(SAaTsG) wanzia : TECHTRAN™ MANUAL - AUTOMATIC’ TRANSMISSION:SERVICE GRO[kJ ATSG & 4 & °eapic TRANSMISSION SERVICE o INTRODUCTION NISSAN - L4N71B ka —_— The L4N71B transmission is a 4 speed reardrive automatic transmission. Some of these units have a computer comers converter clutch. The removat-installation, teardown-assembly, sm trouble shooting of this unit is covered in detail. We thank the Nissan Corporation for the illustrations and information that made this booklet possible The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL CONSULTANT ED KRUSE LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161 4GENERAL SERVICE ON-VEHICLE seni, ee REMOVAL-INSTALLATION . DISASSEMBLY ..... REPAIR COMPONENTS .. ASSEMBLY ........ TROUBLE SHOOTING ...... SERVICE DATA SPECIFICATIONS .. AUTOMATIC TRANSMISSION SERVICE GROUP LER EER@Ww | ATSG DESCRIPTION OF E4N71B AUTOMATIC TRANSMISSION SERVICE GROUP 5TSG Technical Service Information GENERAL SERVICE NOTICE Repair Notes. ‘® Before proceeding with disassembly, thorough- ly clean the outside of the transmission. It is important to prevent the internal parts of the transmission from becoming contaminated by dirt or other foreign matter. '* Disassembly should be done in a clean work area, Use a nylon cloth or paper towel for wiping parts clean. Common shop rags can leave lint ‘that might interfere with the transmission’s operation. ‘© When disassembling parts, be sure to place them in order in parts rack so they can be put back in the unit in their proper positions..-—\ © All parts should be carefully cleaned with.a general purpose, non-flammable solvent before inspection or reassembly. © Gaskets, seals, and O-rings should be replaced. It is also very important to perform functional ‘tests whenever it is designated. © The valve body contains many precision parts CONTROL VALVE UPPER BODY Control Valve. Manus aie ‘and requires extreme care when parts are removed and serviced, Place removed parts on parts rack so they can be put back in the valve body in the same positions and se- ‘quences, Care will also prevent springs and small parts from becoming scattered or lost. ‘© Before assembly, apply a coat of recommended A.T.F. to all parts. Vaseline may be applied to O-rings and seals. Do not use any grease. * Care should be taken to avoid damaging O-rings, seals and gaskets when assembling. Abbreviations used throughout this section stand for the following: .. Automatic transmission fluid cnennes Drive range 1st gear Dg smn Drive range 2nd gear sme Drive range 3rd gear Drive range 4th gear Overdrive 1 range 2nd gear 1 range 1st gear a [rn Pressure mocifar vale |] wean nt ane Banat shite valvePAATSG Technical Service Information GENERAL SERVICE NOTICE Control Valve (Cont'd). CONTROL VALVE LOWER BODY Lock-up Control Valve and O.D. Cancel Valve. peed =" sin Locks control waive SEY 2) Retaining pin ©.D. cancel valveTechnical Service Information GENERAL SERVICE NOTICE Oil Channel. Oil channels which connect components are located in the areas shown below. OIL CHANNELS IN OIL PUMP i pump cover side (or tockup contrat) OIL CHANNELS IN TRANSMISSION CASE Front face side (To contol vave) Governor feed (rom contol valve) OIL CHANNELS IN 0.D. CASE In regards to one-way Bug, refer 0 page AT-31Technical Service Information GENERAL SERVICE NOTICE OIL CHANNELS IN DRUM SUPPORT High ever utah Forward clutch Direc (eer pressure ten pressure From 34 site wned — Coit pum dicharge hole Oil Channel (Cont'd). rent) Lo 4 0.0, lubrication OIL CHANNELS IN CONVERTER HOUSING (For lockup contro!) To lock-up control valve Mechanical Operation In the E4N71B automatic transmission, each part operates as shown in the following table at each gear select postion. 0.0. band servo | Hi8h leonard | Low & | 2nd band servo ange Direct revere [Forward | Low & Jone way | Parking " ou ciuten’ | pow cures T asoiy Yaease | | tren | brane [appy [Renae | Sue | 20H Pak on | (on) | on oN on Revere on | om | on | on oN on Neural on | on | on oo | ow | om | on on on o ON (ON) ON ‘ON ON (Second) . Dy a ay on | om | on | com | on ton | oF ee oN, ‘ON ON (ON) ON (001 2 | second | on | om | on oN oN 7 tana) | ON | om | on on on 1 t a on | om | ow on | on on ‘The low & reverse brake is applied in “"1~ range to prevent frge wheeling when cossting and sllows engine brakingATSG Technical Service Information GENERAL SERVICE NOTICE Hydraulic Control Circuits si oo. tee Fore Lowa ferque converter it feancel | pivect 0.0. band luteh clutch yg reverse tor on iret Ouest SO ont thee) oe rae OC On O 1 Ont check valve Dowsite rolnoia lpackuo halve Tstand shite ave Theale ele vive Primary Note: Macked X are dain 10Technical Service Information ON-VEHICLE SERVICE Control Valve. 1. Drain fluid by removing oil pan. 2. Remove kickdown solenoid and vacuum dia- phragm & rod. Be careful not to lose vacuum rod. Comes eal ~ 1 ane (357 235mm (1.38inl 325mm (0.98 nl 3, Remove control valve assembly. © After installing control valve to transmission case, make sure that control lever “can be moved to all positions. 6. Install kickdown solenoid and vacuum dia- phragm & rod. Make sure that vacuum diaphragm rod does not interfere with side plate of control valve. Be careful not to drop manual valve out of valve body. 4, Disassemble, inspect and assemble control valve assembly. Refer to Control Valve Body. 5. Install control valve assembly. ‘© Set manual shaft at Neutral, then align manual plate with groove in manual valve of control valve assembly. ‘© Securing bolts come in 3 different lengths. ulTechnical Service Information ON-VEHICLE SERVICE — Extension Oil Seal Replacement 1. Remove oil seal. 2. Apply coat of A.T.F. to oil seal surface, then drive new oil seal into place. 3 Coat sealing lips with vaseline, then install propeller shaft Parking Component 1. Remove oil pan. 2. Remove propeller shaft. 3. "Remove speedometer pinion. 4. Support transmission with a jack, then remove rear mounting bolts. 12TSG Technical Service Information ON-VEHICLE SERVICE —Parking Component (Cont'd). 5. Remove rear extension bolts, then draw out rear extension with rear mounting. 6 Remove contro: vaive assembly. 7. Inspect and repair parking components. Check ‘component parts for wear or damage. Governor Valve Assembly —___ 1. Drain oil by removing oil pan, 2. Remove rear extension with rear mounting, 3. Remove governor valve assembly. 4. Inspect and repair governor valve assembly. Refer to Governor for inspection, Inhibitor Switch Adjustment —_ Disconnect harness at connector, then remove in- hibitor switch. © Check continuity at “N”, and “R” ranges. © With control lever held in “Neutral”, turn manual lever an equal amount in both direc- tions to see if current flow ranges are nearly the same. (Current normally begins to flow before manual lever reaches a angle of 1.5° in either direction.) If current flows outside normal range, or if normal flow range is oyt of specifications, properly adjust inhibitor switch. Adjust inhibitor switch as follows: 1, Place the manual vaive in Neutral (vertical position) 2. Remove the screw. 13Technical Service Information ON-VEHICLE SERVICE ——Inhibitor Switch Adjustment (Cont'd) 3. Loosen the attaching bolts. 4, Using an aligning pin, [2.0 mm (0.079 in) dia.] move the switch until the pin falls into the hole in the rotor. 5. Tighten the attaching bolts equally. 6. Recheck for continuity. If faulty, replace the switch, Manual Linkage Adjustment Move the shift lever from the “P”’ range to "1" range. You should be able to feel the detents in each range, If the detents cannot be felt or the pointer indicat- ing the range is improperly aligned, the linkage needs adjustment. 1, Place shift lever in “N" range. 2. Loosen locknuts. 3. Move range selector lever to the “N' range. i 4, Tighten lock nuts when floor contro! lever is in “N"' range and pushed against the “P”” range side, 5. Move control lever from “P" range to “1” range. Make sure that control lever can move smoothly and without any sliding noise. ge selector ever 14Technical Se rvice Information ON-VEHICLE SERVICE Vacuum Diaphragm Rod. Adjustment Remove diaphragm from transmission case. Using @ depth gauge, measure depth “L”. Be sure vacuum throttle valve is pushed into valve body as far as possible, Check “L"” depth with chart below and select, proper length rod. Vacuum diaphragm “Teanaminion ca wal =a / “U" Depth Ete / \ Vcnen meteaie vay apse DMPO 8 Voeuum diaphragm rod selection Measured depth "L"] Rod length ‘mm (in) sna” | Part number Under 25.55 23.0 (1.0089) (az) | 31982-xo108 2565-2605 295 (0098 1.0256) | (x.161) | 31992-Xor08 26.18 - 26.55 200 (1.0205 -1.0883) | (.181) | 31892" x0100 26.65 27.05 305 (1.0492. 