Automatic Transmission - F4A42 PDF [PDF]

Zitiervorschau

Black plate (1,1)

Transmission & Clutch Overhaul

3.3

TRANSMISSION OVERHAUL (AUTOMATIC)

F4A42 23A AUTOMATIC TRANSMISSION

Model YR 2007 English Edition RDWE-1GA082 Destination: all September 2007 Printed in Malaysia Copyright Perusahaan Otomobil Nasional Berhad (Company No.: 100995-U)

Black plate (2,1)

Printed in Malaysia 27 September 2007 Eng

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TRANSMISSION OVERHAUL (AUTOMATIC)

TC03

Content

/I

23A AUTOMATIC TRANSMISSION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-DIMENSIONAL CROSS-SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/1 23A/1 23A/2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/3 23A/3

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4 VALVE BODY SPRING IDENTIFICATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/5 SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/5 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/10 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/10 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/11 23A/11

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/16 23A/16 23A/20 23A/36

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/62 23A/62 23A/63

UNDERCOVER CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/64 23A/64

UNDERDRIVE CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/65 23A/65 23A/66

REVERSE AND OVERDRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/68

Copyright Perusahaan Otomobil Nasional Berhad (Company No.: 100995-U)

Printed in Malaysia 27 September 2007 Eng

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Content DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/68 23A/69 23A/70

PLANETARY CARRIER ASSEMBLY . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/74 23A/74 23A/75

LOW-REVERSE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/76 23A/76 23A/77

SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/77 23A/77 23A/78

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/79 23A/79 23A/80 23A/80

TRANSFER DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/81 23A/81 23A/82 23A/83

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/84 23A/84 23A/85 23A/85

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/87 23A/87 23A/90 23A/90

DRIVE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A/91 23A/91 23A/92

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the right to make changes at any time without prior notice or obligation.

Printed in Malaysia 27 September 2007 Eng

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Content

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NOTE

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23A

AUTOMATIC TRANSMISSION

/1

GENERAL INFORMATION

GENERAL INFORMATION 1. 2. 3. 4. 5. 6.

WTC23AGINFO005

The combination of highest-precision electronic and mechanical technology heralds a new era in automatic transmission performance. The gear shifting clutches use a hydraulic balancing mechanism to enable gear shifting at extrahigh engine speed. The number of shafts has been decreased to two, increased use has been made of metal plates and the one-way clutch has been abolished, which all contribute to reduce the weight. Increased meshing ratios and improved rigidity of the gear supports and casing result in less noise. In addition, adoption of a new-developed automatic transmission fluid (ATF). The number of oil cooler feed tubes is increased to two.

3-DIMENSIONAL CROSS-SECTION

DOIIT23AR9225

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AUTOMATIC TRANSMISSION

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GENERAL INFORMATION

/2

SECTION VIEW

WTC23AGINFO006

DOIIT23AR9226

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23A

AUTOMATIC TRANSMISSION

/3

GENERAL INFORMATION

GENERAL INFORMATION

WTC23AGINFO007

HYDRAULIC CIRCUIT

DOIIT23AR07155

Items 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Reverse clutch Low-reverse brake Second brake Underdrive clutch Overdrive clutch Low-reverse accumulator Second accumulator Underdrive accumulator Overdrive accumulator Damper clutch Fail-save valve A Fail-save valve B Damper clutch control valve Switch valve Low-reverse pressure control valve Second pressure control valve

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Underdrive pressure control valve Overdrive pressure control valve Damper clutch solenoid valve Low-reverse solenoid valve Second solenoid valve Underdrive solenoid valve Overdrive solenoid valve Torque converter pressure control valve Regulator valve Manual valve Oil filter Oil pan Oil pump Relief valve Oil strainer

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SPECIFICATIONS

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SPECIFICATIONS

WTC23ASPECS003

GENERAL SPECIFICATIONS Items

Specification

Transmission Model

F4A42

Transmission type

4–speed forward, 1–speed reverse

Torque converter type

3–element, 1–stage, 2–phase type

Applicable engine

F4PH

Gear ratio

1st

2.842

2nd

1.529

3rd

1.000

4th

0.712

Reverse

2.480

Final gear ratio

4.042

Number of underdrive clutch disc

4

Number of overdrive clutch disc

4

Number of reverse clutch disc

2

Number of low-reverse brake disc

5

Number of second brake disc

3

SERVICE SPECIFICATIONS Items

Standard value

Output shaft preload

0.01-0.09 mm (0-0.003 in)

Brake reaction plate end play

0-0.16 mm (0-0.006 in)

Low-reverse brake end play

1.35-1.81 mm (0.053-0.071 in)

Second brake end play

0.79-1.25 mm (0.031-0.049 in)

Underdrive sun gear end play

0.25-0.45 mm (0.009-0.017 in)

Input shaft end play

0.70-1.45 mm (0.027-0.057 in)

Differential case preload

0.045-0.105 mm (0.001-0.004 in)

Underdrive clutch end play

1.6-1.8 mm (0.062-0.07 in)

Reverse and overdrive clutch return spring end play

0-0.09 mm (0-0.003 in)

Overdrive clutch end play

1.6-1.8 mm (0.062-0.07 in)

Reverse clutch end play

1.5-1.7 mm (0.059-0.066 in)

Backlash between differential side gear and pinion

0.025-0.150 mm (0-0.005 in)

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SPECIFICATIONS

VALVE BODY SPRING IDENTIFICATION TABLE Spring Regulator valve spring

Wire diameter 1.8 mm (0.07 in)

Outside diameter 15.7 mm (0.618 in)

Free length

Number of loop

86.7 mm (3.413 24 mm (0.944 in) in)

Underdrive pressure control 0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984 valve spring in) in) Overdrive pressure control valve

0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984 in) in)

Low-reverse pressure control valve spring

0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984 in) in)

Second pressure control valve spring

0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984 in) in)

Torque converter spring

1.6 mm (0.062 in) 11.2 mm (0.44 in) 34.4 mm (1.354 12.5 mm (0.492 in) in)

Damper clutch control valve 0.7 mm (0.027 in) 5.9 mm (0.232 in) 28.1 mm (1.106 19 mm (0.748 spring in) in) Fail-save valve A spring

0.7 mm (0.027 in) 8.9 mm (0.35 in)

21.9 mm (0.862 9.5 mm (0.374 in) in)

Damping valve spring

1.0 mm (0.039 in) 7.7 mm (0.303 in) 35.8 mm (1.409 17 mm (0.669 in) in)

Line relief valve spring

1.0 mm (0.039 in) 7.0 mm (0.275 in) 17.3 mm (0.681 10 mm (0.393 in) in)

Orifice check ball spring

0.5 mm (0.019 in) 4.5 mm (0.177 in) 17.2 mm (0.677 15 mm (0.59 in) in)

SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT Part name

Thickness

Identification symbol

Part no.

Thrust washer 1.8 mm (0.07 in) (For adjustment of input shaft 2.0 mm (0.078 in) end play) 2.2 mm (0.086 in)

18

MD754509

20

MD754508

22

MD754507

2.4 mm (0.094 in)

24

MD753793

2.6 mm (0.102 in)

26

MD753794

2.8 mm (0.11 in)

28

MD753795

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Thickness

Snap ring 1.6 mm (0.062 in) (For adjustment of underdrive 1.7 mm (0.066 in) clutch and overdrive clutch end 1.8 mm (0.07 in) play) 1.9 mm (0.074 in)

Identification symbol

Part no.

None

MD759666

Blue

MD759667

Brown

MD759668

None

MD752124

2.0 mm (0.078 in)

Blue

MD752125

2.1 mm (0.082 in)

Brown

MD752126

2.2 mm (0.086 in)

None

MD752127

2.3 mm (0.09 in)

Blue

MD752128

2.4 mm (0.094 in)

Brown

MD752129

2.5 mm (0.098 in)

None

MD752130

2.6 mm (0.102 in)

Blue

MD752131

2.7 mm (0.106 in)

Brown

MD752132

2.8 mm (0.11 in)

None

MD752133

2.9 mm (0.114 in)

Blue

MD752134

3.0 mm (0.118 in)

Brown

MD754680

Snap ring 2.2 mm (0.086 in) (For adjustment of low-reverse 2.3 mm (0.09 in) brake and second brake reaction 2.4 mm (0.094 in) plates end plays) 2.5 mm (0.098 in)

Blue

MD754786

Brown

MD754787

None

MD758240

Blue

MD758241

1.6 mm Pressure plate (For adjustment of low-reverse 1.8 mm brake and second brake end 2.0 mm plays) 2.2 mm

(0.062 in)

L

MD759567

(0.07 in)

1

MD759414

(0.078 in)

0

MD759415

(0.086 in)

2

MD759416

2.4 mm (0.094 in)

4

MD759417

2.6 mm (0.102 in)

6

MD759418

2.8 mm (0.11 in)

8

MD759419

3.0 mm (0.118 in)

D

MD759420

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SPECIFICATIONS Part name

Thickness

Identification symbol

Part no.

Snap ring 1.6 mm (0.062 in) (For adjustment of reverse clutch 1.7 mm (0.066 in) end plays) 1.8 mm (0.07 in)

None

MD761085

Blue

MD761086

Brown

MD761087

1.9 mm (0.074 in)

None

MD352137

2.0 mm (0.078 in)

Blue

MD352138

2.1 mm (0.082 in)

Brown

MD352139

2.2 mm (0.086 in)

None

MD352140

2.3 mm (0.09 in)

Blue

MD352141

2.4 mm (0.094 in)

Brown

MD352142

2.5 mm (0.098 in)

None

MD352143

2.6 mm (0.102 in)

Blue

MD352144

2.7 mm (0.106 in)

Brown

MD352145

2.8 mm (0.11 in)

None

MD352146

Snap ring 1.48 mm (0.058 in) (For adjustment of reverse clutch 1.53 mm (0.06 in) and overdrive clutch spring 1.58 mm (0.062 in) retainer end plays) 1.63 mm (0.064 in)

Brown

MD755600

None

MD755601

Blue

MD755602

Brown

MD755603

Thrust race 1.6 mm (0.062 in) (For adjustment of underdrive 1.7 mm (0.066 in) sun gear end plays) 1.8 mm (0.07 in)

—

MD707267

—

MD759681

—

MD723064

1.9 mm (0.074 in)

—

MD754794

2.0 mm (0.078 in)

—

MD707268

2.1 mm (0.082 in)

—

MD754795

2.2 mm (0.086 in)

—

MD723065

2.3 mm (0.09 in)

—

MD754796

2.4 mm (0.094 in)

—

MD724358

2.5 mm (0.098 in)

—

MD754797

2.6 mm (0.102 in)

—

MD754798

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Thickness

Identification symbol

Part no.

