' 23B-1

= ~. I
.....

AUTOMATIC
TRANSAXLE
OVERHAUL
CONTENTS 23309000138

DIFFERENTIAL ........................... 66 General Specifications ........................ 6

Sealants ................................... 11
DRIVE SHAFT OIL SEAL ................. 74
Service Specifications ........................ 6
GENERAL INFORMATION .................. 2 Snap Ring. Spacer. Thrust Washer. Thrust Race
and Pressure Plate For Adjustment . . . . . . . . . . . . 8
LOW-REVERSE BRAKE .................. 60 Torque Specifications . . . . . . . . . . . . . . . . . . . 11
Valve Body Spring Identification Table ......... 7
OIL PUMP ............................... 51

OUTPUT SHAFT ......................... 62

SPEEDOMETER GEAR ................... 73
TRANSAXLE ............................. 16
OVERDRIVE PLANETARY CARRIER ...... 59
TRANSFER DRIVE GEAR ......-.......... 64
REVERSE AND OVERDRIVE CLUTCH .... 55
UNDERDRIVE CLUTCH AND INPUT
BRAKE ........................ 61 SHAFT .................................. 52
SPECIAL TOOLS ........................ 12 VALVE BODY ............................ 69
SPECIFICATIONS .......................... 6
23B-2 AUTOMATIC TRANSAXLE OVERHAUL - General Information

GENERAL INFORMATION 23300010109

(1) The combinationof highest-precisionelectronic (4) Increased meshing ratios and improved rigidity
and mechanical technology heralds a new era of the gear supports and casing result in less
in automatic transaxle performance. noise.
(2) The gear shifting clutches use a hydraulic (5) In addition, adoption of a newly-developed
balancing mechanism to enable gear shifting automatic transmission fluid (ATF) and an
at extra-high engine speeds. external oil filter eliminates the need to
(3) The number of shafts has been decreased to periodically replace the fluid.
two, increased use has been made of metal (6) The number of oil cooler feed tubes is increased
plates and the one-way clutch has been to two.
abolished, which all contribute to reduce the
weight.
 AUTOMATIC TRANSAXLE OVERHAUL - General Information 23B-3
SECTIONAL VIEW
cF4A41>

1 2 3 4 5 6 7 8 9

18 \

17-

13

16

14

1. Reverse clutch 10. Torque converter clutch

2. Overdrive planetary carrier 11. Input shaft
3. Second brake 12. Oil pump
4. Low-reverse brake 13. Converter housing
5. Output planetary carrier 14. Differential
6. Transaxle case 15. Transfer driven gear
7. Transfer drive gear 16. Output shaft
8. Underdrive clutch 17. Rear cover
9. Torque converter 18. Overdrive clutch
23B-4 AUTOMATIC TRANSAXLE OVERHAUL - ..General Information
<F4A42>

1 2 3 4 5 6 7 8 9

/lo

18,

/ l1

17-

' 12

13

16 15

' 14

ATFAl503

1. Reverse clutch 10. Torque converter clutch

2. Overdrive planetary carrier 11. Input shaft
3. Second brake 12. Oil pump
4. Low-reverse brake 13. Converter housing
5. Output planetary carrier 14. Differential
6. Transaxle case 15. Transfer driven gear
7. Transfer drive gear 16. Output shaft
8 . Underdrive clutch 17. Rear cover
9. Torque converter 18. Overdrive clutch
 AUTOMATIC TRANSAXLE OVERHAUL - General Information 23B-5
HYDRAULIC CIRCUIT

EX
TFA1598
2 9 i

1. Reverse clutch 18. Overdrive pressure control valve

2. Low-reverse brake 19. Torque converter clutch control
3. Second brake solenoid valve
4. Underdrive clutch 20. Low-reverse solenoid valve
5. Overdrive clutch 21. Second solenoid valve
6. Low-reverse accumulator 22. Underdrive solenoid valve
7. Second accumulator 23. Overdrive solenoid valve
8. Underdrive accumulator 24. Torque converter pressure control
9. Overdrive accumulator valve
10. Torque converter clutch 25. Regulator valve
11. Fail-safe valve A 26. Manual valve
12. Fail-safe valve B 27. Oil filter
13. Torque converter clutch control 28. Oil filter
valve 29. Oil pan
14. Switching valve 30. Oil pump
15. Low-reverse pressure control valve 31. Relief valve
16. Second pressure control valve 32. Oil strainer
17. Underdrive pressure control valve
23B-6 AUTOMATIC TRANSAXLE OVERHAUL - Specifications
SPECIFICATIONS 23300020135

GENERAL SPECIFICATIONS h
I Items 1 Specifications I
Model F4A41 F4A42

Type Electronically controlled 4-speed full-automatic

Torque Converter I Type 3-element with torque converter clutch

Engine stall speed 1900 - 2400 r/min 2100 - 2600 rlmin

~ _ _ ~ _ ___
Stall torque ratio 2.0 2.0
Gear ratio I 1st I 2.842 I 2.842 I
2nd 1.529 1.529
3rd 1.000 1.ooo
4th 0.712 0.712
Reverse 2.480 2.480
Final gear ratio 4.042 4.042
Speedometer gear ratio (driven/drive) 3 1/36 3 1/36
I
Items Standard value
~ _ _ ~ ~

Output shaft preload mm (in.) ~ 0.01 to 0.09 (0.0004 to 0.0035)

Brake reaction plate end play mm (in.) 1 0 to 0.16 (0 to 0.0063)

Low-reverse brake end play mm (in.) F4A41 1 1.05 to 1.51 (0.0413 to 0.0594)
F4A42 1 1.35 to 1.81 (0.0531 to 0.0713)
Second brake end play mm (in.) F4A41 0.49 to 0.95 (0.0193 to 0.0374)
F4A42 0.79 to 1.25 (0.0311 to 0.0492)
Underdrive sun gear end play mm (in.) 0.25 to 0.45 (0.0098 to 0.0177)
Input shaft end play mm (in.) I 0.70 to 1.45 (0.0276 to 0.0571)
Differential case preload mm (in.) cF4A42> 0.045 to 0.105 (0.0018 to 0.0041)
Underdrive clutch end play mm (in.) I F4A41 1 1.25 to 1.45 (0.0492 to 0.0571)
I F4A42 i 1.65 to 1.85 (0.0650 to 0.0728)
Reverse and overdrive clutch return spring end play mm (in.) I 0 to 0.09 (0 to 0.0035)
Overdrive clutch end play mm (in.) F4A41 1.2 to 1.4 (0.0472 to 0.0551)
_ _ _ _ _ _ _
F4A42 1.6 to 1.8 (0.0630 to 0.0709)
Reverse clutch end play mm (in.) 1.2 to 1.4 (0.0472 to 0.0551)
Backlash between differential side gear and pinion mm (in.) I 0.025 to 0.150 (0.00098 to 0.00591)
 AUTOMATIC TRANSAXLE OVERHAUL - Specifications 239-7
VALVE BODY SPRING IDENTIFICATION TABLE 23302290044

Spring Wire diameter Outside diameter Free length Number of loops

mm (in.) mm (in.) mm (in.)