1.0650) | (1.201) 31032- xo102 over 27.15 310 (1.0689) (1.220) 31932-0101 Downshift Solenoid 1. Remove downshift solenoid and O-ring. Catch oil dropping out of the hole. 2. Check to verify that downshift solenoid is operating properly. If faulty, replace it with a new one. 15Technical Service Information ON-VEHICLE SERVICE When the pedal is fully depressed, a click can be hheard just before the pedal bottoms out, If the click is not heard, loosen the locknut and extend the switch until the pedal lever makes contact with the switch and the switch clicks. Kickdown Switch Adjustment. Do not allow the switch to make contact too soon, This would cause the transmission to downshift on part throttle, DIAGNOSIS: ‘Switch can be heard clicking, and the transmission still does not kickdown: Check the continuity of the switch. Also check for available current. The vehicle upshifts at approximately 55 (1st to 2nd) and 90 km/h (2nd to 3rd) (34 and 56 MPH) only: The kickdown switch may be internally | “shorted. (When the switch is shorted, there is con- tinuity through the switch in any position). © eoov crouno IGNITION SWITCH ‘8 - ee sna] om eset ‘Refer co iat ener — on i @ F8 ep | oa —— 24Technical Service Information DISASSEMBLY 18. Remove control valve body. ‘To prevent brake linings from cracking or peeling, do not stretch the flexible hand unnecessarily. Before removing the brake band, always secure it Remove manual valve from valve body 2s 2 | witha clip as shown in the figure below. precaution, to prevent valve from dropping out Leave the clip in position after r2moving the brake accidentally. rare Fenble toe Sendak ‘Pom (0.08 na. wire 20, Remove 2nd band servo retaining bolts. Apply 19, Remove 2nd brake band strut. Brake band and presure to remove 2nd band serve. clutch & planetary gear pack [including high- reverse clutch (Front), forward clutch (Rear) and front planetary gear] may be removed together. 25Technical Service Information DISASSEMBLY 21. Check oneway clutch to see if it operates property. 22. Remove rear planetary carrier snap ring and rear planetary cartier. 26 24. Remove connecting drum with internal gear. 25. Pry off one end of snap ring with a screwdriver. Remove snap ring from low and reverse brake assembly while applying plier force in direction of arrow.Technical Service Information DISASSEMBLY 27. Remove rear extension. Be careful not to lose retainer washer. 29. Remove governor thrust washer and needle bearing, Remove one-way clutch inner race attaching hex-head slotted bolts using Tool. 128670001 (23689011 27 30. Remove one-way clutch inner race, return ‘thrust washer, low and reverse return spring, and spring thrust ring. 31. Apply air pressure to remove low and reverse brake piston. 32, Remove snap ring, then remove lock ut, ‘manual plate and parking rod. 33. Remove inhibitor switch and manual shaft. 34, Remove O.D. indicator switch and O-ring.Technical Service Information REPAIR FOR COMPONENT PARTS Oil Pump. 1 pum housing Lathe cut eal ring “) ae, Pr . Lock control vale DISASSEMBLY Pais iy 1. Remove pump cover from pump housing. " Lockaup Sine INSPECTION 1. Inspect pump body, bushing and pump shaft, for wear. Inspect gears, lock-up control valve, spring and 2. Stake off retaining pin with a punch [outer dia. } 2, 1.5 to 1.8 mm (0.059 to 0.071 in)], then re- all internal surfaces for damage and visible move lock-up control valve and spring. wore, 28Technical Service Information REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd). Measure clearance between outer gear and | 5, Measure clearance between gears and pump crescent, cover with a feeler gauge and straight edge. Standard clearance: Standard clearance: 0.14 - 0.21 mm (0.0055 - 0.0083 in) 0.02 - 0.04 mm (0.0008 - 0.0016 iri) Wear limit: Wear limit: 0.25 mm (0.0088 in) (0.08 mm (0.0031 in) |. Measure clearance between outer gear and pump housing. Standard clearance: 0.05 - 0.20 mm (0.0020 - 0.0079 in) Wear limit: (0.26 mm (0.0098 in) 29Technical Service Information REPAIR FOR COMPONENT PARTS Oil Pump (Cont‘d). ASSEMBLY 1. Install lock-up control vaive and spring into oil pump cover, then tap new retaining pin. 2. Mount pump housing in Tool and suitable spacer. Set up pump housing with inner and outer pump gears on it and install pump cover to pump housing, Temporarily assemble oil pump. sr2sse0001 (= 1 soacer [Thicke 20m (0.78 3. Set the cover to within the run-out of the specified total indicator reading. Total indicator reading: Less than 0.07 mm (0.0028 in) 4. Tighten pump securing bolts to the specified torque. Recheck run-out. 30 Drum Support DISASSEMBLY 1, Remove drum support and gasket from 0.0. case. 2. Stake off retaining pin with a punch [outer dia, 1.5 to 1.8 mm (0.059 to 0.071 in)], then remove O.D. cancel valve and spring. Don't stake it off from contacting face side. Retaining pin Serine oo. cancel viveATSG Technical Service Information REPAIR FOR COMPONENT PARTS. Drum Support (Cont'd) INSPECTION ‘* Inspect drum support bushing and ring groove areas for wear. ‘Measure clearance between seal ring and ring groove. ‘Standard clearance: 0.05 - 0.20 mm (0.0020 - 0,0079 in) Wear limit: (0.29 mm (0.0079 in) pe cierance Seal ng © Inspect ©.D. cancel valve & spring and all internal surfaces for damage visible wear.Technical Service Information REPAIR FOR COMPONENT PARTS Drum Support (Cont'd) ASSEMBLY 3. Install one-way orifice in 0.0. case. 1. Install 0.0. cancel vaive and spring into drum support, then tap new retaining pins. 2. Install lubrication plug in drum support. 7 One-way orifice ‘Steel ball AN with 0D Sprag 4, Mount oil pump assembly in Tool and suitable > spacer We) | ‘Without 0D Sprag 32Technical Service Information REPAIR FOR COMPONENT PARTS Drum Support 5. Mount 0.D. case, drum support and gasket in oil pump assembly. Ensure O.D. case is inserted properly into oil pump assembly. rum supper. | 011 pume centring to! §12558000" { ‘Spacer 6. Loosen drum support bolts before inserting Tool (J33909). 7. Insert the tapered edge of Too! and install Tool until it completely passes through 0.D. case. (Cont'd). “B Rotate Too! to ensure proper alignment. 9. Tighten drum support bolts while Too! is inside 0.0. case. 10. Remove Too! (33909) 11. Check thedrum support is within the run-out of the specified total indicator reading. Total indicator reading: Less than 0.05 mm (0.0020 in) 334aTsc Technical Service Information REPAIR FOR COMPONENT PARTS Control Valve Body Upper body side QR Site sare tren it ve SFO ” wT ae ee COA) serene ae Eawostetmcap vv FM see oe “a" ge a 34Technical Service Information REPAIR FOR COMPONENT PARTS DISASSEMBLY 1. Remove oil strainer. 2. Separate lower body, separator plate and upper body. Be careful not to scatter or lose orifice check valve, servo orifice check valve, or throttle relief check valve (ball) and related springs, Control Valve Body (Cont'd) and valve bodies. Always use crocus cloth, which is a very fine type of cutting material. Never use emery cloth, as it is too coarse and can scratch the valves or valve bores. Scratches can lead to future deposits of varnish or foreign matter. During cleaning, do not remove the sharp edges of the valve. When edges are rounded or scratched, entry is provided for dirt or foreign matter to work into the sides of the valves and hinder valve move: ment. ‘The valves may be cleaned using alcohol or lacquer thinner. The valve bodies can be dip cleaned with 2 good carburetor cleaner or lacquer thinner. Do not leave valve bodies submerged in carburetor cleafier longer than five minutes. Rinse parts thoroughly and dry. Lubricate all parts in clean A..F. before reassem- bly. 1. Check valves for signs of burning, Replace if beyond clean-up. 2. Check oil strainer Replace if necessary. for general condition. INSPECTION ‘A newly manufactured valve body represents precision manufactured valves assembled with close tolerances into precision bores of the valve body. If inspection reveals excessive clearances, 0.03 mm (0.0012 in} or more, between the valves and the valve body bores, replace the entire valve body rather than attempt rework. If one or more valves are sticking from varnish deposits or burns resulting from deteriorated oil or overheating, you may be able to clean the valves 3. Check separator plate for scratches or damage. Replace if necessary. Scratches or score marks can cause oil to by-pass correct oil passages and result in system malfunction. 