4 ATSG INTRODUCTION FORD CD4E This computer controlled four speed automatic overdrive transaxle first appeared in the 1994 Probe with the 2.0 Liter engine. This unit is also found in the Ford Contours and the Mercury Mystique. This manual covers the teardown inspection and assembly of this unit. Since it is a computer controlled unit we have included the the service codes that can be accessed with a computer scanner. In the diagnostic section the ‘number codes for electrical and hydraulic trouble shooting should not be confused with the service codes. We thank the Ford Motor Company for the illustrations and information that have 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 SUPERVISOR ED KRUSE PETE LUBAN TECHNICAL CONSULTANT TECHNICAL CONSULTANT JIM DIAL TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (305) 670-4161Technical Service Information CD4E Automatic Transaxle DESCRIPTION AND OPERATION Automatic Transaxle. The CD4E transaxle is a four speed front wheel drive automatic ubit with electronic controls for: Electronic Pressure Control (EPC) for shift quality Shift Scheculing “3.2 shift timing Coast braking Torque Converter Clutch (TCC) control ‘The CD4E transaxle uses a comound planetary geerset, chain ¢rive final drive planetary gearset {and an open differential, One band, five riction Clutches, and two one-way clutches provide four forward gear ratios and reverse, ‘The transaxle is a four speed unit with electronic control that is designed for operation in a transverse poertrain of front wheel drive vehicles. ‘The transaxle features a three element torque converter with a torque converter cluten and {eartrain that includes the folowing parts: -Compund planetary gearset “Chain Drive Planetary gearset final drive -Pinion and side gear ditferential The hydraulic control system of the transaxle has five solenoids that control Shift fee! (through line pressure control Shift scheduling (through shift valve position control) ‘Modulated apply of the torque converter clutch Timing of 3:2 shits Engine braking during coast operation ‘TRANSAXLE IDENTIFICATION When servicing the transaxle, refer to the identification tag located on the rear ofthe transaxie case and on the bottom of the main control cover assembly um Fwserses0 | FoR eg Per FaRP-B PRene ATARI" ‘SERIAL NO, INCLUDES BUILD Saree 100 086 Tras PART NO. PREFIX & SUFFIX cauTior Perform line pressure test prior to performing the stall test. Ifline pressure is low at stall, OO NOT PERFORM Stall Test or furthur transaxle damage will occur. DO NOT MAINTAIN WOT in any gear range FOR MORE THAN (5) SECONDS. CAUTION: To verity transmission oil pressure DO NOT CONNECT THE TRANSMISSION TESTER while ‘making the pressure checks,ATSG Technical Service Information DIAGNOSIS AND TESTING ‘CAUTION: The Transmission Tester MUST be moved from the transaxle and the vehicl harness relnatalled to verify those preeaur LUNE PRESSURE SPECIFICATIONS Tine Presse ia Sia Range Selector Poulion cy Par ea T PARK, NEUTRAL eas8 2078 = REVERSE ase cere 782097 ° 310308 153 Te 1280 2 310986 wea 68 * 310386 88 268 (OTHER CONCERN: CLUTCH/BAND APPLICATION CHART #601 ‘Stem Low One-way cuten Beng Guten | “Einen | ove | const | Guten | ‘eaten’ | rive x * x on on [on x x x on [or | on x x x ‘on [on [er [ on x x x x [or | on T= TRANGMITS TOROUE OR = OVERRUNNING Line Prassure Test Chart Ne PREssune TEST era are area eee EE | Low ar ove HIGH ATIOLE WAtLRANGES we Rs L ‘CHECK LOW FLUIO LeveL. RESTRICTED ‘CHECK MAIN REGULATOR VALVE. SOLE. ier siren, Loose Manigooy Save. Noto Sooy ano wana naAWess: RUN NOD Boor Ga ACCUMULATOR BOSY uick Teer ReFEARED TON ELECTR: Te sige coke BxceasWe LeAtAce EALOMGNOSIS IN THES SECTION. SHGRING MAN REGULATOR VALVE SF A"GaMageo INteT Tuse SEAL ON uZsFRSER, GaavacED GaSee’s OM SePARATOR BUATE.DIAGNOSIS AND TESTING (Continued) Technical Service Information Engine Idle Speed Check Fetes to Section 03-044 forthe engineide speed adjustment procedure. Stall Speed Test “The stall test checks the operation ofthe following items: ‘© Converter one-way clutch (© Forward clutch © Low/reverse one-way clutch '# Reverse clutch ‘© Forward one-way clutch « Engine performance NOTE: The stall test should only be performed with the engine and transaxle at normal operating temperatures. WARNING: APPLY THE SERVICE AND PARKING BRAKES FIRMLY WHILE PERFORMING EACH ‘STALL TEST. FAILURE TO SET BRAKES MAY RESULT IN DEATH OR BODILY INJURY. ‘CAUTION: Perform Line Pressure Test prior to performing stall test. It line pressure Is low at Stall, donot pertorm stall test or further transaxle damage will occur. 1. Connect a tachometer tothe engine 2. After tasting each ofthe folowing ranges, D and R, move transaxle range selector lever to N (NEUTRAL) and run engine for about 15 seconds to.allow torque converter to cool before testing next range. CAUTION: Do not maintain WOT in any gear range for more than five seconds. Press accelerator pedal to floor (WOT) in each range. Record rpm reached n each range. Stall speeds should bem appropriate range. ‘CAUTION: If engine rpm recorded by the. tachometer exceeds maximum specified rpm, release accelerator pedal immediately. Clutch or band slippage is indicated. [_trone Stat speeaom 20. Probe 2200-2600, Ifthe stal speeds were oo high, refer tothe folowing ‘Stall Speed Diagnosis Chart. the stall epeeds ware too low, frst check engine tune-up. I engine is OK. Femove torque converter and check torque converter one-way clutch for slippage. ‘ial Speed Dlsgnowl Char ah Spe ow One Way Cum Shift Point Road Test ‘This test veri that the shift control systemis ‘operating properly. 1. Bring engine and traneaxle up to normal operating temperature, 2. Operate the vehicle with the transaxle range selector ever inD poston. 2. Apply minimum throte and observe the speeds at which the upshift occurs and the torque Converter engages. (Refer to Automatic, ‘Transmission Specipcations issue FPS-12160-94). 4. With the vehicle in D (ath gear), depress the ‘Transmission Contol Switch The transaxle ‘should downshift to 3rd gear. Remove foot from ‘accelerator pedal; engine braking should occur. “Torque converter clutch should disengage and thea reapply. 5. Depress accelerator pedal to flooe (WOT), ‘Transaxle should shift trom 3rd to 2nd gear, or Sra to 1st depending on vehicle speed 6. With vehicle D range above 80 km/h (50 meh) andioss than hal throttle, move the transaxle ange selector lever trom range to manual 2 ange and remove fo0t rom accelerator pedal ‘The traneaxle should nmedately downstiftinto 2nd gear. With the vehicle remaining in manual 2 ange, move transaxle range selector lever into ‘anual 1 range, and release accelerator peda ‘Transaxle should cownshit int first gear at speeds BELOW 48-50 km/n (26-32 mat 7. transaxle fails to upshitt/downshitt or torque ‘convertor clutch does not apply andrelease, ‘eter to Diagnosis by Symptom Charts for possible causes.Technical Service Information DESCRIPTION AND OPERATION Component ilustrations Ioumow contmo. | caanxsnart posmon. MASS AR FLOW (MAR, MOBUCE foun Gan eevson SeNSOR 120673 Neaosr (eantor rata, “TRansmission ‘TRANSMISSION CouTROLNoIcATOR | SONIROC SWITCH ro SENSOR ES Caer re) ar eee sem “Tpansmasion SPEEDSENSOR ss) | BRAKE OWOFF (BOO) etiren ace) inact Sharon 13600 + ELECTRONIC pressunE CONTROL SOLENOID (EBC, + ToRQUE ConveRTER GibTow soteNOWD roo) + TRANSMISSION OL TRawousssiow spugigpooy | TEMPERATURE TON SENSOR | yan vee TeMpenarUne Maly + 23HiFT soLENoIDS i (TON SENSOR TH141 fera'ssa Sexson 1a + Sa TMavcoasr cuUTCH SOLENOID STC)DESCRIPTION AND OPERATION (Continued) Technical Service Information INPUTS TO PCM ‘Transmission Oil Temperature (TOT) sensor Manual Lever Postion (MLP) sensor Brake On/Ott (BOO) switch Distributor Ignition (0) System — Crankshatt Postion (CKP) sensor — Ignition Control Module (CM)(124297) '* Mass Aictiow Sensor '* Throttie Position Sensor '* Vehicle Speed Sensor Transmission Control Switch (TCS) Ar Conditioning Clutch (ACO) ‘© Engine Coolant Temperature Sensor «© Transmission Speed Sensor (TSS) ‘OUTPUTS FROM PCM '# Transaxle Solencid Body Assembly — Shift Solenoid #1 (881) — Shift Solenoid #2 (S82) — Electronic Pressure Control(EPC) Solencid — Torque Converter Clutch (TCC) Solenoid — 3-2 Timing Coast Cutch Solenoid (2-2/0) ‘© Transmission Control indicator Lamp (TCL) ain Control Module (CM) 128650: Engine Coolant Temperature (ECT) Sensor 120648: ‘Tho Engine Coolant Tempersture Sensor ECT) detects the tomperature of the engine coolant ang ‘supplies the information to the Powertrain Control Mogule (PCM), : Gey TEST PINES Q— sig ATW Tes PINT Q— Ect ‘Transaxle Function: ECT sensoris used to control Torque Converter Cluteh (TCO) operation. ‘Symptoms: TCC wil always be “OFF” if ECT sensor reads cold ar normal, resulting in reduced uel economy. DTCs: 116. 117 and 148 ‘Transmission Control Switeh (TCS) 72247: “The operation ofthe transaxle js contralled by the Powertrain Control Module (PCM). Many input ‘sensors provide information tothe PCM. The PCM then controis the actuatore which affect traneaxle operation DTos:511, 512400519 ‘The Transmission Control Switch (TCS) ie @ momentary contact ewiten. When thie switeh is 4, a signals santo the Powervain Control (PCM). The PCM then energizes ne \saion Contral indicator Lamp (TCIL) and or disongages 4th goar operation and provides coast braking in 2nd and Sr CoutRoCSwtron Transaxle Function: Disable fourtn gear operation and energizes CCS solenoid in 2nd and 3rd gear for engine braking Symptoms: No overdrive cancel when ewiteh in cycled DTc:659DESCRIPTION AND OPERATION (Continued) Technical Service Information Transmission Control Indicator Lamp (FCIL) Manual Lever Position (MLP) Sensor 7A247: ‘The Transmission Contal indicator Lamp (TOIL) is locatedin the instrument panel andis labeled O/D OFF. The Transmission Control Switeh (TCS) controls the ON/OFF operation ofthe TCI. INSTRUMENT CLUSTER GRAPHICS ‘Transaxle Function: When the arver initially presses tha button ofthe TCS, the TCL turns ONto frdleate that transaxle operation in ath gearis Gisablea. When the crver presses the TCS again. the TOIL tune OFF ‘Symptoms: Ifthe TCL falls ON or OFF, the driver ‘may have an incorrectingication of transaxle operation DTCs: None ‘Transmission Oil Temperature (TOT) Sensor ‘The Transmission Oil Temperature (TOT) sensor is located on the solenoig valve body tis & tomperature-sensitve device called a thermist resistance value ofthe TOT sensor wil vary with ‘emperature. The Powertrain Control Module (PCM) The ‘Transaxle Function: The PCM uses tis signal to otermine sit echeduilng and contro of ine pressure or cold and hot temperatures operation. ‘The PCM also inhibits Torque Canvorter Clutch (TCC) ‘operation at iow transmission emperature. Adjusts Electronic Pressure Control (EPC) pressures for temperature ‘Symptoms: improper TCC operation and EPC DTCs: 696,697. 638 and 657 “The Powertrain Control Module (PCM) sends the Manual Lever Position (MLP) Sensor. The MLP orporates a series of step own resiatore which act as a voliage divider. The POM monitors this voltage which corresponds tothe position ofthe transaxle range solactoriever(P,R,N, 2, 1, The MLP eeneoris located on the top of the tansae, NOTE: The MLP sensor also contains the ‘eutal/ stan, ane backup lamp cicuts ‘TERMINAL LOCATIONS aaaanMaea ‘esr PN O-664 “Ww ‘ard resremvo-nr,] |, > SENEOR VENUE HARNESS ‘Transaxle Function: Determine Electronic Pressure Control (EPC) pressure ‘Symptoms: Harsh engagement and fim shift feel Engine may not crank May cownshit toa lower gear. ‘and or ard gear operation, Transaxle not nicsting the proper ear, No sth gear operation, na manual 1st ‘oar DTCe: 522, 654, 659, 67. 68 and 675 andDESCRIPTION AND OPERATION (Continued) Technical Service Information ‘ake On/ Ott (800) Switch 19480: Air Conditioning Clutch (ACO) 2884: ‘The Brake On/Off (BOO) Switch signals the Powertrain Control Module (PCM) when the brakes fare applied. The BOO switch is closed when the brakes are depressed and open when they a released fo a= S HOT AT ALL TIMES INTERIOR FUSE. SUNCION PANEL sanoes, t spas owore Test PN2 @-so0-4 (09) SwiTeH STOPLAMP, ‘Par OF 2404) ‘Traneaxle Function: Disengage Torque Converter Clutch (760) when brake is applied ‘Symptoms: Failed "ON" - TCC wil not enga Josathe 1/3throttie Falled "OFF" or Not Connected -TCC will not cisengage when brake is applied ‘The A/C Gyclle Switchis ocatedon the suction accumulator drier of an OEM factory-nstaled ait Conditioning system. When the ACC switch contacts ‘lose, the Powertrain Control Module (PCM) receives {2 signal voltage rom the ACC switch indicating that the airconditioning compressor clutch is engaged. froma Bseb) yovewn = rest P10 Sree PREssune ae [| i Seman swine ‘Transaxle Function: The PCM uses the ACC switch signal to agua ine pressure to compensate to: the ‘daitional engine oad. ‘Symptoms: Ifthe ACC switch falls with closed contacts ine pressure wile slightly iow with ac Conditioning OFF-Ithe ACC switch falls with open ‘contacts line pressure wil be slightly nigh with air ‘conditioning ON pre: 539, Te:DESCRIPTION AND OPERATION (Continued) Technical Service Information Distributor ignition (01) System Mass Air Flow (MAF) Sensor 128579: “The Distributor igition (DD system hes a Crankshatt Position (CK) sensor and an ignition Contol Module (IGM), The CKP sensor sends crankshatt position Information tothe ICM, which sends an engine speed signal to the Powertrain Control Module (PCM), GumoN conrROL MoDuLe/TicM). seazor PF caannsuirt posmon (cK, ‘SENSOR PART OF 12127 "saxle Function: The PCM uses the engine 1 signal rom the DI system for control of ine pressure, shift scheduling ane Torque Conver Clutch (TCC). Wide Open Throttle (WOT) shit contro! Is also atfectec by the Dt system input Symptoms: the engine speed signal has a faut, harsh engagaments,trm shits, orlate WOT shite may oceur Aiso, TCC apply may not occur. DTCs: 211-217 and 226-241 ‘The Mass Airflow Sensor (MAF) crecty mei the mass ofthe ar flowing into the engine. Th Sensor output is 0.6. (analog) signal ranging from ‘about 0.5 volts 105.0 volts used by he Powertrain Control Module CM) to calculate the ijeetor pulse ‘width for stoichiometry. For transaxle strategies, he MAF sensor is used for Electronic Pressure Contra! (EPC) pressure control, shift and Torque Converter ‘Guten (7CO) seheauins, TET Ow — TEST PINS Q-MAFRTN—C TEST PIN «0 ‘esr PIN 6) G-PuR GNDLs" Tesrom a @-vown—n TEST PINS? ‘Transaxle Function: EPC Pressure Control, Shit and eC scheduing ‘Symptoms: Incorrect shit schedule, EPC pressure hi ‘orlow, incorrect TCC engagement scheduling and Symptoms similarto.aTrrattle Position (TP) Sensor ‘malfunction. Malfunction incieator Lamp (MIL) on. DTCs: 167, 158, 159, 184 ang 185 10DESCRIPTION AND OPERATION (Continued) Technical Service Information Throttle ition (TP) Sensor 98989: ‘Transmission Speed Sensor (TSS) 7M101: The Thraile Position Sensor (TP) is potentiometer mounted onthe throttle body. The TP the postion athe throttle plate ané sends this. information to the Powertrain Control Module (PCM) fas a varying vottage signal. amaitunction oceurs inthe TP sensor crcut, the POM willrecognize that the TP Seneor signals out of elficetion. The PCM wil hen operate the transaxle at ahigh Electronic Preseure Control (EPC) pressure to prevent transaxle damage. @) ‘1G RIN —O TEST PIN 26 seo rest par \vRE# — TEST PN 26 ‘Transaxle Function: Shift scheduling, EPC and Torque Converter Clteh (TCC) canto, Symptoms: Harsh engagements, fm sit eo! abnormal shift schedule, TCC does not engage, TCC {cling Malfunction indicator Lamp (MIL) on DTCs: 121, 122, 123, 124, 125 and 167 {A Transmission Speed Sensor (TSS) ie amagaetic pickup that sondsa signalto the Powertrain Control Module (PCM) that indicates turoine shaft input speed sam Loresteinse L_orssrews ‘Transaxle Function: Provides converter turbine halt speed information fo Torque Converter Clutch (Too) control strategy. Also usedin determining static Electronic Pressure Contra (EPC) pressure Setting during shits ‘Symptoms: No torque converter engagements oF hareh shifts. No ath gear operation and engine braking in 2nd and 3rd gear. May flash the TC prc: 699 Venicle Sp Soncor (VSS) 9E731: ‘The Vehicle Speed Senear (VSS) ie a magnetic pickup that sonds a signal to the Powertrain Control Module (PCM), This VSS signa tells the PCM the vehicle speed Toninaeed ulTechnical Service Information DESCRIPTION AND OPERATION (Continued) fbicle sensor 731: (Cont ‘The POM controls the operation of he transaxle eee eee through wring fo the solenoid valve body assombly “Transaxle Function: Usedto determine shit ‘mounted on the main control assembly. An electrical eheduling and Electron Pressure Control EPC) ‘Sonnoetoe rom the solanld valve body assembly contol {aston to the top ofthe Wansaxle case, Where ‘Symptoms: Firm shit fel, ebnormal shit schedules, connects to POM wiring. Unexpected downahite may occur at closed trot. ‘The solened vaNe body assemby is serviced as one No dtm gear, No engine braking i 2nd oF 3 part when any ofits components require replacement. Torque Converter Clutch (TCC) apply. May Na ‘Transmission Conteoingiestor Lamp (TCI), Shit Control Solenoids 1 and 2 pre: 452 ‘Shift Solenoids 1 and 2 provide gear contralto the ent valves. Solenoid Valve Body Assembly Shift Solenoid 1 (651) “Transaxle Function: Gear Selection, ‘The solenoid valve body assembly contains the “Transmission Ol Temperature (TOT) sensor, as well ‘$81 Symptoms: improper gear selection depending 28 ive Powertrain Control Module (POM) controlled on failure mode and transaxle range selector lever ‘utput devices. position; reerto Shift Solenoid Application Chart DTCs:621',645*and648* ¢ SectrnePrasne Cont (PC) ssa accuses ‘© Shit Solenoid #1 ($81) ‘82 Symptoms: Improper gear salection depencing Shift Solenoid #2 (882) fon failure mode and ehit control laver position eter ‘© 3:2 Timing Coast Cutch Solenoid (8-2 T/CCS) 1 Shift Solencic Application Chart 1 Torque Converter Ciutch (TCC) solenoid DTCs: 622,648? and647* ‘Torque Converter Clutch (TCC) Solenoid The Torque Converter Clutch (TCO) aolencid is @ Pulse Width Modulating (PWM) style solenoid. The PWM solencid is used te contol the apply and release ofthe bypass clutch inthe torque converter. ‘By moduisting the pulse with of the TCC solanoid the pressure the Sé circuit varies modulating the apply fandelease ofthe bypass cluton inthe torque ‘Transaxle Function: Used to apply and release the Tec. ‘Symptoms: Fallad ON Engine stalls in menual 2nd. Engine lugging, Poor performance at iow engine speeds, harsh shi. Failes OFF -Poor willnot engage. DTCs: 6287 andese" economy, overheating, TOC Electronic Pressure Control (EPC) Solenold “The Electronic Pressure Control EPC) solenoid Variable Force Style (VFS) solenoid, The VFS type solenoids an electro-hydraulic actuator combining & solenoid and a regulating vaive. This solenoid provides Electronic Pressure Control (EPC) which Fegulates line pressure anc ine modulator pressure. Thisis controled by producing a resisting pressure to S200 4 aa nanqoonst the main eguator and ine modulator circuits. The LP Sup.asse SivrensoceNoio fanoLM pressures contrathe clutch applieetion fezecs) pressuces ‘Transaxle Function: Regulates EPC pressure Tah eNaER Ge aTed OMY By EF aRC TTT be pereeicay otner NON lacvoniwited a 2DESCRIPTION AND OPERATION (Continued) Technical Service Information DTCs:624 anders? 8-2 Timing /Coast Clutch Solenoid (3-27/CCS) ‘The 3-2 Timing/ Coast Clutch (821/008) ise Variable Force Style (VES) solenoid, The VFS type ‘solonoidis an electro-nydraulie ctuator combining @ Solenoid and a regulating valve. supplies pressure {othe $9 circuit fo control the release ofthe direct ‘clutch and apply ofthe Intermaciate and Overdrive ‘Band during a 3:2 downshift, This solencid also regulates ihe pressure inthe $3 circuit to control the ‘application and release of he coast clutch Function: Used to contol the apply and sS0 ofthe coast clutch and the lease timing of the deect clutch led ON no engine braking (oxcopt in 13:2 downshifts harsh 4-3 downshifts DTCe:not available at time of pining Electronic Pressure Control (EPC) Solenoid (Cont'd) sin nga Zaciat Laver Posen “Symptoms: Failed ON- minimum EPC pressure sszatweye (tinimurtrans torque capacity). May ash OFF oo | 9) 2 . Transmission Gontrolindiestor Lamp (TCIL) 2 3 2 3 7 Fallog OFF - Maximum EPC praseure, naren a a 2 a 2 ‘engagements anchareh shits, “ 4 7 Iawilnet cownchin tom tna ng ‘hel spoed rope blow tn calbaieg Shift Solenoid Failure “ALWAYS ON” Failed ON due to Powertrain Control Moule (POM) ‘and/or vehicle wiring concerns, and/or solenoid ‘Slectrcaly stuck on, and/or hydraulcaly or ‘mechanically stuck on. 1 | stature on op 1 commana Shift Solenoid Fallure Mode Charts Shift Solenoid Failure “ALWAYS OFF” Falled OFF due to Powertrain Control Module (PCM) ‘and/or vehicle wiring concerne, and/or solenoid lectricaly stuck of, and/or hydraulically oF mechanically stuck of ‘Transaste Range SeeciorLaver Postion “Transat Range Selocior Lave: Poation ‘etal Gear Obtained ni peat] earacrea] Ca Connonay Syaraive carcaled ‘ae speed ropa below tac ‘sz ameye BTechnical Service Information DESCRIPTION AND OPERATION (Co! Solenoid Operations Chart ‘SOLENOID OPERATION CHART — CDSE % PCM Commanded ‘Geet ss sez sauces ree . 1 ov on : D a ore ore ° “ ov corr on ° 1 on on on ' © 2 oF ox corr . 3 ore or ore 2 2 OFF cy OFF “2 x OFF OFF OFF 7 T cy ‘OFF FF o 2 oF FF OFF a a ofr on corr 5) Rowenta onto PCM) commande, (CD4E TRANSAXLE CONNECTOR PIN LOCATIONS (Cont) Pe Description PM Toute 3 rors mn S| SoieoisPower we © [season ma 3 _[ePc Power Te DIAGNOSIS AND TESTING Diagnostic Strategy Troubleshooting an electronically controled automatic pizasz.c transaxle is simplified by using the proven method of dlagnosis. One of the most important things to remember is that there ie adetnte procedure to (CDSE TRANSAXLE CONNECTOR PIN LOCATIONS follow. DO NOT TAKE SHORT CUTS OR ASSUME ma aan Fon Testor THAT CRITICAL CHECKS OR ADJUSTMENTS. HAVE ALREADY BEEN MADE. Folow the + [Fee Powee 1.8 procedures as writen to avoid missing critical 2 [Siena newin « components or steps. (Goninsea) “To properly diagnose « concern, the techrican should have the folowing publications avaiable: 4PAATSG] technical Service Information ELECTRONIC COMPONENTS BACK-UP tights [AA 2 ct SENSOR ‘START. Surtees etacur ‘TERMINAL LOCATIONS ey ec, 40-39 SReLA bees oeheben a Teeadeese | ee 359° BIN as Renae AccY PWR ce AR. can Test 20g! laa T° pi THSENSOR F ‘SOAE CONTOUR, SOLENOID |L_Mvsniaue | INSTRUMENT RE CmNATION MODULE ‘TSS SENSOR TEST PIN 45 yop? TEST PINS HARNESS CONNECTOR, 8ATSG] Technical Service Information DIAGNOSTIC PROCEDURES DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS Three Digit DTC] Component] Description Condition ‘Symptoms 14 ‘System | Pass No fault detected. | Fault not detected by processor. 116 ECT | ECT out of seit | ECT temperature | Re-run self-test at test range. higher or lower | normal operating than expected temperature. during KOEO and KOER. 117 ECT | ECTindicates | ECT temperature | Torque Converter 126°C (254°F) | higher orlower | Clutch will always than expected _| be OFF, resulting during KOEO and | in poor fuel economy. KOER. 118 ECT | ECTindicates | ECT temperature | Torque Converter -40°C (-40°F) | higher or lower | Clutch will always than expected _| be OFF, resulting during KOEO and_| in poor fuel economy. 2 KOEI 124 TP | TP voltage TP was not in the | Re-run at appropriate highviow for —_| correct position for | TP position per self test, for self-test. application. 122, 123,| TP | TP fault codes. | Processor has __| Harsh engagements, 124, 125, detected an error. | firm shift feel, ab- 167 This error may "| normal shift schedule, cause atrans- | torque converter mission concern. | clutch does not Refer to PC/ED | engage. Torque Manual for Converter Clutch __| diagnosis. cycling, 157, 158,| MAF | MAF fault MAF system has | Incorrect shift 159) 184, codes. maltunction which | schedule, hiflow 185 may cause a trans- | EPC pressure. mission concem. | Incorrect converter Refer to PC/ED "| engagement Manual for scheduling, diagnosis. symptoms similar i toa TPS failure. 211-217 | El System | Ei System fault | ignition system has| Engine malfunction, 225-241 codes. malfunction which | no torque converter may cause 2 engagement, late transmission con- | WOT shifts. cern. Refer to the PC/ED Manual for diagnosis. 16ATSG Technical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS [Three Digit DTC |Component| Description Condition ‘Symptoms 452 vss | insufficient Processor Firm shift feel, | input from detected loss of | abnormal shift VSS. vehicle speed schedules, unexpect- signal during ‘ed downshifts may operation. occur at closed | throttle. No 4th gear, no engine braking in 2nd oF 3rd gear. No torque converter clutch apply. May flash TCIL, 522 TR | TRSensor not | Self-test notrun | Rerun self-test in [ee inPARK. _| in PARK. PARK. 536 BOO | Brake not Brake not cycied | Failed ON or not con- actuated during | during KOER. | nected— converter | self-test. BOO | Brake On/Off clutch will not engage switch circuit” | circuit failure. engage at less than failed. 1/8 throttle. Failed OFF ~ con verter clutch will not | disengage when e is brake is applied, 539 AG | AIC switch error] AIC or Defrost ON | Failed ON - EPC | condition may pressure slightly low result from AIC | with A/C off clutch being ON | Failed OFF — EPC during Quick Test. | pressure slightly low 2 with AIC on ear S81 | S81 solenoid | Solenoid 7 circuit | improper gear Gireuit failure. | failed to provide | selection depend- | voltage drop ing on condition | across solenoid. | mode and manual | | Circuit open or | lever position, shorted or See solenoid ON/ processor driver | OFF chart failure during self-test. * Output circuit check, generated only by electrical sympioms. ** May also be generated by some other non-electric transmission hardware system.Technical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS Component] Description Condition ‘Symptoms { 622" $52] SS2solenoid | Solenoid 2 circuit | Improper gear Circuit failure. | failed to provide _| selection depending voltage drop across| on condition mode solenoid. Circuit | and manual lever open or shorted or | position. See solen rocessor drive | ON/OFF chart. failure during self-test. 623 MHIL [MAIL or TCIL | TCIL or MHIL Failed OFF — No or | circuit failure. | circuit open or indication that MHS. TCIL shorted. or TCS mode has been activated. Failed ON ~ Always indicates that the TCS or MHS mode is s active. eae" EPC | EPC Solenoid | Voltage through | Short Circuit — circuit failure, | EPC solenoidis | Causes failsafe ‘open circuit or_| checked and com- | EPC pressure | short to ground. | pared to a voltage | (maximum capacity) | through solenoid | Harsh engagement | after a time delay. | and shifts may flash An error will be TCIL. noted if tolerance _| Short to ground — is exceeded. KOEO| EPC pressure | and continuous | (minimum capacity) self-test. is engine torque (partial fuel shut-off, heavy misfire) and may flash TCIL. oe EPG | OpenPCM | Voltage through | Open circuit — causes output driver | EPC solenoid is | maximum EPC pres- {internal to checked and com- | sure, harsh engage- PCM), pared to a voltage | ments and shifts. through solenoi after a time delay, An error will be noted if tolerance is exceeded. KOEO| and continuous self-test * Oulpul ciouit check, generated only by electrical symptoms. ‘May also be generated by some other non-electric transmission hardware system. asTechnical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS Three DTC| Component | Description | Condition Symptoms 628" TCC | Torque con- | Processor picked _| Failed OFF ~ Poor verter clutch | up an excessive _| fuel economy, over- control engage- | amount of con- | heating, Torque ment error verter clutch slip» | Converter Clutch will page when not engage. May converter was flash TCIL. scheduled to be engaged during | normal vehicle i is operation. 634 | TR |TRSensor | indicated voltage | 2nd or 3rd gear outofrange. | drop across TR~—_| operation, harsh | sensor exceeds | engagements, firm limits established | shift feel, no 3-4 shift, for each position. | may downshift to a lower gear, engine may not orank. No TCC operation. May : | - flash TCIL. 636 TFT | TFToutofST | Transmission not_| Warm vehicle to range. | at operating normal operating temperature during | temperature. i self-test a7, TFT |-40°C (40°F) _| Voltage drop improper torque con- indicated TFT | across TFT sensor | verter clutch oper- sensor circuit | exceeds scale set | ation. Improper EPC open. for temperature of | pressure control. 2 40°C (40°F). 636 TrT | 150°C (802°F) | Voltage drop improper torque con- indicated TFT | across TFT sensor | verter clutch oper- sensor circuit | exceeds scale set | ation. Improper EPC grounded, | for temperature of | pressure control. __| 150°C (302°F). a 639) TSS__| insufficient Input] PCM detected a | No torque converter from Turbine | loss of TSS signal_| engagements or Shaft Speed | during operation. _| harsh shifts. No 4th Sensor. | gear operation and | engine braking in 2nd j and 3rd gear. May i flash TCIL. * Output circuit check, generated only by electrical symptoms. “May also be generated by some other non-electric transmission hardware system, 19Technical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS Three | git DTC | Component | Description Condition ‘Symptoms | 645° | SS1, S82, | 1st gearfailure. | No tstgear. _| Improper gear or internal selection depending | parts, ‘on condition mode and manual lever position: see solenoid) ONJOFF chart. Shift errors may also be due to other internal | transmission con- cerns (e.g., stuck valves, damaged friction material). May fiash TCIL. 646" | SSi, SS2, | 2nd gear failure.