1 1.8(0.071) 1 15.7(0.618) 1 86.7(3.413)

~ ~~

Regulator valve spring 24

~ ~ ~ ~ _ _ ___ __
_ _ _

7
~~

Underdrive pressure control valve 0.7(0.028) 25

spring

Overdrive pressure control valve 0.7(0.028) 25

spring

Low-reverse pressure control valve 0.7(0.028) 7.6(0.299) 37.7(1.484) 1 25

spring
’
Second pressure control valve
spring
0.7(0.028) 7.6(0.299) 37.7(1.484) 1 25
Torque converter spring 1.6(0.063) 1 11.2(0.441) 1 34.4(1.354) 12.5
Torque converter clutch control 0.7(0.028) 5.9(0.232) 28.1 (1.106) 19
valve spring

Fail-safe valve A spring 0.7(0.028) 1 8.9(0.350) I 21.9(0.862) I 9.5

Damping valve spring 1 1.0(0.039) i 7.7(0.303) 35.8(1.409) I 17
Line relief valve spring 1 1.0(0.039) I 7.0(0.276) 17.3(0.681)
-___
238-8 AUTOMATIC TRANSAXLE OVERHAUL - Specifications
SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE
PLATE FOR ADJUSTMENT 23302300044

Thrust washer (For adjustment of input shaft end play)

Thickness Identification Part No. Thickness Identification Part No.
rnm (in.) symbol rnm (in.) symbol

1.8 (0.071) MD754509 2.4 (0.094) MD753793

2.0 (0.079) MD754508 2.6 (0.102) MD753794
2.2 (0.087) MD754507 2.8 (0.110) MD753795

Snap ring (For adjustment of underdrive clutch and overdrive clutch end plays)
Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol rnm (in.) symbol

1.6 (0.063) None MI3759666 2.4 (0.094) Brown MD752129

1.7 (0.067) Blue MD759667 2.5 (0.098) None MD752130
1.8 (0.071) Brown MD759668 2.6(0.102) Blue MD752131
1.9 (0.075) None MD752124 2.7 (0.106) Brown MD752132
2.0 (0.079) Blue MD752125 2.8 (0.110) None MD752133
2.1 (0.083) Brown MD752126 2.9 (0.114) Blue MD752134
2.2 (0.087) None MD752127 3.0 (0.118) Brown MD754680
2.3 (0.091) Blue MD752128

Snap ring (For adjustment of low-reverse brake reaction plate end play)
Thickness
rnrn (in.)
Identification
symbol
p LThickness
(in.) 1 o
a;in
g
:t; Part No.

2.2 (0.087) Blue MD754786 2.4 (0.094) None MD758240

2.3 (0.091) Brown -y MD754787 2.5 (0.098) Blue MD758241

Pressure plate (For adjustment of low-reverse brake and second brake end plays)
Thickness Identification Part No. Thickness Identification Part No.
symbol mm (in.) symbol

MD759567 2.4 (0.094) MD759417

1.8 (0.071) MD759414 2.6 (0.102) MD759418
2.0 (0.079) MD759415 2.8 (0.110) MD759419
2.2 (0.087) MD759416 3.0 (0.118) D MD759420

Snap ring (For adjustment of reverse clutch end play)

- ~

Thickness Identification Part No. Thickness Identification Part No.

mm (in.) symbol mm (in.) symbol
1.9 (0.075) None MD752137 2.4 (0.094) Brown MD752142
2.0 (0.079) Blue MD752138 2.5 (0.098) None MD752143
2.1 (0.083) Brown MD752139 2.6 (0.102) Blue MD752144
2.2 (0.087) None MD752140 2.7 (0.106) Brown MD752145
2.3 (0.091) Blue MD752141 2.8 (0.110) None MD752146
 Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol . mm (in.) symbol

1.48 (0.0583)
1.53 (0.0602)
Brown
None
MD755600
MD755601 1 1.58 (0.0622)
1.63 (0.0642)
Blue
Brown
MD755602
MD755603

Thrust race (For adjustment of underdrive sun gear end play)

Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol

1.6 (0.063) MD707267 2.2 (0.087) MD723065

1.7 (0.067) MD759681 2.3 (0.091) MD754796
1.8 (0.071) MD723064 2.4 (0.094) MD724358
1.9 (0.075) MD754794 2.5 (0.098) MD754797
2.0 (0.079) MD707268 2.6 (0.102) MD754798
2.1 (0.083) MD754795

Spacer (For adjustment of output shaft preload)

Thickness identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol

1.88 (0.0740) 88 MD756579 2.36 (0.0929) 36 MD756591

1.92 (0.0756) 92 MD756580 2.40 (0.0945) 40 MD756592
1.96 (0.0772) 96 MD756581 2.44 (0.0961) 44 MD756593
2.00 (0.0787) 00 MD756582 2.48 (0.0976) 48 MD756594
2.04 (0.0803) 04 MD756583 2.52 (0.0992) 52 MD756595
2.08 (0.0819) 08 MD756584 2.56 (0.1008) 56 MD756596
2.12 (0.0835) 12 MD756585 2.60 (0.1024) 60 MD756597
2.16 (0.0850) 16 MD756586 2.64 (0.1039) , 64 MD756598
2.20 (0.0866) 20 MD756587 2.68 (0.1055) 68 MD756599
2.24 (0.0882) 24 MI3756588 2.72 (0.1071) 72 MD760685
2.28 (0.0898) 28 MD756589 2.76 (0.1087) 76 MD760686
2.32 (0.0913) 32 MD756590

Spacer cF4A41> (For adjustment of differential case end play)

Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol

1.28 (0.0504) N MD710458 1.64 (0.0646) v MD710466

1.37 (0.0539) P MD710460 1.73 (0.0681) X MD710468
1.46 (0.0575) R MD710462 1.82 (0.0717) Z MD710470
1.55 (0.0610) T MD710464
23B-10 AUTOMATIC TRANSAXLE OVERHAUL - Specifications
Spacer <F4A42> (For adjustment of differential case preload)
Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol

0.71 (0.0280) 71 MD754475 1.07 (0.0421) 07 MD720945

0.74 (0.0291) 74 MD727660 1.l0 (0.0433) J MD710454
0.77 (0.0303) 77 MD754476 1.13 (0.0445) D MD700270
0.80 (0.0315) 80 MD727661 1.16 (0.0457) K MD710455
0.83 (0.0327) 83 MD720937 1.19 (0.0469) L MD710456
0.86 (0.0339) 86 MD720938 1.22 (0.0480) G MD700271
0.89 (0.0350) 89 MD720939 1.25 (0.0492) M MD710457
0.92 (0.0362) 92 MD720940 1.28 (0.0504) N MD710458
0.95 (0.0374) 95 MD720941 1.31 (0.0516) E MD706574
0.98 (0.0386) 98 MD720942 1.34 (0.0528) 0 MD710459
1.01 (0.0398) 01 MD720943 1.37 (0.0539) P MD710460
1.04 (0.0409) 04 MD720944

Spacer <F4A41> (For adjustment of backlash between differential side gear and pinion)
Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol
0.75 to 0.82 - MD755179 1.01 to 1.08 MD755175
(0.0295 to (0.0398 to
0.0323) 0.0425)
0.83 to 0.92 MD755178 1.09 to 1.16 MD755176
(0.0327to (0.0429 to
0.0362) 0.0457)
0.93 to 1.OO - MD755177
(0.0366 to
0.0394)

Spacer <F4A42> (For adjustment of backlash between differential side gear and pinion)
Thickness Identification Part No. Thickness Identification Part No.
mm (in.) symbol mm (in.) symbol
0.75 to 0.82 MD722986 1.01 to 1.08 MD722982
(0.0295 to (0.0398 to
0.0323) 0.0425)
0.83 to 0.92 MD722985 1.09to 1.16 MD722983
(0.0327 to (0.0429 to
0.0362) 0.0457)
0.93 to 1.00 MD722984
(0.0366to
0.0394)
 AUTOMATIC TRANSAXLE OVERHAUL - Specifications 23B-11
TORQUE SPECIFICATIONS 23302310047
I