35Technical Service Information REPAIR FOR COMPONENT PARTS Control Valve Body (Cont'd). Numbers stamped on valve springs listed in table below are the same as those in the figure on page AT-32. Valve spring ne @ Premweree [VRE 43.0 (1.693) gulator valve | yG30e wuroo | 38.9 (1.531) @® Pressure modifier valve 185 (0.728) au —_(voe Bo10200) 4. Check oil passages in upper and lower valve shift valve |v@30e turbo | 28.3 (1.114) ocean te peta Pace seretcnen cu y @ 2nd - 3rd shite valve 41.0 1.614) damage that would impair valve movement. Check threaded holes and related bolts and @ Throttle back- Mose 31.8 (1.252) screws for stripped threads; replace as needed. vpvalve — [vaa0e wwro | 36.0(1.417) 5. Check valve springs for damage. Measure fr length of valve springs. If the free length is | © Solenoiddownshiftvalve | 22.0 (0.866) _ ut of specification, replace it. @ Second lock valve 335 (1319) Throttle reer [VG3OE 26.8 1.055) check valve [yGa0E turbo | 24.9 10.980) Orifice check valve 155 (0.610) @ 3rd ath shift valve 30.3 (1.193) Sedna ([VS0E 22.2 (0.878) ® simi timing valve |vG30E turbo | 20.7 (0.815) 36Technical Service Information REPAIR FOR COMPONENT PARTS ASSEMBLY 1. Install orifice check valves, valve springs, throt- tle relief valve spring and steel ball in valve body. orien enc abe rawa ens (cS tat ony site cack save nore renee Upper valve body Orifice eneck valve —@) (front eluteh opted Control Valve Body (Cont'd). 2. Assemble separator plate and upper valve body ‘on lower valve body, then tighten bolts. Reamer bolt When installing these bolts, first be sure to install the two reamer bolts to their original positions. 3. Install oil strainer. Orifice check valve Unit_mm (int Orifice check valve | Diameter “A” | Identification znd |_VG30E | 1.510.059) Gray seo | vege release | turoo 1.4 (0.055) Gray 2nd» 3d shite . (VER0E tudo ony) _| (008°) Black Frontlutch applies | 2.2 0.087) Black | 37Technical Service Information REPAIR FOR COMPONENT PARTS Oil Distributor. INSPECTION ‘© Inspect contacting surface of oil distributor and ring groove areas for wear. © Measure clearance between seal ring and ring groove. Standard clearance: 0.04 - 0.16 mm (0.0016 - 0.0063 in) Wear limit: 0.16 mm (0.0063 in) Seal ing 38TSG Technical Service Information REPAIR FOR COMPONENT PARTS Direct Clutch Lathe cut sain 09 Return spring Driven plate (ste! plate) rive pate (trieion pate)Technical Service Information REPAIR FOR COMPONENT PARTS, Direct Clutch (Cont'd) DISASSEMBLY ‘© Compress clutch springs and remove snap ring from spring retainer with Tool. © For easy removal of piston from drum, mount clutch on drum support. Use an air gun with a tapered rubber up to carefully apply air pres: sure to loosen piston from drum, INSPECTION AND ASSEMBLY 1. Check clutch drive plate facing for wear or damage. Standard thickness: 1.50 - 1.65 mm (0.0591 - 0.0650 in) Wear limit: “1.4 mm (0.055 in) 2. Check for wear on snap ring, weak or broken coil springs, and warped spring retainer. 3. Check the operation of check ball in piston using compressed air. 40 4. Lubricate clutch drum hub and seals, and in- stall inner seal and piston seal as illustrated. Be careful not to stretch seals during install tion. 5. Assemble piston, being careful not to allow seal to kink or become damaged during in- stallation. After installing, turn piston by hand to ensure that there is no binding.Technical Service Information REPAIR FOR COMPONENT PARTS and retainer. Reinstall snap ring. Be sure snap ring is properly seated. 7. Install driven plates, drive plates, and secure ith snap ring. 8. Install retainer plate, O.D. one-way clutch as- sembly, race side, and secure with snap ring. 9. Measure clearance between race side and snap ring. Specified clearance: 00.2 mm (0 - 0.008 in) If necessary, try other race side having dif ferent thicknesses until correct clearance is obtained. Direct Clutch (Cont'd) Thickness rm (in) Part number 0.4 (0.016) 31606-8501 0.6 (0.024) 31608-x8502 0.8 (0.031) 31608-8500 1.0 (0.039) 31606-8503 1.2 (0.047) 31606-x8504 10. Testing direct clutch. jth direct clutch assembled on drum sup- port, direct a jet of air into hole in clutch drum for definite clutch operation. a4 aTSG Technical Service Information REPAIR FOR COMPONENT PARTS. Front Clutch. ining plate ve30e VG30E turboTechnical Service Information REPAIR FOR COMPONENT PARTS DISASSEMBLY © Compress clutch springs and remove snap ring from spring retainer with Tool. 5725420001 1426063-4) © For easy removal of piston from drum, mount clutch on drum support. Use an air gun with a tapered rubber up to carefully apply air pres- sure to loosen piston from drum. INSPECTION AND ASSEMBLY 1. Check clutch drive plate facing for wear or damage. ‘Standard thickné 1.50 - 1.65 mm (0.0591 - 0.0650 in) Wear limit: 1.4 mm (0,055 in) 2. Check for wear on snapring, weak or broken coil springs, and warped spring retainer. 3. Check the operation of check ball in piston using compressed air. Front Clutch (Cont'd) 43 4. Lubricate clutch drum hub and seals, and install inner seal and piston seal as illustrated. Be careful not to stretch seals during instal lation, 5. Assemble piston, being careful not to allow seal to kink or become damaged during installation. After installing, turn piston by hand to ensure that there is no bindingTechnical Service Information REPAIR FOR COMPONENT PARTS 6. Reassemble spring and retainer. Reinstall snap ring. Be sure snap ring is properly seated. 7 8. Install driven plates, drive plates, and secure with snap ring, 9. Measure clearance between retainer plate and snap ring. ‘Specified clearance: 1.6 - 1.8 mm (0.0€3 - 0.071 in) If necessary, try other retaining plates having different thicknesses until correct clearance is obtained. 44 Front Clutch (Cont'd) ‘Available retaining plate Thickness mm (in) Part number 5.0 (0.197) 31867-2900) 5.2 (0.205) 31867-2901 5.4 (0.213) 31967-x2902 5.6 (0.220) 31567-2903, 5.8 (0.228) 31867-X2904 6.0 (0.236) 31867-2905, 6.2 (0.244) 31567-2906 10. Testing front clutch (High-reverse) With front clutch (High-reverse) assembled on drum support, direct a jet of air into hole in clutch drum for definite clutch operation,TSG Technical Service Information REPAIR FOR COMPONENT PARTS Rear Clutch (Forward). {regard to the numberof clutch shests (drive plate and driven plata, refer 125.08. sey wn ) Tee ov ee f athe cu al rng ear eluten drum Service procedures for rear clutch (Forward) are | Testrear clutch essentially the same as those for front clutch (High- reverse), with the following exception: Specified clearance between retainer plate land snap ring: 0.8 - 1.0 mm (0.031 - 0.039 in) 45Technical Service Information REPAIR FOR COMPONENT PARTS Low & Reverse Brake. {In rogrd 0 the numba of clutch sheets (Grive plate and wen patl, ater SDS, Lathe cu set ring ‘Always repice when iassembed, INSPECTION * Examine for damaged drive plate facing and worn snap ring. © Check drive plate facing for wear; if necessary, replace. Drive plate thickness: ‘Standard 1.90 - 2.05 mm (0.0748 - 0,0807 in) Allowable limit 1.8 mm (0.071 in) 46Technical Service Information REPAIR FOR COMPONENT PARTS Brake Band and Band Servo. Brake bends Lathe ct rig a rt \ reg ‘Always ceplace when dastembled Servo retainer A Band servo piston stem INSPECTION © Inspect band friction material for wear. If cracked, chipped or burnt spots are apparent, replace the band. © Check band servo components for wear and scoring. 7TSG Technical Service Information REPAIR FOR COMPONENT PARTS —______ Governor oT TT eric Sorina /~ Pesumalstor 0.0. cae © by Accumtaor iug-/ 0 } vive Soap ring Selig * Remove snap ring, then apply pressure to remove accumulator plug, piston and spring. INSPECTION '* Check governor valves and valve body for indi- cation of burning or scratches, © Check valve springs for damage. Measure free length of valve springs. Free rath Valve soring a es vaso 105 (0418) @amer \VG30E turbo 21.8 (0.858) ‘Secondary NGRE 19.8 (0.780) © Check accumulator components for wear and governor VG30E turbo 19.8 (0.780) ‘scoring. If any abnormalities are found, replace governor body, valves and springs as an assembly. 