| No 2nd gear. Improper gear or internal selection depending parts, ‘on condition mode and manual lever position: see solenoid | | ONJOFF chart. Shift errors may also be | due to other internal | | concems (e.g., stuck | | valves, damaged | friction material). May a _| flash TCI, 647" | "S81, S82, | 3rd gear failure. | No 3rd gear. improper gear or internal selection depending parts. ‘on condition mode and manual lever position: see solenoid ON/OFF chart. Shift errors may also be due to other internal | transmission con- cerns (e.g., stuck valves, damaged | friction material). May | flash TCIL, | * Output circuit check, generated only by electrical symptoms. ** May also be generated by some other non-electric transmission hardware system, 20Technical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS Three 1 Digit OTC |Component| Descrip Condition Symptoms \ 648" | SS1, SS2, | 4th gear failure. | No 4th gear. Improper gear al or internal selection depending parts, on condition mode and manual lever position: see solenoid ON/OFF chart. Shift errors may also be | due to other internal transmission con- cers (0.g., stuck valves, damaged friction material). May flash TCIL. 652" TCC | Torque Gon- | TCC solenoid cir- | Failed ON - Engine verter Clutch | cuit fails to provide | stalls in manual 2nd, solenoid circuit | voltage drop across, engine lugging, poor failure during | solenoid. Circuit | performance at ow self-test shorted or pro- | engine speeds, harsh cessor drive fail- | shifts, ure during self-test. 53) TCS” | Transmission | TCS not cycled | Rerun Seli-Test and Control Switch | during self-test. | cycle switch, No over- ot changing | Circuit open or —_| drive cancel when states during | shorted. switch is cycled. See self-test. : 653 for MHS. 653 MHS | Manual Hold | MHS not cycled __| Rerun On-Board Switch not during self-test. | Diagnostic Test and changing states | Circuit open or | cycle switch. during self-test. | shorted. Failed OFF ~No ‘modification of shitt terns. ailad ON ~ Vehicle will not upshitt/ downshift automat- ically, coast clutch engages in 2nd and 3rd gear. No 4th gear. ‘Output circuit check, generated only by electrical sympioms, “* May also be generated by some other non-electric transmission hardware system. 2ATSG Technical Service Information DIAGNOSTIC TROUBLE CODE DESCRIPTION CHARTS DTC DESCRIPTIONS not changing | states during Open or shorted | circuit, | Three Digit DTC | Component | Description Condition ‘Symptoms 657 TFT [Transmission | Transmission —_ Increase in EPC Overtemp fluid temperature pressure. May flash Condition. exceeded 270°F._| TCIL. 658 es Economy/ E/S not cycled Lack of performance Sport Switch | during KOER. ‘or fuel economy, EPC| pressure slightly high, Shift schedules and. | indicating Park. KOER. torque converter clutch engagement L os delayed. 659) TR | TR Sensor TR Sensor indicat- | EPC pressure ing Park during vehicle drive operation, high, all shifts firm. May flash TCIL. Range Failure). 667 TR — | TR Sensor out | TA Sensor, circuit. | No 4th gear oper of range or PCM shorted | ation, firm shift feel, Shorted circuit | to ground. } no manual 1st gear. or sensor. No TCC operation. li a May flash TCIL. 668 TR | TRSensor out [TR Sensor, circuit | No 4th gear of range. Open | or PCM indicates | operation, firm shitt circuit or sensor open. feel, no manual 1st ES gear. May flash TCIL. 75 TA | TReircuitor | TR Sensor, circuit | No 4th gear oper- sensor signal | or PCM operating | ation, firm shift feel, erratic. (In erratically no manual 1st gear TBD. | S2T/CS [3-2T/CCS ‘3-2T/CCS circuit | Failed ON— no solenoid circuit | fails to provide __| engine braking failure. voltage drop across| (except in OD), solenoid. Circuit | delayed 3-2 open or shorted or | downshifts. processor drive _| Failed OFF - engine Circuit failure during} braking in 2nd/3rd self-test gears, firm or flared | 3-2 downshifts. Harsh ea 4-3 downshitts, 998" | | Failure Mode | Failure detectedin | PCM enables alter- Effect Manage- | one or more critical | ate functions. Check ment (MEM) | inputs for other error codes. failure. | * Output circut check, generated only by electrical symptoms: ** May also be generated by some other non-electric transmission hardware system, 2TSG Technical Service Information DIAGNOSIS AND TESTING (Continued) DIAGNOSIS BY SYMPTOM INDEX ie Ties! achanical/vareue Son sicong a a No Fiat Gear Engases integer Geer 0" Peston) 26 a6 Ne Manual Gear (itin"9" 8) 216 a8 Vehicle Movement with Goa Slactorinthe "Postion 252 362 Diagnostic Routines ENGAGEMENT CONCERN: NO FORWARD 7261 — ELECTRICAL ROUTINE 1201 — MYORAULIC/ MECHANICAL ROUTINE Shit nkages 3900, miacuste,misassenoiag 1+ INSPECT ane SERVICE a resus ADJUST inkage as outinesin = caskets damages INSPECT or mane anaesice ‘Contes BTechnical Servi DIAGNOSIS AND TESTING (Continued) ice Information ENGAGEMENT CONCERN: NO FORWARD (Cont'd) enor bel ap missing raha re ' RETOROLE bots to apecifetions, ot Clutch Ansombiy Forwarg ten Retire Spring amagad 1 Ba Check Valve damaces « Friction Eman severly damaged o worn * Forward Coast Dect tan oinaersamages, esing. ‘naustombied or bing 1 INSPECT tor damage, SEAVICE 1 INSPECT or damage, SERVICE + che a won, am * INSPECTIor damage, SERVICE | msPEct tor camese SERVICE, ‘Low OWC Artem + INSPECT lor damage SERVICE ae regu 1 SPECT or damage. SERVICE aa eauend ENGAGEMENT con: (CERN: NO REVERSE I 7202 — ELECTRICAL ROUTINE Powertrain Control System © Ehcriea pute Outputs, Vehicle Whing Harnaaes, Pomeriia elMoadin sot otnid #1 (0, hana coer Pasion * Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 308 — WYDRAULIG/ MECHANICAL ROUTINE External Shit okay ‘INSPECT and SERVICE a aquired. ADJUST nt Service Mena Aver servicing tage, VERIFY leva poston anno propery adustos REFERS Dicessenbiy/Axsemaly poceduas Service Manel cain pene an PEAFORY Lie Presse VERY et herman ReFERTo + RETOROUE Sonstospectentions (Corton) 24DIAGNOSIS AND TESTING (Continued) Technical Service Information ENGAGEMENT CONCERN: NO REVERSE (Cont'd) 1 home Passages garaged INSPECT or damage and REPLACE + INSPECTIor damage. SERVICE as ecuied (Oi Pump Assembly 1+ RETORQUE bots to specications t-laton cemaged 1 Balicheck Valve camages PERFORM Ar Presi Test 1 INSPECT or eamage. SEBVICE a rogues 1 INSPECT or amage. SEBVICE e requires = INSPECTI6r damage. SEAVICE es requires Tow Reverse Cuich hase 1 Seals rpistoncamaged {= Frcton elements wor or severely damages 1 Paton Retan Srngcamages 1 Wave Soong missing S INSPECTICraamage. SERVICE a raquies INSPECTIorcemape SERVICE se requtes INSPECT for damage SERVICE as raautes ‘SINSPECTIorapring SERVICE a equees 1 INSPECT or domege. SERVICE a8 ecured Ferward/Cosst/Direct Guten Cynder 'PERFORW Ai Prossre Test 1 INSPECT fr garage SERVICE a eco evorae/Overarve Gear Set "Damages INSPECT tor damage SERVICE a acute ENGAGEMENT CONCERN: HARSH REVERSE/FORWARD Ponebie Component TESTRIGALROUTINE: I a * cites owoas venice wentirnnss towers |* Run OBD Tests wih a scanner. SERVICE as Sit fequied. CLEAR codes, ROAD TEST and RERUN O80 Tests, * Condition + A0JUST tito prope ve + INSPECT por Sorvce Maal iatrcton under Fi Conation Cheek ‘Gi aoinia” Front Wheel Drives 1 Service Manel procedures. SERVICE (Conice 25DIAGNOSIS AND TESTING (Continued) Technical Service Information ENGAGEMENT CONCERN: HARSH REVERSE /FORWARD (Cont'd) 7 Damaged misacnsies + Fecre Seaidamages, suggederoetotpotion REPLACE ter anda REPLACE Reciculaton Sas Wain Conti 1 Bote not oruad to specications * Low Reverse Accunuito Piston and Spring (Reverse), Main wat’ Vv, Forwat Accumulator Pon sr Spt, 1 RETOROUE bots 14 ‘ NSPECT{ov damage andREPLACE as require, INSPECT ordamage SERVICE an raqueed SERVICE anregure Forward GL Assembly (Forward Orn) 1 Forwarauten inane damage SERVICE asec SERVICE an requred SERVICE as reaored SERVICE as eauied SERVICE as autos ‘INSPECT Iercamng DisPECTiordamage (SPECT for damag INSPECT er damage. INSPECT lorcamage, SERVICE as rogues, ‘ow Reverse Cl Assembly (Revarze Oy) 1 Saale or Reverse CuichPetn damaged ‘Wave Speng camages «= Paton Bore camaged PERFORM A Pressure Tost. Direct Cluteh Assomay ev 1 Friction Elemente Severely ‘PERFORM Prosaie Test. SERVICE ae requted ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE OR FORWARD bie Component I 3205 — ELECTRICAL ROUTINE 305 — HYORAULIG/MEGHANIGAL ROUTINE 26DIAGNOSIS AND TESTING (Continued) Technical Service Information ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE OR FORWARD (Cont) © Gonanan ‘External tLinkopes # Damages, misadstedormisassombieg [+ spect and SERVICE as required, ADL + CHECK pressure inet. PERFORM Ling Prosture an Stl ‘Speee Test REFER to Pressure Gna 403 for peciications. ental‘ Purp Asser. Cen Aarombles On Fite an Internet Sh Lnkagoe 1 INSPECT and SEAVICE as requires ADJUST kage a uti in \evorpostion sensors propery austee REFER to ‘iPamp Aseomby Bote ottoquedto specications Seal Rings, #304 (Foreard),of #B0e 87 |= RETOROUE botstespectentns [= REPLACE ol pump assent OlFter ang Seal Ase a Valve, an Regulator Valve Low Rew 1 SepartorPiatesdemanea ‘Low Reverss CL Assambly (Rov ‘Pastor or Seals damages [INSPECT for damage, SERVICE e reauires INSPECT for damage, SERVICE ex resuires INSPECT or damage. SERVICE a rece. [+ NSPECT per Service Manual procedures, SERVICE as required * Check al sarapes * Fricion Elemente samaged wor ' Retwn Soring worn. amaged envi: Forward Clutch sembly (Forward Oa) 1 bal cece damanos sing or not sation propertyDIAGNOSIS AND TESTING (Continued) Technical Service Information NO FORWARD AND NO REVERSE ENGAGEMENTS. No Eeetia 307 — HYDRAULIG/MECHANICAL ROUTINE External Shit Linkage Oi Pump Assent FETOROUE bate to speciventions INSPECT tor damage and REPLACE a reauires 1 SPECT Ior damage, SERVICE ae regia + INSPECTIor damage, SERVICE 4s reque our Asem 1 Fitorea!amepee,pugoed or meting REPLACE ter ang seal assemtly pr Somice Manat! | REPLACE RESEAT Recicsating Sea Wain Controle * Gaskets cumaged ETORQUE bot to pectictons 1 INSPECT or damage and REPLACE a = WiSPECT or eamage, SERVICE es reauee * INSPECT ‘or amage, SERVICE as regia, Flywheel (Starter Gear + Daneged, beckon + INSPECTIoraamnoe, SERVICE as require. Torque Converter Assembly ‘= PanpDive Shatner damages 1 Stes broken orcamagee Sinema Bingo comaped broken INSPECT or damage. SERVICE as requ {+ INSPECT traueconvenarusng he procedusinthe Service Turbine Shale Forward/Const/0 1 SPECT or damage, SERVICE a reeves ‘Chain ana Sprocket 2 1 SPECT oy camage, SERVICE ns regure, Final Ocve ana Ditrantal AFR, (Contin) 3DIAGNOSIS AND TESTING (Continued) Technical Service Information NO FORWARD AND NO REVERSE ENGAGEMENTS (Cont'd) 7 INGPECT ior damage, SERVIC INSPECT or damage, SERVIC + INSPECT orcumage, SERVICE a requ, ‘SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING Befarenoe aston 7210 — ELECTRICAL ROUTINE EsmrsiMadoie: shit Sotonis, mana averposton senso, = PERFORM Sum Pan Test ‘Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. “0 = HYORAUUG/WEGRANICAL ROUTINE internal end External Su Lm 1 Dameges, mencusted or misasserbieg 2ST kage as outinedin 1 Deven Gea etaine damagesoemsng 1 wsrecTtordamaae, SERVICE a recures INSPECT lor mage, SERVICE o requred INSPECT or dmege, SERVICE 22 reaures ‘Goto Relerence/Action to dagnoxe apeciicmiasing ily shit Goncern No 12S 1 sain conceresNo 238m shin Concer No Sn + Rovine 222/322, SHIFT CONCERNS: TIMING — EARLY /LATE I Teference/ Action Zit = ELECTRICAL ROUTINE [Cont ogo, Theta Postion Sons. Vencie Speed Sescr, ‘Run OBD Tests with a scanner SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests TAT HYDRAULIC MECHANICAL ROUTINE on 1 seeccometerOrve Geur damages Faserignaaqepment change nie site or Scone 1 INSPECT or mage. SERVICE as INSPECT tor mane, SERVICE 2 recures SHIFT CONCERNS: TIMING — ERRATIC/ HUNTING I eterance Ration Pia — ELECTRICAL ROUTINE Powertrain Control System (Cortoues)DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: TIMING — ERRATIC/HUNTING (Cont'd) > Ena Concone {ContlModce, Shi Solent, Maras Laver Postion Sener, Run OBD Tests with a scanner. SERVICE as required. CLEAR codes. ROAD TEST and RERUN OBD Tests, * INSPECT per Service Manel mstctons vader Fils Condon # Speeaomater rive Gaaraamagee + Soeedomater Goar damages '# INSPECT or damage. SERVICE neque. 5 INSPECT {or damage. SERVICE neque 1 5:2 Tim Valve, Palin Vv, 24 Accunulator, Servo Relases * Pressure Tap Pato/Gasuet camages # 561,682, 227/608 Solenolgmatenction, suc, damaged ‘ RETORQUE bot te spectcains. INSPECT for demage eed REPLACE a equites * INSPECTIevéamage. EAVICE ee equtes 1 ACTIVATE solenlds wih tester NSPECT or damage. SERVICE + in Goncarn Ne +2 St 1 Shit Concar: Soft Sip 12 Shit it Concern: Set Sip 2-36 Concern So Sip 4S * Shi Concam: Son’ Sip 42 Sh 1 snitconcern Haren 3-4 it 1 ait concern Horan 43 Si 1 Shin concern: Haan 32 it + Rowtine 220/200 | Rowine 227/327 SHIFT CONCERNS: FEEL — SOFT/SLIPPING i eterenss Aston Powerirain Control Syatom ‘# Eiecrcal nuts Outputs, Vehicle WiingHerneeses,Powerin Coir Maaue, E> Sole, Hanami Oi Femgerture Sensor, Thote Postion Gonao” Mae Atom Senco = PERFOR San Poi Tent + Run OBD Tests witn a scanne?. SERVICE as Tequired. CLEAR codes. ROAD TEST and RERUN O80 Tests 1 conden INSPECT per Serie Manalinsrocions wader Fd Conon Coninoeey 30DIAGNOSIS AND TESTING (Continued) Technical Service Information ‘SHIFT CONCERNS: FEEL — SOFT/SLIPPING (Cont'a} "+ INSPECT ana SERVICE a aque ADLUS Hncage a cutne in the Senice Marval Aer serving kage, VERIEY mathe Disassenbiy Assert orececuesin Service vans slow orar ani are sot aipping, 6219 Man Conta, On Pump SStamy O1F iter! Seai Asser itresaurs are Ok nda specie shinies stoping, REFER to the sppropeateotie() tor aso! agnosis ‘suit 2 Routine 226/328 Shit 2.2 Routine 227/327 Shit a Routine 226/528 Shit Routine 220/520 ‘Shit 3-2 Routine 200/330 ‘hina Rouine 201/394 Internal Sn inka = Damage, misacted a misessembled 1 isPeCT and SERVICE a eau, ADJUST inkage 28 atin in the Serice tas! Ata servic iwage. VERIFY athe Disnasemtly Assembly arogecues Serce Marl 1 INSPECT gaskets ang REPLACE a5 eae 1 ISPECr orcamage. SERVICE asrequred {INSPECT er amage, SERVICE a5 reauire, INSPECT or damage, SERVICE 3 require, ‘Oi Fiter/SaatAssemoiy 1 Fite Seat damages. 1 nesteuintng Seat damagedor out of poston 1 REPLACE titer ad seal assent 1 REPLACE Receuletna Sea. SHIFT CONCERNS: FEEL — HARSH Possbie Gonpovent Bia — ELECTRICAL ROUTINE Powerirain Control System 1 Elst npute/Outpt, Vaile vvingHarnesses. Power onrolozle, 2 Sotnoia, ranamasion Temperature Sensor, T38, Tv Postion Seng vencie Specs Senso, ans keton Serr F06 Solano anual Lever Potion © PERFOR Tora Gonvarar Gach Operation Took * Run OBD Tests with @ scanner. SERVICE a3 required. CLEAR codes. ROAD TEST and RERUN OBD Tests, 74 — HYORAULIC/MECHANIGAL ROUTINE: { inseEcT pr Service Manasinstucions under Fak Conation ‘GV doin Front Wheel Drvehatta Powertrain Mounts ‘Conteueed 3Technical Service Information DIAGNOSIS AND TESTING (Continued) SHIFT CONCERNS: FEEL — HARSH (Cont'd) Damaged ove, ee ‘= DNSPECT ir damage SERVICE ae reaued 2 Megntine Presse + CHECK pressure at Lng ap. PERFORM in Prossue Tost ane ‘Stal Specs Teste REPERto Pressure Cn s401 fr Specitcatone Npresnuresaretugnor alan arefareh, GO ‘Shin 2:1 Rowling 237/297 # INSPECT or damage. SERVICE as requres 1 Main Reguitor Valve, By-Pass Valve, Loe Modulator Va © eSolenaa suck orsamapes 1+ INSPECT for damage, contamination. ACHVATE solenoid sing 1 SesuratorPate damages, bockes 4 WSPECT ior damage. SERVICE a6 eared Torgue Converter Assembly NOTE Wee apslecsureg sine ‘Pomp Suppor Sel # (CRY eve eshng, missing or damages ‘SHIFT CONCERNS: NO 1ST GEAR, ENGAGES INHIGHER GEAR Component I Retorence/ Acton TEecneuiewrovean secesvengtanenerfovenae [© Run OBD Tests with a scanner. Ssarsuadoa sontonncan wanton Pcckensone” |” SERVICE es required. CLEAR codes, ROAD TEST and RERUN OBD Tests, TiS = HYORAULIC/ MECHANICAL ROUTINE 1 Damages, misadustedormisassembles 1 INSPECT tor proper ait Ieustes REFER a Disessemaiy/Aaserby pace res nts Main Controle + Bote nottoravecto seciteatins ‘+ RETOROUE dots te specications + Gaskets amagee * INSPECT for damage and REPLACE a8 requ 1 Palin Valve. Sotenoi Repuletor Va, Shit Vatves sic, INSPECT or demege. SERVICE asreauies 1 Solero iter Gasket umaged.ormisnssomblad 1 INSPECT or damage. SERVICE ne reauses 1 Hyernube Passages amazes # INSPECTIor damage, SERVICE ex reuse 151,552 Solenosmatuncton © ACTIVATE slang with vane senvice as {207-00854)toetermine a “owmarovtings: (Coninaea) 32DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR (Cont'd) ossibve Component + REFER to Serce Menallr Testo procedwes, SERVICE SHIFT CONCERNS: NO MANUAL 1ST GEAR ible Component T Powertrain Control System 1 Electron nga! Opus, Vehicle Weng Harneses, Powerain + Run OBD Tests with a scanner. SERVICE as Fequifed CLEAR codes. ROAD TEST and RERUN OBD Tests Bie — WYORAULIC/ MECHANICAL ROUTINE 9:4 External SHFLnk micas orm Disssembiy Ansembly proceguesinSerece Mana 1 SeparatorPiaten damagnd o2kee (SPECT foe demape. SERVICE 284 1 ACTIVATE sleoid sing ranamnson + INSPECT tor amago, SERVICE at requ INSPECT or eanage, SERVICE as requred. senvice a SHIFT CONCERNS: 1-2 SHIFT (AUTOMATIC) 1220 — ELECTRICAL ROUTINE Powertrain Control System Cont oaue, Shin Souscide, Marval Lever Poston Sevaar * Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. "320 — RYORAUIG/ MECHANICAL ROUTINE 2 Une Pressure Wain Conver 1 Gaskets camaged 112 sin vate, 2:4 Accumslator, Main Reguitor Vat stuck, stare Tap Please damaged 1 RETOROUE Dots to peciiontont. 