Home

Automatic Transmission Service

1. Transfer drive gear Torque converter clutch Tranfer driven gear Pul Transfer shaft ulse generator B Differential TFA0480 TSB Revision 238 5 4 2 Genera Information SECTIONAL VIEW F4A23 Pulse Planetary f T Rickdown generator A g brake Oil pump Front Low reverse Transfei clutch brake idler near Torque converter ERR c vu 4 Maien KX Ve 6 LEE End clutch Transfer drive gear Transfer driven gear Transfer shaft Pulse generator B TRAO660 KH TSB Revision 23 6 4 2 General Information HYDRAULIC CONTROL SYSTEM Kickdown servo Torque converte Low reverse Front Rear brake End clutch clutch clutch 17 ransmission control unit 15 7 25 24 S ransmission f control unit 3 Torque converter CD clutch control 27 _ 25 242 20 15 20a 12 34 3 vd 2 3 4 928 HHHH Ex 214 shift valve ga pc Rear clutch 9 exhaust valve a ed So ACC orque i Shift control solenoid valve A clutch solenoid EN To lubrication 7 s Front ransmission 23 control unit To lubrication 7 E
2. Regulator valve Pressure A control valve Pressure Control solenoid valve l N R control d Line valve relief valve Ss WA Transmission control unit Oil filter Oil pan TFA0070 TSB Revision 23 8 F4A3 W4A3 General Information HYDRAULIC CONTROL SYSTEM Without torque converter clutch Kickdown servo Torque convertor LOW reverse Front Rear brake clutch clutch 25 24 Q To lubrication JO J Front 24 19 20 EX 23 43 i nna m a shift valve I 9b 9c 5 lt Rear clutch valve E Ege 1 2 shift valve To lubrication Rear Reducing Torque valve convertor eg p Se valve poemes S control Shift control r s wi 2 N D control PON valve valve B Shift control valve s control valve LJ D Pressure Pressure control solenoid valve N R control P valve Pe relieff valve Oil filter control unit 0078 TSB Revision SPECIFICATIONS TRANSAXLE MODEL TABLE
3. A 55 A 8 76 Adjust the kickdown servo by the following procedure a Fit the claw of the special tool in the notch of the piston to prevent the piston from turning and use adapter to secure it as illustrated at left Caution L Do not push in the piston with the special tool 2 When the adapter is installed to the transaxle case do not apply excessive torque but tighten with a hand b Loosen the lock nut until it is about to reach the V groove in the adjusting rod Tighten the special tool inner until it touches the lock nut 175046 TSB Revision 23 50 WAAG Transaxle FWD cylinder counterclockwise and the inner cylinder clock wise to lock the lock nut and the special tool inner SCH N c Fit the special tool outer to the lock nut Turn the outer 6 gt d 3 01 J VS 6 2 ees Ge d Fit torque wrench to the special tool inner to tighten it to a torque of 10 Nm 7 2 ft lbs and loosen Repeat this sequence two times before tightening the special tool inner to 5 Nm 3 6 ft lbs torque Then back off the special tool outer 2 to 21 4 turns e Fit the special tool outer to the lock nut Turn the outer cylinder clockwise and the inner cylinder counterclockwise to unlock the lock nut and the special tool inner Caution When unlocking is carried out apply equal force to both special tools to loosen ve A S SAM em
4. Transaxle control module Transaxle control module 0 Transaxle control module Lack of continuity indicates a poorly adjusted switch or faulty switch Readjust the switch If still without continuity replace the switch TSB Revision F4A2 Transaxle 23 55 89 Install pulse generators and and tighten the bolt to the specified torque Tightening torque 11 Nm 8 16 Pulse generator A ES 90 After applying automatic transmission fluid to the outside surface of the oil pump side cylindrical portion of the torque converter install the torque converter carefully so as not to E give damage to the oil seal lip Make certain that the torque 47 in 2 converter is in mesh with the oil pump drive gear 91 Measure the distance between the ring gear end and the converter housing end The torque converter has been properly installed when the measurement is about 12 mm 47 in TSB Revision 23 56 F4A2 Oil Pump OIL PUMP DISASSEMBLY AND REASSEMBLY Disassembly steps 1 O ring 04 2 Reaction shaft support 4 3 Steel ball GAD 9B4 4 Drivegear AD 9B4 5 Driven gear 6 Seal ring 9A 7 Oil seal 8 Oil pump housing 9 Snap ring 10 Oil seal 1750261 DISASSEMBLY SERVICE POINT AD DRIVE GEAR DRIVEN GEAR REMOVAL 1 Make reassembly alignment marks on the drive and driven gears
5. 8 FRONT CLUTCH 58 TRANSAXLE MODEL TABLE __ 7 GENERAL INFORMATION 2 TORQUE SPECIFICATIONS 14 KICKDOWN SERVO 1 75 VALVE BODY SPRING IDENTIFICATION 9 LOW REVERSE BRAKE 74 SPEEDOMETER GEAR 76 OIL PUMP inanes 56 TRANSAXLE Z aa rere teens 19 PLANETARY GEAR _ 66 TRANSFER DRIVEN GEAR 79 REAR CLUTCH erus 61 TRANSFER SHAFT 78 SPECIAL TOOLS 15 VALVE BODY E 80 23 2 F4A2 General Information GENERAL INFORMATION Precautions to be taken when disassembling and reassembling the transaxle Because the automatic transaxle is composed of component parts of an especially high degree of precision these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them A rubber mat should be placed on the workbench and it should always be kept clean During disassembly cloth gloves or shop towels should not be used If such items must be used either use articles made of nylon or use paper towels All disassembled parts must be thoroughly cleaned Metal parts may be cleaned with ordinary detergents but must be thoroughly air dried Clean the clutch
6. 2 756 1 8 071 70 2 756 2 2 087 70 1 48 1 1 906 40 1 575 42 6 MD707271 MD722552 MD720753 4 1 677 SE MD704936 48 9 1 925 MD707290 MD997854 incl 1 48 9 1 925 MD997847 incl 1 3 1 457 48 9 MD997852 incf 4 41 1 614 39 1 535 38 1 496 MD720010 MD728763 MD728764 48 9 1 4 MD997848 incl 2 MD727787 1 925 055 37 52 48 9 1 457 1 6 MD997849 incl 2 3 2 047 MD720010 1 925 063 48 9 37 1 8 MD997850 incl 3 MD704935 1 9251 1 457 071 37 48 9 1 457 20 MD997851 incl 3 1 925 079 TSB Revision 37 2 1 925 1 457 087 48 9 24 MD997853 incl 4 1 925 1 34757 094 F3A2 Transaxle 20 Apply petrolatum jelly to thrust bearing 12 and secure the bearing on the planetary carrier 21 Mount the planetary carrier on the case 22 Attach thrust race 1 0 and thrust bearing 9 to the forward sun gear Then assemble the reverse sun gear Reverse sun gear 177006t 23 Install the sun gear assembly assembled in step 22 in the planetary carrier 24 Put the brake disc and brake plate in position TSB Revision F3A2 Transaxle 23A 33 reaction plate plate Pressure Brake plate disc 25 Ins
7. ir Regutator valve Low relief L1 EMI Manual valve Ex 1 dg Oil filter mni m A fumi Dee control H ME P RND2L 1710021 o D c 5 2 3 Torque converter To lubrication Front To lubrication Rear Ex Kasa Torque converter Front clutch Kickdown servo Rear clutch Low reverse brake NS Anchor rod em Us ij Kickdown piston valve control valve Line relief Ex N D accumulator p valve Engine I brake valve 1 2 Spe 2 3 shift d shift valve Low relief EZ E a ER Range control a valve Governor M valve ce TFAO057 661 13d0OMN W31SAS 1OHLINOO 9 V uoneunuoju jeeuet Zv d F3A2 Specification 23A 7 SPECIFICATIONS TRANSAXLE MODEL TABLE MODEL 1992 Transaxle model Gear ratio type Speedometer Final gear ratio Vehicle model a ratio F3A21 2 21 2 4 EM 1 Model with torque converter clutch TCC TRANSAXLE MODEL TABLE MODEL 1993 Transaxle model Gear ratio type Speedometer Final gear ra
8. 0608 TSB Revision F4A2 End Clutch 23B 65 DISASSEMBLY SERVICE POINT END CLUTCH PISTON REMOVAL 1 Remove the piston If it is hard to remove place the retainer on the workbench with piston side down and blow air through the oil passage in the back of retainer REASSEMBLY SERVICE POINTS bA SNAP RING INSTALLATION MD998367 Installer zx 1 Fit a new snap ring to the Guide of the special tool and 01 c install it to the retainer Be sure to fit snap ring to the lowest I possible portion of the Guide Put the Installer over the Guide and use a press to install the snap ring in the groove If the snap ring is installed in the groove stop using the press Do not use the press more than necessary Further be sure not to support the portion center protruded portion marked with arrows in the illustration SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value F4A21 F4A22 0 4 0 65 mm 016 026 in F4A23 0 6 0 85 mm 024 031 TSB Revision 23B 66 F4A2 Planetary Gear PLANETARY GEAR DISASSEMBLY AND REASSEMBLY TFA0522 Disassembly steps 964 1 Bolt 2 Lock plate except F4A22 2 MQD6 F4A23 2 LNN
9. 177005 TSB Revision F3A2 Transaxle 23 27 Using a hand pump feed air through the location shown and at the same time read the dial indicator and select a pressure plate to obtain the specified end play Standard value 0 8 1 0 mm 031 039 in After a pressure plate of the appropriate thickness has been selected remove all the mounted parts 2 Place the transaxle case on the workbench with the oil pan mounting surface up 3 Insert the output flange in position with two ball bearings and transfer drive gear attached from the inside of the transaxle case 4 Install the snap ring in the groove of the output flange bearing 5 Apply petrolatum jelly to the spacer and attach the spacer to the case 6 Install the bearing outer race and inner races in the transfer idler gear 23A 28 F3A2 Transaxle 7 Install a new O ring in the groove of the idler shaft and apply a very thin coat of automatic transmission fluid to the O ring 8 Place the transfer idler gear in the case and insert and screw the idler shaft into position 9 Screw in and tighten the idler shaft by using the special tool 10 Insert the special tool into the output flange and measure the preload using a low reading torque wrench Adjust the preload to the standard value by tightening or loosening the transfer idler shaft Standard value 0 8 Nm 6 ft lbs 11 After completing th
10. 269 MEC LOCK NUT INSTALLATION 1 Holding the driven bevel gear in a vice and using the special tool tighten the lock nut to specified torque Driven bevel gear lock nut 150 Nm 108 ft Ibs 2 Lock the lock nut at two positions TSB Revision F4A3 W4A3 Transfer Case 4WD 23C 127 TRANSFER CASE 4WD DISASSEMBLY AND REASSEMBLY 39 Nm 29 ft Ibs Disassembly steps 1 Transfer cover 2 O ring bE 3 Spacer 4 Outer race 0 5 Drive bevel gear shaft 6 Outer race WER 7 Spacer 4 8 Oil seal 9 Transfer case 98410 Drive bevel gear QAD 411 Taper roller bearing GA 9A 12 Taper roller bearing TFAOGO3 TSB Revision 23 128 F4A3 W4A3 Transfer Case 4WD DISASSEMBLY SERVICE POINT TAPER ROLLER BEARINGS REMOVAL w 2 REASSEMBLY SERVICE POINTS AAA TAPER ROLLER BEARING INSTALLATION TFAO301 B4 DRIVE BEVEL GEAR INSTALLATION 1 Install the drive bevel gear to the drive bevel gear shaft with their matching marks in alignment Matching mark 7 RU TSB Revision F4A3 W4A3 Transfer Case 4WD 23C 129 CA OIL SEAL INSTALLATION MD998200 01 25 c rar e hi e hi 22 10080 UA DRIVE BEVEL GEAR SHAFT INSTALLATION 1 Install the drive bevel gear shaft to the transfer case and O N align the matching mark on the transfer case with that on the drive bevel gear shaf
11. REASSEMBLY SERVICE POINTS 4 OIL SEAL INSTALLATION MD998334 01 TSB Revision F4A2 Oil Pump 23 57 BA DRIVEN GEAR DRIVE GEAR SIDE CLEARANCE MEASUREMENT Standard value 0 03 0 05 mm 001 002 in STEEL BALL LOCATION a ss WA REACTION SHAFT SUPPORT INSTALLATION 1 Assemble the reaction shaft support and the pump hous ing and tighten the five bolts by fingers 2 Insert the special tool Guide Pin MD998336 01 in the oil pump bolt hole and tighten the peripheries of the support and housing with the special tool Band MD998335 01 to locate the support and housing 3 Tighten the five bolts to the specified torque EE 4 Make sure that the oil pump gear turns freely 1 175026t O RING INSTALLATION 1 Install a new O ring in the groove of the pump housing and apply petrolatum jelly to the O ring TSB Revision 23 58 F4A2 Front Clutch FRONT CLUTCH DISASSEMBLY AND REASSEMBLY 0029 Disassembly steps 964 1 Snap ring 9842 Clutch reaction plate 3 Clutch disc GAD pAg 4 Snap ring 5 Return spring 6 Front clutch piston 7 D ring 8 D ring 9 Front clutch retainer No of Clutch Discs and Clutch Reaction Plate Model Clutch disc Clutch reaction plate 9 2 SE 6 F4A21 2 3 h F4A22 F4A23 3 4 WOT 2 1750213 TSB Revision F4A2 Front Clutch 23B 59 DISAS
12. AD TRANSFER DRIVEN GEAR REMOVAL 1 Remove the transfer driven gear NOTE If it is hard to remove use the special tool to remove it TSB Revision 23 116 F4A3 W4A3 Center Differential 4WD Bp TAPER ROLLER BEARING REMOVAL MD998348 01 1 Using the special tool remove the taper roller bearing from 4 the transfer driven gear TAPER ROLLER BEARING REMOVAL 1 Using the special tool remove the taper roller bearing from the center differential flange REASSEMBLY SERVICE POINTS 4 SPACERS SELECTION 1 install the spacer side gear rear pinion washer and pinion shaft in the center differential case 2 While pressing the pinion shaft select the thickest spacer to gently rotate the pinion 3 Install the side gear front spacer and center differential flange and tighten the bolts with the specified torque Center differential drive gear bolt 75 Nm 54 ft Ibs 4 Using the front output shaft rotate the side gear front and select the thickest spacer to gently rotate the side gear front BOLT INSTALLATION 1 First apply sealant to the end 5 mm 2 in of the bolt threads and then tighten to the specified torque in the order shown in the figure Center differential drive gear bolt 75 Nm 54 ft Ibs Specified adhesive 3M Stud Locking Part No 4170 or equivalent TSB Revision F4A3 WA4AS3 Center Differential 4WD 23C 117 9064 TAPER ROLLER BEARING
13. F4A2 Differential 23B 71 DIFFERENTIAL DISASSEMBLY AND REASSEMBLY Disassembly steps D4 1 Bolt 2 Differential drive gear QA 9 4 3 Bearing Bd 984 4 Lock pin Aha 5 Pinion shaft Aha 6 Pinion Aa 7 Washer 4 8 Side gear 4 9 Spacer 10 Differential case 160119 DISASSEMBLY SERVICE POINTS A BALL BEARING REMOVAL Taper roller bearing TSB Revision 23B 72 F4A2 Differential LOCK PIN REMOVAL 1 Drive out the lock pin with a punch inserted in hole A 2 Remove the pinion shaft from the case and remove the pinion gears and washers 3 Remove the side gears and spacers from the case Keep the removed gears and spacers for R H side use separated from those for L H side use Lock pin Pinion shaft 160017 REASSEMBLY SERVICE POINTS Aq SPACER SIDE GEAR WASHER PINION PINION SHAFT INSTALLATION 1 With the spacers installed on the back of the differential side gears install the gears in the differential case When reusing the removed parts install them in the original positions noted during disassembly When using new differential side gears install spacers of medium thickness 1 0 807 mm 039 os in 2 Install the washers to the back of the pinion gears install the gears in the differential case and then insert the pinion shaft 3 Measure the backlash between the side gear and pinion gear The backlash should be 0 025 to 0 150 mm 0010 to 005