48Technical Servicé Information REPAIR FOR COMPONENT PARTS Planetary Carrier. INSPECTION '* Check clearance between pinion washer and planetary carrier with a feeler. ‘Standard clearance: 0.20 - 0.70 mm (0.0079 - 0.0276 in) Wear limit: 0,80 mm (0.0315 in) © Check planetary gear sets and bearings for damaged or worn gears. Connecting Drum Assembly. — If one-way clutch is out of order as determined during disassembly, repai 1 2s follows: Remove each snap ring, then draw out one-way clutch inner & outer race. Oneway cletch Connecting drum 2. Inspect one-way sprag and contacting surface for wear or burns. Replace parts as necessary. 3. Assemble those parts. 49Technical Service Information REPAIR FOR COMPONENT PARTS O.D. One-Way Clutch If one-way clutch is out of order as determined | 4. After assembly, check O.D. one-way clutch during disassembly, repair it as follows: 10 see if it operates properly. 1. Remove each snap ring, then draw out 0.0, one-way clutch, 2. Inspect one-way sprag and contacting surface for wear or burns. Replace parts as necessary \- pace site 0.0 clutch 3. Assemble those parts, Pay attention to direction of 0.0. one-way clutch. Rear sideTSG Technical Service Information ASSEMBLY When installing/assembling needle bearing, bearing race, snap ring and thrust washer, use the following illus: tration as a guide to installation procedures and locations. ©. , S o =. © 00 /00 HO % ¢ @ 514ATSG Technical Service Information ASSEMBLY 1. Install parking rod, manual plate, manual plate | 4, Install hex-head slotted bolts. lock nut, parking brake lever and snap rings. 2. Lubricate and install low and reverse piston into the case. ‘3. Install thrust ring, piston return spring, thrust washer and one-way clutch inner race. 52 Check that return spring is centered on race before tightening. 5. Install steel dished plate first, then steel and friction plates, and, finally, retaining plate and snap-ring.Technical Service Information ASSEMBLY 6 After low and reverse brake has been complete- ly assembled, measure clearance between snap ring and retainer plate, If measurement exceeds specifications adjust by replacing retainer plate with one of a different thickness. Low and reverse brake clearance: 0.80 - 1.05 mm (0.0315 - 0.0413 in) ing. Available retainer plates ‘Thickness mm (in) | _ Part number 9.8 (0.386) | 31687-x2900 10.0 (0.304) | 31667-x2901 102 (0.402) | 31667-xz902 YG90E turbo | 40.4 (0.409) 106 (0.417) 108 (0425) _| _31667-%2008 9, Install output shaft and governor distributor 11.8 (0.465) | 31667-xo300 into case. 120(0472) | 31667-xo301 122 (0.490) | 31667-xo302 ae 124 (0.498) | 31667-xo303 126 (0.496) | 31667-x0304 12.8(0.508) | 31667-x0305 7. Check low and reverse brake operation with compressed air. 53TSG Technical Service Information ASSEMBLY 10. Install connecting drum with sprag by rotating | 13. Install snap-ring on shaft. drum clockwise. 11. Check one-way clutch to see if it operates | 14. Secure thrust bearing and thrust washer with properly. vaseline and install rear planetary carrier. pe 15, Install rear planetary carrier snap ring. If you have insufficient space to install snap ring into drum groove, pull connecting deym forward as far as possible, 54Technical Service Information ASSEMBLY 16. Adjust end play as follows: im j it Cute pack 2) Assemble front internal gear, front planetary Front nd ley ame carrier and connecting shell. Secure thrust @ : Tota ene pay bearings with vaseline, Front end play 1) Assemble front clutch (High-reverse) and rear clutch (Forward) drum assemblies together and lay them flat on bench. Be sure rear hub thrust bearing is properly seated. Measure from face of clutch drum to top of thrust bearing race (dimension A). Depth goune 3) Install assembly into transmission case. Check that parts are properly seated before proceed- Higheovere cuter ing with measurements. (rent) drum Forward clutch (Rea drum 55Technical Service Information ASSEMBLY 4) Using a dial gauge or caliper with a seven inch base, measure from rear hub thrust bearing race to case (dimension B). Lo Hignewvere clutch (Front drum / Forward clutch (eae drum 5) Measure from top of drum support shaft (front clutch and rear clutch side) to installed gasket (dimension C). 56 6) Install thrust washer. Measure from top of drum support shaft (front clutch and rear clutch side) to thrust washer (dimension D). “Theat washer (Fen) Front end play = (B — A — 0.1 mm (0.004 in) -(¢-D) Specified front end play: 5 - 0.8 mm (0.020 - 0.031 in) Front end play can be adjusted with front clutch (High-reverse) thrust washers. Available highv-reverse clutch (Front) thrust washer Thickness mm (in) rt number 1.3 (0.051) 31828-0107 1.5 (0.059) 3128x0105, 1.7 (0.067) 31528-x0106 19 (0.075) 31528-x0100 21 (0.083) 31628-x0101 23 (0.091) 31528-x0102 25 (0.098) 31528-x0103, 27 (0.106) 31528-x0104Technical Service Information ASSEMBLY — Total end play {691060000 Total end play = (8 — 0.1 mm (0.004 in)] — c Specified total end play: 0.25 - 0.50 mm (0.0098 - 0.0197 in) Total end play can be adjusted with bearing race. ‘Available oil pump cover beating race ‘Thickness mm (in) Part number 1.2 (0.047) '31556:X0100 1.4 (0.085) 31856-0101 1.6 (0.063) 31886.x0102 1.8 (0.071) 31856-x0103, 20 (0.079) 31886-x0104 22 (0.087) 31856:X0105, aes rer 17. Install brake band, band strut, and band servo. Lubricate servo O-rings before installing. 18. Install and torque the retainer bolts, Loosen piston stem. 57 19. Finger tighten brake band servo piston stem enough to prevent brake band and strut from falling out. Do not adjust brake band at this time. 20. Apply vaseline to bearing race and thrust washer, then mount them on drum support. Stoning nceTechnical Service Information ASSEMBLY 21.Mount drum support gasket @ on drum support after coating with vaseline. Apply ATF. to O-ring of drum support. Align drum support with O.D. case to transmission case and install, dentitieation point of gasket ® Berwoen oi! pure sd 0.0. case (@) te wanamission cars) | 22. Apply A.T.F. to O-ring of drum support, then 2 install drum support and 0.D. case. | Before installing drum support and O.D. case on ‘transmission case, ensure that they have been ‘centered properly. Refer to Component Parts for Drum Support. 23. Temporarily tighten 0.D. case with two con: verter housing securing bolts. Spacer {15mm (059 in) thick] (0.0. exe >| I Son 24. Insert intermediate shaft. Be careful of shaft direction. 58 VG30E mode! Turbo models Ginging » Sirtace Front Front 25. Adjust 0.D. end play. reanane Oil pump oN caster rT ef | L\ me) |F oft | 0.0m \7 rranniice Lae (inline a) \-brum support ©.D. pack end play 1) Assemble direct clutch assembly, 0.D. plane- tary gear set and connecting drum, and install them on 0.0. pack. 0.0. sun gearTechnical Service Information ASSEMBLY 2) Install oil pump bearing, gasket and 0.0. pack on oil pump, and measure dimensions F and H. 3) Attach thrust washer and needle bearing to drum support and O.D. case, and measure dimensions € and G. DT ] 7 — Sa 0.D. pack end play = [E— 0.1 mm (0.004 in)] " Specified 0.D. pack end play: 0.5 - 0.8 mm (0.020 - 0.031 in) 0.D. pack end play can be adjusted with 0.D. thrust washers (these parts are the same as the front clutch thrust washers). 59Technical Service Information ASSEMBLY ‘Available 0.D. thrust washer Thickness mm (in) Part number 13 (0.051) 31828-X8607 1.5 (0.059) 31528-8605 1.7 (0.087) 31528-8606 1.9 (0.075) 31828-8600 21 (0.083) 31528-x8601 23 (0.091) 31528-8602 25 (0.098) 31528-X8603, 2.7 (0.106) 31528.x8604 27. Lubricate 0.D. servo O-rings, then install O.D. band servo, brake band and band strut. .D. total end play 0.0. band servo .D. total end play = [G — 0.1 mm (0.004 in}] -(F-H) ‘Specified 0.D. total end play 0.25 - 0.50 mm (0,098 - 0.0197 in) .D. total end play can be adjusted with 0.D. bearing race. ‘Amalable 0.D. bearing races ‘Thickness mm Part number elias pire 28. Lubricate seal ring of drum support, then 1.4 (0.055) '31603-X8601 install O.D. bearing & race, O.D. thrust washer 1.6 (0.083) 31603-x8602 and 0.D. pack on drum support. Make sure 1.8 (0071) 31603-8603 that brake band strut is correctly installed. 