Nm ft.lbs.
Roll stopper bracket 69 51
Wiring harness bracket 23 17
Control cable bracket 23 17
Eye bolt 30 22
Oil cooler feed tube 11 8.0
Oil filter 12. 8.7
Input shaft speed sensor 11 8.0
Output shaft speed sensor 11 8.0
Manual control lever 22 16
Parkheutral position switch (PNP switch) 11 8.0
Speedometer gear 4.9 3.6
Valve body cover 11 8.0
Valve body mounting bolt 11 8.0
Fluid temperature sensor 11 8.0
Manual control shaft detent 5.9 4.3
Rear cover 23 17
Torque converter housing 47 35
Oil pump 23 17
Transfer drive gear 19 14
Output shaft lock nut 167 123
Output shaft bearing retainer 23 17
Transfer drive gear lock nut 191 141
Differential drive gear 132 98
Valve body 11 8.0
Solenoid valve support 5.9 4.3
Plate _ "
5.9 4.3

23300050040

Items Specified sealant

Rear cover Mitsubishi genuine sealant Part No. MD974421 or equivalent
Torque converter housing Mitsubishi genuine sealant Part No. MD974421 or equivalent
Valve body cover Mitsubishi genuine sealant Part No. MD974421 or equivalent
23B-12 AUTOMATIC TRANSAXLE OVERHAUL - SDecial Tools
SPECIAL TOOLS 23300060111

Tool Tool number and name Supersession Application

MB990607 Removal and installation of
To rque wrench output shaft lock nut
socket

MB990928 Removal of transfer drive gear

Installer adapter bearing

MB990930 MB990930-01 Installation of output shaft taper

Installer adapter roller bearing outer race

MB990931 Installation of cap

Installer adapter

MB990935 Installation of differential taper

Installer adapter roller bearing outer race
<F4A42>

MB990936 MB990936-01 Installation of output shaft taper

Installer adapter roller bearing outer race

~ _ _ _

MB990938 MB990938-01 0 Installation of input shaft

Handle rear bearing
0 Use with installer adapter

MB991625 Removal and installation of

Special socket (41) output shaft lock nut

MB991626 Removal and installation of

Socket (60) transfer drive gear lock nut
 AUTOMATIC TRANSAXLE OVERHAUL - Special Tools 23B-13

TOQJ Tool number and name Supersession Application

MB991628 0 Removal and installation of
Spring compressor low-reverse brake snap ring
0 Measurement of underdrive
clutch and overdrive clutch
end plays

MB991631 Measurement of low-reverse

Clearance dummy plate brake and second brake end
plays

MD998333 MD998333-01 Removal of oil pump

Oil pump remover

MD998334 MD998334-01 Installation of oil pump oil seal

t
.Q Oil seal installer

MD998348
Bearing and gear
MD998348-01 Removal of transfer drive gear
bearing
puller

MD998350 MD998350-01 Installation of output shaft rear

Bearing installer taper roller bearing

I
MD998412 MD998412 Installation of oil pump and
Guide transfer drive gear

I
MD998800 Installationof drive shaft oil seal
Oil seal installer

MD998801 MD998348-01 Removal of each bearing

Bearing remover
23B-14 AUTOMATIC TRANSAXLE OVERHAUL - Special Tools

I Tool number and name

blD998812
nstaller cap
Supersession
2ENERAL SERVICE
rooL
ipplication
Jse with installer and installer
idapter

I
MD998813 3ENERAL SERVICE Jse with installer cap and
Installer - 100 rooL nstaller adapter

MD998814 MlT304180 Jse with installer cap and

Installer - 200 nstaller adapter

MD998819 MD998819 nstallation of differential ball

Installer adapter 3earing <F4A41>
(40)

MD998820 MIT215013 Installation of differential taper

Installer adapter roller bearing <F4A42>
(42)

I
MD998823 0 Installation of output shafl
Installer adapter taper roller bearing
0 Installation of transfer driver
(48)
gear

I
MD998829 MD998829-01 Installation of transfer drive gear
Installer adapter bearing
(60)

I
MD998907 MD998907-01 Removal and installation of
Spring compressor underdrive clutch snap ring

~~

MD998913 MD998913-01 Measurement of low-reverse

Dial gauge brake and second brake end
extension plays
 AUTOMATIC TRANSAXLE OVERHAUL - Special Tools 23B-15

Tool Tool number and name Supersession Application

MI3998917 MD998917-01 Removal of output shaft taper
Bearing remover roller bearing

MD998924 0 Removal and installation of

Spring compressor low-reverse brake snap ring
retainer 0 Measurement of underdrive
clutch and overdrive clutch
end plays
0 Removal and installation of
underdrive clutch and
overdrive clutch snap ring
MD999590 Removal and installation of
Spring compressor overdrive clutch snap ring
23B-I 6 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
TRANSAXLE 23300100226

DISASSEMBLY AND REASSEMBLY

30 Nm
22 ft.lbs.
6
a
ill

9.8 Nm
7.2 ft.lbs.

5.9 Nm

15
Ga

I
2 1
69' Nm
51 ft.lbs.

11 Nm
8.0 ft.lbs.

TFA1875

1. Torque converter 9. Oil filter gasket

2. Roll stopper bracket 10. Input shaft speed sensor
3. Harness bracket 11. Output shaft speed sensor
4. Control cable support bracket 12. Manual control lever
5. Oil level dipstick 13. Parkheutral position switch
6. Eye bolt 14. Speedometer gear
7. Oil cooler feed tube 15. Valve body cover
a. Oil filter 16. Manual control shaft detent
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle ’ 23B-17

TFA1587

17. Fluid temperature sensor 24. Second brake retainer oil seal
18. Valve body 25. Accumulator piston
19. Steel ball 26. Accumulator spring
20. Gasket 27. Accumulator spring
21. Snap ring 28. Manual control lever shaft roller
22. Solenoid valve harness 29. Manual control lever shaft
23. Strainer 30. Parking pawl rod
236-18 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle

4i’ Nm TFA1876
35 ft.lbs.

31. Torque converter housing 37. Thrust washer #1

32. Differential 38. Underdrive clutch and input shaft
33. Spacer <F4A41> 39. Thrust bearing #2
34. Oil filter 40. Underdrive clutch hub
35. Oil pump 41. Outer race
36. Gasket 42. Spacer
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-19
No. of Brake Discs and Plates
Brake Brake Plate

brake
F4A42
Second F4A4 1
brake
F4A42

23
17

71
23B-28 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle

43. Rear cover 68. Low-reverse brake plate

44. Thrust race #8 69. Pressure plate
45. Seal ring 70. Wave spring
46. Input shaft rear bearing 71. Parking pawl shaft
47. Thrust bearing #7 72. Spacer
48. Reverse and overdrive clutch 73. Parking pawl spring
49. Thrust bearing #6 74. Parking roller support shaft
50. Overdrive clutch hub 75. Parking pawl
51. Thrust bearing #5 76. Parking roller support
52. Planetary reverse sun gear 77. Snap ring
53. Snap ring 78. Spring retainer .
54. Second brake piston 79. Return spring
55. Return spring 80. Low-reverse brake piston
56. Pressure plate 81. Transfer drive gear
57. Second brake disc 82. Cap
58. Second brake plate 83. Lock nut
59. Overdrive planetary carrier 84. Output shaft
60. Thrust bearing #4 85. Taper roller bearing
61. Output planetary carrier 86. Collar
62. Underdrive sun gear 87. Outer race
63. Thrust bearing #3 88. Spacer
64. Snap ring 89. Snap ring
65. Reaction plate 90.Outer race
66. Snap ring 91. Transaxle case
67. Low-reverse brake disc
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-21
DISASSEMBLY
Caution
Because the automatic transaxle is manufactured
from high-precision parts, sufficient care must be
taken not to scratch or damage these parts during
disassembly and reassembly.
The working area should be covered with a rubber
mat to keep it clean at all times.
Do not wear any cloth gloves and do not use any
rags during disassembly. Use nylon cloth if you need
to use something.
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.
Clutch discs, plastic thrust plates and rubber parts
should be cleaned with automatic transmission fluid
(ATF) so that they do not become dirty.
If the transmission body has been damaged,
disassemble and clean the cooler system also.