14. 072 Z MD710470 1 85 073 H MD700272 1 88 074 AA MD710471 1 91 075 BB MD71 5955 1 94 076 cc MD71 5956 1 97 078 DD MD71 5957 2 00 079 EE MD71 5958 2 03 080 FF MD71 5959 2 06 081 GG MD71 5960 2 09 082 MD715961 2 12 083 MD71 5962 2 15 085 MD71 5963 2 18 086 MD71 5964 TSB Revision F4A2 Specifications 23 13 Thickness Identification Part No mm in symbol Spacer FAA23 2 21 087 MD715965 Ge EH of differential case 224 088 MD71 5966 2 27 089 MD715967 2 30 091 MD71 5968 2 33 092 MD71 5969 2 36 093 MD71 5970 2 39 094 MD715971 2 42 095 MD722734 2 45 096 MD722735 2 48 098 MD722736 Spacer F4A21 0 75 0 82 MAT 80862 For adjustment of differential 030 032 pinion pankas 0 83 0 92 MA1 80861 033 036 0 93 1 00 MAT 80860 037 039 1 01 1 08 MAT 80875 040 043 1 09 1 16 MA1 80876 043 047 Spacer F4A22 F4A23 0 75 0 82 722986 For adjustment of differential 030 032 oinion backlash 0 83 0 92 MD722985 033 036 0 93 1 00 MD722984 037 039 1 01 1 08 MD722982 040 043 1 09 1 16 MD722983 043 047 TSB Revision 23 14 F4A2 Specifications TORQUE SPECIFICATIONS Manual control shaft set screw Sprag rod support bolts Idler shaft lock plate bolt Transfer shaft lock nut Bearing retainer bolts Oilpaspembly mounting bolts Converter housin
15. Plate No 5 Clutch discs F4A3 W4A3 Front Clutch DISASSEMBLY SERVICE POINT A gt SNAP RING REMOVAL 1 Compress the return spring with the special tool 2 Remove the snap ring REASSEMBLY SERVICE POINTS 4 SNAP RING INSTALLATION 1 Compress the return spring with the special tool 2 install the snap ring CLUTCH PLATE INSTALLATION 1 Install the clutch plate with their missing tooth portions in the illustration in alignment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plate and disc 2 Install the innermost plate with their shear droops directed as shown in the illustration W4A32 Plate No Thickness mm in Identification mark 5 0 197 2 3 1 122 B 3 3 1 122 B 4 3 7 146 None FAA33 WAA33 Plate No Thickness mm in 5 0 197 2 2 087 2 2 087 3 4 2 2 087 TFA0424 3 E TSB Revision F4A3 W4A3 Front Clutch 23C 89 SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value W4A32 0 7 0 9 mm 028 035 F4A33 W4A33 0 8 1 0 mm 031 039 NOTE Position the ga
16. TSB Revision MD955631 MD730931 MD955632 MD730932 MD955633 MD730933 MD955634 MD730934 MD955635 MD730935 MD955636 MD730936 MD955637 MD737444 MD737445 MD737446 MD737447 MD728802 MD728803 MD728804 MD728805 MD728806 MD728807 MD728808 MD728809 MD728810 MD728811 MD72881 2 MD728813 MD72881 4 MD728815 MD728816 MD728817 MD728818 MD728819 MD728820 MD728821 F4A3 W4A3 Specifications 23C 13 Part name Thickness Identification Part No mm in symbol Spacer F4A33 711 A F16A 0 62 0244 62 MD740866 reo agjustment of transfer driven gear 0 65 0256 65 MD740867 0 68 0268 68 MD740868 0 71 0280 71 MD740869 0 74 0291 74 MD740870 0 77 0303 77 MD740871 0 80 0315 80 MD740872 0 83 0327 83 MD740873 0 86 0339 86 MD740874 0 89 0350 89 MD740875 0 92 0362 92 MD740876 0 95 0374 95 MD740877 0 98 0386 98 MD740878 1 01 0398 01 MD740879 1 04 0409 04 MD740880 1 07 0421 07 MD740881 1 10 0433 10 MD740882 1 13 0445 13 MD740883 1 16 0457 16 MD740884 1 19 0469 19 MD740885 1 22 0480 22 MD740886 1 25 0492 25 MD740887 1 28 0504 28 MD740888 1 31 0516 31 MD740889 snap ring 1 76 0693 Brown MD733314 ee output flange 1 82 0717 None MD722538 1 88 0740 Blue MD721014 1 94 0764 Brown MD721015 2 00 0787 None MD721 016 2 06 0811 Blue MD721017 2 12 0835 Brown MD722539 2 18 0858 None MD733315 TSB Revision 2
17. 3 One way clutch outer race 40N un 29 ft bs 4 End plate 84 5 One way clutch 6 End plate 7 Pinion shaft 8 Front thrust washer 9 Spacer bushing 10 Short pinion 11 Roller GAD 9 amp 12 Thrust bearing 4 13 Planet carrier TFA0524 TFA0524 TSB Revision F4A2 Planetary Gear 23B 67 170255 170256 Front thrust washer A Rear thrust washer 17026C DISASSEMBLY SERVICE POINT QA THRUST BEARING REMOVAL 1 Remove the only one short pinion Use care not to drop and lose the 17 rollers in the short pinion Do not remove the other short pinions 2 Remove the thrust bearing REASSEMBLY SERVICE POINTS Aq THRUST BEARING INSTALLATION 1 Install a new thrust bearing on the carrier Make sure that it fits correctly in the spot faced portion of the carrier 2 Apply Vaseline unsparingly to the inside surface of the short pinion and attach the 17 rollers on the surface 3 Line up the holes of the rear thrust washer and front thrust washer A with the shaft hole of the carrier 4 Install the short pinion spacer bushing and front thrust washer and align the holes Use care not to allow the rollers to get out of position TSB Revision 23 68 F4A2 Planetary Gear b Insert the pinion shaft Make sure that the flattened end of pinion shaft is correctly fitted in the hole of the rear thrust plate when the pinion shafts is inserted ONE WAY CLUTCH INSTALLATION 1
18. A O A JE Mai VS wise to lock the lock nut and the special tool inner NC Inner Wrench MD99891 ERE e Outer Wrench Se wus TFA019 998916 3 0 d Fit torque wrench to the special tool inner to tighten it cC OM Torque Gr wrench to a torque of 10 Nm 7 2 ft lbs and loosen Repeat this D Su y sequence two times before tightening the special tool sS inner to 5 Nm 3 6 ft lbs torque Then back off the 2 special tool outer 2 to 2 turns DES SS NSA Fit the special tool outer to the lock nut Turn the outer cylinder clockwise and the inner cylinder counterclockwise to unlock the lock nut and the special tool inner Caution When unlocking is carried out apply equal force to both special tools to loosen f Tighten the lock nut with a hand until it touches the piston Then use torque wrench to tighten the lock nut to specified torque E Torque Lock nut 29 Nm 21 165 ra wrench G o Caution The lock nut may turn with the adjusting rod if tightened quickly with socket wrench or torque wrench g Remove the special tool for securing the piston Install the plug to the Low Reverse pressure outlet and tighten to specified torque 89 Install the kickdown servo switch and fasten with a snap ring TFA0137 TSB Revision W4A3 Transaxle 4WD 23C 83 90 Insert the center
19. AAA 8 Washer 6 9 Side gear 410 Spacer 11 Differential case TFA0263 DISASSEMBLY SERVICE POINTS BEARING REMOVAL 1 Using the special tool remove the bearing TSB Revision F4A3 W4A3 Differential 23C 103 TAPER ROLLER BEARING REMOVAL 1 Using the special tool remove the taper roller bearing 46 LOCK PIN REMOVAL 1 Using pin punch drive out the lock pin NOTE Sometimes the lock pin is removed with a light punch REASSEMBLY SERVICE POINTS Aq SPACER SIDE GEAR WASHER PINION PINION SHAFT INSTALLATION 1 Fit the spacer to the back face of the side gear then install the gear into the differential case 2 Fit washer to back of pinion and rotate two pinions at the same time into position to mesh with the side gear 3 Insert the pinion shaft 4 Measure the backlash between the side gear and pinion Standard value 0 025 0 150 mm 001 0059 in 5 If the backlash is out of specification select the appropriate spacer and disassemble and reassemble the gears as necessary NOTE Adjust so that the backlash in both side gears equals TSB Revision 23C 104 F4A3 W4A3 Differential B LOCK PIN INSTALLATION 1 Align the lock pin hole in pinion shaft with that in the case and install the lock pin Caution 1 Do not reuse lock pins 2 Make the lock pin lower than the surface of the differential case flange 3 Press fitting load is over
20. ae 11 Nm 8 ft lIbs 19N 14 ft Ibs 37 6 8 ft lbs AA 39 40 19N d9 14 ft lbs 959 eme 5 33 Nm C3 24 ft Ibs d 5655 59 Snap 60 Kickdown servo sleeve 61 Kickdown servo piston 62 Spring 63 Anchor rod 64 Output flange 65 Spacer 66 Outer race 67 Transfer shaft and governor 68 Accumulator piston 69 Spring inner 70 Sprinq outer 80 71 O ring 72 O ring 73 SEN screw 74 _O rina 1 Nm 75 Detent ball 76 Spring Parking sprag rod Sprag rod support Control shaft Valve body Oil filter Gasket Oil pan Gasket Drain plug Pulse generator MODEL 1992 only Transaxle case 0935 5 Revision 2 Transaxle 23A 17 DISASSEMBLY 1 Prior to disassembling the transaxle plug all openings and thoroughly clean the exterior of the assembly preferably by steam 2 Place the transaxle on the workbench with the oil pan down 3 Remove the torque converter 4 Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required except when major parts are replaced Thrust washers are located between the reaction shaft support and rear clutch retainer and between the reaction shaft support and front clutch retainer i Mount a dial indicator to the converter housing using the special tool with its plunger seated against the end of the input s
21. can be easily loosened 40 Using an impact driver loosen the screws and remove the bearing retainer 41 Remove the idler shaft lock plate 42 Loosen the transfer idler shaft with the special tool 43 Pull out the transfer idler shaft Remove the transfer idle gear and the two bearing inner races from inside the case Idler shaft 177004 1 TSB Revision 4 2 Transaxle 44 Remove the spacer 45 Remove the snap ring from the output flange bearing E 46 Remove the output flange from the case S lt Ne Sv AX 7 47 Remove the transfer shaft cover 48 Straighten the locking tab of the transfer shaft lock nut where it is bent TSB Revision F4A2 Transaxle 23B 31 49 Secure the transfer shaft on the end of the converter housing 1770039 bO Remove the lock nut Caution The lock nut is a left handed screw b1 Drive out the transfer shaft toward the converter housing end and remove the transfer shaft and transfer driven gear 001 b2 Remove the outer races from the transfer shaft bearing b3 Remove the sprag rod support 1750179 TSB Revision 23B 32 2 Transaxle 54 Remove the set screw and remove the manual control shaft assembly At this time also remove the steel ball seat and spring Setscrew Manual control INSPECTION PULSE GENERATORS 1 Measure the resistance between t
22. his MD998337 01 1 Compress the return spring with the special tool NUN MD998907 01 2 Using a screwdriver remove the snap ring UR 0236 REASSEMBLY SERVICE POINTS Aq WAVE SPRING INSTALLATION 1 Compress clutch reaction plate with the special tool 2 Install the wave spring B4 SNAP RING INSTALLATION 1 Compress clutch reaction plate with the special tool 2 Install the snap ring C CLUTCH PRESSURE PLATE CLUTCH PLATE amp CLUTCH REACTION PLATE INSTALLATION 1 Install the clutch pressure plate clutch plates and clutch d reaction plate with their missing tooth portions in the Z illustration in alignment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plates and disc TFA049 TSB Revision F4A3 W4A3 Rear Clutch 23C 93 2 Install the clutch reaction plate with its shear droop directed Clutch disc as shown in the illustration Shear drop lt m 1 Wave spring Clutch reaction Pressure plate plate Return spring Clutch plate F4A33 W4A33 Wave spring Clutch plate Snap ring Clutch reaction late Clutch discs p TFA0282 Ur 4 SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11lbs force If clearance is out of st
23. 051 None MD731747 For adjustment of front clutch and 1 4 055 Blue MD731748 ESO ene py 1 5 059 Brown MD731749 rear clutch only 1 6 063 None MD731750 1 7 067 Blue MD731 751 1 8 071 Brown MD731 752 1 9 075 None MD731 753 2 0 079 Blue MD731 754 2 1 083 Brown MD731 755 2 2 087 None MD731 756 2 3 091 Blue MD731757 2 4 094 MD731 758 ring 1 05 0413 White MD71 5800 or adjustment of end clutch end play 1 30 0512 Yellow MD715801 1 55 0610 None MD71 5802 1 80 0709 Green MD71 5803 2 05 0807 Pink MD720849 TSB Revision 4 23 12 F4A3 W4A3 Specifications Part name Thickness Identification Part No mm in symbol Snap ring W4A32 1 6 063 MD955630 For adjustment of front clutch and rear clutch end play 1 7 067 MD730930 1 8 071 1 9 075j 2 0 079 2 1 083 2 2 087 2 3 091 2 4 094 2 5 098 2 6 102 2 7 106 2 8 110 2 9 114 3 0 118 Spacer F4A33 022 W4A32 W4A33 0 62 0244 Mma oreload justment of transfer driven gear 0 65 0256 0 68 0268 0 71 0280 0 74 0291 0 77 0303 0 80 0315 0 83 0327 0 86 0339 0 89 0350 0 92 0362 0 95 0374 0 98 0386 1 01 0398 1 04 0409 1 07 0421 1 10 0433 1 13 0445 1 16 0457 1 19 0469 1 28 0504 1 31 0516j
24. 22 Inner Wrench XOT LEA Trans f Tighten the lock nut with a hand until it touches the piston Then use torque wrench to tighten the lock nut to specified torque Lock nut 29 Nm 21 165 Caution The lock nut may turn with the adjusting rod if tightened quickly with socket wrench or torque wrench g Remove the special tool for securing the piston Install the plug to the Low Reverse pressure outlet and tighten to specified torque 77 Install the kickdown servo switch and fasten with a snap ring TSB Revision F4A3 W4A3 Transaxle FWD 23C 51 78 Coat the oil pump drive hub with automatic transmission fluid and install the torque converter Push in firmly so that dimension A in the diagram is the standard value Standard value approx 16 3 mm 642 in TSB Revision 23 52 F4A3 W4A3 Transaxle 4WD TRANSAXLE 4WD COMPONENTS 21Nm 16 ft Ibs 36 Kickdown servo piston 37 Spring 38 Anchor rod 39 Detent assembly 40 Manual control shaft 41 Parking roller support 42 Oil pan 43 Gasket 44 Oil temperature sensor Center support 45 Oil filter Wave spring 46 Valve body assembly Return spring 47 Manual control lever 1 Torque converter 20 Pressure plate 48 Park neutral position switch 2 Oil pump assembly 21 Brake disc PNP switch 3 Gasket 22 Brake plate 49 End clutch shaft 4 Thrust washer 1 23 Reaction plate 50 Bearing retainer
