NOT
SERV'CEAELE

PAHT
lTEI XUIBER OESCRIPTIOX 7G273 wAsHEn TlrRuST (PHFHCv-lCi (SELECTIVE)
t.
t. 7G019 WASHER THRUST (NYLOrq(ORIVE (oFtvEN SPROCT(ET SUPPOfiT-REARI
sPaocKET/srAToRsu PFoRT) e. ?G12| EEARING ASSEMELY {DIRECT CLUTCH HUB)
2. 7GOle WASHER THFUST (NYLONI (DRIVE to. 7G239 BEARING ASSEMBLY (FFON? SUN GEARI
SFROCKET/STATOB SUPPORT) f r- 7s?3e BEAR]NG ASSEMELY {FBONT SUN GEAA)
3. 7G096 wAsHEFr THRUST (STEEL BACKED SRONZE) CASE 12, 7G10/r NOT SERVICEABLE
covER/DBrvEN SPFOCXETI 13. 7G177 EEARING ASSEMBLY (PLANETARY
a. 76115 WASHEB THFTUST (NYLON' (DnryEN THRUST-CET{TER)
SPFOCTGTTSUPPORT) la. 7G105 ilOT SERVICEABLE
5. 7DO1. WASHER THFUST (NYLON} (SELECTIVE) 1t. ?G173 BEARING ASSEUBLY (REAR SUN GEAF)
(SUPPoRTTFORWARD C LUTCH) i6. 7G106 BEARING ASSEMoLY {FIT.IAL DRIVE GEAHNONT)
a. 7DO76 WASHEF THRUST (NYLON) (FORWARO CLUTGH 17. 7G107 BEARTNG ASSEMBLY (FINAL DRIVE GEAR-FEAR)
o.w.c. RACE) rt. 7cro3 WASHER THRUST (STEEL) (SELECTIVE}
7. 7 G r1 6 WASHER THFUST(NYLON!
IO|RECT (DIFFERENTIAL CARRIER)
CLUTCH'OIRECT O.IY.C.} ro. 7G'r12 BEAFING ASSEMSLY (OIFFERENTIAL CAFFIIER)

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
rll
[/srsE l e r v i c el n fo r m a t i o n
T e c h n i c aS
SPECIFICATIONS
CII'TCII AilD EAI{DAPFLEATNNCHAFf
(huthr Ferntd hbnncdhb Facnr Lil fta.lUry Irblct OlF
Cilr lo-lnt Bend Dhtct Ctttch Cfnch Clutc.tt Iryry CMch
Burl Cfildr Clnch
tst GosrMErualt-ow ApplBO Appliad Applkrd Applied Applild
19 Gear(Driw) Applied Applied Appllsd
2rdGmrfmrel Apdind Apdied Apdled lb,lding
3ld Ggar(Drite) Apdi€d ApChrd
4th Gear (O,Brtrirre) Appliet Appli€d APdH f{ddirB
Rsvurse(R) ApdL{ Applied lpplied
tleutral(N) Appli€d
tuk (P) ApCi€d

IORqJE SPECNC^TIODIS
fcflar ]lrrl Lb{r Drlcrlplbn tl.ln r"bf,
'n/ 8-r2 F9
Sryrdw Ptil. tr MainCantrol *t2 7€ Cablo!c Cass
Searer Pbb b Rmp Eody $r2 7.9 Osin Corerto Case(10rrn) $12 7-9
Drii Sprip D Ctrsh CoYlr 9t2 7-9 hrnp Bodyb Chah Cotnr s12 7.9

Argt Covrr o Cs$ 9t2 7-g Ol Pano Crse (bws Reserv*) 1{,16 Itrl2
n, Conuolt v€r to Otain Covr $f2 7-E Uein Corfrd Cotr€rb GheinCover(tbgor Reservoi4 1 & 1 6 10.12
Sddrij b ildr Corsd 912 7-9 t srud tstnr b llarud SMt 1*A r2-16
Lorarpntutiatr Sdro CoYr b Csst $12 7-9 Pat Atunrd b Caso 27-n *n
O,!fihr Sd'ro CorrrCroo 9r2 7.9 Chah Cofi o'Casc (l3rn| n-n *2,
fumpCovcrb PurrpBody $ r2 7-9 Casan Ouh Gocr (13mm) s36 24.$26.6
FnlrTr$oh CGo 9r2 ?-g Chalt Ccnnrut ftmt Stflpotl (l3tnm) n-g TA,
(7mm) '34-{8 2$35
GoYeruCoan to Case $f2 7-g CfninCo,u to FrontSnppott
C.s! b W g.pport $fi! 74 Dttetgrhl BrE b CasE 31-{8 2S5
Gu b Odr Cotret{10 mm} $r2 7-9 Engin b'CasarCasoo Eryho 55{8 11-fi