20. (0.079) 31603-8604 22 (0.087) 31609-8605 Seal ring 26. Adjust 2nd brake band. Tighten piston stem to the specified value. Back off three full turns and secure with lock nut. 60Technical Service Information ASSEMBLY 29, Adjust 0.D. band. Tighten piston stem to the specified value. Back off two full tums and secure with lock nut. 30. Test 0.D. band servo operation with com- pressed air. 31. Install accumulator parts, then secure with snap ring. BY Soring /ecumator Accumulator plug @ ‘Sra tng 0.0. cave 32. Lubricate O-ring of oil pump, then install needle bearing & race and oil pump. Before installing oil pump housing and oil pump on ©.D. case, ensure that they have been ccintered properly. Refer to Pump in Repair for Component parts. 33, Remove the two bolts used to temporarily tighten 0.D. case. Apply sealant to seating surface of converter housing around the bolt holes. [: Ary setane 34, Install converter housing on 0.0. case and tighten to the specified torque. 36, Install input shaft. 36. Before installing valve body assembly perform 2 final operation check of all assembled com- Ponents, with compressed air. 61Technical Service Information ASSEMBLY Air check point Governor From vale! Low a brake 37. Check that parking pawl, pin, spring and washer are assembled correctly. 38. Install rear extension, 39, Install control valve assembly. Be sure manual valve is in alignment with selector pin, Tighten control valve body attaching bolts, ‘Securing bolt comes in three different lengths. 62 3 40mm (1.57 in) 2 35mm (1.28 in) 325mm (0.98 in) After installing control valve to transmission case, ‘make sure that control lever can be moved to all positions, 40. Before installing vacuum diaphragm valve, measure depth of hole in which it is inserted. This measurement determines correct rod length to ensure proper performance. a a \ bo Pe Vreven wore anaesTechnical Service Information ASSEMBLY eects 43, Install inhibitor switch. Check for proper accra ceeamn | aSaaE ‘operation in each range with a circuit tester. tmm tal | mt) | Pat umber Refer to On Vehicle Service Under 25,55 (1.0059) 2.011.142 | 31932-x0103 25.65 - 26.05 (1.0098 - 1.0256) | 795(1-161) | 31932-xo108 26,15 - 26.55 (10208. rege) | 20011.181) | 31932-x0100 26.65 -27.05 (rote2. rosso) | 90501200 | 31932-xo102 Over 27.15 ‘rosgey” | 340(1.220) | 31932-x0101 41, Install vacuum diaphragm. 44. Before installing oil pan, check parking pawl engagement. Make wiring connections to shift switches and low temperature sensor (E4N71B ‘automatic transmission models). Make sure that vacuum diaphragm rod does not interfere with side plate of control valve. 42. Install downshift solenoid, 0.0. cancel sole- noid, and lock-up solenoid. 45. Install oil pan with new gasket. 63ATSG Technical Service Information ASSEMBLY 46. Pour approx. 24iters (2-1/8 US at, 1-3/4 Imp at) of AT-F. into converter housing. 47. Install torque converter to converter housing. Be careful not to scratch front cover oil seal. 64Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES ——Preliminary Checks. (Prior to Road Testing) FLUID LEAKAGE To detect a fluid leak: 1) Raise vehicle. 2) Clean area suspected of leaking. 3) Start engine, apply foot brake, place control lever in drive, and wait a few minutes. 4) Stop engine. 5) Check for fresh leakage. FLUID CONDITION Examine the A.T.F. and note its color, texture, and odor. 1) Dark of Black Fluid: With a burned odor — Worn friction material, 2) Milky Pink Fluid: Water Contamination — Road water entering through filler tube or breather. 3) Varnished Fluid, light to dark brown and tacky: Oxidation = Over or Underfilling. — Overheating. Road Testing. © Before starting road tests, install vacuum gauge, '* Perform road tests, using “Symptom” chart, as, follows: RANGE 1. Place the control lever in ““P*" range and start the engine. Stop the engine and repeat the procedure in all other ranges and neutral. 2. Stop vehicle on a slight upgrade and place con- trol lever in “"P"* range. Release parking brake to make sure vehicle remains locked, " RANGE 1. Manually shift the contro! lever from “P’" to “R", and note shift quality. 2. Drive the vehicle in reverse long enough to detect slippage or other abnormalities. 'N" RANGE 1, Manually shift the control lever from "to “N" and note quality. 2. Release parking brake with control lever in “IN range. Lightly depress accelerator pedal to make sure vehicle does not move. (When Vehicle is new or soon after clutches have been replaced, vehicle may move slightly. This is not a problem.) “D" RANGE 1. Manually shift the gear selector from “N” to “'D" range, and note shift quality. 5Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Using the shift schedule as a reference, drive vehicle in “D" range. Record, on symptom chart, respective vehicle speeds at which up- shifting and downshifting occur. Check that there is not a considerable jolt when shifting gears. Also determine the timing at which shocks are encountered during shifting and which clutches are engaged. rive in tere trate conditions Check to determine if shifting speed changes when accelerator pedal is depressed slowly and when it is depressed quickly. Check to determine if shifting to overdrive gear cannot be made while 0.. control switch is "CANCEL". Road Testing (Cont'd). 66 5. When vehicle is being driven in the 65 to 85 km/h (40 to 53 MPH) range in “Ds range at half to light throttle position, fully depress ac-- celerator pedal to make sure it downshifts from 3rd to 2nd gear. 6. When vehicle is being driven in the 25 to 35 km/h (16 to 22 MPH) (“D," range) at half to light throttle position, fully depress accelerator pedal to make sure it downshifts from 2nd to st gear. RANGE 1, While vehicle is being driven in “2” range, make sure that it does not shift into Ist or 3rd gear, despite speed changes. 2. Shift control lever to “D" range and allow vehicle to operate at 40 to 50 km/h (25 to 31 MPH). Then, shift to “2” range to make sure it downshifts to 2nd gear. RANGE 1, Shift control lever to “1” range and allow vehicle to run. Ensure that it does not upshift, from Ist to 2nd gear although vehicle speed increases, 2. While vehicle is being driven in “1” range, release accelerator pédal to make sure that engine compression acts as a brake. 3. Shift control lever to “D" or "2" range ‘and allow vehicle to run at 20 to 30 km/h (12 to 19 MPH). Then, shift control lever to "1" range to make sure the downshift to 1st gear is madTechnical Service Information TROUBLE-SHOOTING AND DIAGNOSES Road Testing (Cont'd) VEHICLE SPEED WHEN SHIFTING GEARS, 1. Disconnect harness from A/T control unit, Road test the vehicle to determine if all items listed in the following chart are within their specified values. 2. Reconnect harness to A/T control unit. Road test the vehicle to see if shifting corresponds ‘to the specified shift schedule pattern. VG30E engine Vehicle speed ‘Throttle position | Gearshift km/h (MPH) D,+D; 89-67 (37 - 42) D: +05 101 - 109 (63 - 68) Dy +d, = Full throttle D.>Ds 2 D,+0, 89-97 (55- 60) D,+D, 42-50 (26-31) VG30E turbo engine , Vehicle speed Throttle position | Gearshift km/h (MPH) D0, 56 - 64 (35-40) 0; +Ds 93 - 101 (58-63) Dy ~+Ds - Full throttle D.+0y = Dy +D; 84-92 (52-57) D; +0, 44-52 (27-32) 67Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Road Testing (Cont'd). SHIFT SCHEDULE VG30E engine i Upshite a ‘Kickdown range 1 2 aa 21 : 4 on 58: ~ _ a 5 1 2 ne z af ye - : ; ceo as @ i Fou A c oo 3 on ow 7 3 40 90 7 80 9% 190 110 120 190 140 150 oe) SO) dod) ea) Wa) Weo) So) etic send kr OPH) Downs Kickdown renee z E eas 1m 1 oa. el 7 2 | ne : . . z 3 - Hao : : a : an 2 a on : ow © 7 wm 9% 109 rrTechnical Service Information TROUBLE-SHOOTING AND DIAGNOSES Road Testing (Cont'd). VG30E Turbo engine Upshite °” Tecan ane 7 ” on i sn zs z i a8. 