25. 3 7 0 10 1 0 681 276 039 ow relief spring 12 46 6 6 8 0 6 491 260 024 N D accumulator valve 51 92 7 8 25 0 8 spring 2 044 307 031 N D accumulator plug 37 39 13 6 12 1 4 spring 1 472 535 055 Reducing valve spring 40 35 6 8 22 0 8 lt MODEL 1992 only 1 589 268 031 _lutch control valve spring 15 7 6 2 11 0 7 lt MODEL 1992 only 618 244 026 TSB Revision I F3A2 Specifications 23 9 ADJUSTMENT PRESSURE PLATE SNAP RINGS AND SPACERS Part name Thickness Identification mm in symbol ux Pressure plate 5 6 220 56 0731720 of low reverse 5 7 224 57 MD731 721 5 8 228 58 MD727801 5 9 232 59 MD731000 6 0 236 60 MD727802 6 1 240 61 MD731001 6 2 244 62 MD727803 6 3 248 63 MD731002 6 4 252 64 MD727804 6 5 256 65 MD731003 6 6 260 66 MD727805 6 7 264 67 MD731004 6 8 268 68 MD731005 Snap ring 1 6 063 None MD955630 For adjustment of front clutch and 1 7 067 Brown MD730930 rear clutch clearance 1 8 071 Blue MD955631 1 9 075 None MD730931 2 0 079 Brown MD955632 2 1 083 Blue MD730932 2 2 087 None MD955633 2 3 091 Brown MD730933 2 4 094 Blue MD955634 2 5 098 None MD730934 2 6 102 Brown MD955635 2 7 106 Blue MD730935 2 8 110 None MD955636 2 9 114 Brown MD730936 3 0 118 Blue MD955637 Snap ring 1 88 074 MD707501 For adjustment of output flange end play 1 94
26. 5 Front clutch assembly 24 Reverse sun gear 51 Thrust bearing 11 6 Thrust race 3 25 Thrust bearing 8 52 End clutch hub 7 Thrust bearing 4 26 Thrust race 9 53 Thrust washer 8 Thrust washer 2 27 Forward sun gear 54 End clutch assembly 9 Rear clutch assembly 28 Planetary carrier assembly 55 O ring 10 Thrust bearing 5 29 Thrust bearing 10 56 End clutch cover 11 Rear clutch hub 30 Output flange 57 Pulse generator 12 Thrust bearing 7 31 Oil level gauge 58 Lock bolt 13 Thrust race 6 32 Oil filler tube 59 Idler shaft 14 Kickdown band 33 Snap ring 60 Idler gear 15 Kickdown drum 34 Kickdown servo switch 61 Spacer 16 Snap ring 35 Snap ring 62 Gasket TFA0409 TSB Revision F4A3 W4A3 Transaxle 4WD 23C 53 19 Nm 56 11 Nm 14 ft lbs 24 Nm e 11 Nm 8 ft lbs 70 Nm 8ftibs 51 ft Ibs 6 Idler gear cover 71 Center differential assembly 6t Differential bearing retainer 72 Center bearing retainer Spacer 73 Stopper ring 6 Differential front bearing cap 74 Viscous coupling unit 6 Differential assembly 75 Center bearing retainer NOTE 8 Gasket 76 Front output shaft On 1993 and subsequent models marked parts 9 Differential cover 77 Rear output shaft have the connecter directly attached not via a harness 7 Output bearing retainer 78 Transaxle case TFA0411 TSB Revision 23 54 F4A3 W4A3 Transaxle 4WD DISASSEMBLY 1 Clean a
27. Alignment of oil pump housing and reaction shaft support Alignment of oil pump housing and reaction shaft support MD998337 MD998907 01 Spring com pressor MD998338 MD998338 Spring com pressor MD998348 MD998348 01 Bearing puller Disassembly of front clutch and rear clutch Disassembly and reassembly of rear clutch Removal of bearing MD998800 MD998325 01 Oil seal installer Installation of drive shaft oil seal MD998806 Wrench adapter MD998806 Measurement of transfer driven bevel gear drive torque lt 4WD gt TSB Revision F4A3 W4A3 Special Tools 23C 21 Tool Number and Replaced by OTC Application tool name tool number MD998812 General service tool Use with installer and adapter Installer MD998813 General service tool Use with installer cap and adapter P Installer 100 MD998814 MIT304180 Use with installer cap and adapter Installer 200 MD998819 General service tool Installation of each bearing Installer adapter 40 MD998822 MD998822 01 1 Installer adapter Q 46 MD998825 General service tool E adapter 52 MD998827 General service tool Installer adapter 6 MD998829 M D998829 01 Installer adapter 60 MD998830 General service tool Installer adapter 66 Revision 23 22 F4A3 W4A3 Special Tools Number and Replaced by OTC Application tool name tool nu
28. INSTALLATION 1 Using the special tool install the taper roller bearing on the center differential flange TAPER ROLLER BEARING INSTALLATION 1 Using the special tool install the taper roller bearing on the transfer driven gear TSB Revision 23 118 F4A3 W4A3 Front Output Shaft AWD FRONT OUTPUT SHAFT 4WD DISASSEMBLY AND REASSEMBLY Disassembly steps QAD 1 Taper roller bearing GAD 2 Taper roller bearing 3 Front output shaft TFA0244 DISASSEMBLY SERVICE POINT MD998348 01 AD TAPER ROLLER BEARINGS REMOVAL 1 Using the special tool remove the taper roller bearings on both ends of the front output shaft REASSEMBLY SERVICE POINT Aq TAPER ROLLER BEARINGS INSTALLATION 1 Using the special tool press fit the taper roller bearings on both ends of the front output shaft MD998822 01 MD998822 01 TSB Revision F4A3 W4A3 Transfer 4WD 23C 119 TRANSFER 4WD DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Cover E4 2 Cover gasket 04 3 Extension housing assembly 4 Oil guide Ma 5 Transfer case sub assembly B4 6 Spacer 7 O ring 8 Transfer case adapter sub assembly 0601 REASSEMBLY SERVICE POINTS 4 TRANSFER CASE ADAPTER SUB ASSEMBLY INSTALLATION 1 Apply a light and uniform coat of machine blue or red lead to the driven beve
29. REASSEMBLY TFAO262 Disassembly steps 981 Snap ring 2 Stopper plate 4 Bearing GAD 9 4 4 Bearing 4 5 Transfer drive gear 6 Snap rin 7 Output flange 8 Annulus gear DISASSEMBLY SERVICE POINT BEARING TRANSFER DRIVE GEAR REMOVAL 1 Using the special tool remove the transfer drive gear together with two bearings from the output flange Caution Install the special tool in position between the output flange and bearings 2 Using the special tool remove the bearings from both sides of the transfer drive gear TSB Revision 4 W4A3 Annulus Gear and Transfer Drive Gear Set 23C 101 REASSEMBLY SERVICE POINTS pA TRANSFER DRIVE GEAR BEARING INSTALLATION 1 Using the special tool press fit the bearings into both sides of the transfer drive gear TFA0228 0227 2 Using the special tool install the transfer drive gear to the output flange B SNAP RING SELECTION 1 Measure the snap ring groove clearance and select the appropriate spacer to obtain the specified end play Standard value 0 0 09 mm 0 0035 in TSB Revision 23 102 F4A3 W4A3 Differential DIFFERENTIAL DISASSEMBLY AND REASSEMBLY Disassembly steps 9yE4 1 Bolt 2 Differential drive gear Ad 04 3 Ball bearing W4A32 W4A33 64 4 Taper roller bearing F4A33 465 986 5 Lock pin Aa 6 Pinion shaft A A4 7 Pinion
30. Reducing Rear valve Torque converter perez control N D control Shift control Ex valve solenoid valve B B ege ane Shift control valve valve Regulator valve Pressure 5 control valve Lj Pressure Ex control solenoid valve Oil filter Transmission control unit TFA0070 TSB Revision F4A2 Specifications amp 7 SPECIFICATIONS TRANSAXLE MODEL TABLE MODEL 1992 Transaxle model Speedometer Final gear Vehicle model Engine model gear ratio ratio 4615 F4A21 2 MRD1 4G61 DOHC URD F4A22 2 UND 4G93 4G63 4G63 DOHC 4G37 4G63 DOHC 4G64 MPD3 MQD6 MPD MPD1 F4A23 2 LNN TRANSAXLE MODEL TABLE MODEL 1993 Transaxle model Speedometer Final gear Vehicle model Engine model gear ratio ratio F4A22 2 MRF3 CB5A 4693 UNE N11W 4693 MPE4 E33A 4G63 MQE E33A 4G63 DOHC MPE D21A 4G37 MPE1 D22A 4G63 DOHC F4A23 2 LNO N14W N34W 4G64 GEAR RATIO TABLE 1st 2nd 3rd 4th Reverse TSB Revision 23 8 SERVICE SPECIFICATIONS Transfer idler gear bearing preload Nm ft Ibs Input shaft end play Transfer shaft end play Low reverse brake end play Differential case end play End clutch snap ring clearance Oil pump gear side clearance Front clutch snap ring clearance Rear clutch snap ring clearance Output flange bearing end play Differenti
31. and it should always be kept clean e During disassembly cloth gloves or shop towels should not be used If such items must be used either use articles made of nylon or use paper towels e All disassembled parts must be thoroughly cleaned Metal parts may be cleaned with ordinary detergents but must be thoroughly air dried e Clean the clutch disc resin thrust plate and rubber parts by using ATF automatic transmission fluid being very careful that dust dirt etc do not adhere to them Do not reuse gaskets oil seals or rubber parts Replace such parts with new ones at every reassembly The O ring of the oil level gauge need not be replaced Do not use grease other than petrolatum jelly Apply ATF to friction components rotating parts and sliding parts before installation A new clutch disc should be immersed in ATF for at least two hours before installation Do not apply sealer or adhesive to gaskets When a bushing must be replaced replace the assembly in which it is incorporated If the transaxle main unit is damaged also disassemble and clean the cooler system TSB Revision MM M IN UQMVI O Q N n I F3A2 General Information SECTIONAL VIEW MODEL 1992 Torque converter Oil pump Front clutch 23A 3 Planet gear set Rear clutch Transfer idler gear To
32. disc resin thrust plate and rubber parts by using ATF automatic transaxle fluid being very careful that dust dirt etc do not adhere to them Do not reuse gaskets oil seals or rubber parts Replace such parts with new ones at every reassembly The O ring of the oil level gauge need not be replaced Do not use grease other than petrolatum jelly Apply ATF to friction components rotating parts and sliding parts before installation A new clutch disc should be immersed in ATF for at least two hours before installation Do not apply sealer or adhesive to gaskets When a bushing must be replaced replace the assembly in which it is incorporated If the transaxle main unit is damaged also disassemble and clean the cooler system TSB Revision F4A2 General Information 23B 3 SECTIONAL VIEW 4 21 Torque Low reverse converter brake Oil pump Front clutch Planetary gear Kickdown brake Pulse generator A Rear LJ Transfer 77 idler gear End clutch S U H 44 Transfer b H ug drive gear was Transfer Torque converter driven gear lutch Transfer shaft Pulse generator B Differential TFA0550 TSB Revision 23 4 F4A2 General Information SECTIONAL VIEW F4A22 Torque Kickdown brake Low reverss converter rake Pado Qual Pulse Oil pump Front dutch generator A Rear clutch Transfer idler gear End clutch
33. itself to install them on its products previously manufactured C 1992 Mitsubishi Motors Corporation Printed in Japan GROUP INDEX Introduction esee Automatic Transaxle W4A3 INTRODUCTION CONTENTS EXPLANATION OF MANUAL CONTENTS 2 SPECIAL TOOL NOTE _ 5 FORM IN PLACE GASKET 6 TORQUE REFERENCES 5 Disassembly aesti 6 TRANSAXLE TRANSMISSION MODEL TABLE 4 Form In Place Gasket Application 6 Surface Preparation 6 2 INTRODUCTION EXPLANATION OF MANUAL CONTENTS Maintenance Servicing Procedures 1 A diagram of the component parts is provided near the front of each section in order to give the reader a better under standing of the installed condition of component parts 2 The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures the symbol E indicates a non reusable part the tighten ing torque is provided where applicable e Removal steps e Reassembly steps Classification of Service Points When there are major points relative to mainte nance and servicing procedures such as essential maintenance and service points maintenance and service standard values information regarding the
34. replace thrust race 3 and thrust washer 1 to meet the specification Standard value 0 3 1 0 mm 012 039 52 Place approx 10 mm 394 in long and 2 5 mm 10 in dia pieces of solder at the locations shown on the differential assembly TSB Revision 23A 38 F3A2 Transaxle 53 Place approx 10 mm 394 in long and 2 mm 08 in dia pieces of solder at the illustrated locations on the converter housing Place the outer race of transfer shaft front bearing in position 54 Install the converter housing directly to the transaxle case without installing the rubber coated metal gasket b5 Tighten the bolts to the specified torque 56 Loosen the bolts remove the converter housing and remove the flattened solder pieces 57 Measure the thickness of the flattened solder using a micrometer Add the measured solder thickness T to the value 0 38 mm 015 in which corresponds to the gasket thickness Then add to or subtract from that sum a value corresponding to the specified preload or end play range The result obtained is the thickness of the spacer to be selected For the transfer shaft select a spacer whose thickness falls within the range determined by the formulas below T 0 38 mm 015 in 0 1 mm 004 to 2200048 T 0 38 mm 015 in 0 15 mm 006 in For the differential case spacer determine the thickness using the following formulas T 0 38 mm 015 in 0 15
35. section title Indicates the group title ber TSB Revision Indicates the group num page number indicates the Denotes non reusable This number corresponds to the 7 number appearing in Removal steps Disassembly steps In stallation steps or Heassembly Operating procedures cautions on removal installation dis assembly and reassembly are de scribed 4 INTRODUCTION TRANSAXLE TRANSMISSION MODEL TABLE MODEL 1992 j T poe FWD 4 speed Full time 4WD 4 speed Diff Center Diff Vehicle Model Mirage ERES Eclipse 3000GT Expo LRV Expo Galant V4AW2 Part time AWD 4 speed RAAC1 RWD 4 speed Diff Differential VCU Viscous Coupling FWD Front wheel drive RWD Rear wheel drive AWD Four wheel drive Type Vehicle Model 2 3 speed FWD 4 speed W4A32 Full time 4WD 4 speed W4A33 V4AW2 Part time 4WD 4 speed R4AC1 RWD 4 speed Diff Differential VCU Viscous Coupling FWD Front wheel drive RWD Rear wheel drive 4WD Four wheel drive TSB Revision INTRODUCTION 5 SPECIAL TOOL NOTE Please refer to the special tool cross reference chart which is located in the service manual at the beginnihg of each group for a cross reference from the MMC special tool number to the spe
36. spring 2 3 shift valve spring N R control valve spring Reducing valve spring Line relief spring Torque converter valve spring Shift control valve spring Torque converter clutch control valve spring 0 7 028 15 59 7 6 299 7 6 299 6 8 268 6 6 260 7 0 276 9 2 362 8 9 350 7 0 276 9 0 354 5 7 224 6 2 244 52 2 05 26 6 1 047 21 3 839 27 4 1 079 24 4 961 27 5 1 083 32 1 1 264 29 5 1 161 17 3 681 22 6 890 26 8 1 055 14 2 559 TSB Revision e ADJUSTMENT PRESSURE PLATE SNAP RINGS AND SPACERS F4A3 W4A3 Specifications 23C 11 Part name Thickness Identification Part No mm in symbol Pressure plate FAA33 W4A33 5 9 232 A MD731 736 Brakeagietomg pt of low reverse 6 0 236 0 MD731 737 6 1 240 MD731 738 6 2 244 2 MD731 739 6 3 248 3 MD731740 6 4 252 4 MD731 588 6 5 256 5 MD731 741 6 6 260 6 MD731 742 6 7 264 7 MD731743 6 8 268 8 MD731 744 6 9 272 9 MD731 745 Pressure plate W4A32 5 6 220 Y MD731 720 For adjustment of low reverse 5 7 224 Z MD731721 d 5 8 228 8 MD727801 5 9 232 9 MD731000 6 0 236 0 MD727802 6 1 240 MD731001 6 2 244 2 MD727803 6 3 248 3 MD731 002 6 4 252 4 MD727804 6 5 256 5 MD731003 6 6 260 6 MD727805 6 7 264 7 MD731 004 6 8 268 X MD731 005 6 9 272 A MD734766 7 0 276 B MD734767 snap ring FA4A33 W4A33 1 3