1S INSPECT or damage and REPLACE as rut INSPECT Cr aamage. SERVICE as requte 1 INSPECT or aamage. SERVICE as reautes INSPECT orcamage: SERVICE as eaves INSPECT for cumage, SERVICE as rau (Cortnuea) 33Technical Service Information DIAGNOSIS AND TESTING (Continued) SHIFT CONCERNS: 12 SHIFT (AUTOMATIC) (Cont’é) 1 INSPECT or dumage, SERVICE a8 requed # INSPECT Ior damage, SERVICE as reavired 1 Ser Resor Ros ore sanage + INSPECT orcamage. SERVICE as reauied {Low OWG Assembly = ama + NSPECT lor damage, SERVICE a reuires, + INSPECT or canage. SERVICE ae requires 1 Lowandinarmedite Band Ancho Aron camapes ‘ SWSPECT or damage tcamagedREPLACE tho + Porosity leakage in Sere Hoy, Sen Raleasa cue ‘INSPECT cat erieakage/poreety. PERFORM Ar “eat, REPLACE ca SHIFT CONCERNS: 2-3 SHIFT (AUTOMATIC) Possible Component I Retarence/Action 123) — ELECTRICAL ROUTINE wvaing Harnesses,Pewersain | Run OBD Tests with @ scanner. SERVICE as ConeelMul, Soi Sleniés.MansalLeve:PostonSensor” |” ‘oauired. CLEAR codes, ROAD TEST and RERUN OBD Tests, 321 — HYDRAULIC MECHANICAL ROUTINE ‘ast REREAtoProsnare Gna 401 fr specineaon HOT (OK: CHECK ne olowing posse sompornnt: Mann Coto Wain Gontrot 1 Bore not torqued pec * Gasketieane + 2:9 Shit Valve aso No th). Main Regulator ae suck, 1 SS2mmatturction also 4) | INSPECT or daage, ACTATE solenoid by seg ranaminson nspecr INSPECT or nage, SERVICE # INSPECTIorganage, SERVICE ‘+ RETOROUE bots to specications, OPump Assembly 1 Bote nottrauedtospectostions = RETORQUEoIt # INSPECT orcamage ang REPLACE 4 + INSPECT or damage, SERVICE as resi INSPECT tor damage, SERVICE 8 requires ‘INSPECT ov damage, SERVICE as rogues. * Fiction severe samaged, worn {INSPECT er amage, SERVICE as rogues + BaliCheck not seating propery 1 INSPECT or amuge, SERVICE ae requves | Rotun Song Arseny damages ge SERVICE an resuie 1 Oytnser Bre! Spina camages SERVICE a esi 1 ShetsHuncamagea SERVICE a ecuied INT/00 Seno) (Contes) 34DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: 2. SHIFT (AUTOMATIC) (Cont'd) ible Consonant [> RSPECT or damage, SERVICE a required + NSPECTIoreamage. SERVICE aarequtes Intne Servo Apply, Servo Release or Orect Ciuc SHIFT CONCERNS: 3-4 SHIFT (AUTOMATIC) Possible Component I Taterenca/ Action wartain Contol System ‘Elsie epta/ Outputs, Vehicle Wing Hares Sranamiason Carr! Suton TES). ‘Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 78 — HYORAULIG/ MECHANICAL ROUTINE Une pressure 1 CHECK pressure Line tap, PERFORM Lin Presse Tots REFER fo Proasure Chan a0} for rane obeceatons out ot Wain Contrar INSPECT er damage and REPLACE asrequred. 1 ACTIVATE solenoid sing anemston estar SERVICE 25 INSPECT or damage, SERVICE as reales NOTE: AlsgNO na pour ‘n7/00 and damaged wort * Seno Piston Coversamagedrleskng © Songs camagee + INSPECT lorsamage 2 INSPECT tor somage 1 Feetonsoveray camagee worm 1 Chackalleverey damages SERVICE a rocuied Forward OWC Assembly + INSPECT Ice damage, SERVICE ee reauves Cave aio Naas ae + Save Apply and Seno Reena crow 1 INSPECT or damage, SERVICE a reaies PERFORM AiPressure Checks SERVICE SHIFT CONCERNS: SOFT/SLIPPING 1-2 SHIFT ONLY (AUTOMATIC) Posabie Component ConratMcale, PC Solna Transmssion Ot Tam * Run OBD Tests with a scanner. SERVICE as required CLEAR codes, ROAD TEST and RERUN OBD Tests, (Gorteuead 35DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: SOFT/SLIPPING. 112 SHIFT ONLY (AUTOMATIC) (Cont’a) Possibe Component I "FRE — WYORAULIG/ MECHANICAL ROUTINE 1 2st AccumatorPiston ig and Gasket camanee (aio tot 9-4 st, Main oan) sac, # SPECT ‘ WSPECTIor damage, SERVICE as requires. * INSPECTIorgamage, SERVICE as reuie, INSPECT or ganeoe. SERVICE es eguree 1 Pato, Senior Paton Bore camages, msing # 1NTLOD Gare anaor Reverse ton Drum Assembly wor, 1 ser Cover and Seal camages [+ INSPECT lordemege. SERVICE en reaured 1 INSPECT lordarage. SEAVICE a requires 1+ INSPECT lor damage. SERVICE a reguices 1 INSPECT tor damage. SEAVICE on reguras Forward OWC Assembly (sown Ta) Forward Ctch Assembiy (al 1 INSPECT tor gamage. SERVICE 1+ NSPECT tor damage. SEAVICE 8 reauied 1 NSPECT tor damage, SEBVICE a rogues, ce SHIFT CONCERNS: SOFT/SLIPPING 2-3 SHIFT ONLY (AUTOMATIC) T Re 7227 — ELECTRICAL ROUTINE ‘Conrol Moco, EPC Sten, Tanemawion i Temperature Sensor Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. INSPECT for amage ane REPLACE as requres + NSPECT for damage, SEAVICE 2 reaured ain Control (Conia) 36Technical Service Information DIAGNOSIS AND TESTING (Continued) ‘SHIFT CONCERNS: SOFT/SLIPPING 2-3 SHIFT ONLY (AUTOMATIC) (Cont'd) osaiie Component Teterenea/Action ‘Fresno Tag Psa Gaskatoaks = NGPEGT oraamage SERVICE o6 eared Dieet Catch Assembly = PERFORM A Presare Chock erPiaton damages {INSPECT lor camage, SERVICE a8 equted nv - {INSPECT oreumage. SERVICE as waded Imsoed, womer excessive ancl {INSPECT oraamage CHECK ana provesures SERVICE a rogues ‘+ cntchal not eating property INSPEOT for damage. SERVICE ws requed + Rata Sting Assematy camases 1 INSPECTIor damage, SERVICE asreaures. THT/00 Seve 1 Paton or paton bore damags 1+ INSPECT lor ctmage, SERVICE as requ + Senoredorobore genase, {INSPECT oraumage. SERVICE as rogues a Normals. canagee, + INSPECT oreumage. SERVICE as reaued ‘SHIFT CONCERNS: SOFT/ SLIPPING 3-4 SHIFT ONLY (AUTOMATIC) TELEGTRIGAL ROUTINE *exeaenenoeen ence menomareeagereze® |* Run OBD Tests with a scanner. Sensor SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 720 — HYORAULIG/NECHANIGAL ROUTINE ‘Wain Contot ‘ caskerLenns| INSPECT or oumage ana REPLACE as recurs 1 Ue eater Vato, 2-4 Accunsiator Vale PupandSeal (also | lSPECTIoreamage, SERVICE asreauies fom 2 ant) sos samagedr misassored “Pressure Tap ae) Gaseatlonke “s INGPECTIoramage, SERVICE asrequved arate passages gamegod 1S msPECTtoraamage. SERVICE asrequves. 1 Separator Plates camaged or Otten locked INSPECT oraamage,SERVIGE sreguces. 1 1Nt/00 Band under Revers Con Grom Aazmbly Worn, + INSPECT loretmage, SERVICE asreauted 1 Serve cover or Sen zamanes 1 PERFORM Ar Pressure Check, NSPECT fr damage. SERVICE 1 sere Roser Roetore amazes 1 INSPECT for damage, SERVICE asrequtee 1+ sonaoscamapoe SINSOECTloreamage. SERVICE aarequted Direct Chuich Arson = PERFORM AirPresure Check NOTE May slo ave Sd gear aie # Seats amaged, missing “INSPECTIoraamage. SERVICE as requred * cece Ga samened, missing oreaking 1 INSPECT or gamage, SERVICE a 1 Reta Sprngcumages {INSPECT or damage, SERVICE ce 7DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: SOFT/SLIPPING 49 SHIFT (AUTOMATIC) I eteranes Acton Powervain Conta System 1 iecircalinpssOutpite Vehicle Wiring Harnesses, Powertrain ona Mocuia EPS Sole, Voila Speed Sense, Mas * Run OBD Tests with @ scanner. SERVICE as required CLEAR codes. ROAD TEST and RERUN OBD Tests, ain Controt * Serv Release Ste Vive, Man Reguator Vai suck, + RETOROUE bons te spretestions 1+ INSPECT tor damage and REPLACE a ose 1 INSPECT or damege. SERVICE as resus. ‘+ INSPECT for damage, SERVICE a osu. RSPECT for damage, SERVICE as rele, 1 INSPECT or damage, SERVICE as reaures ct Cath AnsembIy = PERFORM air Pressure Crack 1 INSPECT or damage, SERVICE a eae image SEAVICE ae aaused 1 Fection Seman worn, cemages * Cheon Ba not tnctonag 1 Forward lueh Paton and Retwn Sorina damages = PERFORM Ar Pressure Check. ' INSPECT or damage. SEAVICE a requires 1 INSPECT or damage. SEBVICE as required hale Serve Apply, Servolo, Oest PERFORM Ar Presaure Check SERVICE ‘SHIFT CONCERNS: SOFT/SLIPPING 3-2 SHIFT (AUTOMATIC) I Teforenca/Action 236 — ELECTRICAL ROUTINE PowertainContol System ConisiMocuia. EPC Salen, Throte Poston Soeor, Vile ‘Seeeg Sensor aa Arion Sanson 3-2 Timing’ Coast Gates Selena 27/608), + Run OBD Tests with a scanner. SERVICE as requited. CLEAR codes. ROAD TEST and RERUN OBD Tess 355 — HYDRAULIC MECHANICAL ROUTINE ain Contot RETOROUE bts to spacteations 1+ INSPECT tor dage and REPLACE a rogues. {INSPECT or damage, SERVICE a equa # scrware ‘Conimueay 38DIAGNOSIS AND TESTING (Continued) Technical Service Information SHIFT CONCERNS: SOFT/SLIPPING 3-2 SHIFT (AUTOMATIC) (Cont'd) TGraket wana or demenea INSPECT oraams 1 INSPECT orcamage, SERVICE ‘Direct Clutch Assembly = Revun Spring camaged, broken {INSPECT Ier damage, SERVICE asrequres {INSPECT er damage, SERVICE ae regures 1 INSPECT or damage, SERVICE a regu. TNT/00 Band and Servo Assembly 157/00 Bans enaor Reverse Cen Orom Assent worn + INSPECT or damage, SERVICE a rege + INSPECT orcamage, SERVICE as requir. 1 INSPECT or damage, SERVICE asrequred 1 INSPECTIor damage, SERVICE asrequred 4 INSPECT Iov amage, SERVICE a regres 1 castetscamagee 1+ RETOROUE bots to specications {SPECT fr camage and REPLACE 0 requis. [+ NSPECTI0r Gamage. SEBVICE a rere. redamazes (Servo Rod) + INSPECT oraumage. SERVICE asrequres { nsb Ect forteaks PERFORM Ai Posse Check, SERVICE as 1+ INSPECTIoe damage, SERVICE 8 raures ‘SHIFT CONCERNS: SOFT/ 1 SHIFT (AUTOMATIC OR KICKDOWN) I eterense/Astion wartrain Contol System Conteledoe EPC Salen, Tenamieion Ol Torperatre Sons, Tote Posinon Sena, Mase Aton Sensor * Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 31 WORAULIG MECHANICAL ROUTINE [+ INSPECT or damage and REPLACE as requred {INSPECT or lak/ pron REPLACE ae cequred 1 INSPECT tor damage, SERVICE a rogues ‘00 Serve andland Assembly nRatn Goring amass 1 INSPECT lor aamage, SERVICE as resus [INSPECT for damage, SERVICE es reuies 1 Paton oSontacamages -ERFORM Ar Pressure Check 1 INSPECT or damage, SERVICE es required INSPECT Ior damage, SERVICE as reaured + INSPECT or damage, SERVICE as reured ‘SHIFT CONCERNS: HARSH 1-2 SHIFT ONLY (AUTOMATIC) I 722 — ELECTRICAL ROUTINE PowertainContol Syston (Contuaa) »DIAGNOSIS AND TESTING (Cor inued) Technical Service Information ‘SHIFT CONCERNS: HARSH 1-2 SHIFT ONLY (AUTOMATIC) (Cont's) (Conti acu, €>C Saecie,Transmanion Oi ampere or Venice Spang Sear, 708 tte Poston Sener * Run OBD Tests with a scanner. SERVICE as fequired. CLEAR codes. ROAD TEST and RERUN O80 Tests, 359 — HYORAULIC/ MECHANICAL ROUTINE + RETOROUE Dots to spectenins. 1+ INSPECT or mage, SERVICE + INSPECT or damage, SERVICE * Gasket aa 1 INSPECT tor demege ang REPLACE a requies 1 INSPECT lr domege. SERVICE es requires INSPECT or gamese. SERVICE ee regures TWT/OD Band ang Servo Asem 1 17/00 Band ana/or Reverse Cuton Or Asserby wor, + INSPECT lorcamage, SERVICE a requtes 1 INSPECTIoreamage, SERVICE as resures 1 INSPECTIor damage, SERVICE a requires eton Sng camaes > PERFOR A Pressure Chock 1 INSPECT or damage, SERVICE 0 recuree videmasee,RESLACE Ie case SHIFT CONCERNS: HARSH 2. 3 SHIFT ONLY (AUTOMATIC) I Powertrain Control Sysiem /*Run OBD Tests with a scanner. SERVICE as required. CLEAR codes. ROAD TEST end RERUN OBD Tests. 358 — HYDRAULIC [MECHANICAL ROUTINE Sots not toruedte specications Geaetleaks CraNoauntorVahe (ales 1-2ane3-anaran ant, Servo Reteoce Sule Vive such damaged or misansembleg Separator plates camages hyorauic passages cama 1 misPECT tor same end REPLACE ee requires 1 INSPECT for damage. SERVICE exrequces 1 SPECT tordamage. SEAVICE a requres 1 INSPECT tr gamege, SEAVICE ae required 1 Bota nottorquesto specications + Fame suppor sesings #40 #6 camages «+ RETOROUE soi tospectention: {INSPECT tr samage and REPLACE: "PERFORM Ar restore Chace INSPECT Ior damage, SERVICE a regured S INSPECTIor damage. SERVICE a reauredDIAGNOSIS AND TESTING (Continued) Technical Service Information ‘SHIFT CONCERNS: HARSH 2-3 SHIFT ONLY (AUTOMATIC) (Cont'd) eterenca/Aetion 1 Guten ynder pings camages ‘7 INSPECT ior damage, SERVICE 0 requtea 1 INSPECT or damage, SERVICE 24 egure 4 he S010 Asp. Sere le + Str hosborecemases SHIFT CONCERNS: HARSH. -4 SHIFT ONLY (AUTOMATIC) 24 — ELECTRICAL ROUTINE Cictic! pu Outs, Vile Wing Hareeaes, Power nil Mode, Sarno Venen Speos Senesr 3 21/6C8, Manual Lever Postion Sensor Tronamsnon Oi Tompertre ‘Stmor, 708, fwette Postion Sone Mace Alow Saraor-TEC *Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. a4 — HYDRAULIG/MECHANGAL ROUTINE (aio 12 762.9 narsh shi. 32 Como imaged ormanasomalos yer passages camenee + Sepsrator lates camaces, blocked + RETOROUE bots tospectentons (SPECT orenmage andREPLACE as requ. 1 INSPECT or damage, SEAVICE a requires INSPECT for damage SERVICE ee requeed 1 INSPECT fr damage, SERVICE se requted + INSPECT {or damage and REPLACE 8 reaure, 11/00 Band and Servo AnsemDiy 117/00 Bang and Ravarae Cltch Oram Assembly. samagee, ‘rom misessembled 1 sorage camag 1 INSPECTIor damage, SERVICE a required SERVICE a aque Coast Chzh Ansemiy 1 Paton or Soul damaped ising 1 Chace Bart untonng Direct Cluteh Assembly ‘Return Speng camagee # CitenCyngr spines camages SERFORM A Pressure Check 1 INSPECT for damage, SERVICE a ecued 1 INSPECT for damage, SERVICE a ocues. 1¢ INSPECT lor aamege. SERVICE as ecuiod INSPECT for camage, SERVICE a ecued + INSPECTIcr damage, SERVICE 0 recued ca + INSPECTIor damage. SERVICE 2 reguted a TTSG DIAGNOSIS AND TESTING (Continued) Technical Serv ice Information ‘SHIFT CONCERNS: HARSH 4-8 SHIFT ONLY (AUTOMATIC) 235 — ELECTRICAL ROUTINE Eontaitoaue, ES ‘entsie Spees Sensor, ‘Sensor, 185, Thotle Penton Snaot ae Aow San *Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 75 — HYDRAULIC / MECHANICAL ROUTINE Main Contot image SERVICE asreqused { Porosity cro lene, Seat Rings camaged, missing orlesing 5 1 ashe camaged ‘Puno Suppor Seal ngs 2,9, 4 or #5 (Coast and OvectCtch rcate)eamaee TH1/00 Band and Servo + Ser Rosbent camagea 1 Sere eto spang Broce 1 INSPECT for damene. SEAVICE as eases. 4 SPECT or damage. SERVICE a5 require 1 INSPECT or reage, SERVICE se equa # D1SPECT tor damage. SERVICE a eques. 1 PSPECT or damage. SERVICE a8 egure + INSPECT tor damene. SERVICE £6 eau cr ‘SHIFT CONCERNS: HARSH 3 2 SHIFT ONLY (AUTOMATIC) Possibie Component I Powertrain Control System ‘ Electcatinpte Outputs, Vehicle Wing Hares EnralMocsa, EPC Soleo, Manual ver Posten Sanna, ise Speed Ganson 9. 