3) or 50) 0) Vehicle sone kmh (MPH) 69ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Road Test Symptom Chart indetes i Troseshooting 22 z F) 3 yé BF g g es evr not neces 1 enec Ze} Ee | af] ge / eles) [els [3] 3 shaded ies. ref Sf & ] 2 | Sleay a] gs j2x/ s | 2 ze] 2] & |] ¥ | & leg) 2] s [Shi 21 Sf comments PARK LENG.START 7 7 T T ® RANGE | HOLDING { i ® © Man shee Te nance | pevense laa| Manan RN aD ies we ge [ENS START ~1® 7 ol ® ips oeceer} Om avon 12 | SO | T eS [reaper ton >] ee} be Jape a Aurosmtt 23 || ® ® |o @ oh [m lap 7 Te Tl ole T [Anon 34 || @ | oa T [= 0 [> { Or og | State ow" : ee #| (irieew own Te 7 ae TT | [Loe are: | | i 2 | [oe a8 ole a = [Rexsown 43) ® joes f= ed eee «|/@ [EE ke Kicnsown 32 a P@l Fe aa [e Dee at ® a a fi wewooun 2 @ cy Pe 3 [Mens Ba S > ae mance Pa aap aa ole 1 onan Ba ww 7 |e ae. Lame 8e Dew) a ® 5 ance [Acciwevon = o@ 0 | v [eoore ff ef esefor eel pe er| 2}ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Trouble-shooting Chart Numbers are arrange in order of probability. fon vce pg or ence Perform inspections starting with number one and working up. Cited numba indcte tht the wansmision must be removed trom the vehicle @ [ mewamranin wr T | Tomemmnn nme wae [ref fpeefe fp pe © sri sara ne oe © [vere ronin a of. Ps}. tbe © wor cuene Nyt. las feel. off. cp rf eh bated wh ag ae @)6 a © | seo os ip 5 | © | parame mene TT aa |. pies . de @ | mivonin'airmmicmome tral. tas fees)... Lwal. . fos O [Aematintomentanin r?fe. psp os[ sh pp lea ©_[ Foire one ge ton passers mer ® cmoatmwion awe [ties fee elers a ve © vee [seers = fw pala af. [e @ ‘camel 5 i @ | mist oee vom OFF 6 coon : :TSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Trouble-shooting Chart (Cont‘d) Jeon wie —— oo Perform inspections and working up. Cie the transmission mus 7 |; RTs aie alt eee #2 7 Hi Pgh = EER saliiilet 3 memneeere oe] ea Sao: cero Fe oi lero ranean oor ; Talo: yo ® @ Voce ated by gr ehing om "216 Tagen me ae O | tener doar a Aaa © | Fenech ww tan “nr wa 6 [pare @ | fimcammernme~n TL | aalesal..[...[].. Lo... -fo. |... cwrowmmertnarnsememon Ly 23 Jase). ..f...]-..[f.-[.--f-o-].- | a + o[r2 fee a. ; ° ® Eres Sears |e ©.) rife. .faselre @ |Soeemmcememgve [ot pe [esa]. -[-. | fo. ofo- @ | ene wermenmgnstom 1 ys ia a esate. |. & | Rckctowen doe no core ee ei ne faa af ashe. ale. ele. ef doe (cn an eho ie pod peeoccaa a ssa axa anamnte )|SBe sete [ares ete (sorts) tere Oe @ alee elt ‘Bo pcr coment ne -. fra fof -e-P- ff --[--]--- --fo-- 72ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES ——_—Trouble-shooting Chart (Cont'd) Perea negscramged in order of probebiity, fg ay ng gg mo Perform inspections starting with number one ‘8nd working up. Crcled numbers indicate that the transmission must be removed from the ® @ | een Oe ®@ Fare cant an Wd wen engin ter a -o.|. Soe en ww atom ronan neon, : sie ere, | rien snag em LL Taasleal...[....[ ahe.,e. @ [cane onesomenn rane fos eee oa. cove ton ee aot ton ae | ; La. seca craton ks |e |e | See | eel @ |S ee aje2.[-. [of cal. Ps pes) 3 fT asolaeaiaual al. lol -|ooa/esslooa). . al. . -|a| -[eosleoelooal al. ee oo hem 73Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES E4N71B Electrical System/Schematic. BATTERY FUSIBLE LINK IGNITION SWITCH eR Freel on sT ® : Digital type merer tf2_@F ere —_F @: Newile yoe meter IGNITION i RELAY [lho Fuse EF, CONTROL ony AIT RELAY Lame ot Fs} DOWNSHIFT SOLENOID THROTTLE VALVE = SWITCH ASCO. ‘CONTROL, LOCK-UP CONTROL UNIT one Lock. uP SOLENOIO INOISATOR, ‘Ls ComEINATION : eres tT ¢ (Oia pe 4 : ze I TmoTvce of hese EEnson of, tM0Ee voucte ee eee y | Emaar encul Owes % 380) (I, [sues SPEED SENSOR + t steel) kicxpown/” | carrer tL i Saree” = a ™Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES E4N71B Electrical System/Wiring Diagram. iy Hare TE if, geese Fuse BLocK lonor Start ®, POWER suPPLY [IGNITION SWITCH] AUT RELAY ps Hu) onnoue 4008 aNnouD soe 75ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of A/T Control Unit Check voltage between No. 22 terminal (Ground) + [2 [3 [EJ « [5 [3 oa] s [16 [7 and each terminal in the following table using tester and Tool (Diagnostic sub-harness). 6 [7 [2 [2 [10 [a] a2 fre [19 [rao] an [22 {AIT cantral unit harness connactor at teen from front) Note: (14) and (20) isnot used. Main harnas Leck-up contro! unit (34270) Terminal i Teal | Checking input/output signal (Checking method Judgment standard Measure when depressing and releasing | OV if turned on 1 | Downshitt solenci aaneee accelerator pedal while driving vehicle. | 12V if tuned off cicup solen ‘Measure while driving vehicle in“D” | OV if urmed on sil escaseremees range. 12V if tuned off 3 | Throttle sensor (power source) | Connect tester to terminals 3 and 6, BV at all times vottle sensor Measure while operating accelerator Fullclose throttle: 04V 4 | Tren pedal. Fullopen throttle: 4V. 5. | Throttle sensor (ground) = - Measure while operating power shift | OVif turned on 6 eno 0.B- cancel solenoid switch, 12V if turned off Measure while operating 0.0. control | OV if turned to “CANCEL” .D. indiator ar At 1 | baseiiesimetiraed switch 12V if turned to “O/0" |Futt-ctose throttle: More than 4.8V 8 je contact switch tale contact swite Partopen throttle: OV Measure while operating accelerator pedal. Throttle opening 9 | Full throttle contact switch Over 1/2: More than 4.8V Below 1/4: OV 10 ‘Measure with control lever set to ” 12V it set to "2" range range oF other ranges. OV it set to other ranges ‘Check voltage variation while running | Voltage must vary from 11 | Vehicle seed sensor a vehicle over 1 m (31 at very low speed. | OV to approx. SV. 76Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of A/T Control Unit (Cont'd) Terminal | Checking input/output signal Checking method Judgment standard Jack up rear whorls set lever to D range, , D1 range ov 12 | 12 shite switen ‘and measure while accelerating with @ slightly open throttle. oe aed oa ene ss signal Measure by repeatedly releasing venice | 12Vif AS.GO. isset 2 eet ‘speed setting during A.S.C.D. driving. OV if A.S.CO. is released 4 e - a Measure by turing on and off (OV if accelerator switch ison ASC. 0.D. cut signal tor switch during AS.C.D. 8V if accelerator switeh is if driving at D4 speed oft 1, 02, and D3 ranges: OV ‘3-4 shift switch Jack up rear wheels, set lever to D range | D4 range: 5V range, and measure while accelerating with a lightly open throttle. D1 and D2 ranges: OV 16 2.3 shift switch D3 and D4 ranges: 5V 17 | Power source Make ground connection. 12 at all times ‘Measure while operating 0.0 OV if turned to “CANCEL” WJ are erie control switch. 5V if turned to “O/D" Continuity test Zero continuity at 20°C (68°F) or higher When checking in installed state, refer to Continuity at 10°C (50°F) - the items on the right. Remove sensor or lower ae Ct! from transmission and make continuity (Reference) test 5V if ol temp. is over 20°C (68°F) OV it cil temp. is below 10°C (50°F) ey 5 — = : “Measure while operating accelerator Fullopen accelerator: OV a aman et pedal. Less than full open: BV z2__| Ground = = 7Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of Lockup Control Details on each step will be described later. Running test fp Check if lock-up operates normally. |] o.K, (Will not operate. Keeps operating.) nu NG. (See inspection iter-2.) Ts control unit connector \\ (See inspection iterm-1.) Properly connected? 's it soaked with water? NG] (Check if wires for output signals are normal, ‘Are lock-up signals normal? NG Ox (se ——a + rection eam) (See inspection tam3) | Repair connector ‘Are wires for input Check if lock-up solenoid conection Sina norma? Fair wires is property tale na operating normally. NG] JO.K. eae if [t{"—— NG Ox. ‘Se pection ar) | — Real wires Are input sls Repair defects AT ws] ox + Reinstall solenoid proper! Replace control unit. or replace, Properly Tepito pace laine pers 78ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of Lockup Control (Cont'd). INSPECTION POINTS tena itm tobe checked crecking method © Coonect ert contra wit commetor wml, Now 3 snd 22 and cock occu signa whe ing while 1 Lock sos trope dean OV it okup solenoid ion 12V itteckup stoi ot Check i conesor between conve unit andiocup enol 2 Wires for eu son eater Properly connected. Also, check connector for continuity. : © ChecktOringis sale oi of cond Lockup solenoid ie ° ‘© Check operation of solenoid by applying 12V voltage. Check tcamections eprops ade betwen conto ant tnd followng arson. Al, check connect for conduction thot senor ie Ngptivote se 5 nitrate (ranged ‘ Mies fr op signals 2 Shitowiches (12, 20nd 34) * Lowiempertre stace * Kekdown witch © Vette sped sensor * 0.0. awten 5 Taps ras heck tems gen on rpecion# chr on pes ATT nd 75 19ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of O.D. Control Running test (Beekit 0. consals nomar) OX eno) NG] © Check if 0.0. is not released when power shift switch is turned on. © Check if 0.0. is not released in full throttle condition. {See inspection iter-1.) Cheek if 0.0. cancel solenoid {Case O00. control vaive of ‘operates normally. ALT is defective, (Case @) Trower si witch normal heck control uit connector Ox. ispropety connected connectors caked Greck OD. ancl soe Repaicpomer ok <2 noid connector is properly shift switch, (See inspection | connected and functions item) normally. R 7 — = eaircomector | Aaeinput sins normal? 