37. the specified torque Output bearing retainer mounting bolts 24 Nm 18 ft Ibs TFA0168 23 Insert the output flange into the case and install a snap ring around the bearing 24 Install the bearing retainer using new bolts Bearing retainer mounting bolts 20 Nm 15 ft Ibs 25 Caulk the heads of the bolts TFAO169 26 Apply a coating of petrolatum to thrust bearing 10 and attach to the planetary carrier Thrust bearing 10 N TFA0170 TSB Revision F4A3 W4A3 Transaxle 4WD 23C 69 27 Assemble the planetary carrier 28 Assemble the forward sun gear thrust race 9 thrust bearing 8 and reverse sun gear Thrust race 9 1770066 29 Install both sun gears assembled in the previous item into the planetary carrier 30 Assemble the reaction plate brake disc and brake plate TSB Revision 23 70 F4A3 W4A3 Transaxle 4WD TFA0243 Identification of thrust bearings thrust races and thrust washers mm in Outer Inner Thickness Part No Code Outer Inner Thickness Part No Code diameter diameter No diameter diameter No ERE 1 70 55 7 1 4 1 48 1 34 4 MD707271 4 2 7559 2 1929 0551 1 8937 1 3543 L Ld 70 55 7 1 8 2 426 28 MD720753 5 2 7559 2 1929 0709 1 6772 1 1024 LT 1 70 55
38. the special tool to mount the dial gauge on the transmission case and measure the end play of the input shaft TFA0105 MODEL 1992 D T 5 Remove the pulse generator A and S Pad 6 Remove manual control lever then remove park neutral position switch PNP switch TSB Revision 23 26 F4A3 W4A3 Transaxle FWD 7 Remove the oil pan magnets and gasket 8 Remove the oil filter from the valve body 9 Remove the 10 valve body mounting bolts 10 Remove the oil temperature sensor holder and remove the oil temperature sensor harness from the clamp AES i s S Wa Qooro 11 Press the finger of the solenoid valve harness grommet push the grommet into the case and remove the valve body assembly 12 Pull out the oil temperature sensor TSB Revision F4A3 W4A3 Transaxle FWD 23C 27 13 Remove the parking roller support 14 Remove the set screw of the manual control shaft and remove the manual control shaft assembly 15 Remove the detent assembly 16 Remove the differential cover and gasket 17 Remove the differential front bearing cap TFA0555 18 Remove the differential bearing retainer spacer and outer race 19 Remove the differential assembly TSB Revision F4A3 W4A3 Transaxle FWD 20 Take out the end clutch cover installation bolts then remove the cover holder and end clutch cover 21 Remove the end
39. use of special tools etc these are arranged together as major maintenance and service points and explained in detail AD Indicates that there are essential points for removal or disassembly pA Indicates that there are essential points for installation or reassembly Major Maintenance Symbols for Lubrication Sealants and Adhesives Information concerning the locations for lubrica tion and for application of sealants and adhesives is provided by using symbols in the diagram of component parts or on the page following the component parts page and explained The part designation number corresponds to the number in the illustration to indicate removal steps Disassembly steps The part designation number corresponds to the number in the illustration to indicate disassembly steps Installation steps Specified in case installation is impossible in reverse order of removal steps Omit ted if installation is possible in reverse order of removal steps Specified in case reassembly is impossi ble in reverse order of disassembly steps Omitted if reassembly is possible in re verse order of disassembly steps Grease multipurpose grease unless there is a brand or type specified m Sealant or adhesive Brake fluid automatic transmission fluid or air conditioner compressor oil ID Engine oil or gear oil TSB Revision INTRODUCTION Indicates the
40. 03 1 91 0752 91 MD722104 1 94 0764 94 MD722105 TSB Revision FAA3 W4A3 Specifications Part name Thickness mm in Identification symbol 23C 17 Part No Spacer W4A32 W4A33 For adjustment of driven bevel gear mount Spacer W4A32 W4A33 5reloadpstment of front output bearing SEALANTS AND ADHESIVES 0 13 0051 0 16 0063 0 19 0075 0 22 0087 0 25 0098 0 28 0110 0 31 0122 0 34 0134 0 37 0146 0 40 0517 0 43 0169 0 46 0181 0 49 0193 0 52 0205 1 16 0457 1 19 0469 1 22 0480 1 25 0492 1 28 0504 1 31 0516 1 34 0528 1 37 0539 1 40 0551 1 43 0563 1 46 0575 1 49 0587 1 52 0598 1 55 0610 1 58 0622 1 61 0634 1 64 0646 1 67 0657 1 70 0669 1 73 0681 1 76 0693 13 16 19 22 25 28 31 34 37 40 43 46 49 52 MD720353 MD720354 MD720355 MD720356 MD720357 MD720358 MD720359 MD720360 MD720361 MD720362 MD720363 MD720364 MD720365 MD720366 MD736929 MD736751 MD736931 MD7261 66 MD718517 MD71 5818 MD718519 MD71 8520 MD718521 MD71 8522 MD7 18523 MD7 18524 MD71 8525 MD71 5826 MD71 8527 MD7 18528 MD7 18529 MD7 18530 MD71 8531 MD72 1959 MD721960 lt W4A32 W4A33 gt Items Specified sealants and adhesives Transfer extension housing Transfer adapter MITSUBISHI Genuine Part No MD997740 or equivalent 3M Stud Locking Part No 4170 or equiv
41. 06 01 Preload measurement of transfer idler shaft Wrench adapter MD998907 Spring compressor MD998908 Bearing installer MD998910 Bearing installer Disassembly and reassembly of front clutch Press in of transfer shaft rear bearing MD9989 1 0 01 Press in of transfer shaft rear bearing TSB Revision 23 18 F4A2 Special Tools Number and Replaced by OTC Application tool name tool number MD998912 General service tool Press in of transfer shaft rear bearing Handle MD998913 MD998913 01 Measurement of low reverse brake end Dial gauge play extension MD998915 MD998916 1 01 Adjustment of kickdown servo Kickdown servo wrench adapter MD998916 Kickdown servo adjust wrench set MD998918 Kickdown servo wrench TSB Revision F4A2 Transaxle 23B 19 TRANSAXLE 1 Torque converter 2 Converter housing 3 Gasket 4 Oil pump 5 O ring 6 Gasket 7 8 0 1 2 Thrust washer 1 g3sembly Thrust bearing 4 Thrust washer 2 Rear clutch assembly 21 Nm Spacer 16 ft lbs 4 Differential 1 1 1 1 1 16 ft Ibs 15 Thrust bearing 6 16 Glu tc b hub 1 7 Thrust race 7 18 Thrust bearing 8 19 Kickdown band 20 Kickdown drum 21 Snap ring 22 Center support 23 O ring 24 Wave spring 25 Return spring 26 Pressure plate 27 Brake disc 28 Brake plate 29 Reaction plate 30 Reverse sun gear 3
42. 075 0 135 mm 003 0053 in TSB Revision 23 78 F4A3 W4A3 Transaxle 4WD 67 Install a new O ring on the differential rear bearing retainer coat the O ring with automatic transmission fluid then install in the transaxle case and tighten the mounting bolts to the specified torque Differential rear bearing retainer mounting bolts 35 Nm 26 ft Ibs 68 Install the front bearing cap and tighten the bolts to the specified torque Differential front bearing cap mounting bolts 70 Nm 51 165 69 Install the differential cover and a new gasket Differential cover mounting volts 11 Nm 8 165 70 Install the detent assembly 71 Install a new O ring on the manual control shaft assembly coat the O ring with automatic transmission fluid and then insert into the transaxle case 72 Align the groove in the manual control shaft and the set screw hole then install the set screw Manual control shaft set screw 9 Nm 7 ft Ibs 73 Install the parking roller support Parking roller support mounting bolts 24 Nm 18 ft Ibs 0113 TSB Revision BENE cc Oil temperature sensor ooo la w Tr O ring 9 wal F4A3 W4A3 Transaxle 4WD 23C 79 TFAO714 TSB Revision 74 75 76 77 78 79 Insert the oil temperature sensor into the case Install an O ring in the O ring groove at the top of the valve body assembly Re
43. 076 MD707502 2 00 079 MD707503 2 06 081 MD707504 Spacer 0 82 032 MD71 2638 For adjustment of transfer shaft preload 0 85 033 MD71 2639 0 88 035 MD71 2640 0 91 036 MD71 2641 0 94 037 MD71 2642 0 97 038 MD71 2643 1 00 039 MD7 12644 1 03 041 MD71 2645 1 06 042 MD71 2646 TSB Revision 23 10 F3A2 Specifications Part name Thickness Identification Part No mm in symbol Spacer For adjustment of transfer shaft preload 11 09 044 MD71MDT1 2647 2648 1 15 045 MD71 2649 1 18 046 MD71 2650 1 21 048 MD712651 1 24 049 MD71 2652 1 27 050 MD71 2653 1 30 051 MD71 2654 1 33 052 MD7 12655 1 36 054 MD71 2656 1 39 055 MD71 2657 1 42 056 MD71 2658 1 45 057 MD71 2659 1 48 058 MD71 2660 1 51 059 MD71 2661 1 54 061 MD71 2662 1 57 062 MD71 2663 1 60 063 MD71 2664 1 63 064 MD71 2665 1 66 065 MD71 2666 1 69 067 MD71 2667 Spacer 1 31 052 MD706574 For adjustment of differential case 1 40 055 MD706573 1 49 059 MD706572 1 58 062 MD706571 1 67 066 MD706570 1 76 069 MD706575 MD700272 MD71 5956 MD71 5959 MD71 5962 Spacer MA1 80862 For adjustment of differential oinion backlash 1 80861 033 036 0 93 1 00 MA1 80860 MA1 80875 1 09 1 16 MA1 80876 043 047 TSB Revision 2 Specifications 23A 11 TORQUE SPECIFICATIONS Nm Manual control shaft set screw 9 7 S
44. 1 MD740862 MD740863 MD740864 F4A3 W4A3 Specifications Part name Spacer WAA32 W4A33 G leiment of differential case Spacer For adjustment of differential gear and pinion backlash Thickness mm in 1 01 0398 1 10 0433 1 19 0469 1 28 0504 0 75 0 82 0295 0323 0327 0 0362 0 93 1 00 0366 0394 1 01 1 08 0398 0425 1 09 1 16 0429 0457 23 15 Identification Part No symbol MD720943 MD710454 MD71 0456 MD71 0458 MD722986 MD722985 MD722984 MD722982 MD722983 Spacer WA4A32 W4A33 For adjustment of center differential front side ge8nd play Spacer W4A32 W4A33 For adjustment of center differential rear sidegegnd play Spacer W4A32 W4A33 For adjustment of drive bevel gear mount 0 53 0 60 0209 0236 0 69 0 76 0272 0299 0 85 0 92 0335 0362 1 01 1 08 0398 0425 1 17 1 24 0461 0498 0 59 0 66 0232 0260 0 75 0 82 0295 0323 0 93 1 00 0366 0394 1 09 1 16 0429 0457 1 25 1 32 0492 0520 1 34 0528 1 37 0539 1 40 0551 1 43 0563 1 46 0575 1 49 0587 1 52 0598 1 55 0610 1 58 0622 1 61 0634 1 64 0646 1 67 0657 MD727941 MD727934 MD727932 MD727930 MD727928 MD724973 MD724946 MD720681 MD724943 MD724972 MD723600 MD723
45. 1 Thrust bearing 9 32 Thrust race 10 33 Forward sun gear 34 Planetary carrier 35 Thrust bearing 12 TFA0051 TSB Revision 23 20 F4A2 Transaxle 215Nm 156 ft lbs P m5 LE of j 9 Nm cn m7 gt Sne A effi m 3 86 y 33 Nm 24 Nm 24 N EU C ft Ibs 80 Detent spring 74 73 8 1 Sprag rod support 36 Pulse generator 50 Bearing retainer 65 Outer race 82 Parkin raa 37 Spring washer 51 Snap ring 66 Gasket 83 Conife wes a 38 Control lever 52 Lock plate 67 O ring 84 D ring 39 Clamp 53 Idler gear shaft 68 Clip F4A21 85 Transfer shaft cover 40 Park neutral 54 Bearing inner race 69 Valve body 86 Lock nut position switch 55 Idler gear 70 Clamp 87 Driven gear 41 Oil temperature sensor 56 Bearing inner race 71 Gasket 88 Outer race 42 End clutch cover 57 Spacer 72 pan 89 Spacer 43 O ring 58 Snap ring 73 Gasket 90 Transmission case 59 Kickdown servo switch e Pian plug NOTE End clutc 60 Kickdown servo piston 75 O ring 46 Thrust washer 61 Spring p 76 Set screw ae ee 47 End clutch hub 62 Anchor rod 77 O ring have the connector directly 48 Thrust bearing 13 63 Output flange 78 Detent ball attached not via a harness 49 End clutch shaft 64 Transfer shaft 79 Detent seat i 0051 TSB Revision F4A2 Transaxle 23B 21 DISASSEMBLY 1 Prior to disassembling the transaxle plug all openings and tho
46. 3 14 Part name Thickness mm in F4A3 W4A3 Specifications Identification symbol Part No Spacer F4A33 D22A preloadiustment of differential case 0 71 0280 0 74 0291 0 77 0303 0 80 0315 0 83 0327 0 86 0339 0 89 0350 0 92 0362 0 95 0374 0 98 0386 1 01 0398 1 04 0409 1 07 0421 1 10 0433 1 13 0445 1 16 0457 1 19 0469 1 22 0480 1 25 0492 1 28 0504 1 31 0516 1 34 0528j 1 37 0539 71 74 77 80 83 86 89 92 95 98 01 04 e J D K L G M N E 0 P MD754475 MD727660 MD754476 MD727661 MD720937 MD720938 MD720939 MD720940 MD720841 MD720942 MD720943 MD720944 MD720945 MD71 0454 MD700270 MD710455 MD71 0456 MD700271 MD71 0457 MD710458 MD706574 MD71 0459 MD71 0460 Spacer F4A33 Z11 F16A 5reloadjustment of differential case 0 71 0280 0 74 0291 0 77 0303 0 80 0315 0 83 0327 0 86 0339 0 89 0350 0 92 0362 0 95 0374 0 98 0386 1 01 0398 1 04 0409 1 07 0421 1 10 0433 1 13 0445 1 16 0457 1 19 0469 1 22 0480 1 25 0492 1 28 0504 1 31 0516 1 34 0528 1 37 0539 CO o TSB Revision MD754446 MD754447 MD754448 MD754449 MD740846 MD740847 MD740848 MD740849 MD740850 MD740851 MD740852 MD740853 MD740854 MD740855 MD740856 MD740857 MD740858 MD740859 MD740860 MD74086
47. 3 Taper roller bearing B44 Spacer 5 Collar QC 6 Outer race 46 7 Outer race 8 Transfer case adapter GD A 9 Taper roller bearing 0604 DISASSEMBLY SERVICE POINTS LOCKNUT REMOVAL 1 Unlock the lock nut Straighten the bent nut 2 Holding the driven bevel gear in a vice and using the special tool remove the lock nut TSB Revision F4A3 W4A3 Transfer Case Adapter 4WD 23C 125 DRIVEN BEVEL GEAR ASSEMBLY REMOVAL 1 Using a press remove the driven bevel gear assembly TFA029 AC OUTER RACE REMOVAL 1 Remove the outer race striking lightly with a screwdriver etc QD TAPER ROLLER BEARING REMOVAL REASSEMBLY SERVICE POINTS 4 TAPER ROLLER BEARING INSTALLATION MIT304180 TSB Revision 23 126 W4A3 Transfer Case Adapter 4WD B SPACER SELECTION 1 Use the existing spacer to assemble the transfer case adapter 2 Using the special tool check that the bevel gear rotating drive torque is within standard range Standard value 1 0 1 7 Nm 72 1 23 ft Ibs 3 If the rotating drive torque is outside of the standard range adjust using adjusting spacers 2210141 9C TAPER ROLLER BEARING INSTALLATION 0311 D4 DRIVEN BEVEL GEAR INSTALLATION 1 Attach the driven bevel gear to the transfer case adapter and then align their matching marks Matching mark Matching mark