21/0 oe Ol Tampere 188 trote poston eraor hae Atom Sensor TCC * Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. "326 — RYDRAULIC/ MECHANICAL ROUTINE * Gasket amaze + 5:2 Ting Valve, Solenoid Repustor Valve, 9:2 Con Valve = Hyareuc passages damage + RETOROUE bots to soectentions. * INSPECT or damage and REPLACE a ecu. ATE oleae ving tranamanion tester 1 Cons Ctch ions Ox PROCEED Greet Guten hase ‘Direct Ciich Assen = PERFORM a Prosar Cheek 4 2Technica! Service Information DIAGNOSIS AND TESTING (Continued) ‘SHIFT CONCERNS: HARSH -2 SHIFT ONLY (AUTOMATIC) (Cont'd) otabie Component Telerence/Acton > Reta Spring aarages, broken © SPECT fo damage SEAVICE ns required 1 Fecion Elements sama, worn SERVICE ae requred 1 Check Saint exrauting oe, SERVICE ae reqused TNT/00 Bandana Servo Asem SERVICE ab requte rmancCushion Sings damaged. misarsembled |e INSPECT or damage. SERVICE as reauies a inaneambleg {INSPECT or damage. SERVICE a8 reauies {INSPECTIoraamage, SERVICE as eauied INSPECT orcumage arg REPLACE a requces INSPECT er post, rcueed INSPECT or eamage 1 Band Anchordemapes 1 DiSPECT or damage, SERVICE as ecued 1 Servo Restore samaped 4. NSPECTIor damage, SERVICE ae eau ‘TORQUE CONVERTER OPERATION CONCERN: NO APPLY Fazal Component I Raerance aso 1240 — ELECTRIGAL ROUTINE * egaourngntovo vecearmsrumzetezem” |* Run OBD Tests with 2 scanner. ‘Solenoid Brake On/GH Switch, SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 3a — HYBRAULIG/MEGHANIEAL ROUTINE Main Contat Bots nottorauestospacfeatins + RETORQUE bots toapweMentions 3 {INSPECT Iorcamage naREPLACE serequted ie Reuter Valve pas Chich Cont Vane | INSPECT for damage, SERVICE as requires. ‘on afr Vv tk, damage, = Tee Seimoiematnction ‘+ ACTIVATE slenoi sing ranamieion ester SERVICE a8 | INSPECT or amage ane REPLACE a reas INSPECT or damage, SERVICE as reaured. Torque Converter Assembly TORQUE CONVERTER CLUTCH CONCERN: ALWAY'S APPLIED /STALLS VEHICLE Possible Component I Reference Action ‘at — ELECTRICAL ROUTINE * Clnrcimea,renomautn Or Yenpeatswtenese Tee | an BD Tests with a scanner. ee SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 3a] = HYORAUUIGT MECHANICAL ROUTINE Main Contol I ‘Comes BTechnical Serv DIAGNOSIS AND TESTING (Continued) ice Information ‘TORQUE CONVERTER CLUTCH CONCERN: ALWAYS APPLIED /STALLS VEHICLE (Cont'd) teh Corral ave and Plunger aa poked, NOTE Convetercuten ot eppledin tt gearorrevere + Hydraulic Passages damaged ‘+ INSPECT or damape. SEAVIC 2 egies ‘ACTIVATE solenou ving vanamasion eater SERVICE a8 4 SPECT ov camege, SEAVICE a8 raquo ‘OiiPump Assembly «+ Pane Susser # + SenlRagchmages,masng misassembleg ‘= RETOROUE bats to specications ‘nverel Gosia ctmagee 1 cover is heat tangs, REPLACE converte ‘cane + INSPECT tr porosity SERVICE o REPLACE case as OTHER CONCERN: SHIF TLEVER EFFORTS HIGH i 261 — ELECTRICAL ROUTINE 135} — HYDRAULIG/ MEGHANTGAL ROUTINE Brake Sitinerock Internal ong External Shit Unk 04 missdut 1 WSPECT ard SERVICE a required. ADLUSTlokape a ctines in Lever aston Sensors propery agjsine REFER i Disessembly Ascembly proces + INSPECT or damage, SERVICE Main Conta ‘s RETOROUE bote te speciteationt 1 INSPECT or damaae. SERVICE 8 reauies OTHER CONCERN: EXTERNAL LEAKS Ne Eietvieal Concerns 1352 — HYDRAULIG/ MECHANICAL ROUTINE I I + A030 lt rape vl ‘Sesle/Gasneie ‘Deron Seal, Spesaometer Gest, Retsne Sea, Pump, Mal Conte over, Serva Cover Spin Flange Gasne, Convene’ IpeterHuo SancaiLave’ She Sect Oi Levsinacstar Tube + LOCATE soured otleak. SERVICE ae rule I Diteretil fr Converter mpele a lasing PISPECT arias ha {eserconener Housing, NSPECT surtacnomshator Font © LOCATE sows oaah, SERVICE ws required (Cortouaa) + aDIAGNOSIS AND TESTING (Continued) Technical Service Information (OTHER CONCERN: EXTERNAL LEAKS (Cont'd) Possibie Component + LOCATE source tien SERVICE a rogues (OTHER CONCERN: POOR’ VEHICLE PERFORMANCE T Reference Action Powerrain Contra System 1 Bate Engine Concer 1 Electncal nate Outputs Vdc Wing Hamasses, Pomertaa + REFER one Engine suction ofthe Sic Maru * Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests, 759 — HYORAULIG/MECHANIGAL ROUTINE # INSPECT and SERVICE as ecuod, ADJUST inage as outa, Semice anal Ater serving inkage, VERIFY inate Manual, Lever Postion Sensors propery aajuntog REFER TO + c01othe aoropnate agnostic Rostines perce + Goto Reuine #501 Torque Conver REPLACE an vequree OTHER CONCERN: NOISE VIBRATION — FORWARD/REVERSE I Pelsrence Acton 254 — ELECTRICAL ROUTINE No Eeztieal Concerns I 1354 — HYORAULIC/MEGHANIGAL ROUTINE 1s Torque Converter Companente 1 Fistevei (Low) Puma cevton 2 lump nasa © LOCATE souroe of stance, SERVICE as reques. For Nolaes/ Vibrations tha Change with Vehicle Spe * PowanralnMounte Loot, Damaged + Pansiny Goa Sats 1 Forave Comer Assombly + wseect on Senvice 4 WSPECT ior camage, SERVICE as euros ‘Transmssion Shit Cab ora Bracket Vibration, rounding aeTechnical Ser DIAGNOSIS AND TESTING (Continued) vice Information OTHER CONCERN: ENGINE WILL NOT CRANK I 255 — ELECTRICAL ROUTINE (Constivadan Manon Lever Postion Senaar (Gomapedtmsacented) Run OBD Tests with a scanner. SERVICE as required. CLEAR codes, ROAD TEST and RERUN OBD Tests. 35 — HYORAULIG/ MECHANICAL ROUTINE + INSPECT oe damuoe iseesombhy. SERVICE a + ADLUST inkage a outinesin Service seamy/ assem use REFER oO OTHER CONCERN NO PARK RANGE I ataronee/Acton 256 — ELECTRICAL ROUTINE No Eiecticel Concerns I 366. THYDRAULIG/MEGHANAL ROUTINE ‘INSPECT ana SERVICE a Service Hanus Atessetsong nkape, VEAIFY tht te Mal ‘hing, Pu Paatcheing Springs, Paring Paw Sat, Ment ‘Gam hop Laver rer etet Sprig ton Sear Parking Pawi pat Ca, Manual + INSPECT or damage. SERVICE as rogues OTHER CONCERN: TRANSAXLE OVERHEATING Porsibe Component 257 — ELECTRICAL ROUTINE Powertrain Control System CContainedoe, 166 Sienna. Tensmasion OvTempertre Senor ss * Run OBD Tests with a scanner. SERVICE as required, CLEAR codes. ROAD TEST and RERUN OBD Tests, Vetiste Concern Causing Engine Ovarhenting + ADJUST tito proprio Intake Cooler = Damages booked resisted orlaking ‘Coninves) 46Cr ATSG Technical Service Information DIAGNOSIS AND TESTING (Continued) OTHER CONCERN: TRANSAXLE OVERHEATING (Cont'd) ‘INSPECT for damage, SERVICE a resuires 1 SPECT or damage, SERVICE a reaie ' INSPECT or damage, SERVICE a requires 1 TOC Solenoid mation OFF) © ACTIVATE sland sing ransmanon eer. SERVICE 8s “erase Convertor Cuich- No Apoiy = SEE Rovine R207 (Ol Pump Ansomiy INSPECT or camage ansREPLACE segue, 1 INSPECT or anaoe, SERVICE as requres. Chain Pan Masog + INSPECT or mesing pan NSTALL pani ising 1 Suck span rdemanes # INSPECT or damage. SERVICE as required. 4 INSPECT er amage ara REPLACE a reaueod + INSPECT lr damene. SERVICE a reared + INSPECT passages. REFER o Svc Manca or idantontiono 2 TCG. Cr Pessegen sockos arrests Bessagen SEAVICE an reguiee ‘OTHER CONCERN: NO ENGINE BRAKING IN MANUAL 1ST POSITION Possible Component I Teterence/Aciion ELECTRICAL ROUTINE! ' circanpets/ Outputs, Vehicle WiingHarneases,Powernrain | Run OBD Tests with @ scanner. SERVICE as ContotMedse, Timing Coen Chuck Salma femmes CLEAR tide RADI TEST ana RERUN OBD Tests, Perform Stall Speed Tests, 358 — HYORAULIC/ MECHANCAL ROUTINE Main Controle 1 Geskatecamnose 1 INSPECT or damage ang REPLACE as rogues 1 INSPECTIor damage, SERVICE as requ 98 contarietion, ACTIVATE solid with * INSPECT or damage, SERVICE as reauied * INSPECT or damage, SERVICE as requ + INSPECT cr damage, SERVICE as ravi INSPECT or damage. SERVICE as reauted [+ INSPECT lr damage. SERVICE a reaores [+ INSPECT lor demege, SERVICE a roaires, + INSPECT tr damage, SERVICE 0 reaies. 1s Aasenbiy masaserbeg, damaged 1 INSPECT tr damage, SERVICE a egies ‘INSPECT tor damage, SERVICE a requtes a7DIAGNOSIS AND TESTING (Continued) Technical Se! rvice Information (OTHER CONCERN: NO ENGINE BRAKING: IN DRIVE (TCS ON) OR MANUAL 2ND POSITION I 259 — ELECTRICAL ROUTINE Powertrain Control yet 1 Eictrealngeta utp, Veto Wing Harnesses, Ponenin EonioiMada, Timing Cone! Cok Solan.e * Run OBD Tests with a scanner. SERVICE as fequirfed. CLEAR codes. ROAD TEST and RERUN OBD Tests, Perform Stall Speed Tests, 7355 — HYDRAULIC [MECHANICAL ROUTINE Internal or xt = Oarnases. 1 INSPECT and SERVICE a rocures, ADJUST Inkage au ctine in Disensemaiy Assembly recbouesin Sorce Manel Tain Contoie 1 3:4 Shit vag, 12 Sit Va, Pllnvaee, Const ten Coto 1+ 3.2 Tining/CoastCuten Solenoid tek or samag SERVICE as raqoied [Forward OWC Assembly + SPECT ior cama SERVICE asraquens SERVICE asrequved + Pump Suppor #2 or #9Sesl age fore Coutts veut SERVICE se raqueed (OTHER CONCERN: VEHICLE MOVEMENT WITH GEAR SELECTOR IN THE “N" POSITION Ne EectvcslConcerne 362 — HYORAULIC/ MECHANICAL ROUTINE 1 1NSPECT and SERVICE as requis ADJUST naage as ctsneain Seen Mana. er VERY thet he Mans Seeing damned * Gaskets severely mage ump Suppor Seal Ring 32. lankege tram Lube Crcutito FC ceca Forwara/ Cosel Cmich AanBIy 1 Frc platen severaiydemaned + INSPECT for damage, SERVICE a regia 1 INSPECT or dane, SEAVICE as reaies 48DISASSEMBLY Technical Service Information Remove the oll pump drive shat by pling it from ‘the end ofthe turbine shaft assembly, Pullthe transmission speed sensor trom the bore. Poll the olfiler tube from the bore, Ob FUER TUBE tase Remove the olfller tube and discard the ol filer tube grommet. | WM sai is Femove the Vehicle Speed Sensor (VSS) bolt using an 8mm socket,DISASSEMBLY (Continued) Technical Service Information Rlemove the VSS trom the bore. ees Inspect the VS teeth for chips, nicks or concave teeth, Romove the O-ing from the VSS. Discard the Ong. Use an 8mm socket to remove the two Manual Lever Position (MLP) sensor bolts au SensoRy Pull the MLP sensor trom the manual valve detent lever shat Mana. Lever Sexsonras” Use an amnm socket to remove the fourtsen main ‘contro cover bots in the sequence shown, Pu the main control cover assembly from the transaxle case. ‘Separate the main contro cover assembly trom the main control cover gasket. Discard the main ‘contrat cover gasket Inspect the main control cover vent assembly and ‘main control cover grommet 30DISASSEMBLY (Continued) TSG Technical Service Information ‘Remove wiring harness clip from main contol. Pull the main contro sighty away from the transaxle case. Disconnect the Zink from the manual valve ‘CAUTION: Do not pull on the connector wires or ‘Use ahammer on the connector. ‘Sque0ze the retainer tabs ofthe electrical Connector and remove the connector from the Boren the case, Inspect the Oxing for damage. cose TRaNsAe Eteermica _, CONNESTOR Remove the main control from the transaxle case ‘and storein a ean location. ullthe thermostatic ol level contro valve from the transaxle caseDISASSEMBLY (Continued) Technical Service Information and Overdrive Servo G eo Part tom | _Number__| Description + |7F20 intermeciate ana Overarve SewoRetum Spring Resemby 2|- Intermeciate and Overerive Ser od ale tt Se 7H08) ala Intermediate and Oversrive Servo Piston Part of 74188) 5 | 70027 Serve Cover 6 | tHo7e ‘Serva Cover Retaining Ring 1 |ro027 ‘Serve Cover Cap Using a 17mm socket, attach the Servo Cover Romover /Replacer T24P-77000-. to the of pump assembly. WARNING: SERVO AND SERVO COVER ARE UNDER HIGH SPRING FORCE. Use a 15mm socket and screw inthe bolt to ‘compress the servo caver assembly and remove the servo cover retaining ring WARNING: THE SERVO COVER IS UNDER PRESSURE. Remove servo cover cap trom the transaxle case using Jet Plug Remover T77L-9538-8, Discard servo cover cap. aerewa Revues fg, TISSSB v0 cover assemblyTechnical Service Information DISASSEMBLY (Continued) Remove the intermediate and overdrive servo ‘Separate the converter housing trom the piston and return spring. transaxle case. UNTERMEDIATE AND Pr INTERMEDIATE AND ‘Qvenonive senvo Prsrow assemaLy Inspect the folowing intermediate and overdtive serve parts for damage. ‘© Cover with integral seal (¢ Return spring © Apply rod and retaining clip ‘© Piston with integral seal ‘© Cushion spring and backup washer © Case servo bore. Position the transaxle so the converter housing faces up. Use a 10mm socket to remove the twenty Cconvertar housing-totransaxle case bots. Bi Bh = SBureice TpaneaKce SasKET aS Remove the transaxle spit fi tor housing, Discard t asker. Remove the # 15 dtforential bearing (4221), Remove the # 14 dtferential baring shim (4067) (Selective ft trom the ral crve carrier and ifforential assembly, Romove the speedometer drive final rive carrier and altferent HISDEFERENTIAL BEARING ma 2 C> 33Technical Service Information Fomove the rear chain cover (withthe magnet attached) fom the ransaxle case, Check the ‘magnet for excassive metal partici. aeaponan (PART oF rHa90) FRlomove and discard ol fiterrecicuiating regulator exhaust seal Remove tho oil fiter and seal assembly. Discard ‘hol fiter and seal assembly. Remove the # 12 driven sprocket bearing ‘assembly ang the # 11 ven sprocket shim (Golective Mt from the vansaxie case, igpaven senocrer "1 guNEN SPROCKET Beane assemery SMM THOBg rom LUnsnap the goeket enc ofthe manual valve detent lever actuating rod assembly from the parking ‘cam actuator lever assembly. ana vane LUnsnap the socket end of the manual valve detent lever actuating rod assembly from the manual valve detent lever assembly.Technical Service Information DISASSEMBLY (Cor ied) ‘amove the inal drive cari and ditferentil assambiy FINAL DAVE CARRIER ‘NO DIFFERENTIAL ia ‘Remove the front chain cover by unsnappingit from the rear chain cover FRONT CHAN coven aes Remove the # 19 driven sprocket thrust bearing assembly #13 DRWEN spRocKET ‘Fiver Bearine 2semety NOTE: The # 10 drive sprocket thrust washer (76099) may be attached to the converter housing. Remove the #10 dive sprocket thrust washer from the Reverse / Overdrive eng gear assembly. ro oRIvE SPROCKET SARUST WASHER, 76088 WARNING: WEAR GLOVES AS PROTECTION FROM SHARP CHAIN AND SPROCKET TEETH. Litt the orive chain assembly, drivan sprocket ‘assembly, and the Reverse Overdrive ring gear ‘2ssembly together from the transaxle case. AVE CHAN, BND SenoCKETS eparat he crv chain assem fom the Stier racket esse. and he averse verve rng goat assembly. nevenseovenonve HASSE aaa ‘paiven sencciet ReSenaty reise AVE CHAN Eseraly e208 53DISASSEMBLY (Continued Technical Service Information ss pevensioves BING GES Ye Flomove the Reverse Overdrive carrer ‘@ssembly with captured #8 trust bearing. = =) Sais ASSeMaLY AH, Remove the Reverse/Overcrve sun gear and shell assembw Reverse, ) OVERS AND Sve Asonaey tasze NOTE: The #7 Reverse /Overdrive sun gear thrust bearing assembly may be attached to the Reverse /Overdrive sun gear and shell assembly. (62, Remove the #7 Reverse/Overdtive sun gear Remove the Lowintermediate ring gear assembly ate carir thrust bearing assembly may be attached tothe Lowntermediate ring gear assembly. Remove the #6 Lowintermedate carrier thrust ering assembly Coie He, = Remove the #5 Low.ntermediate sun gear thrust Dearing assembly and the forward one-way clutch and Low-itermediate un gear assembly. Ow geror ae » ‘Hoa FORWARD ONE-WAYDISASSEMBLY (Continued) Technical Service Information NOTE: THo #4 turbine shat thrust boaring assembly ‘may be attached o the forward one-way clutch and Lowsintermediate sun gear assembly. Remove the #4 turbine shaft thst bearing ‘HCTURBNE SHAFT