Remove the torque converter.

Remove each bracket.
Remove the oil level gauge.
Remove the eye bolt, gasket and the oil cooler feed tube.
Remove the oil filter and oil filter gasket.

Remove the input shaft speed sensor and output shaft

speed sensor.

‘ I ’ speedsensor.
7 lnputshaftspeed 1-( r
J sensor ’

TFA1551

Manual control lever (7) Remove the manual control lever, and then remove the
\ parkheutral position switch.
Parkheutral
Caution
Make sure that the valve body is installed before
removing the manual control lever locking nut.
23B-22 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(8) Remove the speedometer gear.

n (9) Remove the valve body cover.

TFA1385

~~

(10) Remove the manual control shaft detent.

Manual control ~

=EE! shaft detent

(11) Disconnect the harness connectors of the valve body.

,1386

(12)Remove the valve body mounting bolts (28 pieces).

(13) Remove the fluid temperature sensor.
Caution
Make sure that the manual control lever and the
parwneutral position switch are removed.

TFA1387
AUTOMATIC TRANSAXLE OVERHAUL
* .
- Transaxle 23B-23
(14)Remove the valve body, gasket and the steel balls (2
pieces).
Caution
Do not lose the steel balls (2 pieces).

TFA1388

(15)Remove the snap ring, and then remove the sc,znoid

valve harness.

(16) Remove the strainer and the second brake retainer oil
seal.

(17) Remove each accumulator piston and spring.

I’ I For low-reverse brake

12 I For underdrive clutch
For second brake
For overdrive clutch

(18) Remove the manual control lever shaft roller.

(19)Remove the manual control lever shaft and the parking
pawl rod.
23B-24 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(20) Remove the torque converter housing mounting bolts
(18 pieces), and then remove the torque converter
housing.
’

I I

(21)Remove the O-rings ( pieces).

(22)Remove the differential and the spacer. <F4A41>

(23)Remove the differential. <F4A42>

(24)Remove the oil filter.

 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-25
(25) Remove the oil pump mounting bolts (6 pieces).
I I (26)lnstall the special tool (MD998333) in the hole A.

(27)Screw the special tool to remove the oil pump.

(28)Remove the oil pump gasket.

(29)Remove thrust washer #I.

Thrust
,washer #I

(30)Hold the input shaft, and then remove the underdrive

clutch.

(31)Remove thrust bearing #2.

Thrust bearing #2
23B-26 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(32) Remove the underdrive clutch hub.

(33)Remove the rear cover.

(34)Remove the thrust race #8.
(35)Remove the seal rings (4 pieces) from rear cover.
(36)Remove the input shaft rear bearing.

(37) Remove the O-rings (3 pieces).

(38)Remove the reverse and overdrive clutch and the thrust

bearing #7.

(39) Remove the overdrive clutch hub and the thrust bearing
#6.
AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-27
(40) Remove thrust bearing #5.

(41)Remove the planetary reverse sun gear.

(42)Remove the snap ring.

(43)Remove the second brake piston and the return spring.

(44) Remove the pressure plate, brake discs and brake

plate(s).
Number of brake discs and plates

I Al-rMode' ~ Brake disc ~ Brake plate

1 Pressure
plate
I F4A41 12
I F4A42 1 3
23B-28 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(45) Remove the overdrive planetary carrier.

(46) Removethe output pmetary carrier andthe thrust bearing

#4.

(47) Remove the underdrive sun gear and the thrust bearing
#3 from the output planetary carrier.

(48)Remove the snap ring.

I
(49)Remove the reaction plate and the brake disc.
AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-29
(50)Remove the snap ring.

(51)Removethe brake plates, brake discs and pressureplate.

Number of brake discs and plates
A / l Model Brake disc Brake plate Pressure
plate
F4A41 3 3 1
F4A42 4 4 1
~ ~~

(52) Remove the wave spring.

(53)Remove the parking pawl shaft, and then remove the

spacer and parking pawl spring.

(54)Remove the two parking roller supporf shafts, and then

remove the parking pawl case and parking roller support.
23B-3Q AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(55)Use the special tool to remove the snap ring.
(56)Remove the spring retainer, return spring and the
low-reverse brake piston.

(57) Remove the transfer drive gear mountingbolts (4 pieces).

(58) Remove the transfer drive gear.

(59)Remove the cap.

(6O)Straighten the locking tab of the output shaft lock nut.

AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-31
(61)Use the special tool to remove the output shaft lock nut.
Caution
The lock has left-handed threads.

k;' TFA1427

(62) Remove the output shaft bearing retainer mounting bolts.

(63)Tap on the rear of the output shaft to remove the output

shaft, taper roller bearing and the collar.

(64)Remove the spacer and the outer race.

(65)Remove the snap ring.

(66) Remove the differential bearing outer race and spacer

from the torque converter hosing. cF4A42>
(67)Remove the differential bearing outer race from the
transaxle case. cF4A42>
23B-32 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle

REASSEMBLY
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. Immersea 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.

(1) Use the special tools to tap the differential bearing outer
MB990938
1
race in the transaxle case. <F4A42>

(2) Install the low-reverse brake piston, return spring, and

spring retainer.
(3) Use the special tools to install the snap ring.
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle * 23B-33
(4) Install the wave spring.

(5) Replace the pressure plate of the low-reverse brake with

the special tool, and then install the brake disc, brake
Snap ring plate and snap ring as shown in the figure.
Number of brake discs and plates
MB991631
A/T Model Brake disc I Brake plate ~ Special tool
F4A41 4 3 1
F4A42 5 4 1
TFAl776

(6) Install the reaction plate and the used snap ring.
Snap ring
(7) Move the special tool to measure the end play, and then
replace the snap ring installed in step (6) to adjust the
end play to standard value.
MB991631 Standard value: 0 - 0.16 mm (0 - 0.0063 in.)