1 an] NG] ]OK Repair slo wit aa ce lero bd Repucwowtevave switch.) [Replace conval anit] ae INSPECTION POINTS ee ection Item obecmaied | Checking mated oaee |r irs oaley wel GT ineea icon eer Ser if 0.0. solenoid clicks. Inspect following items given in flow chart on pages AT-74 and 75, © Shift switches (1-2, 2-3 and 3.4) © Vehicle speed sensor © Full throttle contact switch © Kickdown switch Low-temperature sensor 2 Input signals ——Details on each step will be described later. Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Running test ‘Check if 0.0. controt is ‘normally provided during ASCO. running, Inspection of Parts Related to A.S.C.D.. END switch is turned on while running at 04 speed © Vehicle will not run at D4 speed, © 0.D. will not be released even if accelerator switch or resume '* 0.0. will not be released even if vehicle speed slows down to over 6 km/h (4 MPH) while running at D4 speed with A.S.C.D. set. with AS.C.D. set. ee by (Check and repair. (See inspection (See item-2.) inspection item-1.) {See inspection item.) Wiring \Y.G/“AS.CD. cruise ‘Output signal normal? signals normal? wiring normal? NG. OK. OK S NG] TOK (See ee = (See inspection J inspection iter-3.) Vinsoection item-4.) = $iten-7.) Inspect AS.C.0. \ n.G./AS.C.0. 0.0. cut \ 0.x. ‘Check if 0.0. cancel sole- controlle signals normal? ‘noid is properly installed fess inapeenn and funetions normally. 1 item-5.) NG OK. Repair wires. | | N.G./“ Defects in \ 0.K. Replace Reinstall solenoid |,_| harness control unit. correctly or replace, Repair wires, Parts related to Repair defects in A/T. AS.CD. controller 81Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of Parts Related to A.S.C.D. (Cont'd) INSPECTION POINTS Inspection No, tem to be checked Checking method 1. Connect tester to connector terminals, Nos. 13 and 22, of lock-up control unit. | 2. teasure by repeatedly releasing vehicle speed setting 1 AS.C.D. cruise signals during AS.C.D. driving, Proper indication: ASOD. isset: 12V ASG. is released: OV 2 AS.C.D. wiring harness Refer to section EL for AS.C.D. 3 AS.C.D. controller Refer to section EL for AS.C.O. 1. Connect tester to connector terminals, Nos. 15 and 22, of lock-up control unit, 2, Measure by repeatedly releasing vehicle speed setting 4 AS.C.D. 0.0. cut signals during A.S.C.D, driving in D4 speed. Proper indication: Accelerator pedal is depressed: OV Accelerator pedal is released: 5V 5 AS.C.D. wiring harness Refer to section EL for AS.C.D. Check connector between control unit and 0.0. cancel 6 eee eames solenoid for connections and continuity. Apply 12V voltage to solenoid proper to see if it operates 7 0.0. cancel solenoid peea 82TSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Inspection of Kickdown Control. Running test ls kickdown achieved? END (See No] (See inspection item-2.) inspection item-1.), (See inspection item-4,) 0k. /"kickdown switch \__N.G./" Downshift solenoid \0.k. Input signal signals normal? signals normal? wiring normal? NG. NG] Ox Replace control Repair wires, |*— (See unit. inspection item-5.) Check if downshift — {See inspection item-3.) rsieasia parisons nic. /Isharess in Property. 00d condition? NG Ox 4 Oe Replace. |+—— Repair harness. = Repair defects |,_ t in ast. Repair kickdown switch, INSPECTION POINTS Inspection No. Item to be checked Checking method Listen for a “click” to be emitted by downshift solenoid 1 Downshift solenoid signals when accelerator pedal is fully depressed and ignition switen is "ON". Connect tester to connector terminals, Nos. 21 and 22, of lock- Up control unit. Measure while operating accelerator pedal 2 Kickdown switch signals Uden senate ON, Less than full open: 5V A Cees Check connector between kickdown switch and control unit for proper connection and continuity. Check connector between downshift solenoid and contral 4 Input signal wiring ene _ iunit for proper connection and continuity. : eee fool ey voltage to solenoid proper to see if it functions 83Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Troubles Detected by Self-diagnosing and Their Indication ____ Troubleshooting procedure Before trouble-shooting the lock-up control unit, operate the self-diagnosis function as follows: 1, Turn 0.0. control switch to “O/D”. 2. Turn the ignition switch to “ON” Do not start the engine. 3. Press the kickdown switch to “ON” for at least one second. 4. Start the engine and run the vehicle about 20 km/h (12 MPH), and check to see whether or not an abnormal condition exists. Turning the ignition switch to “OFF” or “ACC” cancels the self-diagn steps over again, function. If cancelled, repeat 5. Ian abnormal condition is indicated, track down the cause of the problem in accordance with the chart {as shown below, Power shift indicator flickers at Power shift indicator flickers at intervals of 1 second. intervals of 1/4 second, —-—, Tndiator Wkers when vile i ae Gaatots eisai Indicator flickers when vehicle is © Throttle sensor defect 2. im second gen or faster than 13 Unapection 2). the 1-2 shift occurs t0 15 km/h (8 to 9 MPH). @® Harness is broken between throttle sensor and lock up I ] cone @ Lock-up contro! unit malfune- © Broken wires between shift © Vehicle speed sensor defective tions. switch and eckup cont Unipection-1) unit harness. @® Harness is broken between @® Srift switch malfunctions. vehicle speed sensor and lock-up control unit. 84Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES INSPECTION POINTS Troubles Detected by Self-diagnosing and Their Indication (Cont’d)—___ No. of inspection (Checking item Checking method Vehicle speed sensor |. Connect tester to connector terminals, Nos. 11 and 22, of lock- up control unit. 2. Check voltage variation by running vehicle over 1 m (3 ft) at very slow speed. Proper indication: Voltage must vary from OV to over SV. ‘Throttle sensor - Connect tester to connector terminals, Nos. 4 and 22, of lock- ‘up control unit. 2. Measure voltage while operating accelerator pedal Proper indication: ‘Accelerator pedal in fullclose thrott ‘Accelerator pedal in full open throttle position: 4V 85Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES WE we Ons ‘oon 7 Test port for F range LINE PRESSURE Install pressure gauge to line pressure port. 2. Warm up engine until engine oil and A.T.F reach operating temperatures, A.T.F. temperature: 50 -80°C (122 - 176°F) 3. Set parking brake and block wheels. 4, Measure line pressure at idle and at stall point while depressing brake pedal fully. Pressure Testing Atidling \VG30E engine without turbo Range Line pressure kPa (kg/em?, psi) R 549 - 686 (5.6 - 7.0, 80 - 100) ° 314-373 (32-38, 46 -54) 2 569 - 1,128 (5.8 -11.5, 82 - 164) 1 314-373 (3.2-3.8, 46 - 54) VG30E turbo engine Range Line pressure kPa (kg/em?, psi) R 333 - 432 (3.4 - 4.4, 48 - 63) ° 255 -353 (2.6 -3.6, 97 -51) 2 588 -1,177 (6.0 - 12.0, 85- 171) 1 255 - 355 (2.6 -3.6, 37-51) Atstall test 1. Start engine and place select lever in range. 2. Apply foot brake and accelerate to wide-open throttle. 3. Quickly note the line pressure and immediately release throttle. 4, Shift select lever to “"N”. 5. Cool off A.T.F. 6. Perform line pressure testing in the same man- er as in steps 2 through 6 with select lever in "2", "1" and “R”, respectively. © Do not perform tests for more than five seconds at any shift range. © Do not proceed to next “range” test immedi- ately after one “range” test is done. Wait until oil temperature decreases. 86Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Pressure Testing (Cont'd). VG30E engine without turbo Range Line pressure kPa (ka/em?, psi) “a | 2087-2,979 (923-242, 317-344) “op | __1,457-1,275 (118-1300, 168-185) 2 1,187 - 1,275 (11.8 - 13.0, 168 - 185) 1 1,187 - 1.275 (11.8 - 13.0, 168 - 185) ‘VG30E turbo engine Range Line pressure KPa (kg/em?, psi) R 2,148 - 2,442 (21.9- 24.9, 311 -354) ° 1,824 - 1,981 (18.6 -20.2, 264 - 287) 2 1,824 1,981 (186 -20.2, 264 -287) 1 1,824 - 1,981 (18.6 -20.2, 264 287) Judgment by measuring line pressure If line pressure does not rise, first check to make sure that vacuum hose is connected properly. 