Spacer 1.88 mm (0.074 in) (For adjustment of output shaft 1.92 mm (0.075 in) preload) 1.96 mm (0.077 in)

88

MD756579

92

MD756580

96

MD756581

2.00 mm (0.078 in)

00

MD756582

2.04 mm (0.08 in)

04

MD756583

2.08 mm (0.081 in)

08

MD756584

2.12 mm (0.083 in)

12

MD756585

2.16 mm (0.085 in)

16

MD756586

2.20 mm (0.086 in)

20

MD756587

2.24 mm (0.088 in)

24

MD756588

2.28 mm (0.089 in)

28

MD756589

2.32 mm (0.091 in)

32

MD756590

2.36 mm (0.092 in)

36

MD756591

2.40 mm (0.094 in)

40

MD756592

2.44 mm (0.096 in)

44

MD756593

2.48 mm (0.097 in)

48

MD756594

2.52 mm (0.099 in)

52

MD756595

2.56 mm (0.1 in)

56

MD756596

2.60 mm (0.102 in)

60

MD756597

2.64 mm (0.103 in)

64

MD756598

2.68 mm (0.105 in)

68

MD756599

2.72 mm (0.107 in)

72

MD760685

2.76 mm (0.108 in)

76

MD760686

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SPECIFICATIONS Part name

Thickness

Identification symbol

Part no.

Spacer: 0.71 mm (0.027 in) (For adjustment of differential 0.74 mm (0.029 in) case preload) 0.77 mm (0.03 in)

71

MD754475

74

MD727660

77

MD754476

0.80 mm (0.031 in)

80

MD727661

0.83 mm (0.032 in)

83

MD720937

0.86 mm (0.033 in)

86

MD720938

0.89 mm (0.035 in)

89

MD720939

0.92 mm (0.036 in)

92

MD720940

0.95 mm (0.037 in)

95

MD720941

0.98 mm (0.038 in)

98

MD720942

1.01 mm (0.039 in)

01

MD720943

1.04 mm (0.04 in)

04

MD720944

1.07 mm (0.042 in)

07

MD720945

1.10 mm (0.043 in)

J

MD710454

1.13 mm (0.044 in)

D

MD700270

1.16 mm (0.045 in)

K

MD710455

1.19 mm (0.046 in)

L

MD710456

1.22 mm (0.048 in)

G

MD700271

1.25 mm (0.049 in)

M

MD710457

1.28 mm (0.05 in)

N

MD710458

1.31 mm (0.051 in)

E

MD706574

1.34 mm (0.052 in)

O

MD710459

1.37 mm (0.053 in)

P

MD710460

0.75-0.82 mm (0.029Spacer: (For adjustment of backlash 0.032 in) between differential side gear 0.83-0.92 mm (0.032and pinion) 0.036 in)

—

MD722986

—

MD722985

0.93-1.00 mm (0.0360.039 in)

—

MD722984

1.01-1.08 mm (0.0390.042 in)

—

MD722982

1.09-1.16 mm (0.0420.045 in)

—

MD722983

Printed in Malaysia 27 September 2007 Eng

Black plate (15,1)

AUTOMATIC TRANSMISSION

23A

SPECIFICATIONS

/10

TORQUE SPECIFICATIONS Items Transmission

Components

Value

Roll stopper bracket

7.0 kgm (70 Nm; 4.697 ft.lbs)

Wiring harness bracket

2.3 kgm (23 Nm; 1.543 ft.lbs)

Control cable bracket

2.3 kgm (23 Nm; 1.543 ft.lbs)

Eye bolt

3.1 kgm (31 Nm; 2.08 ft.lbs)

Oil cooler feed tube (to transmission case)

1.0 kgm (10 Nm; 0.671 ft.lbs)

Oil cooler feed tube (to roll stopper bracket)

1.1 kgm (11 Nm; 0.738 ft.lbs)

Pulse generator A

1.1 kgm (11 Nm; 0.738 ft.lbs)

Pulse generator B

1.1 kgm (11 Nm; 0.738 ft.lbs)

Manual control lever

2.2 kgm (22 Nm; 1.476 ft.lbs)

Inhibitor switch

1.1 kgm (11 Nm; 0.738 ft.lbs)

Valve body cover

1.1 kgm (11 Nm; 0.738 ft.lbs)

Valve body mounting bolt

1.1 kgm (11 Nm; 0.738 ft.lbs)

Fluid temperature sensor

1.1 kgm (11 Nm; 0.738 ft.lbs)

Manual control shaft detent

0.6 kgm (6 Nm; 0.402 ft.lbs)

Rear cover

2.3 kgm (23 Nm; 1.543 ft.lbs)

Torque converter housing

4.8 kgm (48 Nm; 3.221 ft.lbs)

Oil pump

2.9 kgm (29 Nm; 1.946 ft.lbs)

Transfer drive gear

3.4 kgm (34 Nm; 2.281 ft.lbs)

Output shaft lock nut

17.0 kgm (170 Nm; 11.408 ft.lbs)

Output shaft bearing retainer

2.9 kgm (29 Nm; 1.946 ft.lbs)

Oil filler plug

3.3 kgm (33 Nm; 2.214 ft.lbs)

Oil drain plug

3.3 kgm (33 Nm; 2.214 ft.lbs)

Transfer drive gear lock nut

19.5 kgm (195 Nm; 13.086 ft.lbs)

Differential drive gear

13.5 kgm (135 Nm; 9.059 ft.lbs)

Valve body

1.1 kgm (11 Nm; 0.738 ft.lbs)

Solenoid valve support

0.6 kgm (6 Nm; 0.402 ft.lbs)

Plate

0.6 kgm (6 Nm; 0.402 ft.lbs)

SEALANTS Items

Specified sealant

Rear cover Torque converter housing

Part no. MD974421 or equivalent

Valve body cover

Printed in Malaysia 27 September 2007 Eng

Black plate (16,1)

23A

AUTOMATIC TRANSMISSION

/11

SPECIAL TOOLS

SPECIAL TOOLS

WTC23ASTOOL002

TOOLS Tool

Number

Name

Use

MB990607

Torque wrench socket

Removal and installation of output shaft lock nut

MB990928

Installer adapter

Removal of transfer drive gear bearing

MB990930

Installer adapter

Installation of output shaft taper roller bearing outer race

MB990931

Installer adapter

Installation of cap

MB990935

Installer adapter

Installation of differential taper roller bearing outer race

MB990936

Installer adapter

Installation of output shaft taper roller bearing outer race

DOIIT23AR9005

DOIIT23AR9006

DOIIT23AR9007

DOIIT23AR9008

DOIIT23AR9009

DOIIT23AR9010

Printed in Malaysia 27 September 2007 Eng

Black plate (17,1)

Tool

AUTOMATIC TRANSMISSION

23A

SPECIAL TOOLS

/12

Number

Name

Use

MB990938

Handle

 Installation of input shaft rear bearing  Use with installer adapter

MB991625

Special socket (41)

Removal and installation of output shaft lock nut

MB991626

Socket (60)

Removal and installation of transfer drive gear lock nut

MB991628

Spring compressor

 Removal and installation lowreverse brake snap ring  Measurement of underdrive clutch and overdrive clutch end plays

MB991631

Clearance dummy plate Measurement of lowreverse brake and second brake end plays

MB991790

Spring compressor

DOIIT23AR9011

DOIIT23AR9012

DOIIT23AR9013

DOIIT23AR9014

DOIIT23AR9015

DOIIT23AR07153

Printed in Malaysia 27 September 2007 Eng

Measurement of reverse clutch end play

Black plate (18,1)

23A

AUTOMATIC TRANSMISSION

/13

SPECIAL TOOLS Tool

Number

Name

Use

MD998333

Oil pump remover

Removal of oil pump

MD998334

Oil seal installer

Installation of oil pump oil seal

MD998348

Bearing and gear puller Removal of transfer drive gear bearing

MD998350

Bearing installer

Installation of output shaft

MD998412

Guide

Installation of oil pump and transfer drive gear

MD998800

Oil seal installer

Installation of drive shaft oil seal

DOIIT23AR9016

DOIIT23AR9017

DOIIT23AR9018

DOIIT23AR9019

DOIIT23AR9020

DOIIT23AR9021

Printed in Malaysia 27 September 2007 Eng

Black plate (19,1)

Tool

AUTOMATIC TRANSMISSION

23A

SPECIAL TOOLS

/14

Number

Name

Use

MD998801

Bearing remover

Removal of each bearing

MD998812

Installer cap

Use with installer and installer adapter

MD998813

Installer-100

Use with installer cap and installer adapter

MD998814

Installer-200

Use with installer cap and installer adapter

MD998820

Installer adapter (42)

Installation of differential taper roller bearing

MD998823

Installer adapter (48)

Installation of output shaft taper roller bearing

DOIIT23AR9022

DOIIT23AR9023

DOIIT23AR9024

DOIIT23AR9025

DOIIT23AR9027

DOIIT23AR9028

Printed in Malaysia 27 September 2007 Eng

Black plate (20,1)

23A

AUTOMATIC TRANSMISSION

/15

SPECIAL TOOLS Tool

Number

Name

Use

MD998829

Installer adapter (60)

Installation of transfer drive gear bearing

MD998903

Spring compressor

Removal and installation of one-way clutch inner race snap ring

MD998907

Spring compressor

Removal and installation of underdrive clutch snap ring

MD998913

Dial gauge extension

Measurement of lowreverse brake and second brake end plays

MD998917

Bearing removal

Removal of output shaft taper roller bearing

MD998924

Spring compressor retainer

 Removal and installation of low-reverse brake snap ring  Measurement of underdrive clutch and overdrive clutch plays

DOIIT23AR9029

DOIIT23AR07154

DOIIT23AR9030

DOIIT23AR9031

DOIIT23AR9032

DOIIT23AR9033

Printed in Malaysia 27 September 2007 Eng

Black plate (21,1)

Tool

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/16

Number

Name

Use

MD995566

Claw

Removal of each outer race

MD999590

Spring compressor

Removal and installation of overdrive clutch snap ring

DOIIT23AR9034

DOIIT23AR9035

TRANSMISSION

WTC23ASHAUL022

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07149

Printed in Malaysia 27 September 2007 Eng

Black plate (22,1)

23A

AUTOMATIC TRANSMISSION

/17

TRANSMISSION

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply sealant — Non- reusable part Disassembly steps 1. 2. 3. 4. 5. 6.