Remove the turbine shaft assembly. TRAN SHAFT, ASSemal 7213 Remove the assem Fev cata (C1610) eyinder assembly and reverse clutch ‘drum assembly sStinancieonst, Seer eRES > eet y Sasecuey ASS Toh NOTE: The # t pump support thrust bearing assembly ‘may be attached to tha reverse clutch drum assembly FRomove the # 1 pump support thrust bearing assembly pay suppor. Resenaur ma) Low One-Way Clutch Assembly Low one-way ctu mera Low one-way Store aSseMeLy abee Flomove the low one-way clutch retaining ring, 37Technical Service Information Remove the low one-way clutch thrust pate, NOTE: Te low one-way clutch assembly should be emoved ae an aseamdly. Remove the ow one-way clutch assembly Low one-way aa Yaoes Low/Reverse Clutch ‘Gorimued) Pat Part tem | Number _| Description tom |__number__| Description + | row, 5 | 7ET6 ‘Low Reverse Cuich nora] 2 | rose Spline Clutch ates 3 | 70483 6 | 78086 7 | 78070 Low Reverse Clutch Wave 4 | rosa Spring 38see ee EEECEEeeeEegeeEeE eEEEEE EE CeEEEEegeeEEegEEE EEE EEE ATSG Technical Service Information DISASSEMBLY (Continued) Remove the low reverse clutch wave spring. Remove the low reverse clutch plates. owevense LOWREVERSE PLATE Tous LOWMEVERSE oma soune Starts cre 2utthelow reverse catch piston trom the bore fFricriong 7864 Beyer Use a screwdriver to romove the low reverse Remove the low reverse clutch piston outer soa Clutch return spring retaining rng. is isto from the low /reverse clutch piston. Discard the outer seal Lowmevense cuuTcH Ay REMAN Sr FETANNG ANG ERERESTEN rouce Sh} APTA SMM Remove the low /reverse clutch return spring assemby.DISASSEMBLY (Continued) Technical Service Information Flamove the low /reverse clutch piston inners from the low reverse cutch piston, Discard th inner seal Lowmevens SLUTEH PsTON 7O«02 Position the transaxle withthe oll pump assembly facing up. Use an Bmm socket to remove the nine ol pump assembly bots. Install Side Hammer Ad Purp Removal Bolte To and impact 7 100-A ane remove the ol pump assembly from the transaxle case. Slide Hammer TSOT- ‘pact SUE uD nase Sotp-reteo-8 ‘Side the intermediate and overdrive band ‘assembly rom the case, reRwebiTe AND OVERDRIVE BAND. ‘ASSEMBLY Poet Inspect the intermediate and overdrive band ‘assembly for wear. DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES Planetary Gearsets and Chain Drive Parts Inspect the Lowintermediate sun gear assembly (part of the forward one-way civic) for damage and weer: © Goartoath ‘© Thrust bearing surfaces (© Bushing surtace LowaNreRMeniare SON GEAR ASSEMBLY, PART OF 7A085) Inspect the Lowintermediate carrier assembly: '¢ Pinion gear teeth © Spline toothTechnical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) = Pion gor surface 1 Bushing surtace 1 Pion goer beerinas eee eon Inspect the Reverse/ Overdrive carer assembly: {6:18 t00.72mm (0.006 to 0.028 inch). ‘Pinon gar tooth 1 Cutch plat spine eth 1 Prion goer bearings 1 Treustboaring sutaces somarenmeniare Bushing surfaces Rages ‘© 9 Threstboarng captured between the ined Dinos and ari pussies neversvovenonve ear Sage sneer Inapectthe Lowsnermacate ing gear assembly: © oar tao «© Spine oth (© Thrust bering surteces ‘© Bushing surface 1 Lugtontn| pinlon gear end pay. End play should be between 6.15 100.72mm (0.605 t0 0.039 inch). Betmica aan Inspect the Reverse Oveccrive sun ger and shot assem for damage and wer © oar tooth # Lugteotn Thrust bearing surtaces 1 Bushing sutace 61Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Inspect the criven sprocket assembly: * Gear teeth © Parkinglock i teeth 1 Driven sprocket teeth ‘© Thrustbearng ertaces| Bearing sutaces © Rivets Bushing surtacee Inspect drive chain assembly for excessive stretching, wear, o ight Iinks. wan A Litt the fina dive ring gear rom the converter housing. Inspect the gear and housing lug teeth. FINAL ORE RINacean Tre 2Technical Service Information ‘Use an 8mm socket to remove the diferential ube tube bok Assembly Push the diferentia lube tube inte the converter housing. ‘Seat the end ofthe diferenta lube tube with Lube Tube Replacer TO¢P-77000-V1 (part of Lube Tubs Repiacer Set T34P-77000-0). Clean al parts thoroughly inclasn solvent and low cry witn moisture‘tes compressed at HYDRAULIC PASSAGES CONVERTER HOUSING hd Uso an 8mm socket to instal and tighten the ferential lube tube bolt to 13 em (10 Io)Technical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) NOTE: The final drive ring gear wit fit easly into the Converter housing. it does aot. fip the inal crve ring (ear over. ‘Lower the fina drive ring gear into the housing. SPECIAL SEAVICE TOOL(S) REQUIRED Case sembly Deseiption Tealnumber Use a screwdriver to remove the final drive ibe tube from the transaxle case, Use Rr Lube Tube Seal Replacer ‘T91P-76085-A to remove the final rive ibe tube seal from the transaxle case, Insta the ol ube connector on the converter housing, Tighten the oll tube connector to 40 Nem Boh. 4TSG DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Use O-Ring Tool T7 1P-19703-C to remove the parking paw shat. move the parking brake paw assembly and parking paw return spring, PARKING BRAKE PA ASSEMBLY CAUTION: Do not damage the transaxle cose bore during seal removal. Use a screwdriver to remove the manual control lever seal. Discard the seal, Remove the manual valve actuator rod (nk). CAUTION: Do not damage the transaxle case ling eur re two retaining pins, ong on either side lve detent lever (7A1 15). Protect the transaxio case with wood and use @ pal of side cutter to remove the manual valve ‘etent lever shaft retaining pin, Discard the ‘anual valve detent lever shaft retaining ph. MANUAL vatye 9) SHAFT RETAINING BRTat0DDISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information move the park pawi ratcheting spring. PARK Paw Barone Femove the manual control lever assembly. Use a 24mm socket to remove the manual control lever shat nt Remove the actuating cam. parking ‘cam actuator lover park lever spacer (7286), ‘and manual cont Part Item | Number __| Description + [PKs ‘Manual Control Lever Shalt ner 2 | F286 Park Lover Spacer 2 | reas Manual Contol Lever Shat 4 [rant Parking Cam Actuator Lover ‘Assert 5 |7r954 Parking Paw Aetuating Cam Use a 7mm socket fo remove the parking paw! shat retainer and bolt assembly. PARIONG Paw 66DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) TSG Technical Service Information CAUTION: Do not damage the: ‘Sealing surtace. Protect the case with wood and ust Cutters to remove the manual shaft retaining pi (76100). Discard the manual shaft retaining pin. Remove the mansal valve detent lever assembly ‘and manual vaive detent ever shaft fromthe ‘ransaxe case, ord CAUTION: Do not damage the transaxle case String eal removal Use a serowdever to ramove th manual cont Seal ascomay rom he ansani case, scare Svea Gy Remove the line pressure port plug trom the Wansexle case, Remove the ol ube connector. tube connector seal ou ruse oan Inspect the of Insta the manual valve detent over assombly ‘and manual valve detent levers ana hat into the case, SHAFT TOs ASSEMBLY TANSTechnical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) CAUTION: Do not allow the manual shart pin to make contact withthe transaxi Use a hammer and a punch to install the manual ‘valve detent lever shat ratalning pr Install the parking paw! shat, SAAS Toor Install the parking pawi shaft retainer and bolt ‘sssembly. Use a 7mm socket to tighten the parking paw shaft retainer bot to 8 Nim (6 Et) erty thatthe manual valve detent lever sembly rotates freely. Install the manual vaive actuator rod (Z-nk). PAR ING PAM ‘SHAET RETAINER Bout" Use Throttie Shaft Seal Replacer T81P-70337-A fr equivalent to nstall the manual controllever eal ‘nstal the parking brake pawl assembly and Parking paw return spring, PARKING PAM, REN a rasa 68DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information ‘Assemble the parking pawl actuating cam, parking cam actuator lever assembly, park lever ‘Space’ on the manual control lever shaft Part tom | Number _| Description + [PKs ‘Marvel Conol ever Shaft 2 |re2e6 Park Lever Spacer 3 |7c483 Marual Cont Lever Shatt a [rant Parking Cam Actuator Lever assem 5 |rease Parking Paw Actuting Cam NOTE: Verity that the manval control lever shatt ‘assembly can move freely. 16. Install the manvel contro lever shaft assembly Into the trancaxle case, Install the manual contro lever shatt nut. Uso @ ‘24mm socket to tighten the manual control lever ‘hat nut fo 74 Nem (55 1, 69Technical Service Information DISASSEMBLY AND ASSEMBLY OF 'SUBASSEMBLIES (Continued) Forward One-Way Clutch and Low-intermediate Sun Ges Assembly Part Part tom | __Number__| Description tem | _Number__| Description += Low:intermediate Sun Gear e|> Forward One: Way Chtch ‘Assembly Part of 7A080) (utor Race (Part of 74089) 2- 7 |rowe et Clutch Mud Retaining a |- ej- Coast cuten Hub (Part ot ‘Ta088) a|- o|- Lube Grooves wo |= Thick End Cap (Pent of s|- }One- Wey Cater 7A080) Sprag Assembly Pert of a fe Thin End Cap (Part 074086) TAO) s2_ | riaas. Retaining Ring ‘Conimuead 70DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Forward One-Way Clutch Disassembly ‘Carefully remove the coast clutch hub ri ring. EGS evan rin 7122 Remove the forward one-way clutch outer race ‘and sprag assembly with ond caps. FORWARD ONE.WAY ceurcn ouTeR RACE AND. SeRAG ASSEMBLY ‘Seperate the sprag assembly and end caps from the outer race, Note the positon ofthe end caps. ‘They are of different thickness and are not interchangeable. FORWARD ONE-WAY tureH SeRAG ssemacy ~ PARTOF Ta099) & (PART oF 7A008) Remove the forward one-way clutch retainer. FORWARD ONE.WAY ELUTeM RETAINER (PART OF 72008) nDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information Remove the retaining ring, ine ras Bow dry with moisture ‘Compressed ai Inspect the forward one-way clutch parts for ‘damage and wear: © Outer race ‘ace and Low-iniermediate sun gear bly © Lube holes © Coast etch hub Assembly SPECIAL SERVICE TOOL(S) REQUIRED SerapResiacer To2P-77000-5 ‘natal the retaining ring. RETANING ING Hs NOTE: Te tabs on the retainer shoul be facing Install the forward one-way clutch retainer FORWARD ONE.WAY ClutewaetaNen (Pant oF 72089) ‘entity the thick and thin ond caps. ran i UT LL] ‘Thick ‘Assemble the forward one-way clutch sprag assembly and end caps. FORWARD ONE-WAY ctuterseraG Sssemacy ~ PARTOF Ya009) (PART OF 74080) Use Sprag Replacer T94P-77000-J to install the ‘Sprag assembly and end caps inthe out 2Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Install the coast clutch hub, ttem | _ Number _ | Deserition 9th etaning ing shoud point + [= Forward One-Way Ghtch towards the coast cut hb Seagineenty art Install the coast clutch hb etiing rng. 2 |reee-rre003 | Sorea Re a |= Forward One-Way Cutch const wren nue Corward One Wey Cinch SSEMRSARE Se Sow (ar of 8089) a|- Twek ena ep Partat Tabsai sl. ‘Trin End Cap Part 74089) NOTE: Lube grooves face up (away from sun gear) Flip the outer race and sprag assembly (with end ‘caps) over and instal onthe forward one-way ‘latch inner race, OUTER RACE AND Soaas ASSEMBLY iPan oF 7A065) Lube gaooves ‘Check the operation ofthe forward one-way ‘luteh wth the Loveintermadiate sun gear facing up. It should work as follows: ‘© Hold the outer race with one hand. ‘© Rotate the Lowrintermediate sun gear clockwise. The Lowinterm ‘Should rotate witha slight attempting to rotate the out rowan S0NGeaR assemecy (Pant OF 7a089) 2Technical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) ‘© Rotate tne Low-ntermeciate sun gear e counterclockwise, The Low-intermediate sun See (988r should rotate the outer race Low One-Way Clutch Assembly" ‘The folowing ilustrations an exploded view ofthe low ‘one-way clutch move the roller assembly. power Part jm | _Number__| Description [= {Low One-Way Cuich nner Face (Pert ol 7A0BS) s|- Low One-Way Clateh Outer Face (Par of 72089). ale Identitcation Groove. S1— a Clean all parts thoroughiy in clean solvent and Low One-Way Clutch Assembly blow dry with moisture-tree compressed ai Disassembly Position the iow one-way clutch o thatthe inner ‘and outer race grooves are facing UP. 74Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Inspect the low one-way clutch parts for damage and weer: © outer race «roller assembly 19 habe holes Assombly NOTE: The outer tabs othe roller assembly must be facing up 1. Insta the roller assembly into the outer Final Drive Carrier and Differential Assembly Disassembly NOTE: Do not remove the final drive pinion shat retaining ring. Use a punch te remove the pinion shat ol in CAUTION: The inner race groove must face up. Install the inner race with the groove facing up. mere (Check the operation of the low one-way clutch 2s follows: 1 Hold the outer race. «Rotate the inner race clockwise. The inner Face should rotate with a sight drag without attempting to rotate the outer race. ‘Rotate the inner race counterciockwise. The inner race should rotate the outer race. 75Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Remove the sitferntial pinion gears and abtferential pinion trust washers (4230). DlereenmiaL PION GEAa Inspect the fina rive planet and carrier pinion gear fond play. End play shouldbe between 0.17 0 0.65mm (0.008 to 0.025 inch). Banton TROST WASHERS 4250 Remove the differential side gears and citterential side goer thrust washers (4226). DFFERENTIAL Sie cear aver wasven Assembly renenrv Insta the ctferenti! side gears and diferential Soecan~ | side goar thrust washers 38 J ynusr WASHER (Clean al parts thoroughly in lean solvent and Blow cry with moisture ree compressed a Inspect the diferentia parts for damage and © oar teeth ‘© thrust washer surtace «© thrust bearing surface, © pinion shat Inspect the fina rive planet and carter (7F465): ‘Pinion gear teeth «© Pinion gear bearings © Thrust bearing surfaces © Bushing surtaces 16TSG DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Install the diferential pinion gears and dtteretial ‘side gear thrust washers. DlereneNTAL =e Install the ctferential pinion shat. pion Saar RoLupa Forward/Coast/Direct Clutch Cylinder ‘Assembly and Reverse Clutch Drum (Disassembly) Disassembly ‘Support the assembly of the Forward/Coast/ Direct clutch cyinder assembly {and reverse clutch drum assembly on a block of wood 80 that the reverse clutch hu faces Upward, This wil ease reverse clutch hub retaining ring removal Drecranran snonevense eturen baum Sesenat LOCK oF Wooo Use a par of snap ring piers to remove the Feverse cluten nub ataining rng 7ATSG Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Remove the reverse clutch hub. Flomove the direct clutch hub and shell fom the Forward/Goast/Direct clutch cylinder. inecr cur RUB ano Swett ASSEMELY 7006 FRlomove the two reverse clutch cyinders (70020) trom the Forward /Coast Di cylinder assembly. Discard seals ae Remove the #2 direct clutch thrust washer from ‘he Forward/Coast/Direct clutch cylinder, Re eyiinder' the Forward/Coast/Direct clutch hub seal Discard the sea low reverse clutch, 78Technical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Reverse Clutch Pat Part tem | _Number__| Description ttom | _number_| Description + [70256 Reverse Clutch tub 6 |7eaaz Reveree Cutch Exeraal ing Ring Spline CiutehPiates (Stoo) 2 | 70391 ‘aten Hu 7 | rH22s: Retaining Ring 