TFAl777

(8) Replace the pressure plate of the second brake with the
Second special tool, and then install the brake disc and brake
piston Snap ring
plate as shown in the figure.
Return spring
(9) Install the return spring, second brake piston and snap
ring.
Number of brake discs and plates
MB991631
A/T Model Brake disc Brake plate Special tool
F4A41 2 1 1
TFA1778
F4A42 3 2 1

(1O)Move the special tool (MB991631) to measure the end

play.
Standard value:
-
0.49 - 0.95 mm (0.0193 0.0374 in.) <F4A41>
-
0.79 1.25 mm (0.0311 -
0.0492 in.) <F4A42>
23B-34 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
Remove the special tool. Use the following formula to
determine the proper thickness range for the pressure
plate. Install the correct size pressure plate based on
your calculations.
A Reference: Pressure Plate Thickness
A=Special tool end play measurement determined
MB99163 1 earlier in this step.
F4A41
TFAl779
Metric values: [A+(2.0 mm - 0.95 mm)] to.[A+(2.0 mm
- 0.49 mm)]
English values: [A+(0.079 in. - 0.037 in.)] to [A+(0.079
in. - 0.019 in.)]
(Please use the above format for the end play
measurement text in step 14.)
F4A42
Metric values: [A+(2.0 mm - 1.25 mm)] to [A+(2.0 rnm
- 0.79 mm)]
English values: [A+(0.079 in. - 0.049 in.)] to [A+(0.079
in. - 0.031 in.)]
(11)Turn the transaxle over.

(12)lnstall the special tool (MD998913) in a dial gauge, and

then move the special tool (MB991631) to measure the
axial play.
Standard value:
-
1.05 1.51 mm (0.0413 - 0.0594 in.) <F4A41>
-
1.35 1.81 mm (0.0531 - 0.0713 in.) <F4A42>

Reference
Select a pressure plate which thickness is within the
following value, and replace the special tool mounted
at the step (5) with it.
MD998913
F4A41
[A (moving amount) + thickness of the special tool 2.0
mm (0.079 in.) - 1.51 mm (0.0594 in.)] to [A (moving
amount) + thickness of the special tool 2.0 mm (0.079
in.) - 1.05 mm (0.0413 in.)
TFA1780 F4A42
[A (moving amount) + thickness of the special tool 2.0
mm (0.079 in.) - 1.81 mm (0.0713 in.)] to [A (moving
amount) + thickness of the special tool 2.0 mm (0.079
in.) - 1.35 mm (0.0531 in.)]
(13)Remove the parts installed from steps (4) to (12).
AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-35
(14)Usethe special tools to tap the output shaft bearingouter
race in the transaxle case.
(15)lnstall the snap ring and the thinnest adjustment spacer
[1.88 mm (0.0740 in.)].
NOTE
The spacer may have to be replaced with one having
an adequate thickness after the end play of the output
shaft is checked in step (19).

(16)Tighten the mounting bolts of the output shaft bearing

retainer to the specified torque.

(17)lnstall the output shaft in the transaxle case, and then

use the special tool to install the collar and taper roller
bearing in the output shaft.

(18)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 torque again.
Caution
The lock nut has left-handed threads.

(19)Move the output shaft to measure the shaft end play,

and then replace the spacer installed in step (15) with
a new one which thickness is within the following value.
A=Shaft end play mm (in.)
B=Thickness of spacer assembled in step (15) [1.88
mm (0.0740 in.)]
Metric values: [A+B+O.Ol mm] to [A+B+0.09 mm]
American values: [A+B+0.0004 in.] to [A+B+0.0035
in.]
23B-36 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(20)Prevent the lock nut from turning (two parts).

(2l)lnstall the cap as shown in the figure.

1 I ,MB990938

(22)Use the special tool to install the transfer drive gear.

(23)Tightenthe four mounting bolts of the transfer drive gear

to the specified torque.

(24)Install the parking pawl, spacer, and spring. Then install

the parking pawl shaft.
AUTOMATIC TRANSAXLE OVERHAUL - Transaxle ’ 23B-37

(26) Install the underdrive sun gear and thrust bearing #3

to the output planetary carrier.
Caution
Be sure to install the thrust bearing in the correct
direction.

TFA1543
23B-38 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle

#8 #? #6 #5 #4 #3 #2 #1 TFA1537

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

mm (in.)

O.D. I.D. Thickness Part number

59 (2.32) 47 (1.85) 1.8 (0.071) MD754509

59 (2.32) I 47 (1.85) 1 2.0 (0.079) MD754508

59 (2.32) 47 (1.85) 2.2 (0.087) MD754507

59 (2.32) 47 (1.85) 2.4 (0.094) MD753793

59 (2.32) 1 47 (1.85) I 2.6 (0.102) I MD753794

59 (2.32) 47 (1.85) I 2.8 (0.110) ~ MD753795

49 (1.93) 36 (1.42) ~ 3.6 (0.142) 1 MD756846

I 3 6 (0.142) 1 MD756846
~

49 (1.93) ~ 36 (1.42)

45.3 (1.783) I 31 (1.22) 1 F 3 (0.130)

~
I MD757647 ~

49 (1.93) 36 (1.42) 3.6 (0.142) MD756846

49 (1.93) 36 (1.42) 3.6 (0.142) MD756846

59 (2.32) 37 (1.46) 2.8 (0.110) MD754595

48.9 (1.925) 37 (1.46) 1.6 (0.063) MD707267

48.9 (1.925) 37 (1.46) 1.7 (0.067) MD759681

48.9 (1.925) 1 37 (1.46) I 1.8 (0.071) I MD723064

 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-39

Symbol O.D. I.D. Thickness Part number

#8 48.9 (1.925) 37 (1.46) 1.9 (0.075) MD754794

#8 48.9 (1.925) 37 (1.46) 2.0 (0.079) MD707268

#8 48.9 (1.925) 37 (1.46) 2.1 (0.083) MD754795

#8 48.9 (1.925) 37 (1.46) 2.2 (0.087) MD723065

#8 48.9 (1.925) 37 (1.46) 2.3 (0.091) MD754796

#8 48.9 (1.925) 37 (1.46) 2.4 (0.094) MD724358

#8 48.9 (1.925) I 37 (1.46) I 2.5 (0.098)

#8 48.9 (1.925) 37 (1.46) I 2.6 ( 0 . 1 0 2 ) 4 7 9 8

(27) Install the output planetary carrier and thrust bearing #4.
Caution
Be sure to install the thrust bearing in the correct
direction.

(28) Install the overdrive planetary carrier.

(29)Install the planetary reverse sun gear.

23B-40 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle

(30) Install the wave spring.

(3l)lnstall the pressure plate, brake disc, and brake plate.

Number of brake discs and plates
A/T Model Brake disc Brake plate Pressure
plate
F4A41
F4A42

(32)lnstall the snap ring.

(33) Install the reaction plate.

(34)lnstall the snap ring.

 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-41
(35) Install the brake disc, brake plate, and pressure plate.

(36) Install the return spring and second brake piston.

(37)lnstall the snap ring.

(38) Install thrust bearing #5.

Caution
Be sure to install the thrust bearing in the correct
v\ ,Thrust bearing #5 I direction.

(39) Install the overdrive clutch hub and thrust bearing #6

to the reverse and overdrive clutch.
Caution
Be careful about the installation direction of the thrust
bearing.
23B-42 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(40) Installthe reverse and overdriveclutch, and thrust bearing
#7.
Caution
Be careful about the installation direction of the thrust
bearing.

(41) Install the three O-rings.

a I (42) Install the input shaft bearing.

I kMB9g0g38 (43)lnstall the four seal rings.

I I I 1 (44)lnstall used thrust race #8, and then the rear cover.
(45)Measure end play of the underdrive sun gear. Replace
the thrust race installed in step (44) to adjust the play
to the standard value. Refer to the chart on P.23B-37
or the appropriate parts number.
Standard value: 0.25 to 0.45 mm (0.0098 to 0.0177
in.)
NOTE
Installing the underdrive clutch hub makes it easy to
measure the end play of the underdrive sun gear.

(46)Apply liquid gasket to the mating surface of the rear cover.