Torque converter Roll stopper bracket Control cable support bracket Oil level gauge Eye bolt Oil cooler feed tube

T1 : 1.1 kgm (11 Nm; 0.738 ft.lbs) T2 : 2.2 kgm (22 Nm; 1.476 ft.lbs) T3 : 3.1 kgm (31 Nm; 2.08 ft.lbs)

7. 8. 9. 10. 11. 12.

Pulse generator A Pulse generator B Manual control lever Inhibitor switch Valve body cover Manual control shaft detent

T4 : 1.0 kgm (10 Nm; 0.671 ft.lbs) T5 : 0.6 kgm (6 Nm; 0.402 ft.lbs) T6 : 7.0 kgm (70 Nm; 4.697 ft.lbs)

DOIIT23AR07150

— Lubricate all internal parts with automatic transmission fluid during reassembly

Printed in Malaysia 27 September 2007 Eng

Black plate (23,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/18

— Non- reusable part Disassembly steps 13. 14. 15. 16. 17. 18. 19.

Fluid temperature sensor Valve body Steel ball Gasket Snap ring Solenoid valve harness Strainer

20. 21. 22. 23. 24. 25. 26.

Second brake retainer oil seal Accumulator piston Accumulator spring Accumulator spring Manual control lever shaft roller Manual control lever shaft Parking pawl rod

T1 : 1.1 kgm (11 Nm; 0.738 ft.lbs)

DOIIT23AR07151

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply sealant — Non- reusable part Disassembly steps Printed in Malaysia 27 September 2007 Eng

Black plate (24,1)

23A

AUTOMATIC TRANSMISSION

/19

TRANSMISSION

27. 28. 29. 30. 31. 32.

Torque converter housing Differential Oil filter Oil pump Gasket Thrust washer #1

33. 34. 35. 36. 37.

Underdrive clutch and input shaft Thrust bearing #2 Underdrive clutch hub Outer race Spacer

T7 : 2.9 kgm (29 Nm; 1.946 ft.lbs) T8 : 4.8 kgm (48 Nm; 3.221 ft.lbs)

DOIIT23AR07152

— Lubricate all internal part with automatic transmission fluid during reassembly

— Apply sealant — Non- reusable part

Printed in Malaysia 27 September 2007 Eng

Black plate (25,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/20

Disassembly steps 38. Rear cover 39. Thrust race #8 40. Seal ring 41. Input shaft rear bearing 42. Thrust bearing #7 43. Reverse and overdrive clutch 44. Thrust bearing #6 45. Overdrive clutch hub 46. Thrust bearing #5 47. Planetary reverse sun gear 48. Snap ring 49. Second brake piston 50. Return spring 51. Pressure plate 52. Second brake disc 53. Second brake plate 54. Planetary carrier assembly 55. Snap ring 56. Reaction plate 57. Snap ring 58. Low-reverse brake disc 59. Low-reverse brake plate 60. Pressure plate 61. Wave spring

62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84.

T7 : 2.9 kgm (29 Nm; 1.946 ft.lbs) T9 : 2.3 kgm (23 Nm; 1.543 ft.lbs)

T10 : 3.4 kgm (34 Nm; 2.281 ft.lbs) T11 : 17.0 kgm (170 Nm; 11.408 ft.lbs)

Parking pawl shaft Spacer Parking pawl spring Parking roller support shaft Parking pawl Parking roller support Snap ring One-way clutch inner race O-ring Spring retainer Return spring Low-reverse brake piston Transfer drive gear Cap Lock nut Output shaft Taper roller bearing Collar Outer race Spacer Snap ring Outer race Transmission case

DISASSEMBLY

WTC23ASHAUL023

CAUTION (1) Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly. (2) The working area should be covered with a rubber mat to keep it clean at all times. (3) Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if you need to use something. (4) Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air. (5) Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so that they do not become dirty. (6) If the transmission body has been damaged, disassemble and clean the cooler system also.

Printed in Malaysia 27 September 2007 Eng

Black plate (26,1)

23A

AUTOMATIC TRANSMISSION

/21

TRANSMISSION 1. 2. 3. 4. 5.

Remove the torque converter. Use the dial gauge to measure the input shaft end play. Remove each bracket. Remove the oil level gauge. Remove the eye bolt, gasket and the oil cooler feed tube.

DOIIT23AR07001

6.

Remove the Pulse generator A and Pulse generator B. Symbol

Description

7

Pulse generator A

8

Pulse generator B

DOIIT23AR07002

7.

Remove the manual control lever, and then remove the inhibitor switch. Symbol

Description

9

Control lever

10

Inhibitor switch

CAUTION Make sure that the valve body is installed before removing the manual control lever installation nut.

DOIIT23AR07003

8.

Use the special tool to remove the valve body cover. Symbol 11

DOIIT23AR07004

Printed in Malaysia 27 September 2007 Eng

Description Valve body cover

Black plate (27,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/22

9.

Remove the manual control shaft detent. Symbol 12

Description Manual control shaft detent

DOIIT23AR07005

10. Disconnect the harness connectors of the valve body. Symbol

Description

18

Harness connectors of the valve body

DOIIT23AR07006

11. Remove the valve body mounting bolt (28 pieces). 12. Remove the fluid temperature sensor. Symbol

Description

13

Fluid temperature sensor

CAUTION Make sure that the manual control lever and the inhibitor switch are removed.

DOIIT23AR07007

13. Remove the valve body, gasket and the steel balls two pieces. Symbol

DOIIT23AR07008

Description

14

Valve body

15

Steel balls

16

Gasket

CAUTION Do not lose the steel balls (2 pieces).

Printed in Malaysia 27 September 2007 Eng

Black plate (28,1)

23A

AUTOMATIC TRANSMISSION

/23

TRANSMISSION 14. Remove the snap ring, and then remove the solenoid valve harness. Symbol

Description

17

Snap ring

18

Solenoid valve harness

DOIIT23AR07009

15. Remove the strainer . Symbol 19

Description Strainer

DOIIT23AR07010

16. Remove the second brake retainer oil seal. Symbol

Description

20

Second brake retainer oil seal

DOIIT23AR07168

17. Remove each accumulator piston and spring. Symbol

Description

A

For low-reverse brake

B

For underdrive clutch

C

For second brake

D

For overdrive clutch

DOIIT23AR07011

Printed in Malaysia 27 September 2007 Eng

Black plate (29,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/24

18. Use the magnet to remove the manual control lever shaft roller. Symbol

Description

24

Manual control lever shaft roller

DOIIT23AR07169

19. Remove the manual control lever shaft and parking pawl rod. Symbol

Description

25

Manual control lever shaft

26

Parking pawl rod

DOIIT23AR07012

20. Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing. Symbol

Description

27

Torque converter housing

DOIIT23AR07164

Printed in Malaysia 27 September 2007 Eng

Black plate (30,1)

23A

AUTOMATIC TRANSMISSION

/25

TRANSMISSION 21. Remove the O-rings two pieces. Symbol E

Description O-rings

DOIIT23AR07014

22. Remove the differential. Symbol 28

Description Differential

DOIIT23AR07015

23. Remove the oil filter. Symbol 29

Description Oil filter

DOIIT23AR07016

24. Remove the oil pump mounting bolts (6 pieces).

DOIIT23AR07017

Printed in Malaysia 27 September 2007 Eng

Black plate (31,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/26

25. Install the special tool (MD998333) as shown in illustration.

DOIIT23AR07018

26. Screw the special tool to remove the oil pump. Symbol 30

Description Oil pump

27. Remove the oil pump gasket. Symbol 31

Description Oil pump gasket

DOIIT23AR07165

28. Remove the thrust washer #1. Symbol 32

Description Thrust washer #1

DOIIT23AR07019

29. Hold the input shaft, and then remove the underdrive clutch. Symbol 33

DOIIT23AR07020

Printed in Malaysia 27 September 2007 Eng

Description Underdrive clutch

Black plate (32,1)

23A

AUTOMATIC TRANSMISSION

/27

TRANSMISSION 30. Remove the thrust bearing #2. Symbol 34

Description Thrust bearing #2

DOIIT23AR07021

31. Remove the underdrive clutch hub. Symbol 35

Description Underdrive clutch hub

DOIIT23AR07022

32. 33. 34. 35.

Remove Remove Remove Remove

the the the the

rear cover. thrust race #8. seal rings. input shaft rear bearing.