1) When line pressure is low at all positions, the problem may be due to: Wear on interior of oil pump Oil leakage at or around oil pump, control valve body, transmission case or governor Sticking pressure regulator valve Sticking pressure modifier valve 2) When line pressure is low at a particular posi- tion, the problem may be due to the following If oil leaks at or around forward clutch (rear) fF governor, line pressure is low in “D”, “2” or "1" range but is normal in “R” range. If oil leaks at or around low and reverse brake circuit, line pressure becomes low in “R” or “P" range but is normal in “D”, “2” or “1” range. 3) When line pressure is high, pressure regulator valve may have stuck. 87Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES Stall Testing The stall test is an effective method of testing clutch and band holding ability, torque converter one-way clutch operation, and engine performance. A stall test should only be performed as a last resort because of the high fluid temperature it generates and the excessive load it places on the engine and transmission, CAUTION: a. Transmission and engine fluid levels should ‘always be checked and fluid added as needed. b. Run engine to attain proper warm-up. During test, never hold throttle wide-open for more than 5 seconds. 4. Do not test more than two gear ranges without driving vehicle to cool off engine and trans- mission, STALL TEST PROCEDURE 1. Set parking brake and block wheels. 2. Install a tachometer driver during test. 3. Start engine and place select lever in “D” range. 4. Apply foot brake and accelerate to wide-open throttle. 5. Quickly note the engine stall speed and imme- diately release throttle. where it can be seen by Stall revolution: \VG30E engine without turbo 2,150 - 2,450 rpm \VG30E turbo engine 2,500 - 2,800 rpm 88 No Shift select lever to “N’, Cool off A.T.F. Perform stall tests in the same manner as in steps 3 through 7 with select lever in “1” and “R", respectively.ATSG Technical Service Information TROUBLE-SHOOTING AND DIAGNOSES STALL TEST ANALYSIS ne! ee eet aoe aa ke ee ee ee rochin rostow Perea, etna clutch slips damaged (slipping), or J engine is not performing vereverse clutch Lock-up clutch is dragging, me properly, (Front) or low & rev. converter one-way clutch is 1” range test brake slips. damaged (slipping), or 0. *[ NG. + Cision? | Sr eee cea caine ce eras mae & rent ae ot sontsawe — omebooe ieaiae ea een ee eee ne ee | a oo ere fa If converter one-way clutch is stuck, vehicle will have poor high speed performance and low engine rpm when it is raced in “N" range. If converter one-way clutch is slipping, vehicle will be sluggish up to 50 or 60 km/h (30 or 40 MPH). 89ATSG Technical Service Information SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications ___________ Specifications and Adjustment__ Enns now (es | =e = = x08 xs179, ‘ria veraniaion moa zara — Torque conte nenbly umber noose and cco os c Satire vate 20:1 ie 2ass Tbe ofr pet 2 2 be tas8 ee BS Naber of ren pater 2 2 oo osee — op one caance mm On Snr | 0-0210-o00e1 naosmenaon | auconsse woramion aie Alona lime 92 (00001 5 70ers i on 5 xbteny wr us moa standard 190-1185 (0501-00880) Ee boo a ‘towable i vst00se) Trikes pa rm tnt | number tmcenen orveeenae | 240006) | 37606.x0507 x0309 58 (0228) | 31567-xz908 126 (0.496) | 31667-x0308 6.010.236) | 31567-x2005 | 12800508) | s1667-x0005, 6210240) | 31567-x2006 ——— ese | Sees Thickness of etining | plate “Thickness mm nl Fear chun (Forward) Sroma Vneerxzsco INaebarot dea pas fe A 9.810386) | 31667-x2900 10.010.396) | 31667-42901 Number of ivan plates 6 6 10.2 (0402) | 31667-xz902 10. 0.409) | 51667-x2909 Cieorance mm tinh tosioerni | 31667.x2008 08-10 08-19 408 0425) | 31667.x2005 ae {0.031 -0.039) | (0031 -0.0291 eee Allowable iit 1510058) | 1.510059) Drive pete thickness 2ra brake band toe tn) Piston size mm fin) Standard 1150-1.65 10.0581 - 0.0850) Bia ia. raven | 6013.35) Allowable iit 4 (00551 Smal i sore | 44.73) Thicke vor 0.0 brake band me inh number Piston se mm tn} ef 890, soa | 601236) Sze | as6rx2008 smal aoirs7) | aoinsn Seen 640252) | 31507-xa600 sotretaning | 650.260) | 31507-x8601 Frontend play rms) | 05-08 (0020-0033) pm 6.8 0268) | 31597.xz800 oo 7010276) | 31597-x2601 Thickness fen 7.210283) | 31597-x0900 sve in umber 7410291) | 31537-x0s01 1300051) | 31526.x0107 eee eee Thickness of nigheevere | 15 (0050) | 315280105 uten (Front trust 37 0067) | 31528-xo105 washer 1910075) | 31528.x0100 2.110083) | 31526:xo10 231009 | 31526-x0102 250088) | 31526-xo103 2710106) | 31526.x0108Technical Service Information SERVICE DATA AND SPECIFICATIONS (S.D.S.) Specifications and Adjustment (Cont'd). Touteedsiy __omim | 028-080 loo0e corer) | Otpamadaunnce mamta) Outer gor pune outing Teens | peasumae Sunes 2.08 -0.2010.0020-0.0079) mm tal ‘Monette 225 (0.00861 Taveomn |aresexcrc | Ouergewarmcen Treaneustoi pimocowr | 4 tooss) | stsexoier 0114.0.21 (0.085 0.080) meres 1.6 (0.063) | 31556-xo102 Riowabietinis 0.25 10.0096) rata | 31ss6x0103 | Gewspunecomr 2oroors | srssexoroe ‘Stara 02-004 00008-00016) ee aoeigl siescaiae ‘Aton 208 (0.0031 DDipekend pay emin) | 05-08 (0020-0000 Thekren 0.08 -0.20 (90020-0097) mm (in) Part umber Allowable limit 0.20 (0.0079) Tavoosn | swzexeea? | naar oo, mun +3 o0so) | siszexeeos | sul snging groove a 1710067 | 315z6xes08 Stan 008 -0.36 core 0008s) Vo taors) | 2152=xa600 | __Alowabietms 0820065) 2110083) | a1szexaeo1 | Penwtryeanie mm ba 23 tcosn | s1s2exa602 |" crewmnce renown son i “Sancrd a 9.0.70 00079-00276) 2.710.106) _ | 31628-xB604 Allowable limit 0.80 (0.0315) OD.wimeney nmin | m-as0(oome-co1en | Soop ee ean ema ‘Less than 0,07 (0.0028) i tne rn Tate [team | 8 __ew oew au of dm apport Les than 05 (0020 1.2 (0.087) | 31603-x8600 0.0. case Loman ‘Trcenee of 0.9. bewing ree | 14086) | steosxasoy |< 1 0060) | 3160x8602 taioon | sreoaxeeca 2.010.079) | 31603-x8604 STALL REVOLUTION aatcoen | sreoanasos Pf ON Tes cape wien wr 2180-260 om Vai0e wreo wane 2500-2800 om 92Technical Service Information SERVICE DATA AND SPECIFICATIONS (S.D.S.) Tightening Torque Unie em kom tel ‘ransmision instalation rive plate to 1937-187 140-160. 101-116 Crankshatt Drive plate ro torque 39-49 40-50 29-26 Converterhousingto «39-49 4.05.0 29-36 engine Rear mounting bracket 31-42 32-42 23-31 Rear mounting bracket 31-42 3.2-43 29-31 te rer ineulator Rear mounting member 59-78 60-80 43-58 tobody ‘Component part — Tranamision case to converter housing 44-54 45-55 99-40 ‘Transmission cate to 20-25, 20-25 14.18 Oit pan to transmission 5-7 08-07 36-81 2nd serv pieton retainer to tant 2nd piston stem (when {cjustng band brake) Zhd piston stem lock nut 15-39 07-09 51-65 A2e15e1 12-15 gett 15-40 11-29 Oneway clutchinner 13-18 1.3-1.8 9-13 ‘ce to transmission Control val body to §.4-7.4 0,550.75 40-54 ‘wanamiasion cane Lovervaiw bodyto «25-34 025-035 18-25 oper valve body 0.0. serve pron tain 0 0.0. cate (0.0. platon stem (when scjustng band brake 0.0. piston stem tock nut Side plate t0 control valve body Nutfor control valve 5-7 reamer bolt Oilstniner to tower 3-4 vive body Governor vive body to 5-7 oll diatibutor i pump housing to ‘ll pump cover Inhibitor switeh to ‘wanumission case W015 10-15 7-11 7-10°2 07-102 51-7292 18-39 25-34 15-40 11-29 025-025 18-25 05-07 03-04 22-29 05-07 36-51 43-58 7-86-81 93 Unie Nm om fee Manual shaft lock nut 29-39 -3.0-40 22-29 it cooler pipe to 29-49 30-50 22-36 ‘wanemission case est plug (oll pressure 14-21 14-24 10-15 Inspection hole) ‘Support actuator B11 08-11 58-80 (parking rod inserting Position) to rear extension rum support to 19 07-09 51-65 0.0, eae +1 Turn back three turns after tightening *2 Turn back two tuene after tighteningATSG Technical Service Information SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Too! Tool name sro7e70000 =~) {sTo7@so000) Ce “Transmission case stand 'ST25850000 Sliding hammer ee (025721-A) ‘6G91060000 (=) (GG93010000) (125703) Torque wrench 'ST25570001 (J23859-A) ($125670000) (023659-1) Hexhead extension ‘8725420001 (226063) (S125420000) (126063-A) Clutch spring compressor —— tron 2B Socket extension 'ST25580001 C- (il pump assembling gauge 725085001 Y c=) g Oil pressure gauge set KV318K0010 Le (534270) Diagnostic sub-harness (433909) Transmission alignment arbor 94Pring ants°¢0. Prinreb isa.