4 Be sure to install the transaxle case within 15 minutes
@2m m after applying liquid gasket.
($0.08in.)
Liquid gasket:
MlTSUBlSHl genuine sealant Part No. MD974421
or equivalent
(47)After installation, wait at least one hour. Never run the
transaxle or let ATF touch the adhesion surface during
that time.
TFA1525
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-43
(48)lnstall the rear cover, and tighten its mounting bolts to
the specified torque.

(49)lnstall the underdrive clutch hub.

(50) Install thrust bearing #2.

Caution
J \\ /Thrust bearing#2
Be sure to install the thrust bearing in the correct
direction.
~

I " /' TFA1.562

(51)Hold the input shaft, and install the underdrive clutch.

(52)lnstall the used thrust washer #l.

23B-44 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(53)Use the special tool to install a new oil pump gasket
and oil pump.
Caution
Never reuse the old gasket.
(54)Tightenthe oil pump mountingboltsto the specifiedtorque.

(55)Measure end play of the input shaft. Replace the thrust

washer installed in step (52)to adjust the play to the
standard value. Refer to the chart on P.23B-37 for the
appropriate parts number.
Standard value: 0.70 to 1.45 mm (0.0276 to 0.0571
in.)

(56)lnstall the oil filter.

cF4A41> (57)Install the differential.

cF4A42>
 AUTOMATIC PRANSAXLE OVERHAUL - Transaxle 23B-45
(58)Place a solder (approx. 10 mm (0.39 in.) in length, 3
Solders rnm (0.12 in.) in diameter) on the differential as shown
in the figure. <F4A41 only>

(59)Place a solder (approx. 10 mm (0.39 in.) in length, 3

mm (0.12 in.) in diameter) on the torque converter housing
as shown in the figure. cF4A42 only>

TFA1527 I
(60)Install the torque converter housingto the transaxle case
without applying sealant. Tighten its mounting bolts to
the specified torque.
(61)Loosen the bolts, and remove the solder.

(62) Use a micrometerto measure the thickness of the pressed

solder. Select a spacer which thickness is within the
following value. Refer to the chart on P.238-37 for the
appropriate parts number.
F4A41
- -
[T 0.045 mm (0.0018 in.)] to [T 0.165 mm (0.0065
in.)]
F4A42
[T + 0.045 mm (0.0018 in.)] to [T + 0.105 mm (0.0041
in.)]

(63)lnstall the spacer selected in the above step. cF4A41

only>
23B-46 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(64)Assemblethe spacer selected in step (62) to the torque
converter housing. Use the special tool to press in the
outer race. eF4A42 only>

(65)Apply liquid gasket to the mating surface of torque

converter.
Be sure to install the transaxle case within 15 minutes
after applying liquid gasket.
Liquid gasket:
MlTSUBlSHl genuine sealant Part No. MD974421
or equivalent
(66)After installation, wait at least one hour. Never run the
transaxle or let ATF touch the adhesion surface during
TFA1530 that time.

(67) Install the two O-rings.

(68)lnstall the torque converter, and then tighten its 18

mounting bolts to the specified torque.

(69)lnstall the manual control lever shaft and parking pawl

rod.
(70) Install the manual control lever shaft roller.
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-47
(7l)lnstall the accumulator pistons, new seal rings, and
springs.
NOTE
The accumulator springs are identified as shown in the
1 2 3 4 figure.

TFA1531

I For low-reverse brake

For underdrive clutch
For second brake
For overdrive clutch

(72)lnstall the strainer and second brake retainer oil seal.

(73)lnstall the solenoid valve harness, and then secure the

snap ring to the connector groove.

(74)lnstall the valve body, gasket, and two steel balls.

T FA1388
23B-48 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(75) Install the fluid temperature sensor.
(76) Install the 28 valve body mounting bolts.

TFA1387

(77)Connec the valve body connectors.

Cable Connector

colour

red, red

Second solenoid valve

Damper clutch control Black

yellow

(78) Install the manual control shaft detent.

2.-
Manual control d
shaft detent -
~

-
(79)Apply liquid gasket to the mating surface of the valve
body cover.
Be sure to install the transaxle case within 15 minutes
after applying liquid gasket.
Liquid gasket:
MlTSUBlSHl genuine sealant Part No. MD974421
or equivalent
(80)After installation, wait at least one hour. Never run the
transaxle or let ATF touch the adhesion surface during
TFA 1532 that time.
 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle 23B-49

n (81) Install the valve body cover, and then tighten its mounting
bolts to the specified torque.

(82)Install the speedometer gear.

a Manual control lever

(83) Install the parkheutral position switch and manual control
lever.

(84) Installthe input shaft speedsensor and output shaft speed

sensor.

I lnmt shaft <, 7 m r

(85)Applya small amount of ATF to the oil filter gasket. Tighten

the filter to the specified torque.
Oil
filter Standard value: 12 Nm (8.7 ft.lbs.)
gasket
238-50 AUTOMATIC TRANSAXLE OVERHAUL - Transaxle
(86) Install the eye bolt, a new gasket, and the oil cooler feed
tube.
(87) Install the oil dipstick.
(88) Install the brackets.

(89)lnstall the torque converter, and secure it so that the

shown dimension (A) meets the reference value.
Reference value: approx.12.2 mm (0.480 in.)
Caution
Apply ATF to the oil pump drive hub before installing
*A the torque converter. Be careful not to damage the
oil seal lip when installing the torque converter.

TFA1534
 AUTOMATIC TRANSAXLE OVERHAUL - Oil Pump 23B-51

OIL PUMP 23300130126

DISASSEMBLY AND REASSEMBLY

to all moving parts 4

ATFA1369

Disassembly steps
,Bd 1. O-ring
2. Seal ring
,A+ 3. Oil seal
4. Oil pump assembly

"11- MD998334
REASSEMBLY SERVICE POINTS
.A+ OIL SEAL INSTALLATION

TFA1431

.B+ 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.
23B-52 AUTOMATIC TRANSAXLE OVERHAUL - Underdrive Clutch and Input Shaft

UNDERDRIVE CLUTCH AND INPUT SHAFT 23302450015

DISASSEMBLY AND REASSEMBLY

\
12
8
1

transmission fluid
to all moving parts
I before installation.

1 1
Number of clutch discs and plates

rA41
Model

F4A42
r u t c h disc
4
Clutch plate

1
Clutch reaction
plate

Disassembly steps
1. Snap ring 9. Spring retainer
2. Input shaft F A + 10. D-ring
3. Seal ring 11. Return spring
4. Snap ring 12. Underdrive clutch piston
5. Clutch reaction plate F A + 13. D-ring
6. Clutch disc F A ( 14. D-ring
7. Clutch plate 15. Underdrive clutch retainer
8 . Snap ring
 AUTOMATIC TRANSAXLE OVERHAUL - Underdrive Clutch and Input Shaft 23B-53
Dl SASSEMBLY S ERVICE POINT
MD + A b SNAP RING REMOVAL

I TFA1432

REASSEMBLY SERVICE POINTS

A
.( D-RING INSTALLATION
Apply ATF, blue petrolatumjelly or white Vaselineto the D-ring,
and install it carefully.

.B+ SNAP RING INSTALLATION

_ I _

TFAl432

b C ( CLUTCH PLATEKLUTCH DISC/CLUTCH REACTION

PLATE INSTALLATION
(1) Align the space between the teeth (part A) of the clutch
plate, clutch disc and clutch reaction plate to the outer
circumference hole (part B) of the underdrive clutch
retainer.
Caution
Immerse the clutch disc in ATF before assembling
it.