48. 3 Apply petrolatum jelly to thrust bearing 12 and secure the bearing on the planetary carrier 24 Mount the planetary carrier on the case TSB Revision F4A2 Transaxle 23B 39 25 Attach thrust race 10 and thrust bearing 9 to the forward sun gear Then assemble the reverse sun gear 26 Install the sun gear assembly assembled in step 25 in the planetary carrier TSB Revision a RU I la sv 23 40 4 2 Transaxle ZU 7 E 1 2 4 5 6 7 8 9 10 11 12 13 Select Select 1750186 IDENTIFICATION OF THRUST BEARINGS THRUST RACES AND THRUST WASHERS OD ID Thickness Part No Identification 0 D LD Thickness Part No Identification marking marking 70 557 14 1 1 48 1 34 4 MD707271 4 2 756 2 193 055 1 906 1 354 70 55 7 1 8 2 40 21 24 MD722552 5 2 756 2 193 071 1575 827 094 F4A21 F4A22 70 55 7 2 2 3 40 21 1 8 MD720751 5 2 756 2 193 087 1 575 827 071 4 23 70 55 7 2 6 4 426 28 MD720753 6 2 756 2 193 102 1 677 1 102 70 557 1 8 MD707290 F4A21 2 54 38 7 1 6 MD704936 7 2 756 2 193 071 0729336 F4A22 F4A23 2 126 1524 063 48 9 37 1 0 997854 incl 1 52 36 4 MD720010 8 1 925 1 457 039 2 047 1 433 489 37 1 2 MD997847 incl 1
49. 4 Nm 18 ft Ibs TSB Revision 2 Transaxle 67 Install the O rings in the O ring grooves at three locations on the valve 170002 68 Install new seal rings in the groove of the accumulator piston and coat the rings with automatic transmission fluid 69 Install the accumulator piston in the transmission case and install the two springs e m Accumulator L X is piston AW 70 Install the valve body in the transaxle case while fitting the detent plate pin in the gap between the lands of the manual valve 71 Replace the O ring of the solenoid valve connector with a Gasket new one MODEL 1992 only surface of transaxle case fuc 72 Insert the solenoid valve connector into the case Be sure that the notched part of the connector faces as shown in the illustration MODEL 1992 only 73 Tighten the valve body mounting bolts 10 pieces to the specified torque A bolt 18 mm 709 in long B bolt 25 mm 984 in long C bolt 40 mm 1 575 in long 1700024 TSB Revision 2 Transaxle 23A 41 74 Install the oil filter and tighten the four oil filter mounting bolts to the specified torque Specified torque 11 Nm 8 ft Ibs 75 Install the magnet to one of the recesses provided inside the oil pan Be sure to remove metal particles from the magnets and clean the inside of the oil pan beforeha
50. 41 28 MD728763 9 1925 1 457 047 1 614 1 102 48 9 37 14 MD997848 nc 0 2 39 28 1 2 MD728764 10 1 925 1 457 055 1 535 1 102 047 48 9 37 1 6 MD997849 Incl 2 38 222 MD727787 11 1 925 1 457 063 1 496 0 874 FAA21 F4A22 d 48 9 37 1 8 MD997850 incl 3 42 4 22 2 MD722797 11 1 925 1 457 071 1 669 0 874 F4A23 48 9 37 2 0 MD997851 incl 3 3 52 36 4 _ MD720010 12 1 925 1 457 079 2 047 1 433 F4A21 F4A22 48 9 37 2 2 0997852 incl 4 54 36 4 _ MD 19846 12 1 925 1 457 087 2 126 F4A23 MD997853 incl 4 58 44 MD724206 13 2 283 1 732 TSB Revision F4A2 Transaxle 23B 41 27 Put the brake disc and brake plate in position Brake plate Brake reaction plate Brake disc Pressure plate Return spring 175020 28 Install the pressure plate which was selected in Step 1 29 Install the return spring 30 Apply petrolatum jelly to the wave spring and attach the wave spring to the center support 1750193 TSB Revision 23B 42 F4A2 Transaxle 31 Install the two new O rings on the hydraulic pressure holes of the center support Apply automatic transmission fluid to the O rings O ring 1750194 32 Attach the special tool to the center support Install the center support slowly in the transaxle case grasping the special tool Caution MD998905 01 1 During installation take care not to let
51. 5 000 N 1 100 Ibs 90 TAPER ROLLER BEARING INSTALLATION 1 Using the special tool press fit the bearings into both sides of the differential case BEARING INSTALLATION TFMOOOE E BOLTS INSTALLATION 1 Apply ATF to the differential drive gear bolts install and tighten with specified torque in the order shown in the figure Differential drive gear bolt 135 Nm 98 ft Ibs TSB Revision F4A3 W4A3 Kickdown Servo 23C 105 KICKDOWN SERVO DISASSEMBLY AND REASSEMBLY m1 S Disassembly steps 1 O rin 7 2 Kickdown servo sleeve 3 D ring 4 Seal ring 5 Lock nut 6 Kickdown servo rod 7 Kickdown servo piston 1750299 TSB Revision 23 106 F4A3 W4A3 Low Reverse Brake LOW REVERSE BRAKE Disassembly steps 1 Low reverse brake piston 2 D ring 3 D ring 4 Center support TFA0386 TSB Revision F4A3 W4A3 Speedometer Gear 23C 107 SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Dn Disassembly steps 1 O ring MA 2 Spring pin riven gear Oil seal 5 Sleeve 201078 REASSEMBLY SERVICE POINT Sleeve SPRING PIN INSTALLATION O ring 011 seal Driven gear 1 Drive a new spring pin into the sleeve Make sure that the slit in the spring pin does not face the gear TSB Revision 23 108 W4A3 Valve Body VALVE BODY Viewed from A DISASSEMBLY AND REASSEMBLY Disassemblysteps 1 Manual valve E4 2 Press
52. 6 MD727805 6 7 264 67 MD731 004 6 8 268 68 MD731 005 6 9 272 69 MD734766 7 0 276 70 MD734767 ring 1 6 063 MD955630 For adjustment of front clutch and 1 7 067 MD730930 ear clutch clearance 1 8 071 MD955631 1 9 075 MD730931 2 0 079 MD955632 2 1 083 MD730932 2 2 087 MD955633 2 3 091 MD730933 2 4 094 MD955634 2 5 098 MD730934 2 6 102 MD955635 2 7 106 MD730935 2 8 110 MD955636 2 9 114 MD730936 3 0 118 MD955637 TSB Revision F4A2 Specifications 23B 11 Part name Thickness Identification Part No mm in symbol Snap ring 1 05 041 White MD71 5800 For adjustment of end clutch clearance 1 30 051 Yellow MD715801 1 55 061 None MD715802 1 80 071 Green MD71 5803 2 05 081 Pink MD720849 Snap ring 1 82 072 None MD722538 For adjustment of output flange 1 88 074 Blue MD721014 bearing end play 1 94 076 Brown MD721015 2 00 079 None MD721016 2 06 081 Blue MD721017 2 12 083 Brown MD722539 Spacer 1 20 047 20 MD7231 60 For adjustment of transfer shaft preload 1 23 048 23 MD723161 1 26 050 26 MD723162 1 29 051 29 MD7231 63 1 32 052 32 MD7231 64 1 35 053 35 MD723165 1 38 054 38 MD7231 66 1 41 056 41 MD723167 1 44 057 44 MD723168 1 47 058 47 MD727169 1 50 059 50 MD723170 1 53 060 53 MD723171 1 56 061 56 MD723172 1 59 063 59 MD7231 73 1 62 064 62 MD7231 74 1 65 065 65 MD
53. 601 MD723602 MD723603 MD723604 MD723605 MD723606 MD723607 MD723608 MD723609 MD7261 70 MD7261 71 TSB Revision 23 16 F4A3 W4A3 Specifications Part name Thickness Identification Part No mm in symbol Spacer W4A32 W4A33 1 28 0504 B28 MD726167 aa ari isimpnt of drive bevel gear 1 31 0516 B31 MD7261 68 1 34 0528 B34 MD7261 69 1 37 0539 B37 MD724326 1 40 0551 B40 MD724327 1 43 0563 B43 MD724328 1 46 0575 B46 MD724329 1 49 0587 B49 MD724330 1 52 0598 B52 MD724331 1 55 0610 B55 MD724332 1 58 0622 B58 MD724333 1 61 0634 B61 MD724334 1 64 0646 B64 MD724335 1 67 0657 B67 MD724336 1 70 0669 B70 MD724337 1 73 0681 B73 MD724338 1 76 0693 B76 MD724339 1 79 0705 B79 MD724340 1 82 0717 B82 MD724341 1 85 0728 B85 MD724342 3pacer W4A32 W4A33 1 19 0469 19 MD726172 Fa astigigent of driven bevel gear 1 22 0480 22 MD722081 1 25 0492 25 MD722082 1 28 0504 28 MD722083 1 31 0616 31 MD722084 1 34 0528 34 MD722085 1 37 0539 37 MD722086 1 40 0551 40 MD722087 1 43 0563 43 MD722088 1 46 0575 46 MD722089 1 49 0587 49 MD722090 1 52 0598 52 MD722091 1 55 0610 55 MD722092 1 58 0622 58 MD722093 1 61 0634 61 MD722094 1 64 0646 64 MD722095 1 67 0657 67 MD722096 1 70 0669 70 MD722097 1 73 0681 73 MD722098 1 76 0693 76 MD722099 1 79 0705 79 MD722100 1 82 0717 82 MD722101 1 85 0728 85 MD722102 1 88 0740 88 MD722 1
54. 7 2 2 3 54 38 7 1 6 MD704936 6 2 7559 2 1929 0866 2 1260 1 5236 0630 70 55 7 2 6 4 52 36 4 MD720010 7 2 7559 2 1929 1024 2 0472 1 4331 70 55 7 1 8 MD729336 W4A32 2 41 28 1 2 MD728763 W4A32 2 7559 2 1929 0709 MD731212 W4A33 1 6142 1 1024 0472 ge 48 9 37 1 0 MD997854 incl 1 45 28 MD735062 W4A33 1 9252 1 4567 0394 1 7717 1 1024 48 9 37 I 1 2 MD997847 incl 1 39 28 MD728764 W4A32 1 9252 1 4567 0472 1 5354 1 1024 1024 ES 48 9 37 1 4 MD997848 incl 2 46 31 0 8 MD735063 W4A33 1 9252 1 4567 0551 1 8110 1 2205 0315 Ts 48 9 37 1 6 MD997849 incl 2 52 36 4 MD720010 10 1 9252 1 4567 0630 2 0472 1 4331 3 48 9 37 1 8 MD997850 incl 3 58 44 MD724206 11 1 9252 1 4567 0709 2 2835 1 7323 48 9 37 2 0 MD997851 incl 3 1 9252 1 4567 0787 48 9 37 2 2 MD997852 incl 4 1 9252 1 4567 0866 48 9 37 24 MD997853 incl 4 1 9252 1 4567 0945 TSB Revision FAA3 W4A3 Transaxle 4WD 23C 71 gt gt 31 Assemble the pressure plate used in disassembly and install the return spring Caution Position the return spring correctly when installing M 4 DX i a NN TFAO0589 32 Apply a coating of petrolatum jelly to the wave spring and attach it to the center support 1750193 33 Mount the special tool on the center support
55. 723175 1 68 066 68 MD723176 1 71 067 71 MD723177 1 74 069 74 MD7231 78 1 77 070 77 MD723179 1 80 071 80 MD723180 pacer F4A21 1 31 052 E MD706574 or adjustment of differential case 1 40 055 None MD706573 nd play 1 49 059 C MD706572 1 58 062 B MD706751 1 67 066 A MD706570 1 76 069 F MD706575 1 85 073 H MD700272 1 94 076 cc MD71 5956 2 03 080 FF MD725959 2 12 083 MD71 5962 TSB Revision 23B 12 Part name F4A2 Specifications Identification Part No symbol Thickness mm in Spacer FAA22 1 85 073 MD700272 For adjustment of differential case 1 94 076 MD71 5956 eng play 2 03 080 MD715959 2 12 083 MD715962 2 21 087 MD71 5965 2 30 091 MD71 5968 2 39 094 MD71 5971 2 48 098 MD722736 2 57 101 MD731402 Spacer F4A23 1 10 043 J MD71 0454 For adjustment of differential case 1 136044 D MD700270 end play 1 16 046 K MD710455 1 19 047 L MD71 0456 1 22 048 G MD700271 1 25 049 M MD710457 1 28 050 N MD710458 1 31 052 E MD706574 1 34 053 0 MD71 0459 1 37 054 P MD71 0460 1 40 055 None MD706573 1 43 056 Q MD71 0461 1 46 057 R MD71 0462 1 49 059 C MD706572 1 52 060 S MD710463 1 55 061 T MD71 0464 1 58 062 B MD706571 1 61 063 U MD71 0465 1 64 065 V MD71 0466 1 67 066 A MD706570 1 70 067 W MD710467 1 73 068 X MD71 0468 1 76 069 F MD706575 1 79 070 Y MD71 0469 1 82
56. 890 21 354 839 27 4 27 5 1 083 961 7 11 24 4 961 5 9 0 9 5 7 6 8 6 8 12 276 6 6 15 5 6 6 15 5 6 13 9 23B 9 mm in Wire diameter 1 3 0 45 0 7 0 8 0 7 0 6 0 6 1 0 039 N R control valve spring 8 0 7 028 Shift control valve spring 26 8 5 7 22 0 5 1 055 224 020 Relief spring 17 3 7 0 10 1 0 681 276 039 Torque converter clutch control valve 15 7 6 2 10 5 0 7 spring F4A21 F4A22 618 244 028 Torque converter clutch control valve 14 2 6 2 9 5 0 7 spring FAA23 559 244 028 TSB Revision 23 10 F4A2 Specifications ADJUSTMENT PRESSURE PLATE SNAP RINGS AND SPACERS Part name Thickness Identification Part No mm in symbol Pressure plate F4A21 5 6 220 56 MD731 720 of low reverse 5 7 224 57 MD731721 5 8 228 58 MD727801 5 9 232 59 MD731 000 6 0 236 60 MD727802 6 1 240 61 MD731 001 6 2 244 62 MD727803 6 3 248 63 MD731002 6 4 252 64 MD727804 6 5 256 65 MD731 003 6 6 260 66 MD727805 6 7 264 67 MD731 004 6 8 268 68 MD731 005 Pressure plate FAA22 FAA23 5 6 220 56 MD731720 rereasiustngyt of low reverse 5 7 224 57 MD731721 5 8 228 58 MD727801 5 9 232 59 MD731 000 6 0 236 60 MD727802 6 1 240 61 MD731001 6 2 244 62 MD727803 6 3 248 63 MD731 002 6 4 252 64 MD727804 6 5 256 65 MD731 003 6 6 260 6
57. 9 in and the right and left gear pairs should have equal backlash If the backlash is not within the specified range disassemble and reassemble them using spacers selected for correct backlash Backlash 0 025 0 150 mm 0010 0059 in B4 LOCK PIN INSTALLATION F4A21 1 Align the lock pin hole in the pinion shaft with that in the NONIS case and press fit the lock pin until its protrusion is 3 mm EIERE 0 12 in or less Caution 1 Do not reuse the lock pin 2 Do not use a lock pin which requires only 2000 N 440 Ibs or less force for installation Lock pin Protrusion lt Installation chamfered TSB Revision F4A2 Differential 23B 73 Differential case 4 LOCK PIN INSTALLATION F4A22 1 Align the lock pin hole in the pinion shaft with that in the case and press fit the lock pin until its sink from the differential case end is 1 mm 04 in or more Caution Installation 1 Do not reuse the lock pin direction 2 Do not use a lock pin which requires only 2000 N 440 Ibs or less force for installation chamfered DA LOCK PIN INSTALLATION F4A23 1 Align the lock pin hole in pinion shaft with that in the case and install the lock pin Caution The lock pin should be lower than the differential case flange surface TFA051 ALA BEARING INSTALLATION Taper roller bearing 04 BOLT TIGHTENING 1 Apply automatic transmission fluid to the bolts and tighten the bo
58. CIFICATIONS 7 DRIVE GEAR SET rentes 54 Adjusting Pressure Plate DIFFERENTIAL eitis 56 Snap Rings and Spacers 9 DRIVE SHAFT OIL SEAL 61 Gear Ratio Table iced ino oA Et 7 FRONT CLUTCH 46 Service Specifications 7 GENERAL INFORMATION 2 Transaxle Model Table 7 KICKDOWN SERVO 58 Torque Specifications 11 LOW REVERSE BRAKE 59 Valve Body Spring Identification 8 OIL PUMP oce rna 44 SPEEDOMETER GEAR 60 PLANETARY GEAR nnns 51 TRANSAXLE 3 niii irai 15 REAR CLUTCH 48 TRANSFER SHAFT GOVERNOR 62 SPECIAL TOOLS eege 12 VALVE BODY G 63 23 2 F3A2 General Information GENERAL INFORMATION Precautions to be taken when disassembling and reassembling the transmission e Because the automatic transaxle is composed of component parts of an especially high degree of precision these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them A rubber mat should be placed on the workbench
59. ERVICE POINT AD BEARING REMOVAL 177004 04180 0507 TSB Revision F4A2 Transfer Driven Gear 23B 79 TRANSFER DRIVEN GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps GAD pA 1 Bearing 2 Transfer driven gear 0657 DISASSEMBLY SERVICE POINT BEARING REMOVAL REASSEMBLY SERVICE POINT bA BEARING INSTALLATION 4 TSB Revision 23 80 F4A2 Valve Body VALVE BODY DISASSEMBLY AND REASSEMBLY Viewed from A 20 9 wl 5 Nm 4 165 Disassembly steps 1 Manual valve EA 2 Pressure control solenoid valve amp 3 Shift control solenoid valve bE 4 Shift control solenoid valve E4 5 Torque converter clutch solenoid 6 Pipe 7 Valve stopper 8 N D control sleeve 9 N D control valve D 10 Lower valve body sub assembly 11 Lower separating plate 12 Nut 13 Jet 4 14 Relief spring 64 15 Steel ball 964 16 Oil filter B4 17 Upper valve body sub assembly 5 Nm 4 18 Steel ball ll 4 ft Ibs A4 19 Teflon ball sS 420 N D plate 21 Block 22 Upper separating plate 23 Dowel bushing 24 Intermediate plate 25 TSB Revision F4A2 Valve Bod 23B 81 9 25 5Nm 4 ft lbs 25 Front end cover 36 26 Pressure control spring 37 27 Pressure control valve 38 28 Torque converter control spring 39 29 Torque conv
60. ING INSTALLATION 7 zT ef TSB Revision NOTES