Symbol

Description

38

Rear cover

39

Thrust race #8

40

Seal rings

41

Input shaft rear bearing

DOIIT23AR07023

36. Remove the O-rings (F) (3 pieces). Symbol F

DOIIT23AR07024

Printed in Malaysia 27 September 2007 Eng

Description O-rings

Black plate (33,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/28

37. Remove the reverse and overdrive clutch and the thrust bearing #7. Symbol

Description

42

Thrust bearing #7

43

Reverse and overdrive clutch

DOIIT23AR07025

38. Remove the overdrive clutch hub and the thrust bearing #6. Symbol

Description

44

Thrust bearing #6

45

Overdrive clutch hub

DOIIT23AR07026

39. Remove the thrust bearing #5. Symbol 46

Description Thrust bearing #5

DOIIT23AR07027

40. Remove the planetary reverse sun gear. Symbol

Description

47

Planetary reverse sun gear

DOIIT23AR07028

Printed in Malaysia 27 September 2007 Eng

Black plate (34,1)

23A

AUTOMATIC TRANSMISSION

/29

TRANSMISSION 41. Remove the snap ring. Symbol 48

Description Snap ring

DOIIT23AR07029

42. Remove the second brake piston and the return spring. Symbol

Description

49

Second brake piston

50

Rreturn spring

DOIIT23AR07030

43. Remove the pressure plate, second brake discs and second brake plate(s). Symbol

Description

51

Pressure plate

52

Second brake discs

53

Second brake plate

No. of brake discs and plates

DOIIT23AR07031

Brake disc

Brake plate

Pressure plate

3

2

1

Printed in Malaysia 27 September 2007 Eng

Black plate (35,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/30

44. Remove the planetary carrier assembly. Symbol

Description

54

Planetary carrier assembly

DOIIT23AR07032

45. Remove the snap ring. Symbol 55

Description Snap ring

DOIIT23AR07035

46. Remove the reaction plate and the brake disc. Symbol 56

Description Reaction plate

DOIIT23AR07036

47. Remove the snap ring. Symbol 57

DOIIT23AR07037

Printed in Malaysia 27 September 2007 Eng

Description Snap ring

Black plate (36,1)

23A

AUTOMATIC TRANSMISSION

/31

TRANSMISSION 48. Remove the low-reverse brake plates, lowreverse brake discs and pressure plate. Symbol

Description

58

Low-reverse brake discs

59

Low-reverse brake plates

60

Pressure plate

No. of Low-reverse brake discs and plates Brake disc

Brake plate

Pressure plate

5

4

1

DOIIT23AR07038

49. Remove the wave spring. Symbol 61

DOIIT23AR07039

Printed in Malaysia 27 September 2007 Eng

Description Wave spring.

Black plate (37,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/32

50. Remove the parking pawl shaft, and then remove the spacer and spring. Symbol

Description

62

Parking pawl shaft

63

Spacer

64

Spring

DOIIT23AR07166

51. Remove the two parking roller support shafts, and then remove the parking paws case and parking roller support. Symbol

Description

65

Parking roller support shafts

66

Parking paws case

67

Parking roller support

DOIIT23AR07167

Printed in Malaysia 27 September 2007 Eng

Black plate (38,1)

23A

AUTOMATIC TRANSMISSION

/33

TRANSMISSION 52. Use the special tool to remove the snap ring. Symbol 68

Description Snap ring

DOIIT23AR07042

53. Remove the one-way clutch inner race, Oring, spring retainer, return spring and the low-reverse brake piston. Symbol

Description

69

One-way clutch inner race

70

O-ring

71

Spring retainer

72

Return spring

73

Low-reverse brake piston

DOIIT23AR07171

54. Remove the transfer drive gear mounting bolts as follows: First remove 4 or 3 bolts, then turn the gear 1/8 turn (458) and remove the remaining 3 or 4 bolts (7 bolt in total).

DOIIT23AR07043

Printed in Malaysia 27 September 2007 Eng

Black plate (39,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/34

55. Remove the transfer drive gear. Symbol 74

Description Transfer drive gear

DOIIT23AR07044

56. Remove the cap. Symbol 75

Description Cap

DOIIT23AR07045

57. Straighten the locking tab of the output shaft lock nut. Symbol 76

Description Output shaft lock nut

DOIIT23AR07046

58. Use the special tool to remove the output shaft lock nut. CAUTION The lock nut is a left-handed screw (anticlock wise).

DOIIT23AR07047

Printed in Malaysia 27 September 2007 Eng

Black plate (40,1)

23A

AUTOMATIC TRANSMISSION

/35

TRANSMISSION 59. Remove the output shaft mounting bolt (4 pieces).

DOIIT23AR07048

60. Tap on the rear of the output shaft to remove the output shaft, taper roller bearing and the collar. Symbol

Description

77

Output shaft

78

Taper roller bearing

79

Collar

DOIIT23AR07170

61. Remove the spacer and the outer race. Symbol

Description

80

Outer race

81

Spacer

DOIIT23AR07172

Printed in Malaysia 27 September 2007 Eng

Black plate (41,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/36

62. Remove the snap ring. Symbol 82

Description Snap ring

DOIIT23AR07050

63. Remove the differential bearing outer race and spacer from the torque converter housing. Symbol

Description

27

Torque converter housing

36

Outer race

37

Spacer

DOIIT23AR07173

64. Remove the differential bearing outer race from the transmission case. Symbol 83

REASSEMBLY

DOIIT23AR07174

Description Transmission case WTC23ASHAUL024

CAUTION (1) Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling. (2) Never use grease other than blue petrolatum jelly and white Vaseline. (3) Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them. (4) Never apply sealant or adhesive to gaskets. (5) When replacing a bushing, replace the assembly which it belongs to. (6) Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something. (7) Change the oil in the cooler system.

Printed in Malaysia 27 September 2007 Eng

Black plate (42,1)

23A

AUTOMATIC TRANSMISSION

/37

TRANSMISSION 1.

Use the special tools to tap the differential bearing outer race in the transmission case.

2.

Use the special tools to tap the output shaft bearing outer race in the transmission case. Install the used spacer and snap ring.

DOIIT23AR07051

3.

DOIIT23AR07052

4.

Use the special tool (MB998412) to install the tranfer drive gear. 4.1 First tighten 4 mounting bolts, then turn the transfer drive gear bearing to tighten 3 mounting bolt (7 bolt in total). Specified torque: 3.4 kgm (34 Nm; 2.281 ft.lbs)

DOIIT23AR07176

Printed in Malaysia 27 September 2007 Eng

Black plate (43,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/38

5.

Install the low-reverse brake piston, return spring and spring retainer. 5.1 Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race with O-ring to transfer drive gear bearing so that the notches fall along the A—A line. Symbol

Description

A

Line

B

Notches

69

One-way clutch inner race

84

Transmission case

DOIIT23AR07175

6.

Use the special tools install the snap ring. Symbol 68

Description Snap ring

DOIIT23AR07042

7.

Install the wave spring. Symbol 61

DOIIT23AR07039

Printed in Malaysia 27 September 2007 Eng

Description Wave spring

Black plate (44,1)

23A

AUTOMATIC TRANSMISSION

/39

TRANSMISSION 8.

Install the low-reverse brake disc, lowreverse brake plate, special tool (MB991631) and snap ring as shown in the figure. Symbol MB991631

Description Special tool

57

Snap ring

58

Low-reverse brake disc

59

Low-reverse brake plate

DOIIT23AR07177

Number of Low-reverse brake disc and plates Brake disc

Brake plate

Special tool

5

4

1

NOTE: Do not install the pressure plate at this time. 9.

Install the reaction plate and the used snap ring. Symbol

Description

55

Snap ring

56

Reaction plate

DOIIT23AR07178

10. Move the special tool to measure the end play, and then replace the snap ring installed in step 9 to adjust the end play to standard value. Standard value:0 ~ 0.16 mm (0.006 in)

DOIIT23AR07054

Printed in Malaysia 27 September 2007 Eng

Black plate (45,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/40

11. Install the second brake disc, second brake plate and replace the pressure plate of the second brake with the special tool (MB991631) as shown in the figure. Symbol

Description

52

Second brake disc

53

Second brake plate

Number of Second brake disc and plates DOIIT23AR07180

Brake disc

Brake plate

Special tool

3

2

1

12. Install the return spring, second brake piston, and snap ring. Symbol

Description

50

Return spring

49

Second brake piston

48

Snap ring

DOIIT23AR07179

13. Move the special tool (MB991631) to measure the end play. Standard value (Reference): 0.79 mm (0.031 in) ~ 1.25 mm (0.049 in)

DOIIT23AR07056

Printed in Malaysia 27 September 2007 Eng

Black plate (46,1)

23A

AUTOMATIC TRANSMISSION

/41

TRANSMISSION Select a pressure plate which thickness is within the following table, and replace the special tool mounted in the step 10 with it. [A (movement amount) + thickness of the special tool (2.0 mm (0.078 in)) 1.25 mm (0.049 in)] to [A (movement amount) + thickness of the special tool ( 2.0 mm (0.078 in)) - 0.79 mm (0.031 in)].

DOIIT23AR07181

Pressure plate: Movement amount

Thickness

ID symbol

Part No.

0.6~0.8 mm

1.6 mm

L

MD759567

0.8~1.0 mm

1.8 mm

1

MD759414

1.0~1.2 mm

2.0 mm

0

MD759415

1.2~1.4 mm

2.2 mm

2

MD759416

1.4~1.6 mm

2.4 mm

4

MD759417

1.6~1.8 mm

2.6 mm

6

MD759418

14. Reverse the transmission . 15. Install the special tool (MD998913) in a dial gauge, and then move the special tool (MB991631) to measure its movement. Standard value of end play (Referance): 1.35 mm (0.053 in) ~ 1.81 mm (0.071 in)

DOIIT23AR07058

Reference Select a pressure plate which thickness is within the following table, and replace the special tool mounted at the step 6 with it. [A (movement amount) + thickness of the special tool (2.0 mm (0.078 in)) 1.81 mm (0.071 in)] to [A (movement amount) + thickness of the special tool ( 2.0 mm (0.078 in)) - 1.35 mm (0.053 in)]

DOIIT23AR07182

Printed in Malaysia 27 September 2007 Eng

Black plate (47,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/42

Pressure plate: Movement amount

Thickness

ID symbol

Part No.

1.0~1.2 mm

1.6 mm

L

MD759567

1.2~1.4 mm

1.8 mm

1

MD759414

1.4~1.6 mm

2.0 mm

0

MD759415

1.6~1.8 mm

2.2 mm

2

MD759416

1.8~2.0 mm

2.4 mm

4

MD759417

2.0~2.2 mm

2.6 mm

6

MD759418

2.2~2.4 mm

2.8 mm

8

MD759419

2.4~2.6 mm

3.0 mm

D

MD759420

16. Remove the parts installed from steps 7 to 15. 17. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque. Specified torque: 2.9 kgm (29 Nm; 1.946 ft.lbs)

DOIIT23AR07048

18. Install the output shaft in the transmission case, and then use the special tool to install the collar and taper roller bearing in the output shaft.