Clutch (2) Install the clutch reaction plate in the shown direction.
Clutch
/ reaction Number of clutch discs and plates
plate

plate

Clutch discs TFAl889

23B-54 AUTOMATIC TRANSAXLE OVERHAUL - Underdrive Clutch and Input Shaft

-
b D + SNAP RING INSTALLATION
Check that the clearance between the snap ring and the
clutch reaction plate is within the standard value.
Standard value:
1.25 to 1.45 mm (0.0492 to 0.0571 in.) cF4A41>
1.65 to 1.85 mm (0.0650 to 0.0728 in.) cF4A42>
When measuringthe clearance, use the special tool to press
the clutch reaction plate evenly. If not within the standard
value, select a snap ring to adjust.
- _ I -
 AUTOMATIC TRANSAXLE OVERHAUL - Reverse and Overdrive Cluich 23B-55
REVERSE AND OVERDRIVE CLUTCH 23302480014

DISASSEMBLY AND REASSEMBLY

Number of clutch discs and plates (Overdrive)

plate

Disassembly steps
1. Snap ring A
.( 11. D-ring
2. Clutch reaction plate 12. Return spring
3. Clutch disc 13. Overdrive clutch piston
4. Clutch plate .A+ 14. D-ring
5. Snap ring .B+ 15. Reverse clutch piston
6. Clutch reaction plate .A+ 16. D-ring
7. Clutch disc 17. Reverse clutch retainer
8. Clutch plate .A+ 18. D-ring
9. Snap ring .A+ 19. D-ring
10. Spring retainer
23B-56 AUTOMATIC TRANSAXLE OVERHAUL - Reverse and Overdrive Clutch
DISASSEMBLY SERVICE POINT
(A, SNAP RING REMOVAL

- TFA1438

REASSEMBLY SERVICE POINTS

A
.( D-RING INSTALLATION
Apply ATF, blue petroleum jelly or white Vaseline to D-ring,
and install carefully.

F B I REVERSE CLUTCH PISTON INSTALLATION

Align the outer circumference holes (parts A and B) of the
reverse clutch piston and the reverse clutch retainer to
assemble them.

C
,( SNAP RING INSTALLATION
(1) Use the special tool to install the snap ring.

- TFA1438

(2) Check that the clearance between the snap ring and
the return spring retainer is within the standard value.
When measuring the clearance, press the return spring
retainer by the weight of 49 N (11 Ibs.) evenly. If not
within the standard value, select a snap ring to adjust.
Standard value: 0.01 to 0.10 mm (0 to 0.0035 in.)
 AUTOMATIC TRANSAXLE OVERHAUL - Reverse and Overdrive Clutch 23B-57
Clutch b D + CLUTCH PLATEKLUTCH DISC/CLUTCH
Clutch REACTION PLATE INSTALLATION
reaction
/ plate Install the clutch reaction plate in the shown direction.
Caution
Immerse the clutch disc in ATF before assembling the
clutch disc.
Number of clutch discs and plates
Clutch disc
Clutchdiscs TFA1889 Model plate

.Ed 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.
Standard value:
1.2 to 1.4 mm (0.0472 to 0.0551 in.) <F4A41>
1.6 to 1.8 mm (0.0630 to 0.0709 in.) <F4A42>

.F+ CLUTCH PLATEKLUTCH DISC/CLUTCH

REACTION PLATE INSTALLATION
(1) Align the space between the teeth (part A) of the clutch
plate, clutch disc and clutch reaction plate to the outer
circumferencehole (part B) of the reverse clutch retainer.
Caution
Immerse the clutch disc in ATF.

-
/
\ TFA1444

Clutch (2) Install the clutch reaction plate in the shown direction.
Clutch
reaction
/ plate

Clutch discs TFA1889

23B-58 AUTOMATIC TRANSAXLE OVERHAUL - Reverse and Overdrive Clutch

' .G+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, press the clutch reaction plate by
the weight of 49 N (11 Ibs.) evenly. If not within the standard
value, select a snap ring to adjust.
Standard value: 1.2 to 1.4 mm (0.0472 to 0.0551 in.)

I TFA1446 I
 AUTOMATIC TRANSAXLE OVERHAUL - Overdrive Planetary Carrier 23B-59
OVERDRIVE PLANETARY CARRIER 23302510010

DISASSEMBLY AND REASSEMBLY

parts with automatic

transmission fluid during

2
TFAl372

Disassembly steps
1. Snap ring
2. Overdrive planetary carrier
3. Overdrive annulus gear
23B-60 AUTOMATIC TRANSAXLE OVERHAUL - Low-reverse Brake
LOW-REVERSE BRAKE 23300370076

DISASSEMBLY AND REASSEMBLY

parts with automatic

transmissionfluid during

TFA1373

Disassembly steps
,A+ 1. D-ring
.A+ 2. D-ring
3. Low-reverse brake piston

REASSEMBLY SERVICE POINT

F A ( D-RING INSTALLATION
Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,
and install carefully.
 AUTOMATIC TRANSAXLE OVERHAUL - Second Brake 23B-61

SECOND BRAKE 23302540019

DISASSEMBLY AND REASSEMBLY

TFA1374

Disassembly
1. Second brake retainer
2. D-ring
3. Second brake piston
4. D-ring

REASSEMBLY SERVICE POINT

F A + D-RING INSTALLATION
Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,
and install carefully.
23B-62 AUTOMATIC TRANSAXLE OVERHAUL - Output Shaft
OUTPUT SHAFT 23302570018

DISASSEMBLY AND REASSEMBLY

Lubricate all internal
parts with automatic
transmissionfluid during
reassembly.

8 4

83

TFAl375

Disassembly steps
4 A b bC+ 1. Transfer driven gear
2. Bearing retainer
.
B
+ 3. Outer race
(B, .A+ 4. Taper roller bearing
5. Output shaft

MD998917
M DISASSEMBLY SERVICE POINTS
AAkTRANSFER DRIVEN GEAR REMOVAL

I I1 \I TFA1447
 AUTOMATIC TRANSAXLE OVERHAUL - Output Shaft 239-63
+ B F TAPER ROLLER BEARING REMOVAL

MD998801 i
\

T FA14 48

H I REASSEMBLY SERVICE POINTS

.A+ TAPER ROLLER BEARING INSTALLATION

MD998823

TFAldA9

.B+ OUTER RACE INSTALLATION

E5- MD998812
.C+ TRANSFER DRIVEN GEAR INSTALLATION

I 1 TFA1451 I
238-64 AUTOMATIC TRANSAXLE OVERHAUL - Transfer Drive Gear

TRANSFER DRIVE GEAR 23302600014

DISASSEMBLY AND REASSEMBLY

Apply automatic
transmission fluid DJ1
to all moving parts I 191 Nm
2
1 I / 141 ft.'bs.

TFAI 376

Disassembly steps
4- .B+ 1. Lock nut
+BF .A+ 2. Transfer drive gear bearing
3. Transfer drive gear

DISASSEMBLY SERVICE POINTS

4 A b L O C K NUT REMOVAL
(1) Using a punch, straighten the locking tab of the lock
nut.
 AUTOMATIC TRANSAXLE OVERHAUL - Transfer Drive Gear 23B-65
(2) Use the special tool to remove the lock nut.

+ B F TRANSFER DRIVE GEAR BEARING REMOVAL

MD998348

MB990928

TFA1453

n I REASSEMBLY SERVICE POINTS

F A + TRANSFER DRIVE GEAR BEARING INSTALLATION
MD9 MD998812

TFA1454 I
F B d 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.
Standard value: 191 Nm (141 ft.lbs.)