2 | 70483 iutch Proasure 8 | 76385 4 | 70408 8 |re07e 5 | ro16 Ciuten internat 10 | 70044 teh Pia ‘assemtly (notion) Contnuead nevense clurox Prescune LATE RETAINER SNAP FING 75483 Femove the reverse Guich plates. Inspect for damage andweer. EvERsE clue ESERNAC SPOREDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information RETAINING FING aos Romove the spring compressor to release the pressure on the reverse clutch return spring ‘assembly. Remove the reverse cutch retum ‘pring assembly. Reverse cuuToH RETURN SPRING. ASSEMBLY 70335 Romove the reverse clutch piston assembly with ins integral seats REVERse cLuToH PISTON ASSEMBLY ‘Soak the internal spline clutch plates in clean transmission fd for 18 minutes before assembly. Insta the reverse clutch piston assembly in Flverse Clutch Piston Seal Protector ‘T94P-77000-02 (part of Cutch Piston Seal Protector Sizer Set T94P-77000-D), REVERSE CLUTCH PISTON ‘SEAL ProvEcTOR Use Reverse Cutch Piston Seal Protector ‘Ta4P-77000-02 (part of Guich Piston Seal Protector Sizer Set T94P-77000-D) to instal the fevarse cuch ston essenby wih negra seals Reverse cLuTcH Revense cuuTcH Bhuw roo Install the reverse clutch return spring assembly. Reverse c.uron RETUaN senING. ASSEMBLY 70835 80DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Use @ pair of snap ring pliers to install the retaining rng RETAINING. ING Tze. omove the spring compressor. Install the reverse clutch plates. iateacatics a evense cuurou ute sare, BRESCORE PEATE Install the reverse clutch pressure pate retainer snap ring (Selective ft), Sea mo Use a teeler gauge to measure the clearance Detwoon the reverse clutch pressure plate and etainer Revense cuutcH nevense cuter Ponte Tone ‘The standard clearance is 0.33 to 0.89mm (0.01 00.04 inch). tthe clearance isnot within the specication, select and instal the proper thickness snap ring to obtain the standard clearance. Teeness me 788-149 (0.055 100.059) 1.58-169(0.08016 0084) £66178 (0.08610 0070) Forward/Coast/Direct Clutches The folowing ilustration isan exploded view ofthe forwarg clutch rect clutches. sl4ATSG Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued)ATSG Technical Service Information DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Part Description tom | Number _| Description Direct Catch Return Spring 76 [Tie Forward Catch Spring Aasemy Retaining Ring Direct Caton Piston nner Lip wile Clearance tr Fingers onthe Seal Fonwarg Gatch Piston 8 | 7az8e Direct Cuteh Piston se | reeaz Const CistehExtoral Spline Reseniy Giiten Petes (Steed | 7ases Direct Cuten Piston Outer 10 | 78168 Goest Ciuten internal Spine Lip Seat Gluten Patea rction) 10 | 76120 Forward! Cosst/Diect 20 | re08s. CGoest ClutenPreseure Pate ‘Cuten Cynder Assembly 2 | 7o164 Forward Clutch internal 11 | 7as48 Forwara Cuten Piston Inner ‘Spine Clten Plates UpSeal ration 12 | raze Forward Cluten Piston 22 | rose Forward Clten External hecamtly Spline cluten Pl » 19 | rasa Forwerd Clutch Pieton Outer 2 | ra08e Upset v4 | ra282 (Coast luton Piston ang 2 | rosea Seal Asseriy Retaining Ping 1s |ro200 Forward Coast Guten Fotum Spring Assorely Conmed Forward/Coast/Direct Clutches onscr eure. Disassembly ess SPECIAL SERVICE TOOL(S) REQUIRED ‘Deveription Tes number ‘Gatch Spring Compressor TesL77616-4 Ring Too! rrip-r6708.¢ ‘Remove the direct cutch pressure plate retaining ring Er ouToH PRESSURE RATE. Reread sec RETAINING RING Cuuron PoaTes, rou 83DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information Use Clutch Spring Compressor TESL-77515-Ato ‘compress the drect clutch suppor and spring (7238). pincer cuuTom RETURN SoRING, ASSEMBLY 77255 pa of raping per toremove te rect htc sprog retin move the ang conpragsarendramove the direct clutch return spring assert Remove the cect clutch piston assombiy. Remove the direct clutch piston outer ip seal {rom the drect clutch piston assembly. Discard winecr wren Paro ‘84Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Remove the drect clutch piston nner lip seal trom ‘the Forward /Coast/ Direct clutch cylinder assombiy. Discard the seal. Flip the Forward Coast Direct clutch cylinder ‘over. Remove the forward clutch pressure plate retaining ring. Part tem | Number _| Description 7a086 Forward Clutch Proseure Remove the forward and coast clutch plates. 2 | reaez 2 | ree 4 | re4ee 5 | 7e086 6 | 78164 Claten interna ‘Spline Cten Plates ratio 85DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Use Clutch Spring Compressor TESL-T7515-A to ‘compress the forward coast clutch return spring assembly Use a pair of snap rng piers to remove the forward clutch spring retaining ring, Remove the spring compressor and the forward/coast cluten rturn spring assembly. 14, Use a pair of needle nose pers to remove the forward and coast clutch piston. Use O-Ring Too! T7 1P-19703-C to remove the clutch piston ine ip saa from the Forward Coast/Diect clutch evinder assembly Discard the seal FRlomove the forward clutch piston outer ip seal Discard the seal FoRWaRo cuuTCH Piston rage rerun Bae 86Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) ‘Separate the coast clutch piston assembly with FoRWanO intogral seal trom the forward clutch piston assembly. CP SEAL abs Insta the forward clutch piston essembly in tho Forward /Coast/ Direct cluton cyinder assembly, Insta the coast clutch piston assembiy in Coast Glutch Piston Seal Protector T94P-7700003 (Gart of Cutch Piston Seal Protector Sizer Set ‘Ta4P-77000D), Astombly SPECIAL SERVICE TOOL(S) REQUIRED ‘Devcrption Teainunber ‘Goasi Guten Piston SealPrvector | TeaP-77000-05, ‘Soak the internal spine cltch plates incloan ansmiesion hid for 16 minutes before ascombly. Insta the forward clutch piston inner lip seal in the Forward’ Coast/ Direct clutch eyinde assembly. Use Coast Cutch Piston Seal Protector T94P-77000-03 (part of Cutch Piston Seal Protector/ Sizer Sot T94P-77000-D) to neta the ‘coast clutch piston nto the forward luton piston assembly Install the forward clutch piston outer ipa the forward clutch piston assembly. FORWARDICOAST/ Biaeor cute SrNDEa ASSEMBLY ‘87DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information Remove the spring compressor to rk pressure on the reverse cluten return epeing, ‘assembly. Remove the reverse clutch return ‘spring assambiy Reverse cuutcn Bevense cuurcH PistoN ASSEMBLY 7E079, ‘Soak the internal sping cutch plates in clean transmission fuid for 18 minutee before Install the roversa clutch piston assembly in Reverse Cluten Piston Seal Protector ‘Ta4P-77000-D2 (part of Clutch Piston Seal Protector/Sizer Set 194P-77000-0), REVERSE CLUTCH PISTON SEAL prorecron Use Reverse Clutch Piston Seal Protector ‘T94P-77000-02 (part of Cutch Piston Seal Protector Sizer Set T94P-77600-D) to instal the reverse clutch piston assembly with integral ‘Seale, Revense cuutcn Peron scat RevEnse cuuTeH’ aun 7D Install the reverse clutch return spring assembly. 88ATSG Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Install the forward /coast clutch return spring ‘assembly, Use Clutch Spring Compressor TEEL-77518-A to Compress the forward coast cluichretum spring ‘assembly. Use a pair of snap ring piers to install the forward ‘clutch Spring retaining rng. Pat Mem | _Number 7e086 7eee2 7er64 ra08s 2 2 4 | res 6 |raree Install the forward clutch pressure plate retaining Remove the spring compressor. Install the forward and coast clutch plate 89Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Install the direct clutch return apring assembly. Use a pak of snap ring ples to install the direct clutch spring retaining fing. Remove the spring compreesor. Install the drect clutch plates. ‘Measure the direct clutch clearance as folows: lal indicator onthe side of the orward/Coast/ Direct clutch cylinder ‘assembly and zero the needle onthe direct ‘lutoh pressure plate, 90Pree ee ee ee reer eee eee eee eee eee ee eee ee eee Hee eee eee Hee eee eee eee eee eee Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) ronwano cfurcn Paescune ene RETANER ANG Use a tecier gauge to measure the between the forward clutch pressure ph the forward clutch pressure plate retar Fomwao cuurcH Preset RETAINER SNAP RING 7b Feeen guue The standard clearance is 0.500 1.09mm (0.02 100.04 inch). Ifthe clearance isnot within the specification, select and install the proper thickness forward clutch pressure pl ting to obtain the standard cearanc ‘Snap rng sizes are as folows: taining Thieknans mE 7.261.38(608000.054) 1.36.49 0085.0.059) 1:52.69 (0086-0080) 1651.75 (0086-0069), Install the direct clutch piston inner lip salin the Forward/ Coast/Direc clutch cyinder assembly piaeor cuutcH Piston NES Gpsea Install the direct clutch piston outer ip seal on the Greet cluteh piston assemoly. pipes cxurTon Pistoy oure GBSEAC Tass Inetall he direct clutch piston assembly inthe Forward /Coast/Direct cutch =yinder assembiy. 91Technical Service Information DISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Inetallthe two roverse clutch eytinder seals. race the Forward/Coast/Direct clutch cylinder ‘assembly on a block of wood 60 that the direct, ‘cutch faces upward, onwanoyconsts CyuMber ASSEMBLY Er) ‘Lock oF woo Install the direct cutch hub and shell on the Forward/Coast Direct clutch cylinder. 92DISASSEMBLY AND ASSEMBLY OF 'SUBASSEMBLIES (Continued) Pr Technical Service Information 1 Use two picks to pullthe direct clutch pressure plate upward. Observe the dal incicator, Feading. Duc Notcaro Nagnlerie BASE Drseinor ‘u, moIcATOR | PuUNGER ‘© Make a second measurement onthe opposite side, Average the two measurements to get the clearance. ‘The standard clearance is 0.52 to 1.12mm (0.02 100.04 inch. tthe clearance isnot within the specification, select and instal the proper thickness direct clutch pressure plate retainer snap ring to obtain the standard learance, Retaining ring sizes are as folows: Thickness neh) 1.28-138(005..050) 139-149 (005505) Forward/Coast/Direct Clutch Cylinder ‘Assembly and Reverse Clutch Drum Assembly (Assembly) Assombly ‘SPECIAL SERVICE TOOL(S) REQUIRED Description Goan Guth Piston Se Sizer CAUTION: The tabs on the #2 direct clutch thrust washer must be seated in the direct clutch ‘Support and sprit Install the #2 direct clutch thrust washer on the Forward Coast Direc clutch eying with the cing down, Reverse cute EyUinben SEAS <_Y Gir >) wrone 93SUBASSEMBLIES (Continued) Technical Service Information DISASSEMBLY AND ASSEMBLY OF Install the reverse clutch hub retaining rng Reverse cLutca US Reames ‘Turn the assembly over and install the Forward/ Coast Direct Clch cylinder hub seal ‘onthe Forward’ Coast/Direct clutch cyinder. (Oli Pump Assembly Disassembly Use a Torx® T30 socket to remove the six pump ‘suppor bolts Separate the pump support assembly ol pump body separator plate, and pump body separator plate gasket (738 1 trom the ol pump body. So0y. ‘bump Booy SEPARATOR SEPARATOR Rao. PUSE GASKET 78a ou PuMe. Seat hoes upume PART oF Ten 94Technical Service Information Remove the ol pump drive gear assambly and ol amp drive gear insert (7402) from the oi pump 0a. on. pu on. PUMP, Saive Gear Brive Gena INSERT ASSEMGLY \ Pantor é AC KX IO 2 ftom \ Aa PS \ Re ae le Femove theo pump erven goa om theo 3 |= Spon Spor Sealing panp boa ae Stpmpsuponseainng ae ‘Ol PUMP. aoe Sites 5|2 3rPune Suppo sealing Bree alt unrtyoe romsourte o|- Rovrtacaten «|= Oren uten(bo) ne Forensic FO) ae Cont Gutenteo) (Gan allparts thoroughly in clean solvent and iow dry with moisture-ree compressed af Inspect the ol pump body and gears: © Driven gear teeth © Drive goar tooth © Gear bore ‘© Crescent Part © Lube passages andholes ttem {| _Number__[Description += Lube (From Gooler Te Inspect the pump support apply crcut passages and lube passages. Crew) Goaat citer (co) Direct Ciuen 00) Forward Guten (Fo) Reverse Clutch (RO) Converter Cltch Bypass (cays 95Technical Service Information Insta the oll pump driven gear inthe oll pum body with the identification cot facing down, lL PUMP, SaivEN Sean (PART OF Vato) IDENTIFICATION Install the oll pump crve gear assembly end oll ‘Bump drive gearinsertin the ol pump body. ‘Ol PUMP. Shwe Coan, Ot PUM Baie GeaR Use Gauge Bar T97P-77000-@ and a depth ‘micrometer to measure the clearance between ‘each gear and the oll pump body face, ‘The alowabve clearance for each gears 027 to 080mm (0.001 to 0.002 inch). I the clearance ‘exceeds the specification, replace the ol pump assembly. NOTE: install the alignment pins inthe holes shown. Install Pump Alignment Pins T94P-77000- inthe ‘il pump body. re ABs Filthe pump gear cavity wth ATF tothe top of the gears. Instal the oll pump body separator plate and Purp body separator plate gasket onthe oll ump body. pump on pum Augen PINs Seay" ‘ose 7000.8 (PART OF Fao Install the pump support assembly ont ll pump ume Soon sSsevely 96‘SUBASSEMBLIES (Continued Technical Service Information DISASSEMBLY AND ASSEMBLY OF Install and tighten the four pump support bolts to 181m (10 bf) and remove the alignment pins. Install and tighten the two remaining pump support bolts to 13 Nim (10 Ib). on. pum sooy Paar OF 7a00 ou pump SEAL TAz@ NOTE: Ensure thatthe pump support seas rings are overianped correct Install the seven pump support seal rings onthe ‘pump support assembly. Pvp support SeataINes tr wrong se gero Install the oll pump drive shatt. Use a torque wrench to rotate the oll pump ceive hat. The maximum rotating torque 8 O.3Nem (2 Install the #1 pump suppor thrust bearing on to ‘the pump suppor. Pour automatic transmission collon seal rings. Fanost Bean Forward/Coast/Direct clutch cylinder ‘and the reverse clutch arum (70044) onto the pump support. Ac check the Forward Coast Direct clutch tyinder and reverse clutch drum by blowing moisture free compressed ai, reguated to 40psi into te passagesin the ol pump Body. ‘With each application of ai you should hear the ‘apply of@ alten pack. Ahising or high pit ‘squeal indicates that a sealis damaged or torn. Investigate to find the source and make necessary corrections. Part ttem | Number __| Description Converter Cutch Bypass (a ‘ot apply a pressure) Reverse Gulch Passage 97Technical Service Information Main Control Disassembly ‘Remove manual vale from main contro. ~ CAUTION: Do not attempt to remove the solenoid valve body wiring cover. Use an 8mm socket to remove the two solenoid valve body bolts. Remove the solenoid valve. body. Remove the solenoid valve body gasket trom the ‘accumulator body assembly, Discard the ‘Solenoid valve body gasket. SOLENOD VALVE Boor Saaxer PRessune rap PLATE BOUTS Femove tne pressure tap pate gaskot rom accumulator body Discard he seater Use an umm sockst to remove the three contro valve body-to-ranstor plate bot, Remove the ‘manual valve detent spring assombly Use a 7mm socket to remove the three pressure tap plate bolts. Remove the pressure tap plat. 98Pere ee ee eee eee eee ee ee eee eee eee ee eee eee eee eee eee ee eee eee ee eee eee eee Technical Service Information Remove the three accumulator body to-transfer plate bots, aa Remove the accumulator body assembly, ‘accumulator body separator plate and ‘accumulator body separator gaskets from the Contr valve body assembly. accuMuLAToR accumutar Bobr'asseualy SeFanaton PUATE (Pan OF Tato panror tatoo sggoaron Been Seiaron Bee Bor BEEF on Remove the contol valve body assembly, valve ‘body separating plato and valve body separator plate gaskets (70 100) from the transfor pate. vaLve B00" CONTROL SePaRATOR wave Buare Boor gashers ASSEMBLY ‘SEDARATING, Trassrey Bate past Baa oF Beto Remove the intermediate and Overdrive ‘accumulator valve plug retaining plate from the ‘accumulator ody assemaly AccumuLaTon Boby ASSEMBLY (PART OF 7A100) INTERMEDIATE ANO Svenonive ACCUMULATOR Vatve Pua evan Thread a MBX: botinto the Intermediate and Overdrive accumulator valve plug. Remove the Intermediate and Overdrive accumulator valve INTERMEDIATE AND SvEnonive ACCUMULATOR Vatve pu0e (PART OF 7a1001 Remove tha Intermediate and Overdrive accumulator plug seal. Discard the seal eae Seen are CAUTION: Remove and clean one valve at.atime to avoid incorrect installation. 