DOIIT23AR07060

Printed in Malaysia 27 September 2007 Eng

Black plate (48,1)

23A

AUTOMATIC TRANSMISSION

/43

TRANSMISSION 19. Apply ATF to a new lock nut, and use the special tool to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified again. Specified torque: 17.0 kgm (170 Nm; 11.408 ft.lbs) CAUTION The lock nut is a left-hand screw (anti clockwise).

DOIIT23AR07061

20. Move the output shaft to measure operating amount, and then replace the spacer installed in step 3 with a new one which thickness is within the following value. [A (operating amount) + B (thickness of the old spacer) + 0.01 mm (0 in)) to [A (operating amount) + B (thickness of the old spacer) + 0.09 mm (0.003 in)]

DOIIT23AR07062

21. Stake the lock nut with a punch (two pleces).

DOIIT23AR07063

22. Install the new cap as shown in the figure. Symbol 75

DOIIT23AR07064

Printed in Malaysia 27 September 2007 Eng

Description Cap

Black plate (49,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/44

23. Install the parking pawl, spacer, and spring. Then install the parking pawl shaft. Symbol

Description

62

Parking pawl shaft

63

Spacer

64

Spring

66

Parking pawl

DOIIT23AR07183

24. Install the parking roller support, and then the two parking roller support shafts. Symbol

Description

65

Parking roller support shaft

67

Parking roller support

DOIIT23AR07184

Printed in Malaysia 27 September 2007 Eng

Black plate (50,1)

23A

AUTOMATIC TRANSMISSION

/45

TRANSMISSION

DOIIT23AR07069

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

O.D

I.D

Thickn- Part number Symbol ess

O.D

I.D

Thickn- Part number ess

59 mm (2.322 in)

47 mm (1.85 in)

1.8 mm MD754509 (0.07 in)

#1

48.9 mm (1.925 in)

1.6 mm MD707267 37 (0.062 mm (1.45- in) 6 in)

#8

59 mm (2.322 in)

47 mm (1.85 in)

2.0 mm MD754508 (0.078 in)

#1

48.9 mm (1.925 in)

1.7 mm MD759681 37 (0.066 mm (1.45- in) 6 in)

#8

59 mm (2.322 in)

47 mm (1.85 in)

2.2 mm MD754507 (0.086 in)

#1

48.9 mm (1.925 in)

37 1.8 mm MD723064 mm (0.07 (1.45- in) 6 in)

#8

59 mm (2.322 in)

47 mm (1.85 in)

2.4 mm MD753793 (0.094 in)

#1

48.9 mm (1.925 in)

37 1.9 mm MD754794 mm (0.074 (1.45- in) 6 in)

#8

Printed in Malaysia 27 September 2007 Eng

Symbol

Black plate (51,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/46

O.D

I.D

Thickn- Part number Symbol ess

O.D

I.D

Thickn- Part number ess

Symbol

59 mm (2.322 in)

47 mm (1.85 in)

2.6 mm MD753794 (0.102 in)

#1

48.9 mm (1.925 in)

37 mm (1.456 in)

2.0 ml MD707268 (2.105 U.S.qts; 1.736 Imp.qts)

#8

59 mm (2.322 in)

47 mm (1.85 in)

2.8 mm MD753795 (0.11 in)

#1

48.9 mm (1.925 in)

37 2.1 mm MD754795 mm (0.082 (1.45- in) 6 in)

#8

49 mm (1.929 in)

36 3.6 mm MD756846 mm (0.141 (1.41- in) 7 in)

#2

48.9 mm (1.925 in)

37 2.2 mm MD723065 mm (0.086 (1.45- in) 6 in)

#8

49 mm (1.929 in)

36 3.6 mm MD756846 mm (0.141 (1.41- in) 7 in)

#3

48.9 mm (1.925 in)

37 2.3 mm MD754796 mm (0.09 (1.45- in) 6 in)

#8

45.3 mm (1.783 in)

31 mm (1.22 in)

3.3 mm MD757647 (0.129 in)

#4

48.9 mm (1.925 in)

2.4 mm MD724358 37 (0.094 mm (1.45- in) 6 in)

#8

49 mm (1.929 in)

3.6 mm MD756846 36 (0.141 mm (1.41- in) 7 in)

#5

48.9 mm (1.925 in)

2.5 mm MD754797 37 (0.098 mm (1.45- in) 6 in)

#8

49 mm (1.929 in)

3.6 mm MD756846 36 (0.141 mm (1.41- in) 7 in)

#6

48.9 mm (1.925 in)

2.6 mm MD754798 37 (0.102 mm (1.45- in) 6 in)

#8

59 mm (2.322 in)

2.8 mm MD754595 37 (0.11 in) mm (1.456 in)

#7

—

—

—

—

—

25. Install the overdrive planetary carrier assembly. Symbol

Description

54

Overdrive planetary carrier assembly

DOIIT23AR07032

Printed in Malaysia 27 September 2007 Eng

Black plate (52,1)

23A

AUTOMATIC TRANSMISSION

/47

TRANSMISSION 26. Install the planetary reverse sun gear. Symbol 47

Description Planetary reverse sun gear

DOIIT23AR07028

27. Install the wave spring. Symbol 61

Description Wave spring

DOIIT23AR07039

28. Install the pressure plate, low-reverse brake disc, and low-reverse brake plate. Symbol

Description

58

Low-reverse brake disc

59

Low-reverse brake plate

60

Pressure plate

Number of low-reverse brake discs and plates DOIIT23AR07071

Brake disc Brake plate 5

Printed in Malaysia 27 September 2007 Eng

4

Pressure plate 1

Black plate (53,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/48

29. Install the snap ring. Symbol 57

Description Snap ring

DOIIT23AR07072

30. Install the reaction plate. Symbol 56

Description Reaction plate

DOIIT23AR07073

31. Install the snap ring. Symbol 55

Description Snap ring

DOIIT23AR07074

32. Install the second brake disc, second brake plate , and pressure plate. Symbol

Description

51

Pressure plate

52

Second brake disc

53

Second brake plate

DOIIT23AR07075

Printed in Malaysia 27 September 2007 Eng

Black plate (54,1)

23A

AUTOMATIC TRANSMISSION

/49

TRANSMISSION Number of second brake discs and plates Brake disc Brake plate 3

Pressure plate

2

1

33. Install the return spring and second brake piston. Symbol

Description

49

Second brake piston

50

Return spring

DOIIT23AR07076

34. Install the snap ring. Symbol 48

Description Snap ring

DOIIT23AR07077

35. Install the thrust bearing #5. Symbol 46

Description Thrust bearing #5

CAUTION Be careful about the installation direction of the thrust bearing

DOIIT23AR07078

Printed in Malaysia 27 September 2007 Eng

Black plate (55,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/50

36. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch. Symbol

DOIIT23AR07079

Description

43

Reverse and overdrive clutch

44

Thrust bearing #6

45

Overdrive clutch hub

CAUTION Be careful about the installation direction of the thrust bearing 37. Install the reverse and overdrive clutch, and thrust bearing #7. Symbol

DOIIT23AR07080

Description

42

Thrust bearing #7

43

Reverse and overdrive clutch

CAUTION Be careful about the installation direction of the thrust bearing 38. Install the three O-rings. Symbol F

DOIIT23AR07024

Printed in Malaysia 27 September 2007 Eng

Description O-rings

Black plate (56,1)

23A

AUTOMATIC TRANSMISSION

/51

TRANSMISSION 39. Use the special tool and tap the input shaft bearing in the rear cover. 40. Install the two seal rings in the grooves of the rear cover. 41. Install the thinnest thrust race #8 on the thrust bearing #7.

DOIIT23AR07081

42. Measure end play of the underdrive sun gear and record the measurement value. Symbol 35

DOIIT23AR07082

Description Underdrive clutch hub

NOTE Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear. Standard value: 0.25 mm (0.009 in)~ 0.45 mm (0.017 in) Select a thrust race #8 whose thickness corresponds to the measured value from the table below, and replace the thrust race installed in step 41 with the selected one. Thrust race #8 Mesurement value

Thickness

Part No.

0.3~0.4 mm

1.6 mm

MD707267

0.4~0.5 mm

1.7 mm

MD759681

0.5~0.6 mm

1.8 mm

MD723064

0.6~0.7 mm

1.9 mm

MD754794

0.7~0.8 mm

2.0 mm

MD707268

0.8~0.9 mm

2.1 mm

MD754795

0.9~1.0 mm

2.2 mm

MD723065

1.0~1.1 mm

2.3 mm

MD754796

1.1~1.2 mm

2.4 mm

MD724358

1.2~1.3 mm

2.5 mm

MD754797

1.3~1.4 mm

2.6 mm

MD754798

Printed in Malaysia 27 September 2007 Eng

Black plate (57,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/52

43. Squeeze out the liquid gasket of 1.6 mm (0.062 in) in diameter and apply it to the shown points of the rear cover. Liquid gasket: Sealant Part No. MD974421 or equivalent

DOIIT23AR07083

44. Install the rear cover, and tighten its mounting bolts to the specified torque. Specified torque: 2.3 kgm (23 Nm; 1.543 ft.lbs)

DOIIT23AR07095

45. Install the underdrive clutch hub. Symbol 35

Description Underdrive clutch hub

DOIIT23AR07022

46. Install the thrust bearing #2. Symbol 34

Description Thrust bearing #2

CAUTION Install the thrust bearing in correct direction.

DOIIT23AR07084

Printed in Malaysia 27 September 2007 Eng

Black plate (58,1)

23A

AUTOMATIC TRANSMISSION

/53

TRANSMISSION 47. Hold the input shaft, and install the underdrive clutch. Symbol 33

Description Underdrive clutch

DOIIT23AR07020

47.1 Place two beads of solder [each 10 mm in length, 3.5 mm in diameter] on the underdrive clutch retainer as shown in the illustration. Symbol

Description

A

Input shaft

B

Underdrive clutch retainer

C

Two beads of solder

DOIIT23AR07188

47.2 Install special tool in the illustrated place. 47.3 Install the oil pump to the transaxle case. NOTE Do not instal the oil pump gasket at this time. 47.4 Tighten the oil pump mounting bolts (6 pieces) to the specified torque. Specified torque: 2.9 kgm (29 Nm; 1.946 ft.lbs) DOIIT23AR07085

47.5 Remove the oil pump mounting bolts. 47.6 Using special tool, remove the oil pump, and then take out the crushed solders.