(2) Use a punch to caulk the nut at two points.

23B-66 AUTOMATIC TRANSAXLE OVERHAUL - Differential

DIFFERENTIAL 23300310094

DISASSEMBLY AND REASSEMBLY

6, I
10
2
TFAl556

Disassembly steps
FE( 1. Differential drive gear A
,( 6. Pinions
(A, FD( 2. Ball bearings <F4A41> FA( 7. Washers
(BF FC( 3. Taper roller bearings <F4A42> A
,( 8. Side gears
FB( 4. Lock pin F A 4 9. Spacers
FA( 5. Pinion shaft 10. Differential case

DISASSEMBLY SERVICE POINTS

+ A b BALL BEARING REMOVAL
 AUTOMATIC TRANSAXLE OVERHAUL - Differential 23B-67
4 B F TAPER ROLLER BEARING REMOVAL
MD998801

REASSEMBLY SERVICE POINTS

F A + SPACER, SIDE GEAR, WASHER, PINION, PINION
SHAFT INSTA LLATl0N
(1) After a spacer has been mounted on the back surface
of the side gear, install the side gear in the differential
case.
NOTE
When a new side gear is to be installed, mount a medium
thickness spacer [0.93 to 1.00 mm (0.0366 to 0.0395
in.)].
(2) Set the washer on the back of each pinion, and put both
pinions simultaneouslyin mesh with the side gears. While
rotating them, install them in position.

(3) Insert the pinion shaft.

08

(4) Measurethebacklashbetweenthe sidegearsand pinions.

Standard value:
0.025 to 0.150 mm (0.00098 to 0.00591 in.)
(5) If the backlash is out of specification, select a spacer
and re-measure the backlash.
NOTE
Adjust until the backlashes on both sides are equal.
23B-68 AUTOMATIC TRANSAXLE OVERHAUL - Differential
I Differential
b B + LOCK PIN INSTALLATION
(1) Installthe lock pin so that it will be orientedin the direction.

F?--'
b C + TAPER ROLLER BEARING INSTALLATION
MD998812

b D + BALL BEARING INSTALLATION

M D 9 9 8 8 l 2 4

MD998819
Bearing

'FM0008

b E + DIFFERENTIAL DRIVE GEAR INSTALLATION

Apply ATF to the bolt, tighten the bolts to the specified torque
in the shown sequence.
 AUTOMATIC TRANSAXLE OVERHAUL - Valve Body 23B-69
VALVE BODY 23300550076

DISASSEMBLY AND REASSEMBLY

1 1
5.9 Nm
4.3 ft.lbs. Lubricate all internal
parts with automatic
transmissionfluid during
\
l3 reassembly.

11
\
11-

I 11 Nm
8 8.0-ft.lbs.
11 Nm
6 8.0 ft.lbs.
I1
5.9 Nm TFA1378
4.3 ft.lbs.

Disassembly steps
1. Solenoid valve support .B+ 11. Steel ball (orifice check ball)
+AF FC+ 2. Underdrive solenoid valve .B+ 12. Spring
+AF FC+ 3. Second solenoid valve 13. Plate
+AF FC+ 4. Torque converter clutch control so- FA+ 14. Damping valve
lenoid valve FA+ 15. Damping valve spring
+AF bC+ 5. Overdrive solenoid valve F A 4 16. Steel ball (line relief)
+AF FC+ 6. Low-reverse solenoid valve .A+ 17. Spring
7. Manual valve FA+ 18. Steel ball (orifice check ball)
8. Cover FA+ 19. Spring
9. Plate 20. Inside valve body assembly
10. Outside valve body assemblv
23B-70 AUTOMATIC TRANSAXLE OVERHAUL - Valve Body

40

TFA1589

21. Roller 30. Fail-safe valve A sleeve

22. Torque converter clutch control 31. Fail-safe valve A2
valve sleeve 32. Fail-safe valve A spring
23. Torque converter clutch control 33. Fail-safe valve A1
valve 34.Plate
24. Torque converter clutch control 35. Plug
valve spring 36. Torque converter valve
25. Plate 37.Torque converter valve spring
26. Screw 38.Plate
27. Regulator valve spring 39. Fail-safe valve B sleeve
28. Regulator valve 40. Fail-safe valve B
29. Plate 41. Inside valve body
 AUTOMATIC TRANSAXLE OVERHAUL - Valve Body 23B-71

I
la
I
Lubricate all internal
parts with automatic
transmissionfluid during
reassembly.
54
53
I

i--

TI7
58

51

TFA1590

42. Roller 52. Switching valve

43. Overdrive pressure control valve 53. Roller
sleeve 54. Underdrive pressure control valve
44. Overdrive pressure control valve sleeve
45. Overdrive pressure control valve 55. Underdrive pressure control valve
spring 56. Underdrive pressure control valve
46. Roller spring
47. Low-reverse pressure control valve 57. Roller
sleeve 58. Second pressure control valve
48. Low-reverse pressure control valve sleeve
49. Low-reverse pressure control valve 59. Second pressure control valve
spring 60. Second pressure control valve
50. Plate spring
51. Plug 61. Outside valve body
23B-72 AUTOMATIC TRANSAXLE OVERHAUL - Valve Body
DISASSEMBLY SERVICE POINT
4- SOLENOID VALVES REMOVAL
NOTE
Store each solenoidvalve seperately,accordingto its location,
to avoid incorrect reassembly.

Steel ball and spring Damping valve REASSEMBLY SERVICE POINTS

.A+ SPRING/STEEL BALUDAMPING VALVE/DAMPING
VALVE SPRING INSTALLATION

.B+ SPRING/STEEL BALL INSTALLATION

.C+ SOLENOID VALVES INSTALLATION

(1) Apply ATF, blue petroleumjelly or white Vaseline to O-ring,
and install carefully.
(2) Install the solenoid valves by referringto the marks during
disassembly.
2
No. 1 Name 1
1 Underdrive solenoid valve
2 Second solenoid valve
TFA1458
3 Torque converter clutch control solenoid valve
4 1 Overdrive solenoid valve I
5 1 Low-reverse solenoid valve ~~ -~ I
 AUTOMATIC TRANSAXLE OVERHAUL - Speedometer Gear 23B-73
SPEEDOMETER GEAR 23300400098

DISASSEMBLY AND REASSEMBLY

I Lubricate all internal

iI parts with automatic

transmissionfluid during
reassernbly.

-4

ZTFM0371

Disassembly steps
1. O-ring
2. Speedometer driven gear
F A 4 3. Oil seal
4. Sleeve

REASSEMBLY SERVICE POINT

.A+ OIL SEAL INSTALLATION
Insert the oil seal in the position and direction shown in the
figure.

ZTFM0372
23B-74 AUTOMATIC TRANSAXLE OVERHAUL - Drive Shaft Oil Seal

DRIVE SHAFT OIL SEAL 23300430059

DISASSEMBLY AND REASSEMBLY

parts with automatic

transmission fluid during
reassembly. "1

TFA1380

Disassembly steps
.A+ 1. Oil seal
2. Torque converter housing
F B I 3. Oil seal
4. Transaxle case

REASSEMBLY SERVICE POINT

F A + OIL SEAL INSTALLATION
AUTOMATIC TRANSAXLE OVERHAUL - Drive Shaft Oil Seal 23B-75
b B + OIL SEAL INSTALLATION