61. INSTALLATION 1 Drive a new spring pin into the sleeve Make sure that the slit in the spring pin does not face the gear O ring Driven gear S Spring pin TSB Revision F3A2 Drive Shaft Oil Seal 23A 61 DRIVE SHAFT OIL SEAL DISASSEMBLY AND REASSEMBLY B D 13 Disassembly steps 1 Converter housing 2 Transmission case 4 3 Oil seal 1750298 REASSEMBLY SERVICE POINT OIL SEAL INSTALLATION MD998325 01 17015 TSB Revision 23 62 F3A2 Transfer Shaft Governor TRANSFER SHAFT GOVERNOR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Seal ring 2 Set screw Locknut Governor body Filter Snap ring Governor weight Spring retainer Governor spring 10 Governor valve GAD 9A 11 Taper roller bearing 12 Transfer shaft TFAO505 84 Co I 0 On gt CO DISASSEMBLY SERVICE POINT TAPER ROLLER BEARING REMOVAL REASSEMBLY SERVICE POINTS TAPER ROLLER BEARING INSTALLATION B4 FILTER INSTALLATION 1 If dust has accumulated inside the filter replace it with a new one TSB Revision F3A2 Valve Bod 23A 63 VALVE BODY DISASSEMBLY AND REASSEMBLY Viewed from A 4 ft Ibs Disassembly steps Manual valve Throttle cam Distance piece Return spring Bracket Kickdown valve Kickdown sprin Regulator plug A Regulator plug B 0G4 10 Lower valve body sub assembly 11 Lowe
62. Kickdown servo switch ring Kickdown servo piston Opring Anchor rod Detent assembly Manual control shaft Parking roller support Oil pan Gasket Oil temperature sensor Oil screen Valve body assembly Manual control lever Park neutral position switch PNP switch End clutch shaft Bearing retainer Thrust bearing 11 End clutch hub Thrust washer End clutch assembly O ring End clutch cover Pulse generator Lock bolt Idler shaft Idler gear Spacer Gasket 0409 23 24 F4A3 W4A3 Transaxle FWD 19 Nm 14 ft lbs 31 24 Nm 18 ft Ibs 33 34 35 36 37 38 Nm 9 Nm 28 ft Ibs 7 ft lbs 4 11 Nm 8 ft lbs 39 e 24 Nm 7 18 ft lbs 4 51 ft Ibs 63 Idler gear cover 64 Differential bearing retainer 65 Outer race 66 Differential front bearing cap 67 Differential assembly 68 Gasket 69 Differential cover NOTE 70 Outer bearing retainer On 1993 and subsequent models marked parts 71 Transfer shaft have the connecter directly attached not via harness 72 Transaxl ansaxle case TSB Revision F4A3 W4A3 Transaxle FWD 23C 25 DISASSEMBLY 1 Clean away any sand mud etc adhered around the transaxle 2 Place the transaxle assembly on the workbench with the oil pan down 3 Remove the torque converter 4 Use
63. MD997849 incl 2 3 48 9 1 925 37 1 46 1 1 071 MD997850 incl 3 58 2 28 44 1 73 MD724206 48 9 1 925 37 1 46 1 0 079 MD997851 incl 3 48 9 1 925 31 1 46 1 1 087 MD997852 incl 4 48 9 1 925 31 1 46 1 4 094 MD997853 incl 4 TSB Revision n F4A3 W4A3 Transaxle FWD 23C 39 19 Assemble the pressure plate used in disassembly and install the return spring Caution Position the return spring correctly when installing 20 Apply a coating of petrolatum jelly to the wave spring and attach it to the center support 21 Mount the special tool on the center support install 2 new O rings and push into the transaxle case Caution 1 Coat the O rings with automatic transmission fluid and align the oil holes 2 Do not move the wave spring out of position when installing 22 Install the snap ring 23 Use a thickness gauge and measure the end play of the f low reverse brake Adjust to the standard value by selecting i the proper pressure plate E Standard value 1 0 1 2 mm 039 047 Kee TSB Revision EIC d Anchor rod g kk 7 U AE KOL Y NS Op ei 68 TFAO17 If MD998830 lt j 0 Ju ae SECH SR 558 F4A3 W4A3 Transaxle FWD 24 Install the air exhaust plug and then install the plug Air exhaust pl
64. MODEL 1992 F4A3 W4A3 Specifications 23C 9 Transaxle Gear ratio Speedometer Final gear Vehicle model Engine model model type gear ratio ratio FAA33 1 UP61 A 29 36 4G63 DOHC TIC MNP2 A 28 36 3 958 Z11A 6G72 DOHC MNN3 A 28 36 3 958 F16A 6G72 MNNA A 28 36 3 958 F16A 6G72 DOHC br A 28 36 3 958 F16A 6G72 DOHC W4A32 1 UNN A 28 36 4 422 N44W 4G64 WNA B 28 36 4 750 N21W 4G93 UQA2 B 30 36 4 422 E38A 4G63 DOHC WAA33 1 UP6 A 29 36 4 422 D27A 4G63 DOHC TIC TRANSAXLE MODEL TABLE MODEL 1993 Transaxle Gear ratio Speedometer Final gear Vehicle model Engine model model type gear ratio ratio s nr VK F4A33 1 UP61 A 4 376 D22A 4G63 DOHC T C MNP A 20062806 3 958 Z11A 6G72 DOHC MNP9 A 3 958 F16A 6G72 MNPC A 28362836 3 958 F16A 6G72 DOHC MNPE A 28 36 3 958 F16A 6G72 DOHC W4A32 1 UNO B 28 36 4 422 N24W N44W 4664 WNF 1 A 29 3628 36 4 750 N21W 4G93 WAA33 1 UP61 4 422 D27A 4G63 DOHC TIC NOTE 1 Model without torque converter clutch 2 Model with 4 wheel steering oil pump drive gear GEAR RATIO TABLE 1st 2nd 3rd 4th Reverse TSB Revision 23 10 SERVICE SPECIFICATIONS Transfer driven gear preload Center differential case preload Low reverse brake end play Input shaft end play Differential case preload F4A33 Front differential case end play W4A32 W4A33 Differential gear and pinion backlash Oil pump side clearance O
65. Push the one way clutch into the outer race Make sure that arrow on the outside circumference of cage is directed upward as shown in the illustration when the one way clutch is pushed in BOLT INSTALLATION NOTE Do not reuse the pre coated bolt F4A22 and F4A23 TSB Revision F4A2 Planetary Gear 23B 69 ANNULUS GEAR AND TRANSFER DRIVE GEAR SET DISASSEMBLY AND REASSEMBLY Disassemblv steps 0 1 Snap ring QA 96 2 Bearing 9B 3 Transfer drive gear 462 4 4 Bearing 5 Snanrina 6 Output flange 7 Annulus gear 170178 DISASSEMBLY SERVICE POINTS BEARING REMOVAL TRANSFER DRIVE GEAR REMOVAL MD998348 01 CE or BEARING REMOVAL E g 8 ge Lett Z lt a 1 Ural TSB Revision 23 70 F4A2 Planetary Gear REASSEMBLY SERVICE POINTS 4 BEARING INSTALLATION Groove 984 TRANSFER DRIVE GEAR INSTALLATION 1 Install the transfer drive gear in proper direction The direction can be identified by the groove provided in one of the pinion side surfaces Install in this direction 47 7 Caution p Replace the output flange and transfer drive gear as a set TFAO503 BEARING INSTALLATION TFAO384 00 SNAP RING SELECTION 1 Select a snap ring which should be the thickest one that can be installed in groove Standard value 0 0 06 mm 0 0024 in 170120 TSB Revision
66. SEMBLY SERVICE POINT AD SNAP RING REMOVAL 1 Compress the return spring with the special tool 2 Remove the snap ring MD998337 01 MD998907 01 1750264 REASSEMBLY SERVICE POINTS SNAP RING INSTALLATION 1 Compress the return spring with the special tool 2 Install the snap ring MD998337 01 MD998907 01 CLUTCH REACTION PLATE INSTALLATION 1 Install the clutch reaction plate with their missing tooth portions amp in the illustration in alignment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plate and disc TFAO498 2 Install the innermost the reaction plate with their shear droops directed as shown in the illustration Identification of reaction plate mm in FAA21 FAA22 except F4A22 2 MQD6 F4A22 2 MOD6 F4A23 Identifi Thick Plate No Thick Identifi Thick ness cation ness cation ness mark mark I ERO EN BE None 3 7 146 3 1 EIN RN 3 7 146 None 3 7 146 None Plate No 3 Plate No 1 Plate No 2 F4A22 F4A23 Plate Plate Plate No 2 Shear droop SS TSB Revision 23B 60 F4A2 Front Clutch ALA SNAP RING SELECTION 1 Check clearance between the snap and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 I
67. STOPPER PLATE INSTALLATION TSB Revision F3A2 Valve Body STOPPER PLATE INSTALLATION 9C SPRING STEEL BALL LOCATION 04 STEEL BALLS LOCATION Steel balls 1700065 Eq UPPER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Install the special tools on the upper valve body 2 Fasten the upper valve body intermediate plate and upper separating plate together with the eight bolts Remove the special tools 1700062 TSB Revision F3A2 Valve Body 23A 67 E STEEL BALL SPRING LOCATION Steel balls Ge LOWER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Install the special tools on the intermediate plate 2 Secure the lower valve body with the 13 bolts Remove the special tools TSB Revision NOTES AUTOMATIC TRANSAXLE F4A21 22 F4A23 CONTENTS ANNULUS GEAR AND TRANSFER SPECIFICATIONS 7 DRIVE GEAR SET 69 ADJUSTING PRESSURE PLATE DIFFERENTIAL Qu iu sas 71 SNAP RINGS AND SPACERS 10 DRIVE SHAFT OIL SEAL 77 GEAR RATIO TABLE 7 END CLUTCH stau ate cien 64 SERVICE SPECIFICATIONS
68. Service Manual AUTOMATIC TRANSMISSION 1992 1993 FOREWORD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations In formation in this manual is divided into groups by transaxle or transmission models Each group is further divided to address individual components within the group These groups contain general information specifica tion removal and installation disassembly and reassembly procedures for the components The first page of each group contains an alphabetical index to assist in finding the location of the component The information descriptions and spe cifications were in effect at the time this manual was released This BAcKup DSM manual ts to be used ONLY as a please DO NOT REDISTRIBUTE WHOLE GE mme This BACKUP was sold to you under the fact that yoU do ndeed OWN GENUINE DSM MANUAL It CANNOT BE considered a REPLACEMENT unless your or g nal m nUal was lost or destroyed please See README N or README HTML for addltlonal Informat on Thank YOU Gimmiemymanual hotmail com WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH National Institute for AUTOMOTIVE SERVICE EXCELLENCE MITSUBISHI MOTOR SALES OF AMERICA Inc Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon
69. Using the special tool push in the kickdown servo and remove the snap ring y MD998341 01 TSB Revision F4A3 W4A3 Transaxle 4WD 23 61 41 Remove the kickdown servo piston 42 Remove the anchor rod Anchor rod DN J 43 Remove the plug then remove the air exhaust plug 44 Remove the snap ring M vO X 45 Using the special tool remove the center support MD998905 01 Sx TSB Revision 23 62 F4A3 W4A3 Transaxle 4WD 46 Remove reverse sun gear and forward sun gear together 47 Remove planet carrier assembly 48 Remove the wave spring return spring reaction plate brake discs and brake plates 49 Remove the screws and the rear bearing retainer 50 Remove the snap ring and then remove the output flange assembly TFA0148 TSB Revision F4A3 W4A3 Transaxle 4WD 23C 63 51 Remove the output bearing retainer mounting bolts and then remove the output bearing retainer and outer race TFAO149 S V4 52 Insert a rod 8 31 in in diameter and 200 mm 7 87 in LARLY g B in length from the hole shown in the figure and punch out i 2 the rear output shaft i id d 22 Y ee c N VRS 1822 53 Using the special tool remove the center differential 0152 54 Put bolt M6 into the center bearing retainer and holding that bolt remove t
70. W4A3 Transaxle 4WD 23C 67 14 Install the center bearing retainer so the projection of the stopper bolt fits in the groove of the center bearing retainer 15 Install the special tool in the center differential and install the center differential in the transaxle case 0152 16 Place solder with length approximately 10 mm 39 and diameter of 1 6 mm 06 in on the output bearing retainer at the position shown in the diagram and install the outer race 17 Install the output bearing retainer and tighten the bolts to the specified torque Output bearing retainer mounting bolts 24 Nm 18 ft Ibs 18 Loosen the bolts and remove the output bearing retainer 19 Remove the outer race from the output bearing retainer and remove the solder If the solder is not crushed repeat steps 4 6 using the solder with diameter of 3 mm 12 in Measure the thickness of the crushed solder with a micrometer and select a spacer with a thickness that will provide the standard value for the preload Standard value 0 075 0 135 mm 003 0053 20 Install the spacer selected in the previous item and the outer race on the output bearing retainer TSB Revision 23 68 F4A3 W4A3 Transaxle 4WD 21 Install a new O ring around the outer circumference of the outer bearing retainer 22 Coat the O ring with automatic transmission fluid and tighten the output bearing retainer mounting bolts to
71. a new oil pan gasket and then the oil pan by tightening the 12 bolts to the specified torque Tightening torque 11 Nm 8 ft Ibs 0998916 01 84 Adjust the kickdown servo by the following procedure RE MU a Fit the claw of the special tool in the notch of the piston 777 MD998918 7 to prevent the piston from turning and use adapter to secure it as illustrated at left Caution 1 Do not push in the piston with the special tool 2 When the adapter is installed to the transaxle case do not apply excessive torque but tighten with a hand TSB Revision MD998916 2 01 outer 2 be S MD998916 3 01 inner 175047 TSB Revision F4A2 Transaxle 23 51 b Loosen the lock nut until it is about to reach the V groove in the adjusting rod Tighten the special tool inner until it touches the lock nut c Fit the special tool outer to the lock nut Turn the outer cylinder counterclockwise and the inner cylinder clock wise to lock the lock nut and the special tool inner d Fit torque wrench to the special tool inner to tighten it e to a torque of 10 Nm 7 2 ft lbs and loosen Repeat this sequence two times before tightening the special tool inner to 5 Nm 3 6 ft lbs torque Then back off the special tool inner 2 to 274 turns FAA21 and F4A22 or 212 to 2 turns F4A23 Fit the special tool outer
72. al pinion backlash Pulse generator resistance Pressure control solenoid valve resistance Shift control solenoid valve resistance Torque converter clutch solenoid resistance MODEL 1992 and MODEL 1993 E33A D21A D22A MODEL 1993 C35A N11W N14W N34W F4A2 Specifications F4A21 22 F4A23 F4A22 F4A23 F4A21 4 21 22 F4A23 F4A22 FAA23 F4A21 F4A22 FAA23 F4A21 mm in 0 8 6 1 5 1 1 0 3 21 0 012 039 0 0 025 0 001 1 0 1 2 039 047 0 7 0 9 028 035 0 0 15 0 006 0 4 0 65 016 026 0 6 0 85 024 031 0 03 0 05 001 002 0 7 0 9 028 035 0 4 0 6 016 023 0 4 0 6 016 023 0 3 0 5 012 020 0 0 06 0 002 0 025 0 150 001 006 245 ohm at 20 C 68 F Approx 3 ohm at 20 C 68 F Approx 22 ohm at 20 C 68 F Approx 3 ohm at 20 C 68 F Approx 13 ohm at 20 C 68 F TSB Revision F4A2 Specifications VALVE BODY SPRING IDENTIFICATION Regulator valve spring Torque converter control valve spring Pressure control valve spring Rear clutch exhaust valve spring 2 3 shift valve spring End clutch valve spring F4A2 1 FAA22 End clutch valve spring F4A23 1 2 shift valve spring Reducing valve spring c1 w N A EN 26 6 1 047 Outside Number of diameter loops 1 11 591 Free height 2 047 22 6