99MAIN CONTROL ASSEMBLY 100 o mn Ee AGOS HOLVININDOV — M3IA GAG01dx3MAIN CONTROL ASSEMBLY . oy © Ye, OF ah EXPLODED VIEW — VALVE BODYDISASSEMBLY AND ASSEMBLY OF ‘SUBASSEMBLIES (Continued) Technical Service Information Installa new intermediate and Overdrive accumulator plug seal onthe Intermediate and Overcrve accumulator valve plug and coat with petroleum ely, INTERMEDIATE AND oe ACCUMULATOR, Ube Seat THe Ghily push the iow and intermediate accumulator valve plug until itis lush with accumulator body aseombly, Use a screwcriver to install the intermediate and Overdrive accumulator valve plug inthe ‘sccumulator body assembly. Insta the Intermediate and Overdeve ‘accumulator valve plug retaining plate 9 going too far into the bore and damaging the sel. accumutaTon Soy" assenery [PART OF TA100) INTERMEDIATE AND Gvenoave. AccumuLaron tive pews Berane poste’ Install Valve Body Guide Pins T94P-77000/N in the transfer plat. ube Pe See 7005-N (PART oF 7a100) Insta the valve body separator plate gaskets and valve body separating plate (7008) on the transfer pate SebARAToR Plate Gagkers: yo108 vauve Booy SEPARATING PLATE PART | OFFA100) ‘Transren Puate (arr OF rao) 102DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Technical Service Information Instat the control valve body assembly. Asana ra lPART OF a0 ‘ransreh Poste (PART Fait Install the accumulator body separator plate and ‘Gaskets on the control valve body assembly. accumuLaToR 800¥ AccumuLaToR Booy SERARATOR Seoanaron Gageers race gontaon vauwe Sobv aasenely (ant oF A100) Install the accumulator bosy assembly. ACCUMULATOR Soby'assemacy (Pant OF 7atoD| contro! vatve Booy agency PART OF 7A00) Install anc tighten the three accumulator body-to-ranster pate Botts to 10 Nem (7 Bt) the three contro valve body-totranster Bate bolts and ‘assembly. Tighten the control valve ‘body-to-transtr pate bots to 10 Nem (7 lo) comtnae an Install the pressure tap plate, gasket and three bolts on the accumulator body assembly. Tighten the pressure tap plate bolts to 8 Nem (6 Ib- PRESSURE TAP PLATE BOLTS a) 103Technical Service Information NOTE: Match the solenoid valve body gasket t0 passages, Insta the solenoid valve body and solenoid vaive ody gasket on the accumulator Body assembly, Install the two solenci valve body bolts. Tighten the solenoid valve body bots to 10 Nem (7 Io) sotenoo Vaure Boor Bouts ia Remove the valve body guide pins. Install manval valve, NOTE: Store main controtin clean location unt re-assembl, ASSEMBLY (Continued) ‘Side the intermediate and overarwe ound ‘assembly ino the transaxle case, INTERMEDIATE AND Seno Se See Sea Lower the oll pump assembly into the transaxle uum Install the low reverse clutch piston outer seal on ‘the ow reverse clutch piston Lowevense turer ston F008Technical Service Information ‘ASSEMBLY (Continued) Install he low reverse clutch wave spnng. Install the low /reverse clutoh plate low /reverse clutch pressure pate. Lowrevense. ‘Cute pressure, PLATE rao soweserse owes aed aon sta ba to rover chron ng eae aie sian seb. sonmereescouren Sma, Sods CAUTION: The low one-way cl Instaliedin this position for ms purposes only. Instal he low one-way catch thrust plate Low one-way cute Sanus PLATE ra09e Use a screwariver to instal the low /reverse ‘latch return spring retaining rng. spams guren SHERERE Ea Use a teoier gauge to measure the clearance betwoen the ow roverse clutch pressure plate tothe ow one-way et thrust plato, Make & Second measurement on the opposite side, [hverage the two measurements to obtain the Purposes only. clearance, 105Technical Service Information ASSEMBLY (Continued) \ oe =o The standard clearance i 0.54 0 1. 47m (0.02 eee evar roger Hiceemene iui Bice een soein Ree twane nee Iatly eee zen oroera (2.87-2.47 (0.1100.097) [on ‘One tooth of the low reverse clutch pressure notched tor iantiication. emo. 1 low one-way clutch thrust plate, low /reverse clutch pressure pate, low reverse ‘dutch external spine ch pate (stoe), low reverse clatch internal spin cktch pates (icon), and the low reverse clutch wave spring. ws Remove the seal sizer trom the Forward Coast Direct clutch eyinder assembly 106Technical Service Information Install the assembly of Forward/Coast Direct (F/C/D) cylinder assembly and reverse clutch ‘rum assembly. eer Insta the turbine shatt assembly. assembly SeTURBNE shar Taps BEARING ASSEwaLY sHoze Install the forward one-way clutch and Low.intermediate sun gear assembly. KoRwano one way cuuTOH ARO See NTERMEDY St oean Assent Install the #5 Lowintormediate sun gear thrust bearing assembly, Insta the Lowintermediate carrier assembly LowanrenmeDiare Sain ABseely 107(Continued) Technical Service Information Install the #6 Low-Intermediate carrie thrust Dearing assembly. 16 Low.NTERMEDIATE ‘Ganaten aust Sean sasoneuy Install the Lowintermediate ring gear assembly. yowaeenenare BER NSSeMELY bearing assemoly. 7 REVERSE/OVEROAIVE Sun cear ‘Fanos Seanina ASseveur torre Instalthe Reverse / Overdrive sun gear and shell assembly. evensezovenonve no SaetL ASSONBLY asa6 Install the Rev cartier assembly with the captured #8 thrust bearing. evERse/ovERDANE 70008 > Install the low /reverse clutch plates. sgumpeneecuren SQUARE GTO" recess eat road Install the low /reverse clutch pressure plate Previously selected, 108ATSG Technical Service Information instal the low reverse clutch wave spring ‘Snap the socket end ofthe manual valve detent lever actuating rod on the parking eam actuator Lowmevense cron lever WAVE SPRING 78070 Manat, Yate Insta the ow one-way cutch Parnas ak 1D. ring onthe inner ring facing up. ceo tes Low ove way ‘Snap the opposite socket endo the manual valve Siren asseaur detent lever actuating rod assembly onthe mmanval valve detent ever assemby. anual vaiye LA RSCEMOLY Tats or thrust Pate, Install the iow one-way clutch t Low one.way, tore ier PLATE 70008 "7000-81, Preload ‘Tool Adapter TS4P-77000-F2, Prelcad Too! Aigner T34P-77000-RG, and Preload Algner pter TO4P-77000-Ré (al are part of Pretoad ‘Too! Adapter Aigner Set T94P-77000-A), on the Roverse/Overcrive carrier assembly as shown. Install and tighten the four bats to 13.5Nem (10. SS — J flan ~ fotten ‘BAPTA 109Technical Service Information Install Gauge Bar T94P-77000-0 with short spacers across the transaxle case, GAUGE BAR, SS) Subtract simonsionB trom dimension Ato got mension C. Use dimension C to select the proper #11 driven ‘sprocket shim from the folowing char. Use a depth micrometer to measure the cistance ‘rom the top ofthe gauge bar to the be ‘surface on the Fleverse / Overdrive carrier ‘assembly. This is dimension B, 14364. 17em 2252 ton (see 3800) {osr-o8s (357-36. {0e0-07e0) 1996-13850 185-1759 (330s) (ore:ce0D 1382 13.680 ersten (545.5350 ee 0020 ‘Measure the sistance from the top ofthe gauge asses a Darto the #12 drven sprocket bearing assembly Surlace area ofthe transaxle case. Ths is 348-1330 "32.220 Simension & (220: s2000 (osereaen DEPTH McROMETER Installthe selected # 11 driven sprocket shim on the transaxle cass, Remove the gauge bar and preload tool. Installthe selection #11 criven sprocket shim on ‘the tranaaxie case. lstal ne #12 von sprocket Bearng assembly. rz pewven ‘SpaockeT tear v0 DRIER, ‘SenooxeT BeARNG Lubricate the needles and # 18 driven sprocket Dearing assembly. 110Technical Service Information Install the #9 Reverse /Ovordrve ring gear thrust Dearing assembv — z NOTE: Installation of the Flaverse /Overdrive rng gear ‘assembly at this ime is for measurement purposes, only. Install the Reverse / Overdrive Rng Gear assembly for gauging ony Install Preload Tool Aigner T84P-77000-R3 (part ‘of Pretoad Too! Adapter /Agner Set ‘T94P-77000-R) on the shat Install and tighten the four bolts to 13.5 N-m (10 +) Install Preload Tool T94°-77000-81 (part of Preload Tool Adaptor / Aigner Set TS4P-77000-R) on the Reverse Overdrive ing gear assembly, Gauge Bar T94P-77000-0 with short ‘onthe ransaxie case. cause ean Faserg000 Use a depth micrometer to measure the distance fom the top ofthe Gauge Barto the face of the Feverse/Overrve ring gear assembly. This imension A. beers machOweren {Use combined thickness 25.4mm (1.00 inch) of Gauge Bar T84P-77000-G and shor spacers es distance ‘Subtract dimension trom dimension B to get ‘dimension C. on C to select the proper # 10 crve ust washer trom the following chart Dimension | woTmemen (ouoseiny endo) (asses) (oro'sesiny exa.oraie) {oeo:oren) (orssons iene ca6'n) | Femove the gauge bar and preload tool. nL‘ASSEMBLY (Continued) Technical Service Information ‘Apply petroleum jlly tothe selected # 10 ). Gauce BAR GAUGE Ban, ‘Seircryeco-o Spaces Set Beebo Bar‘ASSEMBLY (Continued) Technical Service Information Use a dopth micrometer to measure the distance from the top ofthe gauge ber to the shim surface ‘area ofthe final ve carrer and dterential ‘assembly, Make two measurements and ‘average, This is dimension A. DEPTH MICROMETER Use combined thickness of gauge bar with ong spacers 177.8mm (7.00 inches) as distance B. ‘Subtract dimension A trom dimension 8 to got sdmension C. jmension Oto select the proper #14 ifferental bearing shim trom the following chart. Eocsorii es cect ee mmr (ia maar [ga meee (eka emove the gauge bar and spacers. 14 dtforential bearing shim. Insta the # 18 difterential bearing. eS nisorrenemiaN BEAAING et seorrrenenma, Became sa ‘oer Save Stan was [Attach the transaxle spit flange gasket to the fransaxle case. ES remeice Se7 GRUNGE G7 Gasker 78555 14Technical Service Information ‘ASSEMBLY (Continued) Install the twenty converter housing to-transaxle ‘case bots, T Part housing-to-transaxt tem | Number __ | Description I+) in the sequence shown. «y= Tnlormesiate and Oversive Serve Piston Assembly (Part euties) 5 | 70027 Serve Cover 8 | Hos ‘Serve Cover Retaining Ring 7_| 70027 Serve Cover Cap Lubricate and inetal the intermediate and ‘overdrive servo piston and return spring, assemby in the transaxle case bore. Install Servo Piston Rod Selector T94P-77000M onthe piston. NOTE: Logs o the too ft into servo cover retaining ‘ing groove. Loosely assemble the logs and bar from Servo Picton Hod Selector Te4P-77000-M in case bere. Part tem | Number + [F201 ela Identitontion Groove Area a Intermediate ang Overdrive Serva Apply Roa Pert! tr onimueadASSEMBLY (Continued) Technical Service Information ‘Tighten the bas to the legs using bolts provided. (6ibin). Installa depth micrometer onthe head of the ‘elector tool, Measure and record the distance to the bao! the salactor too! (distance A). ter bolton the servo tool uti the piston movement stops. Measure and record Sistance to bar (distance B). ‘Subtract A from to obtain travel. S3inm | zee) ote) ieee | ze (oss e8i0) Faarareen | 2 Basia | vosinm ESonn | Gael (odes toein) Ifthe distance is not witin the travel ‘specication, replace the intermedi (Overdrive serve piston and recheck. Flemove the servo piston selection too Installthe servo cover inthe case. Install Servo Cover Remover /Roplacer T94P-770004. WARNING: SERVO RETURN SPRING FORCE IS VERY HIGH. ‘Compress the servo cover and install the servo cover retaining ring ‘Remove the Serve Cover Remover /Replacer ‘TeaP-7 7000. Install serve cover cap in transaxle case using ‘Servo Pug Replace, / Needle Bearing Roce! ‘ToaP-77000-£2 (part of T84P-77000 Needle Bearing Remover /Replacer/Recelver - Servo hug Replacer), Install Transmission Test Plate T94P-77000'S ‘and Test Plate Mounting Screws T82P-7006-C. CAUTION: Do not check the coast clutch since the piston may be forced out of the torward clutch piston. Use @ rubber tiped blow gun and 40 psi of {tered compressed air to check the folowing ‘clutch hyrauieceuts for function andleakage. nd 16ASSEMBLY (Continued) Technical Service Information Part tom | _Number__| Description Reverse Clutch Forward Clteh Direct Cuten Low/Reverse Guten Senor as Serve Apply 940.77000-8 _| Transmission Tost Pate Iter leakage is detected, disassemble the ‘transaxle and locate source of leakage. Remove Transmission Test Plate T4P-77000-S and Test Plate Mounting Screws T82P-7008-C, Install the thermostatic ol level control vaive in the transaxle case. THenmosraric ee uc CONTROL vaLvE waar Sour Install the bracket and the bot. Tighten the thermostatic ol evel control valve bracket bott to 12Nem (9 bt Install the Oxing on CO4E transaxte electrical connector. CAUTION: Do not pull wires or damage connector Body. lace the main control sightly away from the transaxle case and push the electrical ‘connector ito its bore. Align the Z-Ink inthe manual valve. Install wiring harness ci. Insta the 12 main control bolts. Tighten the main control bots to 10 Nem (7b inthe Sequence shown. contratlever bolt and the manual contra lover‘ASSEMBLY (Continued) Technical Service Information Use Shifter Shaft Alignment Too! T94P-77000-H tomove the manual contol lever shaft to the "0" install the pin to hold the tool a Move the manual valve detent lever assembly to the" in, MANUAL VALVE DETENT LEVER ASSEMBLY ‘Loosen the nut onthe bal stud forthe manual valve detent lever actuating rod assembly, Use @ 1Omm wrench onal tighten the nut on the bal Remove the sitter pa. Remove the pin and shitter shaft alignment tol Insta the manual control lever assembly and bolt using 10mm socket. Tighten the manual Ccontrollever bol to 25 Nem (18 bf 118ATSG Technical Service Information ASSEMBLY (Continued) Rotate manual valve detent lever assembly to N position Install the main control cover gasket on the main ‘control cover as [Attach the main contol cover assembly tothe transaxle case. Inatal the fourteen main control cover bots. ‘Tighten the main control cover bolts 20 Nem (15 Ibs) inthe sequence shown. Place the Manuel Lever Position (MLP) sensor, ‘on tha manual valve detent lever shaft. Sone Use MLPS Alignment Tool T82P-70010-AH to ‘align the MLP sensor on the manual valve detent ‘hat and transaxle case. {netall and tighten the MLP sensor bolts to 10 Nem (7 Toe. 119Technical Service Information Install the Oving on the Vehicle Speed Sensor (88). Push the VSS into the bore, Install the VSS bolt. Use an &mm socket to tighten the VSS bolt to 8 Nom (4Ib-). Install a new cil tube filer grommet into the ‘ansaxe case, eae Ieee Install the ol file tube. Instat the o fle tube bot. Tighten the ol filer tube bolt to 8 Nim (6 >), ouruter See vials Install the transmission speed sensor o-ring on the transmission speed sensor. Apply alight coat of petroleum ely tothe Oring. Install the of pump arve turbine shaft assembly ftnto the end ofthe ‘on pump, Srive SHaer 75928