DOIIT23AR07018

Printed in Malaysia 27 September 2007 Eng

Black plate (59,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/54

47.7 Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Symbol T

Description Thickness

47.8 Select a thrust washer #1 whose thickness corresponds to the measured value from table below.

DOIIT23AR07088

Thrust washer #1: Measurement valuet

Thickness

ID symbol

Part No.

2.25~2.45 mm

1.8 mm

18

MD754509

2.45~2.65 mm

2.0 mm

20

MD754508

2.65~2.85 mm

2.2 mm

22

MD754507

2.85~3.05 mm

2.4 mm

24

MD753793

3.05~3.25 mm

2.6 mm

26

MD753794

3.25~3.45 mm

2.8 mm

28

MD753795

48. Install the used thrust washer #1 that was selected in step 47.8 on the underdrive clutch retainer. Symbol 32

Description Thrust washer #1

DOIIT23AR07019

49. Use the special tool to install a new oil pump gasket and oil pump. CAUTION Never reuse the old gasket. 50. Tighten the oil pump mounting bolts to the specified torque. Specified torque: 2.9 kgm (29 Nm; 1.946 ft.lbs)

DOIIT23AR07085

Printed in Malaysia 27 September 2007 Eng

Black plate (60,1)

23A

AUTOMATIC TRANSMISSION

/55

TRANSMISSION 51. Measure end play of the input shaft meets the standard value. Standard value: 0.70 mm (0.027 in)~ 1.45 mm (0.057 in)

DOIIT23AR07086

52. Install the oil filter. Symbol 29

Description Oil filter

DOIIT23AR07016

53. Install the differential. Symbol 28

Description Differential

DOIIT23AR07015

54. Place a solder (approx. 10 mm (0.393 in) in length, 3 mm (0.118 in) in diameter) on the torque converter housing as shown in the figure. Symbol G

DOIIT23AR07087

Printed in Malaysia 27 September 2007 Eng

Description Solder

Black plate (61,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/56

55. Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to the specified torque. Specified torque: 4.8 kgm (48 Nm; 3.221 ft.lbs) 56. Loose the bolts, and remove the outer race and solder.

DOIIT23AR07013

57. Use a micrometer measure the thickness of the pressed solder. Select a spacer which thickness is within the following value. Symbol T Standard value:

Description Thickness 0.045 mm (0.001 in) ~ 0.105 mm (0.004 in)

DOIIT23AR07088

58. Assemble the spacer selected in step 57 and install the outer race to the torque converter housing. Use the special tool to press in the outer race.

DOIIT23AR07089

59. Squeeze out the liquid gasket of 1.6 mm (0.062 in) in diameter and apply it to the shown points of torque converter . Liquid gasket: Part No. MD974421 or equivalent

DOIIT23AR07090

Printed in Malaysia 27 September 2007 Eng

Black plate (62,1)

23A

AUTOMATIC TRANSMISSION

/57

TRANSMISSION 60. Install the two O-rings. Symbol E

Description O-rings

DOIIT23AR07014

61. Install the torque converter, and then tighten its 18 mounting bolts to the specified torque. Specified torque: 4.8 kgm (48 Nm; 3.221 ft.lbs)

DOIIT23AR07013

62. Install the manual control lever shaft and parking pawl rod. Symbol

Description

25

Manual control lever shaft

26

Parking pawl rod

63. Install the manual control lever shaft roller.

DOIIT23AR07185

Printed in Malaysia 27 September 2007 Eng

Black plate (63,1)

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/58

64. Install the accumulator pistons, new seal rings, and springs. NOTE The accumulator springs are identified as shown in the figure. Symbol A B C D

For For For For

Description low-reverse brake underdrive clutch second brake overdrive clutch

DOIIT23AR07091

65. Install the strainer. Symbol 19

Description Strainer

DOIIT23AR07010

66. Install the second brake retainer oil seal. Symbol

Description

20

Second brake retainer oil seal

DOIIT23AR07168

Printed in Malaysia 27 September 2007 Eng

Black plate (64,1)

23A

AUTOMATIC TRANSMISSION

/59

TRANSMISSION 67. Install the solenoid valve harness, and then secure the snap ring to the connector groove. Symbol

Description

17

Snap ring

18

Solenoid valve harness

DOIIT23AR07009

68. Install the valve body, gasket, and two steel balls. Symbol

Description

14

Valve body

15

Steel balls

16

Gasket

DOIIT23AR07008

69. Install the fluid temperature sensor. Symbol

Description

13

Fluid temperature sensor

70. Install the 28 mounting bolts of the valve body.

DOIIT23AR07007

71. Connect the connectores of the valve body.

DOIIT23AR07092

Printed in Malaysia 27 September 2007 Eng

Black plate (65,1)

No.

AUTOMATIC TRANSMISSION

23A

TRANSMISSION

/60

Part to be connected

Cable color

Connector housing color

1

Underdrive solenoid valve

White, red, red

Black

2

Overdrive solenoid valve

Orange, red

Black

3

Low-reverse solenoid valve

Brown, yellow

Milky white

4

Second solenoid valve

Green, red, red

Milky white

5

Damper clutch control solenoid valve

Blue, yellow, yellow

Black

6

Fluid temperature sensor

Black, red

Black

72. Install the manual control shaft detent. Symbol 12

Description Manual control shaft detent

DOIIT23AR07005

73. Apply the liquid gasket to the valve body cover. Liquid gasket: Part No. MD974421 or equivalent

DOIIT23AR07093

74. Install the valve body cover, and then tighten its mounting bolts to the specified torque. Symbol 11

Description Valve body cover

Specified torque: 1.1 kgm (11 Nm; 0.738 ft.lbs)

DOIIT23AR07187

Printed in Malaysia 27 September 2007 Eng

Black plate (66,1)

23A

AUTOMATIC TRANSMISSION

/61

TRANSMISSION 75. Install the inhibitor switch and manual control lever. Symbol

Description

9

Manual control lever

10

Inhibitor switch

DOIIT23AR07003

76. Install the Pulse generator A and output Pulse generator B. Symbol

DOIIT23AR07002

Description

7

Pulse generator A

8

Pulse generator B

77. Install the eye bolt, a new gasket, and the oil cooler feed tube. 78. Install the oil dipstick. 79. Install the brackets. 80. Install the torque converter, and secure it so that the shown dimension meets the reference value. Reference value:approx 12.2 mm (0.48 in) CAUTION Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.

DOIIT23AR07094

Printed in Malaysia 27 September 2007 Eng

Black plate (67,1)

AUTOMATIC TRANSMISSION

23A

OIL PUMP

/62

OIL PUMP

WTC23ASHAUL025

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07096

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply ATF, blue petrolatum jelly — Non-reusable part Disassembly steps 1.

O-ring

2. 3.

Seal ring Oil seal

4.

Oil pump assembly

Printed in Malaysia 27 September 2007 Eng

Black plate (68,1)

23A

AUTOMATIC TRANSMISSION

/63

OIL PUMP REASSEMBLY SERVICE POINTS WTC23ASHAUL026 OIL SEAL INSTALLATION Use the special tool to tap the oil seal in the oil pump assembly.

DOIIT23AR07097

O-RING INSTALLATION Install a new O-ring to the outer groove of the oil pump, and apply ATF, blue petrolatum jelly or white Vaseline to the outer inside diameter of the O-ring. Symbol

Description

A

O-ring

B

Outer groove

DOIIT23AR07098

Printed in Malaysia 27 September 2007 Eng

Black plate (69,1)

AUTOMATIC TRANSMISSION

23A

UNDERCOVER CLUTCH AND INPUT SHAFT

/64

UNDERCOVER CLUTCH AND INPUT SHAFT

WTC23ASHAUL027

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07099

Number of clutch disc and plates Clutch disc

Clutch plate

Clutch reaction plate

4

4

1

Lubricate all internal parts with automatic transmission fluid during reassembly.

— Apply ATF, blue petrolatum jelly — Non-reusable part

Printed in Malaysia 27 September 2007 Eng

Black plate (70,1)

23A

AUTOMATIC TRANSMISSION

/65

UNDERDRIVE CLUTCH AND INPUT SHAFT

Disassembly steps 1. Snap ring 2. Input shaft 3. Seal ring 4. Snap ring

9. Spring retainer 10. D-ring 11. Return spring 12. Underdrive clutch piston 13. D-ring

5.

Clutch reaction plats

14. D-ring

6.

Clutch disc

15. Underdrive clutch retainer

7.

Clutch plate

8.

Snap ring

UNDERDRIVE CLUTCH AND INPUT SHAFT WTC23ASHAUL028 DISASSEMBLY SERVICE POINTS SNAP RING REMOVAL Use the special tools to remove the snap ring. Symbol 8

Description Snap ring

DOIIT23AR07100

UNDERDRIVE CLUTCH PISTON REMOVAL Use air pressure to remove the underdrive clutch piston.

DOIIT23AR07156

Printed in Malaysia 27 September 2007 Eng

Black plate (71,1)

AUTOMATIC TRANSMISSION

23A

UNDERDRIVE CLUTCH AND INPUT SHAFT

/66

REASSEMBLY SERVICE POINTS D-RING INSTALLATION Apply ATF, blue petrolatum jelly or white Vaseline to new D-ring and install carefully. Symbol 10, 13,14

Description D-ring

DOIIT23AR07101

SNAP RING INSTALLATION Use the special tools to install the snap ring. Symbol 8

Description Snap ring

DOIIT23AR07100

CLUTCH PLATE / CLUTCH DISC / CLUTCH REACTION PLATE INSTALLATION 1.