73. alent Front bearing retainer bolts Center differential flange bolts 3M ATD Part No 8001 or equivalent Air breather TSB Revision 23 18 F4A3 W4A3 Specifications TORQUE SPECIFICATIONS TRANSAXLE Nm ft lbs Air exhaust plug 33 24 Differential cover bolt 11 8 Differential drive gear bolt 135 98 Differential front bearing cap bolt 70 51 Differential rear bearing retainer bolt 35 26 End clutch cover bolt 11 8 Idler gear cover bolt 11 8 Idler shaft lock bolt 38 28 Park neutral position switch PNP switch bolt 11 8 Kickdown servo lock nut 29 21 Manual control lever nut 19 14 Manual control shaft set screw 9 7 Oil drain bolt 33 24 Oil filter bolt 6 5 Oil lever gauge guide bolt 24 18 Oil pan bolt 11 8 Oil pressure check plug 5 4 Oil pump assembly mounting bolt 21 16 Oil pump bolt 11 8 Output bearing retainer bolt 24 18 Output flange bearing retainer bolt 20 15 Parking rod support bolt 24 18 Pulse generator bolt 11 8 Roll stopper bracket bolt 49 35 Shift control cable bracket bolt 24 18 Speedometer gear locking plate bolt 5 4 Transaxle mount bracket bolt 70 51 Valve body assembly mounting bolt 11 8 Valve body bolt 5 4 Center bearing retainer stopper bolt W4A32 W4A33 5 4 Center differential drive gear W4A32 W4A33 75 54 Front bearing retainer bolt W4A32 WAA33 49 35 TRANSFER W4A32 W4A33 Cover mounting bolt Driven bevel gear lock nut Extension housing mounting bolt Oil drain plug Oi
74. an gasket 9 Remove the oil filter TSB Revision 2 Transaxle IO Remove the oil temperature sensor bracket mounting bolts and remove the oil temperature sensor from its bracket Using a screwdriver push out the rubber plug working Oil temperature from inside the case and remove the oil temperature sensor from the case MODEL 1992 7 6 1750423 0733 11 Remove the clip from the solenoid valve connector F4A21 only 1750154 12 With their catches pressed down force the harness grommet and connector into the transaxle case 4 22 23 F4A21 ho 1 Push Catch Push catch 175042 13 Remove the valve body mounting bolts indicated by arrows and remove the valve body from the transaxle case TSB Revision F4A2 Transaxle 14 Remove the end clutch cover 15 Remove the end clutch assembly 16 Remove the thrust washer from the input shaft end 17 Remove the end clutch hub and the thrust bearing TSB Revision F4A2 Transaxle 23B 25 18 Pull out the end clutch shaft 19 Remove the 14 bolts indicated by arrows and remove the converter housing and gasket 20 Remove the six oil pump mounting bolts indicated by arrows 21 Screw the special tools MD998333 01 into the bolt holes marked 4 22 Grasping the special tools remove the oil pump Then remove the gasket 23 Rem
75. andard value select a snap ring to obtain the standard value Standard value W4A32 0 4 0 6 mm 016 024 in F4A33 W4A33 1 0 1 2 mm 039 047 1750275 EA INPUT SHAFT INSTALLATION 1 Install the input shaft with its oil groove aligned with the oil hole in the rear clutch retainer TSB Revision 23 94 F4A3 W4A3 End Clutch END CLUTCH DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Seal ring B4 2 Snap ring 3 Clutch reaction plate 4 Clutch disc 5 Clutch plate 4 6 Snap ring 7 Washer 8 Return spring QAO 9 End clutch piston 10 Oil seal 11 D ring 12 End clutch retainer 13 Oil seal TSB Revision 0607 0608 F4A3 W4A3 End Clutch 23C 95 DISASSEMBLY SERVICE POINT END CLUTCH PISTON REMOVAL 1 Remove the piston If it is hard to remove place the retainer on the workbench with piston side down and blow air through the oil passage in the back of retainer REASSEMBLY SERVICE POINTS AA SNAP RING INSTALLATION 1 Using the special tool fit the snap ring Caution Make sure that the snap ring is fitted in position in the groove B4 SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 165 force If clearance is out of standard value select a snap ring to obtain the standard value Sta
76. ant Mitsubishi genuine sealant Part No MD997740 or equivalent NOTE Squeeze out sealant from the tube uniformly and con tinuously in adequante amount 2210131 Eq SEALANT TO COVER GASKET APPLICATION Specified sealant 3M ATD Part No 8660 or equivalent TSB Revision 23 122 W4A3 Transfer 4WD 2210061 2210095 TSB Revision TOOTH CONTACT ADJUSTING PROCEDURES T Standard tooth contact pattern A Small end side B Drive side tooth face Side on which force acts when running forward Big end side D Coast side tooth face Side on which force acts when reversing Tooth contact pattern produced when drive bevel gear height is too large Cause The driven bevel is too close to the drive bevel gear Remedy Use thicker bevel gear mount adjusting spacer to separate the driven bevel gear more from the drive bevel gear Tooth contact pattern produced when driven bevel gear height is too small Cause The driven bevel gear is too separated from the drive bevel gear Remedy Use thinner driven bevel gear mount adjusting spacer to bring the driven bevel gear more closer to the drive bevel gear W4A3 Transfer 4WD 23 123 1 If correct tooth contact cannot be obtained even by change of the driven bevel gear mount adjusting spacer Jrive bevel gear increase or decrease the drive bevel gear preload em Drive bevel gear 9 p moont adjusting apacer Geteste ad
77. ar set and thrust bearing 12 Lett my di bearing 12 36 Remove the wave spring return spring reaction plate brake discs and brake plates 37 Remove the idler shaft lock plate Idler shaft lock plate 1700037 38 Loosen the transfer idler shaft with the special tool 39 Pull out the transfer idler gear shaft and remove the transfer idler gear the two bearing inner races and the spacer Transfer Spacer idle gear 1700039 TSB Revision A 24 F3A2 Transaxle 40 Remove the bearing retainer Bearing retainer 41 Remove the snap ring from the output flange bearing 42 Remove the output flange and thrust race 13 from the case 43 Remove the snap ring from the transfer shaft 44 Drive the transfer shaft out toward the torque converter housing to remove the shaft and the transfer driven gear TSB Revision F3A2 Transaxle 23 25 45 Remove the snap ring and then the tapered roller bearing Innerrace inner and outer races Outer race Snap ring ei N 72 75 Sprag rod support gt 46 Remove the sprag rod support 47 Remove the set screw and remove the manual control shaft assembly At this time remove also the steel ball and spring REASSEMBLY 1 Before reassembling the transaxle measure the end play in the low reverse brake and select a pressure plate to obtain the specified end pla
78. backlash is not within the specified range disassemble and reassemble them using spacers selected for correct backlash Backlash 0 025 0 150 mm 0010 0059 in DA LOCK PIN INSTALLATION 1 Align the lock pin hole in the pinion shaft with that in the case and press fit the lock pin until its protrusion is 3 mm 12 in or less Caution 1 Do not reuse the lock pin 2 Do not use a lock pin which requires only 2000 N 440 Ibs or less force for installation GA BEARING INSTALLATION D4 DRIVE GEAR TIGHTENING 1 Apply automatic transmission fluid to the bolts and tighten the bolts to the specified torque in the sequence shown in the illustration 23 58 2 Kickdown Servo KICKDOWN SERVO DISASSEMBLY AND REASSEMBLY 19 Nm 14 ft Ibs B Disassembly steps 8 1 Seal ring B 2 Seal ring 59 7 3 Cover 4 Kickdown servo rod 5 Pin 6 6 Plug 7 Spring 8 Kickdown piston valve 1700055 9 Kickdown servo piston 1700055 TSB Revision F3A2 Low Reverse Brake 23A 59 LOW REVERSE BRAKE DISASSEMBLY AND REASSEMBLY M2 Disassembly steps 1 Low reverse brake piston 2 D ring 3 D ring 4 Center support TFA0386 TSB Revision 23 60 F3A2 Speedometer Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 O ring pAg 2 SE 3 Driven gear 4 Oil seal 5 Sleeve 201078 Sd REASSEMBLY SERVICE POINT Sleeve SPRING PIN
79. bs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value F4A22 F4A23 0 7 0 9 mm 028 035 in F4A21 0 4 0 6 mm 016 024 in NOTE To install the return spring snap rings set the rings with their end gaps 180 apart TSB Revision F4A2 Rear Clutch 23B 61 REAR CLUTCH DISASSEMBLY AND REASSEMBLY No of Clutch Discs and Plates Disassembly steps 1 Seal ring 04 2 Input shaft 3 O ring 4 Snap ring 5 Thrust race 6 Seal ring CA 7 Snap ring 8 Clutch reaction plate 9 Clutch disc 984 10 Clutch plate 11 Clutch pressure plate GAD pAg 12 Wave spring 13 Return spring 14 Rear clutch piston 15 Rear clutch retainer 16 D ring 17 D ring TFAO 621 1750215 TSB Revision 23B 62 F4A2 Rear Clutch DISASSEMBLY SERVICE POINT WAVE SPRING REMOVAL 1 Compress the return spring with the special tool 2 Using a screwdriver remove the wave spring Z 1750274 REASSEMBLY SERVICE POINTS bA WAVE SPRING INSTALLATION 1 Compress clutch reaction plate with the special tool 2 Install the wave spring MD998337 01 MD998338 Z 1750274 CLUTCH PRESSURE PLATE CLUTCH PLATE CLUTCH REACTION PLATE INSTALLATION 1 Install the clutch pressure plate clutch plates and clutch reaction plate with their missing tooth portions in the illustration in ali
80. cases however the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool A flat gasket scraper may be lightly hammered in between the joined surfaces In this case however care must be taken to prevent damage to the joined surfaces Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces using a gasket scraper or wire brush Check to ensure that the surfaces to which the FIPG is to be applied is flat Make sure that there are no oils greases and foreign substances deposited on the application surfaces Do not forget to remove the old sealant remained in the bolt holes Form In Place Gasket Application When assembling parts with the FIPG you must observe some precautions but the procedure is very simple as in the case of a conventional precut gasket Applied FIPG bead should be of the specified size and without breaks Also be sure to encircle the bolt hole circumference with a completely continuous bead The FIPG can be wiped away unless it is hardened While the FIPG is still moist in less than 15 minutes mount the parts in position When the parts are mounted make sure that the gasket is applied to the required area only The FIPG application procedure may vary on different areas Observe the procedure described in the text when applying the FIPG TSB Revision AUTOMATIC TRANSAXLE F3A21 CONTENTS ANNULUS GEAR AND TRANSFER SPE
81. cial tool number that is available in your market TORQUE REFERENCES General tightening torque is as shown in the following table The specific part tightening torque is shown at the beginning of each group Bolt with spring washer Flange bolt Head mark 4 Head mark 7 Head mark 10 Head mark 4 Head mark 7 Size mm dia x pitch 5x0 8 6x1 0 8x 1 25 10 x 1 25 12 x 1 25 14x 1 5 TSB Revision 6 INTRODUCTION FORM IN PLACE GASKET The transaxle and transmission have several areas where the form in place gasket FIPG is in use To ensure that the gasket fully serves its purpose it is necessary to observe some precautions when applying the gasket Bead size continuity and location are of paramount importance Too thin a bead could cause leaks Too thick a bead on the other hand could be squeezed out of location causing blocking or narrowing of the fluid feed line To eliminate the possibility of leaks from a joint therefore it is absolutely necessary to apply the gasket evenly without a break while observing the correct bead size The FIPG used in the transaxle and transmission is a room temperature vulcanization RTV type and is supplied in a 120 gram tube Part No MD997740 Since the RTV hardens as it reacts with the moisture in the atmospheric air it is normally used in the metallic flange areas Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method In some
82. clutch assembly 22 Remove the thrust plate 23 Remove the end clutch hub 24 Remove the thrust bearing 11 NOTE It may be stuck to the end clutch hub 25 Pull out the end clutch shaft TSB Revision F4A3 W4A3 Transaxle FWD 23C 29 26 Remove the idler gear cover mounting bolts then remove the idler gear cover and gasket 012 27 Disengage the bolt stopper and remove the bolt 28 Using the special tool pull out the idler shaft and then remove the idler gear and bearing inner race MD998904 d e 29 Remove the spacer 30 Remove oil pump installation bolts TSB Revision 23 30 4 W4A3 Transaxle FWD 31 Use the special tool and remove the oil pump 32 Remove thrust washer 1 thrust race 3 33 Hold the input shaft and remove the front clutch assembly and rear clutch assembly together 34 Remove the thrust bearing 5 35 Remove the clutch hub NOTE The thrust race may be stuck to the clutch hub c 7 Revision F4A3 W4A3 Transaxle FWD 23C 31 36 Remove the thrust bearing 7 37 Remove the kickdown drum 38 Remove the kickdown band 39 Remove the kickdown servo cover snap ring Then remove the kickdown servo switch 40 Using the special tool push in the kickdown servo and remove the snap ring 2 TSB Revision 23 32 W4A3 Transaxle FWD 41 Remove the kickdown
83. clutch spring 51 End clutch valve 52 End cover 53 Plug Except models with torque converter clutch 54 Torque converter clutch control die Models with torque 55 Torque converter clutch control valve converter clutch 56 Torque converter clutch control spring 57 N R control valve 58 N R control spring 59 Adjusting screw 60 Reducing spring 61 Reducing valve 62 Lower valve body TFA0622 TSB Revision F4A3 W4A3 Valve Body N D MD998226 01 XS e 9 Ses E e AO H 1 175033 1750305 23C 111 Aq STOPPER PLATE N D PLATE TEFLON BALL STEEL BALL LOCATION 1 Install the stopper plates N D plate teflon ball and steel balls into the upper valve body as shown B UPPER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Install the special tool and secure the upper separating plate and intermediate plate with eight mounting bolts Then remove the special tool FILTER STEEL BALL RELIEF SPRING INSTALLATION 1 Install the oil filter two steel balls and spring to the intermediate plate D LOWER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Mount the special tool to the intermediate plate 2 Install the separating plate TSB Revision 23 112 F4A3 W4A3 Valve Body 3 Secure the lower valve body wit