Ol Pr$npAsry. b llah Cctuol $r2 7-9 csse b R6YqSeoutcfi sctgtl 1&t2 7€

l{rtJ $.rt Sridr o Gs $r2 7€ Caseb Rcrtsc Chrbht*n 3{-a7 25{5

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TRANSMISSION
AUTOMATIC GROUP
SERVICE
tt2
 T e c hn i c a l S e r v i c e I n f o r m a t i o n
AXOD-E
1993 - UP WIRE HARNESS VIEW
AXOD-E
199T.1992 WIRE HARNESS\rIEW
WEIIts CASBCOITINECK)I
vtEv FAfxrftllEB wsnS eAs
OONNBSftN.ONIHE SDEOF
lNBIRATNAXT
l. ss2PowER( RED)
2. SS2GROUND ( BLUE)
3. SS3GROT.JND( BLACK)
4. SS3POWER ( Y-ELInW)
s. ssl PowER( wHrrE )
6. SSl GROLTND( YELTOW)
AUTOMATIC
TRANSMISSION
SERVICEGROUP
ll3
CONNECTOR
TOP \rIEW
1. EPC GROUND ( BLUE )
2. EPC /MCCC POWER ( GREEN )
3. SS3GROUNT)( YELLOW )
4. MCCC GROUND ( BROWN )
5. SS1,SS2,SS3POWER ( RED )
6. SSl GROUND ( ORANGE )
7. TOT - (BLACK )
8. SS2GROUFTD( PINK )
BITCKOR(il,ty
CASE
Y|EW TASMT TEB BIAG, ON.CNAY
CASE SNNECION.ON TIIE TOP
1. EPCPOWER( WHITE ) OrIEBITAI|EAXLE
2. T(}T ( YELLOW )
3. TOT ( BLL,E)
4. rus- MLUS POWER( RED )
s. LUS- MLUS GROUND( BLACK )
6. EPCcROt ND ( OREEN)
YlHrsG T e c hn i c a l S e r v i c eI n fo r m a t i o n

AXOD-E
VAL\M BODY IDENTIFICAYION

Onthispagethevalvebodyborcshavebeenassigned Thevalvesandspringshavebeendrawnto
numbers.
slrowthe valvesand springsin their propcr locations.Eachvalve is alsoshownproperlyorientedand
properlyidentified,asshownonthefollowingpages.

AUTOMATIC ISS
TRANSM GROUP
IONSERVICE
It4
glnrsE T e c h ni c a l S e r v i c eI n f o r ma t i o n

AXOD -E
VALVE BODY BORE I\ruMBERS AND
VALYE IDENTIF'ICATION

BORE VALVE DESCRIPTION

NUMBER I{I]MBER
32 I PRESSURBFAILSAFEVALVE
33 2 BACKOTTTVALVE(FOT,JNDINEARLY l99l ONLY)
33 3 BACKOTnVALVE(LATE l99l TOPRESENT)
34 4 ACCUMUI,ATORREGI]LATORVALVEPLIJNGER
34 5 ACCTJMT'LATORREGI'LATORVALVE
35 6 I-2CAPACITYMODI,JI-A|TORVAL\IE
36 7 CONVERTERCLUTCHCONTROLVALVEPLI]NGER
16 8 CONVERTERCLUTCHCONTROLVALVB
37 9 MAIN REGT]LATORBOOSTVALVE SLEEVE
37 IO MAINREGULAX'ORBOOSTVALVE
37 1l I{AIN REGL]LAtrORVALVE ( NOTE DIRECTION OF SPRING SEAT)
38 L2 CONVERIBRCLIJTCHREGI,JLATORVALVE
38 13 SHIFTSOLEMODREGULATORVALVE
39 14 MANUALVALVE
40 15 2-3SHrTVerve
4I 16 I-2SHIFTVALVE
42 17 INTERMEDIAIBCLUTCHSHUTTLEVALVE
43 18 3-4SHIFTVALVE
44 19 FORWARDCLUTCHCONTROLVALVE
45 20 PTJLL-INCONTROLVALVE
4s 2t 3-2CONTROLVALVE
46 22 NEUTRAL/DRWEENGAGEMENTCONIROLVAIVE
47 23 2-3 SERVOREGIJLATORVALVE

AUTOMATIC
TRANSMISSION
SERVICE
GROUP
lI5
UZ,FrsE T e c h ni c a l S e r v i c eI n f o r ma t i o n

a
\w 6
w
,2L-
ftnb-
wh \-<EARLy
"t
.g- : t99l ONLY
\- tr- |
"a..--

l-.F.t \

1. PRESSUREFAILSAFEVAL\IE
2. BACKOUT VALVE ( EARLY 1991)
3. BACKOUT VALVE ( CURRENT)
4. ACCUMULATORREGULATOR VALVE PLIJNGER
5. ACCUMULATORREGULATORVALVE
6. 1 .2 CAPACITYMODULATORVALVE

TRANSMISSION
AUTOMATIC GROUP
SERVICE
r16
VlRrsE T e c hn i c a lS e r v i c eI n f o r ma t i o n

7.CON\MRMR CLUTCH CONTROLVALVE PLUNGER

8. CO}.I\/ERTERCLUTCH CONTROL VALVE
9. IVIAINREGULATORBOOSTVALVE SLEEVE
IO.MAIN REGULATORBOOSTVAL\|E
I 1. I\{AIN REGULATORVALVE
I 2. CO}IVERTERCLUTCH REGIJLATORVALVE
13.SHIFT SOLENIODREGTJLATOR VALVE

ISS
TRANSM
AUTOMATIC GROUP
IONSERVICE
t17
 7AT5G T e c hn i c a l S e r v i c eI n f o r ma t i o n

14.I.{ANUAL VAL\IE
15.2-3 SHIFTVALVE

AUTOMATIC
TRANSM
ISSION
SERVICE
GROUP
It8
 glsrsE T e c hn i c a lS e r v i c eI n f o r m a t i o n

%K
w
6

1 6 .I - 2 S H I F T V A L \ M ,
17.INTERMEDIAIE CLUTCH SHUTTLEVALVE
18.3 .4 SHIFTVAL\TE
19.FORVITARD CLIJTCH CONTROLVAL\TE

AUTOMATIC
TRANSMI$SION
SERVICE
GROUP
lt9
 HTSE T e c hn i c a lS e r v i c eIn f o r ma t i o n

20. PULL - IN CONTROL VAL\IE

21..3.2 CONTROLVALVE
22. NEUTRAL / DRIVE ENGAGEMENT CONTROLVALVE
23. 2 - 3 SERVOREGI'LATOR VALVE

AUTOMATIC IONSERVICE
ISS
TRANSM GROUP
120