Align each teeth missing part of the clutch plate, clutch disc and clutch reaction plate to the outer circumference hole of the underdrive clutch retainer. Symbol

DOIIT23AR07102

Description

A

Teeth missing part

B

Outer circumference hole

CAUTION Immerse the clutch disc in ATF before assembling it.

Printed in Malaysia 27 September 2007 Eng

Black plate (72,1)

23A

AUTOMATIC TRANSMISSION

/67

UNDERDRIVE CLUTCH AND INPUT SHAFT 2.

Install the clutch reaction plate in the shown direction. Symbol

Description

5

Clutch reaction plate

6

Clutch discs

7

Clutch plates

C

Shear droop

Number of clutch discs and plates DOIIT23AR07103

Clutch disc Clutch plate Clutch reaction plate 4

4

1

SNAP RING INSTALLATION Check that the clearance between the snap ring and the clutch reaction plates is within the standard value. When measuring the clearance, use the special tool to press the clutch reaction plate evenly. If not within the standard value, select a snap ring to adjust. Standard value: 1.6-1.8 mm (0.062-0.07 in)

DOIIT23AR07104

Printed in Malaysia 27 September 2007 Eng

Black plate (73,1)

AUTOMATIC TRANSMISSION

23A

REVERSE AND OVERDRIVE CLUTCH

/68

REVERSE AND OVERDRIVE CLUTCH

WTC23ASHAUL029

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07105

Number of clutch disc and plates Clutch disc

Clutch plate

Clutch reaction plate

4

4

1

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply ATF, blue petrolatum jelly — Non-reusable part

Printed in Malaysia 27 September 2007 Eng

Black plate (74,1)

23A

AUTOMATIC TRANSMISSION

/69

REVERSE AND OVERDRIVE CLUTCH

Disassembly steps 1. Snap ring

10. Spring retainer 11. D-ring

2.

Clutch reaction plate

3.

Clutch disc

4.

Clutch plate

5.

Snap ring

6.

Clutch reaction plate

15. Reverse clutch piston

7.

Clutch disc

16. D-ring

8.

Clutch plate

9.

Snap ring

17. Reverse clutch retainer 18. D-ring

12. Return spring 13. Overdrive clutch piston 14. D-ring

19. D-ring

DISASSEMBLY SERVICE POINT WTC23ASHAUL030 SNAP RING REMOVAL Use the special tools to remove the snap ring. Symbol 9

Description Snap ring

DOIIT23AR07106

OVERDRIVE CLUTCH PISTON REMOVAL Use air pressure to remove the overdrive clutch piston.

DOIIT23AR07157

Printed in Malaysia 27 September 2007 Eng

Black plate (75,1)

AUTOMATIC TRANSMISSION

23A

REVERSE AND OVERDRIVE CLUTCH

/70

REVERSE CLUTCH PISTON REMOVAL Use air pressure to remove the reverse clutch piston.

DOIIT23AR07158

REASSEMBLY SERVICE POINTS D-RING INSTALLATION Apply ATF, blue petrolatum jelly or white vaseline to new D-ring and install carefully. Symbol

Description

11, 16, 14, 18, 19 D-ring

DOIIT23AR07113

REVERSE CLUTCH PISTON INSTALLATION Align the outer circumference holes of the reverse clutch piston and the reverse clutch retainer to assembly them. Symbol

Description

A&B

Outer circumference holes

DOIIT23AR07107

SNAP RING INSTALLATION 1. 2.

Set special tools as shown in the illustration. Tighten the nut on the special tool to press down on the spring retainer and reverse clutch retainer, and then install the snap ring. Symbol 9

DOIIT23AR07106

Printed in Malaysia 27 September 2007 Eng

Description Snap ring

Black plate (76,1)

23A

AUTOMATIC TRANSMISSION

/71

REVERSE AND OVERDRIVE CLUTCH 3.

Check that the clearance between the snap ring and the return spring retainer is within the standard value. If not within the standard value, select a snap ring to adjust. Standard value: 0 mm (0 in)

DOIIT23AR07108

CLUTCH PLATE / CLUTCH DISC / CLUTCH REACTION PLATE INSTALLATION Install the clutch reaction plate in the shown direction. Symbol

DOIIT23AR07103

Description

6

Clutch reaction plate

7

Clutch discs

8

Clutch plates

C

Shear droop

CAUTION Immerse the clutch disc in ATF before assembling the clutch disc. Number of clutch discs plates Clutch disc

Clutch plate

Clutch reaction plate

4

4

1

Printed in Malaysia 27 September 2007 Eng

Black plate (77,1)

AUTOMATIC TRANSMISSION

23A

REVERSE AND OVERDRIVE CLUTCH

/72

SNAP RING INSTALLATION Check that the clearance between the snap ring and the clutch reaction plate is within the standard value. When measuring the clearance, use the special tool to press the clutch reaction plate evenly. If not within the standard value, select a snap ring to adjust. Symbol 5

Description Snap ring

Standard value:

1.6 mm (0.062 in)

DOIIT23AR07159

CLUTCH PLATE / CLUTCH DISC / CLUTCH REACTION PLATE INSTALLATION 1.

Align each teeth missing part (part A) of the clutch plate, clutch disc and clutch reaction plate to the outer circumference hole (part B) of the reverse clutch retainer. Symbol

Description

A

Teeth missing of the clutch plate, clutch disc and clutch reaction plate

B

Outer circumference hole of the reverse clutch retainer

DOIIT23AR07110

CAUTION Immerse the clutch disc in ATF.

Printed in Malaysia 27 September 2007 Eng

Black plate (78,1)

23A

AUTOMATIC TRANSMISSION

/73

REVERSE AND OVERDRIVE CLUTCH 2.

Install the clutch reaction plate in the shown direction. Symbol

Description

2

Clutch reaction plate

3

Clutch discs

4

Clutch plates

C

Shear droop

DOIIT23AR07111

SNAP RING INSTALLATION 1.

Install the snap ring into the groove of reverse clutch retainer. Symbol 1

2. 3.

Description Snap ring

Set special tools MB991790 and MD998924 as shown in the illustration, and compress the clutch element. Check that the clearance between the snap ring and the clutch reaction plates is within the standard value, if not within the standard value, select a snap ring to adjust. Standard value: 1.5 mm (0.059 in)

DOIIT23AR07160

Printed in Malaysia 27 September 2007 Eng

Black plate (79,1)

AUTOMATIC TRANSMISSION

23A

PLANETARY CARRIER ASSEMBLY

/74

PLANETARY CARRIER ASSEMBLY

WTC23ASHAUL031

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07161

Apply automatic transmission fluid to all moving parts before installation. Disassembly steps 1. Stopper plate 2. One-way clutch 3. Snap ring 4. Output planetary carrier 5. Thrust bearing #3

6. 7. 8. 9. 10.

Underdrive sun gear Thrust bearing #4 Snap ring Overdrive planetary carrier Overdrive annulus gear

Printed in Malaysia 27 September 2007 Eng

Black plate (80,1)

23A

AUTOMATIC TRANSMISSION

/75

PLANETARY CARRIER ASSEMBLY REASSEMBLY SERVICE POINTS WTC23ASHAUL041 THRUST BEARING #3 / THRUST BEARING #4 INSTALLATION Check the installation direction of thrust bearings number #3 and #4, and install them as shown. Symbol

Description

5

Thrust bearings #3

7

Thrust bearings #4

DOIIT23AR07162

ONE-WAY CLUTCH INSTALLATION Insert the one-way clutch into the overdrive annulus gear so that the arrow points to the output planetary carrier side. Symbol

Description

2

One-way clutch

4

Output planetary carrier

10

Overdrive annulus gear

DOIIT23AR07163

Printed in Malaysia 27 September 2007 Eng

Black plate (81,1)

AUTOMATIC TRANSMISSION

23A

LOW-REVERSE BRAKE

/76

LOW-REVERSE BRAKE

WTC23ASHAUL032

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07115

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply ATF, blue petrolatum jelly — Non-reusable part Disassembly steps 1.

D-ring

2.

D-ring

3.

Low-reverse brake piston

Printed in Malaysia 27 September 2007 Eng

Black plate (82,1)

23A

AUTOMATIC TRANSMISSION

/77

SECOND BRAKE REASSEMBLY SERVICE POINT D-RING INSTALLATION Apply ATF, blue petrolatum jelly or white Vaseline to new D-ring and install carefully.

DOIIT23AR07117

SECOND BRAKE

WTC23ASHAUL033

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07116

— Lubricate all internal parts with automatic transmission fluid during reassembly

— Apply ATF, blue petrolatum jelly

Printed in Malaysia 27 September 2007 Eng

Black plate (83,1)

AUTOMATIC TRANSMISSION

23A

SECOND BRAKE

/78

— Non-reusable part Disassembly steps 1. 2.

Second brake retainer D-ring

3. 4.

Second brake piston D-ring

REASSEMBLY SERVICE POINT D-RING INSTALLATION Apply ATF, blue petrolatum jelly or white Vaseline to new D-ring and install carefully.

DOIIT23AR07118

Printed in Malaysia 27 September 2007 Eng

Black plate (84,1)

23A

AUTOMATIC TRANSMISSION

/79

OUTPUT SHAFT

OUTPUT SHAFT

WTC23ASHAUL034

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07119

— Lubricate all internal parts with automatic transmission fluid during reassembly — Non-reusable part Disassembly steps 1.

Transfer driven gear

2. 3.

Bearing retainer Outer rece

4.

Tapper roller bearing

5.

Output shaft

Printed in Malaysia 27 September 2007 Eng

Black plate (85,1)

AUTOMATIC TRANSMISSION

23A

OUTPUT SHAFT

/80

DISASSEMBLY SERVICE POINTS NOTE: Recomended to use hydraulic machine i.e press machine to perform the diassembly service point. TRANSFER DRIVEN GEAR REMOVAL Use the special tool, press the output shaft to remove the transfer driven gear.

DOIIT23AR07120

TAPER ROLLER BEARING REMOVAL Use the special tool, press the output shaft to remove the taper roller bearing.

DOIIT23AR07121

REASSEMBLY SERVICE POINT NOTE: Recomended to use hydraulic machine i.e press machine to perform the reassembly service point. TAPER ROLLER BEARING INSTALLATION Use the special tools to install the taper roller bearing.

DOIIT23AR07122

OUTER RACE INSTALLATION Use the special tools to install the outer race.

DOIIT23AR07123

Printed in Malaysia 27 September 2007 Eng

Black plate (86,1)

23A

AUTOMATIC TRANSMISSION

/81

TRANSFER DRIVE GEAR TRANSFER DRIVEN GEAR INSTALLATION Use the special tools to install the transfer driven gear.

DOIIT23AR07124

TRANSFER DRIVE GEAR

WTC23ASHAUL035

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07125

— Lubricate all internal parts with automatic transmission fluid during reassembly — Non-reusable part

Printed in Malaysia 27 September 2007 Eng

Black plate (87,1)

AUTOMATIC TRANSMISSION

23A

TRANSFER DRIVE GEAR

/82

Disassembly steps 1.

Lock nut

2. 3.

Transfer drive gear bearing Transfer drive gear

T1 : 19.5 Kgf.m

DISASSEMBLY SERVICE POINTS LOCK NUT REMOVAL 1.

Pull up the turning stopper of the lock nut.

2.

Use the special tool to remove the lock nut.

DOIIT23AR07126

DOIIT23AR07127

TRANSFER DRIVE GEAR BEARING REMOVAL Use the special tools to remove the transfer drive gear bearing.

DOIIT23AR07128

Printed in Malaysia 27 September 2007 Eng

Black plate (88,1)

23A

AUTOMATIC TRANSMISSION

/83

TRANSFER DRIVE GEAR REASSEMBLY SERVICE POINTS TRANSFER DRIVE GEAR BEARING INSTALLATION Use the special tools to install the transfer gear bearing.

DOIIT23AR07129

LOCK NUT INSTALLATION 1.

Apply ATF to a new lock nut and tighten it to the specified torque. Then turn back one turn, and tighten to the specified torque again.

2.

Use punch or other to prevent the nut from turning (two points).

DOIIT23AR07127

DOIIT23AR07130

Printed in Malaysia 27 September 2007 Eng

Black plate (89,1)

AUTOMATIC TRANSMISSION

23A

DIFFERENTIAL

/84

DIFFERENTIAL

WTC23ASHAUL036

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07131

Lubricate all internal parts with automatic transmission fluid during reassembly Disassembly steps 1.

Differential drive gear

6.

Washers

2.

Taper roller bearing

7.

Side gears

8.

Spacers

9.

Differential case

3.

Lock pin

4.

Pinion shaft

5.

Pinions

T1 : 13.5 kgm (135 Nm; 9.059 ft.lbs)

Printed in Malaysia 27 September 2007 Eng

Black plate (90,1)

23A

AUTOMATIC TRANSMISSION

/85

DIFFERENTIAL DISASSEMBLY SERVICE POINTS WTC23ASHAUL037

NOTE: Recomended to use hydraulic machine i.e press machine to perform the diassembly service point. TAPER ROLLER BEARING REMOVAL Use the special tool, press the differential case to remove the taper roller bearing.

DOIIT23AR07132

REASSEMBLY SERVICE POINTS NOTE: Recomended to use hydraulic machine i.e press machine to perform the reassembly service point. SPACER, SIDE GEAR, WASHER, PINION, PINION SHAFT INSTALLATION 1.

DOIIT23AR07133

2.

3.

Install the spacers to the back side of the side gears, and then assemble the side gears into the differential case. NOTE : Select the medium size spacer 0.93~1.00 mm (0.036~0.039 in) when assembling a new side gear. Attach the washers to the back side of the pinions, engage the pinions simultaneously to the side gears, and settle the gears by turning. Insert the pinion shaft.

DOIIT23AR07134

Printed in Malaysia 27 September 2007 Eng

Black plate (91,1)

AUTOMATIC TRANSMISSION

23A

DIFFERENTIAL

/86

4. 5.

Measure the backlash between the side gears and pinions. Standard value:0.025-0.150 mm (0-0.005 in) If not within the standard value, change a spacer and measure the backlash again. NOTE : Adjust so that both backlashes are equal.

DOIIT23AR07135

LOCK PIN INSTALLATION Install the lock pin in the shown direction. Symbol

Description

4

Lock pin

5

Pinion shaft

10

Differential case

DOIIT23AR07136

TAPER ROLLER BEARING INSTALLATION Use the special tools to install the taper roller bearing. Symbol 3

Description Taper roller bearing

DOIIT23AR07137

DIFFERENTIAL DRIVE GEAR INSTALLATION Apply ATF to the bolt, tighten the bolts to the specified torque in the shown sequence. Specified torque: 13.5 kgm (135 Nm; 9.059 ft.lbs)

DOIIT23AR07138

Printed in Malaysia 27 September 2007 Eng

Black plate (92,1)

23A

AUTOMATIC TRANSMISSION

/87

VALVE BODY

VALVE BODY

WTC23ASHAUL038

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07139

— Lubricate all internal parts with automatic transmission fluid during reassembly — Non-reusable part Disassembly steps 1. 2.

Solenoid valve support Underdrive solenoid valve

11. Steel ball (orifice check ball)

3.

Second solenoid valve

4.

Damper clutch control solenoid valve

13. Plate 14. Damping valve

5.

Overdrive solenoid valve

15. Damping valve spring

6.

Low-reverse solenoid valve

16. Steel ball (line relief)

7. 8. 9. 10.

Manual valve Cover Plate Outside valve body assembly

17. Spring

12. Spring

18. Steel ball (orifice check ball) 19. Spring 20. Inside valve body assembly

Printed in Malaysia 27 September 2007 Eng

Black plate (93,1)

AUTOMATIC TRANSMISSION

23A

VALVE BODY

/88

T1 : 0.6 kgm (6 Nm; 0.402 ft.lbs) T2 : 1.1 kgm (11 Nm; 0.738 ft.lbs)

DOIIT23AR07140

Lubricate all internal parts with automatic transmission fluid during reassembly Disassembly steps 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Roller Damper clutch control valve sleeve Damper clutch control valve Damper clutch control valve spring Plate Screw Regulator valve spring Regulator valve Plate Fail-save valve A sleeve Fail-save valve A2

32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

Fail-save valve A spring Fail-save valve A1 Plate Plug Torque converter valve Torque converter valve spring Plate Fail-save valve B sleeve Fail-save valve B Inside valve body

Printed in Malaysia 27 September 2007 Eng

Black plate (94,1)

23A

AUTOMATIC TRANSMISSION

/89

VALVE BODY

DOIIT23AR07141

Lubricate all internal parts with automatic transmission fluid during reassembly Disassembly steps 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.

Roller Overdrive pressure control valve sleeve Overdrive pressure control valve Overdrive pressure control valve spring Roller Low-reverse pressure control valve sleeve Low-reverse pressure control valve Low-reverse pressure control valve spring Plate Plug

52. 53. 54. 55. 56. 57. 58. 59. 60. 61.

Switching valve Roller Underdrive pressure control valve sleeve Underdrive pressure control valve Underdrive pressure control valve spring Roller Second pressure control valve sleeve Second pressure control valve Second pressure control valve spring Outside valve body

Printed in Malaysia 27 September 2007 Eng

Black plate (95,1)

AUTOMATIC TRANSMISSION

23A

VALVE BODY

/90

DISASSEMBLY SERVICE POINT WTC23ASHAUL039 SOLENOID VALVES REMOVAL Mark solenoid valves by white paint to make reassembly easier. Symbol

DOIIT23AR07145

Description

2

Underdrive solenoid valve

3

Second solenoid valve

4

Damper clutch control solenoid valve

5

Overdrive solenoid valve

6

Low-reverse solenoid valve

REASSEMBLY SERVICE POINTS SPRING / STEEL BALL / DAMPING VALVE / DAMPING VALVE SPRING INSTALLATION Insert the spring, steel ball, damping valve and damping valve spring in the position as shown in illustration. Symbol

DOIIT23AR07142

Description

14

Damping valve

15

Damping valve spring

16, 18

Steel ball

17, 19

Spring

SPRING / STEEL BALL INSTALLATION Insert the spring and steel ball in the position as shown in illustration. Symbol

Description

11

Steel ball

12

Spring

DOIIT23AR07143

Printed in Malaysia 27 September 2007 Eng

Black plate (96,1)

23A

AUTOMATIC TRANSMISSION

/91

DRIVE SHAFT OIL SEAL SOLENOID VALVES INSTALLATION 1. 2.

Apply ATF, blue petrolatum jelly or white Vaseline to O-ring, and install carefully. Install the solenoid valves by referring to the marks during disassembly. Symbol

Description

2

Underdrive solenoid valve

3

Second solenoid valve

4

Damper clutch control solenoid valve

5

Overdrive solenoid valve

6

Low-reverse solenoid valve

DOIIT23AR07144

DRIVE SHAFT OIL SEAL

WTC23ASHAUL040

DISASSEMBLY AND REASSEMBLY

DOIIT23AR07146

— Lubricate all internal parts with automatic transmission fluid during reassembly

Printed in Malaysia 27 September 2007 Eng

Black plate (97,1)

AUTOMATIC TRANSMISSION

23A

DRIVE SHAFT OIL SEAL

/92

— Non-reusable part Disassembly steps 1. Oil seal 2. 3.

Torque converter housing Oil seal

4.

Transmission case

REASSEMBLY SERVICE POINT OIL SEAL INSTALLATION Use the special tool to install the oil seal.

DOIIT23AR07147

OIL SEAL INSTALLATION Use the special tool to install the oil seal.

DOIIT23AR07148

Printed in Malaysia 27 September 2007 Eng

Black plate (98,1)

23A

AUTOMATIC TRANSMISSION

/93

DRIVE SHAFT OIL SEAL

NOTE

Printed in Malaysia 27 September 2007 Eng

Black plate (99,1)

TRANSMISSION OVERHAUL (AUTOMATIC)

TC03

INDEX

/1

Printed in Malaysia 27 September 2007 Eng

F4A42

Model YR

2007

English Edition

RDWE-1GA082 September 2007 Printed in Malaysia

Black plate (100,1)

Content 3

Printed in Malaysia 27 September 2007 Eng