84. dri Torque converter Planetary clutch Front Rear gear ing 23C 5 ansfer ve gear Center differential TFA0103 23 6 F4A3 W4A3 General Information SECTIONAL VIEW W4A33 without torque converter clutch Planetary Oil pump gear Kickdown brake Rear Low reverse clutch brake Front clutch a Torque converter Transfer idler gear drive gear d CD AMILA Be a les LCR ee D m 8 Viscous coupling Front output shaft TSB Revision Center differential TFA0102 F4A3 W4A3 General Information 23 7 HYDRAULIC CONTROL SYSTEM With torque converter clutch Kickdown servo Low reverse Front Rear brake clutch clutch K 4 eo control unit II SCH el N Torque converter 2 3 4 3 shift valve Torque convertor ek clutch control valve TCC control valve 8 9b9C c Rear clutch exhaust valve Torque converter clutch solenoid TCC solenoid To lubrication Front To lubrication lt Rear Torque g convertor control valve Reducing valve N D control valve 8l Shift controlE solenoid valve B Shift control
85. e sensor harness at the position shown in the diagram Especially be sure to route the pressure control solenoid valve PCSV harness which is separated from other harness as shown in the diagram and fasten the harness with a clamp Failure to fasten it may result in contact with the detent plate or parking rod 23 48 F4A3 W4A3 Transaxle FWD MODEL 1993 o TFA0824 68 Install the oil screen Oil filter mounting bolts 6 Nm 5 165 69 Install the magnets in the oil pan and install the oil pan Oil pan mounting bolts 11 Nm 8 70 Install park neutral position switch PNP switch and manual control lever Park neutral position switch mounting bolts 11 Nm 8 ft Ibs Manual control lever mounting bolt 19 Nm 14 ft Ibs 71 Install the speedometer gear assembly Speedometer gear locking plate mounting bolt 5 Nm 4 165 TFAO10 TSB Revision F4A3 W4A3 Transaxle FWD 23C 49 MODEL 1993 72 Install the pulse generator A and B Pulse generator mounting bolts 11 Nm 8 ft Ibs Caution Install the black tube on the output gear side and the transparent tube on the end clutch side 73 Install the oil filler tube and insert the level gauge Oil filter tube mounting bolt 24 Nm 18 ft Ibs 74 Install the brackets Transaxle mounting bracket bolts 70 Nm 51 ft Ibs 75 Adjust the kickdown servo Transparent 2 VETT lt La
86. e preload adjustment install the idler shaft lock plate The clearance between the idler shaft and the lock plate should be closed in the direction that will prevent idler shaft looseness and then tighten the lock plate bolt to specified torque Tightening torque 24 Nm 18 165 Lock plate 170143 bes Revision F3A2 Transaxle 23A 29 12 Install a new O ring in the groove of the transaxle case and then install the bearing retainer 13 Insert the transfer shaft in the case 14 Mount the special tool on the transmission case to support the transfer shaft 15 Use the special tool to install the bearing inner race on the transfer shaft 16 Install the tapered roller bearing outer race and then the snap ring 17 Use the special tool to install the transfer driven gear on the transfer shaft TSB Revision 23 30 F3A2 Transaxle 18 Install the snap ring on the end of the transfer shaft 19 Coat thrust race 13 with petrolatum jelly and attach it to the output flange TSB Revision F3A2 Transaxle 4 E LE n ee gj L 9 10 11 1 2 12 13 Select 3 4 5 6 7 8 Select 1700047 IDENTIFICATION OF THRUST BEARINGS THRUST RACES AND THRUST WASHERS mm in Identification marking Part No Thickness Identification marking 70 2 756 70 14 055
87. eaction plate brake plate and brake disc in the transaxle case Caution Blow off automatic transmission fluid from the plates and discs with low pressure compressed air b Install the appropriate pressure plate and mount the return spring Caution Make sure that the return spring is mounted in the correct direction Transaxle No of No of model brake discs brake plates F4A21 4 3 Brake Plate Brake reaction plate Brake disc F4A22 F4A23 6 5 Pressure plate Return spring 175020 c Apply petrolatum jelly to the wave spring and attach the wave spring on the center support d Install the two O rings removed during disassembly and coat them with automatic transmission fluid Wave spring e Attach the special tool to the center support and install the support in the transaxle case Caution 1 Install the center support taking care that the waved spring is not out of position 2 Install the two O rings in alignment with the oil holes provided in the transaxle case f Remove the special tool g Install the snap ring TSB Revision 23 34 MIT209038 Brake reaction plate F4A2 Transaxle h Mount the special tool and dial indicator on the rear side of the transaxle case Make sure that the dial indicator rod MD998913 01 is inserted into the transfer idler shaft hole contacting the brake reaction plate at a right angle i Using a pump feed air thr
88. ear clutch hub on the rear clutch 0272 45 nstall thrust race 6 on the end of the rear clutch hub TFA0273 TSB Revision 23 76 FAA3 W4A3 Transaxle 4WD 56 Fit the thrust washer on the return spring of the end clutch 57 Install the end clutch hub on the end clutch assembly 58 Adhere thrust bearing 1to the end of the clutch hub with petrolatum e C d 59 Install end clutch assembly 60 Attach a new O ring to the end clutch cover TSB Revision FAA3 W4A3 Transaxle 4WD 23C 75 0123 TSB Revision 51 52 53 54 55 Measure the end play of the input shaft If not the standard value replace thrust race 3 and thrust washer 1 and adjust to the standard value Standard value 0 3 1 0 mm 012 039 in Install the spacer idler gear and bearing and then insert the idler shaft Caution Assemble so that the identification groove on the idler gear faces the rear Tighten the idler shaft lock bolt together with the new lock plat to the specified torque Bend the three fingers of the lock plate to prevent turning Idler shaft lock bolt 38 Nm 28 ft Ibs Install the idler gear cover and a new gasket Idler gear cover mounting bolt 11 Nm 8 ft Ibs Insert the end clutch shaft from the end with the long spline 23 74 F4A3 W4A3 Transaxle AWD o Wa Thrust bearing 7 46 Install thrust bear
89. er mounting bolts 11 Nm 8 50 Install the differential assembly 51 Place solder with a length of approximately 10 mm 39 in and diameter of 1 6 mm 06 in on the differential rear bearing retainer at the position shown in the diagram and install the outer race 52 Install the differential rear bearing retainer and tighten the bolts to the specified torque 53 Loosen the bolts remove the differential rear bearing retainer and remove the solder If the solder is not crushed repeat steps 51 53 using the solder with the diameter of 3 mm Differential rear bearing retainer mounting bolts 35 Nm 26 ft Ibs 54 Measure the thickness of the crushed solder with a micrometer and adjust by selecting a spacer with a thickness that will provide the standard value for the end play and preload Standard value 0 075 0 135 mm 003 0053 in TSB Revision 23 46 F4A3 W4A3 Transaxle FWD 61 TSB Revision 55 56 57 58 59 60 Install a new O ring on the differential rear bearing retainer coat the O ring with automatic transmission fluid then install in the transaxle case and tighten the mounting bolts to the specified torque Differential rear bearing retainer mounting bolts 35 Nm 26 ft Ibs Install the front bearing cap and tighten the bolts to the specified torque Differential front bearing cap mounting bolts 70 Nm 51 ft Ibs I
90. eripheries of the support and housing with the special tool Band MD998335 01 to locate the support and housing 3 Tighten the five bolts to the specified torque 4 Make sure that the oil pump gear turns freely O RING INSTALLATION 1 Install a new O ring in the groove of the pump housing and apply petrolatum jelly to the O ring TSB Revision 23 86 F4A3 W4A3 Front Clutch FRONT CLUTCH DISASSEMBLY AND REASSEMBLY W4A32 0029 Disassembly steps 1 Snap ring 984 2 Clutch reaction plate presos 3 Clutch disc QAO pAg 4 Snap ring 5 Return spring 6 Front clutch piston 7 D ring 8 D ring 9 Front clutch retainer baonagonb V 2 1750213 1750213 TSB Revision MENDA Ac F4A3 W4A3 Front Clutch 23C 87 DISASSEMBLY AND REASSEMBLY W4A33 TFAO422 Disassembly steps 1 Snap ring 9B 2 Clutch reaction plate 3 Clutch disc B 4 Clutch plate 9845 Clutch pressure plate QA 6 Snap ring 7 Return spring 8 Front clutch piston 9 D ring 10 D ring 11 Front clutch retainer TFA0423 TSB Revision 23 88 MD998337 01 MD998907 01 1750264 MD998337 01 MD998907 01 0498 W4A32 Plate No 4 Shear drop Plate No 3 Plate No 2 sis En 1 Clutch me 0500 Plate No 2 Plate No 1 4 33 W4A33 Plate No 4 shear crop Plate No 3 Snap ring
91. erminals 1 and 2 or 3 and 4 Standard value 245 ohm at 20 C 68 F 2 A too small resistance indicates a short circuit and a too large resistance indicates an open circuit In either case replace the pulse generator assembly 1 2 Pulse generator A 3 4 Pulse generator B 1750010 SOLENOID VALVES WE 1 Measure the resistance between the terminals and valve 2 Torque converter body of each solenoid valve me e Standard value at 20 C 68 F O0 valve A Pressure control solenoid valve Approx 3 Q a 4 am ool solenoid Shift control solenoid valve Approx 22 TENE Torque converter clutch solenoid MODEL 1992 and MODEL 1993 E33A D21A D22A Approx 13 MODEL 1993 CB5A N11W N14W N34W Approx 3 2 A too small or large resistance indicates a short or open circuit In either case replace the solenoid valve assembly 3 Connect a 12V battery between the terminal and body of each solenoid valve and check the operating sound The valve is okay if an operating sound is heard No operating sound indicates that the valve is sticking or has accumulated foreign matter In this case replace the solenoid valve assembly 1750427 TSB Revision F4A2 Transaxle 23B 33 REASSEMBLY 1 Before reassembling the transaxle measure the end play in the low reverse brake and select a pressure plate to obtain the specified end play Use the following procedure a Install the brake r
92. erter control valve 40 30 Adjusting screw 41 31 Regulator spring 42 32 Regulator valve 4 43 33 Shift control spring 4 434 Stopper plate 45 35 Shift control plug 46 Viewed from B 4 ft lbs Rear clutch exhaust valve A Rear clutch exhaust valve B Rear clutch exhaust spring 2 3 4 3 shift spring 2 3 4 3 shift valve Rear end cover Shift control plug B Stopper plate 4 Shift control valve 1 2 shift spring 1 2 shift valve Upper valve body TFA0518 TSB Revision 23 82 F4A2 Valve Body T 52 c Z gt GG fe A 6 58 50 61 ls 57 59 48 Pin 49 Stopper 50 End clutch plug 51 End clutch spring 52 End clutch valve 53 End cover 54 Torque converter clutch control sleeve 55 Torque converter clutch control valve 56 Torque converter clutch control spring 57 N R control valve 58 N R control spring 59 Adjusting screw 60 Reducing spring 61 Reducing valve 62 Lower valve body 054 1 TFA0541 TSB Revision F4A2 Valve Body 23 83 REASSEMBLY SERVICE POINTS Teflon ball 0 ey P IN STOPPER PLATE N D PLATE TEFLON BALL STEEL BALL LOCATION UPPER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Mount the special tools and secure the upper separating plate and intermediate plate with the eight
93. f front clutch Spring compressor MD998913 MD998913 01 Measurement of low reverse brake end Dial gauge play extension TSB Revision 2 Transaxle 23A 15 TRANSAXLE Toraue converter Converter housing Gasket Oil pump O ring Gasket Thrust washer 1 Front clutch assemblv Thrust 3 10 Thrust bearing 4 11 Thrust washer 2 12 Rear clutch assembly 13 Spacer 14 Differential ci OO e 1 21 Nm 16 ft 1 lt As ctn st Ran 16 Clutch hub 17 Thrust race 7 1 8 Thrust bearing 8 19 Kickdown band 20 Kiekdown dram 21 Snap ring 22 Center support 23 Oring 24 Wave spring 25 Return spring 26 Pressure plate 27 Brake disc 28 Brake plate 29 Reaction plate 30 Reverse sun gear 31 Thrust bearing 9 32 Thrust race 10 33 Forward sun gear 34 Planetary carrier 35 Thrust bearing 12 0054 TSB Revision 16 2 Transaxle 36 Control cable 37 Spring washer 38 Control lever 39 Clamp 40 Park neutral position switch PNP switch 41 Bearing retainer 42 O ring 43 Snap ring 44 Lock plate 45 O ring 46 Idler gear shaft 47 Bearing inner race 48 Idler gear 49 Spacer 50 Clip 51 D ring 52 Transfer shaft cover Snap ring 54 Driven gear 55 Snap ring 56 Outer race 57 Bearing inner race 58 Gasket S 17 ft lbs 33 Nm 24 ft ibs
94. g bolts End clutch cover bolts Valve body assembly mounting bolts Oil filter bolts Oil pan bolts Kickdown servo lock nut Park neutral position switch bolts Manual control lever nut Pulse generator bolts Pump housing to reaction shaft support bolts Differential driy a bolts One way clutch outer race lock plate bolts Valve body bolts Pressure check plug Speedometer sleeve locking plate bolt Drain plug End cover bolts Solenoid valve mounting bolts Revision Nm 24 54 215 135 SPECIAL TOOLS F4A2 Special Tools Number and tool name MD998266 Guide pins MD998303 Valve spring compressor MD998316 Dial gauge support MD998319 Transfer shaft retainer MD998325 Differential oil seal installer MD998333 Oil pump remover MD998334 Oil seal installer MD998335 Oil pump band Replaced by OTC tool number MD998266 01 MIT209038 MD998319 01 MD998325 01 MD998333 01 MD998334 01 MD998335 01 MD998336 Guide pin MD998336 01 23B 15 Application Alignment of intermediate plate and valve body ue MD998341 01 Installation and removal of kickdown servo of low reverse brake end play Installation of transfer shaft rear bearing and gear Installation of differential oil seal Removal of oil pump Installation oil pump oil seal Installation of oil pump Alignment of oil pump housing and reacti n shaft suppo
95. gh degree of precision these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them e A rubber mat should be placed on the workbench and it should always be kept clean e During disassembly cloth gloves or shop towels should not be used If such items must be used either use articles made of nylon or use paper towels e All disassembled parts must be thoroughly cleaned Metal parts may be cleaned with ordinary detergents but must be thoroughly air dried Clean the clutch disc resin thrust plate and rubber parts by using ATF automatic transaxle fluid being very careful that dust dirt etc do not adhere to them e Do not reuse gaskets oil seals or rubber parts Replace such parts with new ones at every reassembly The O ring of the oil level gauge need not be replaced Do not use grease other than petrolatum jelly Apply ATF to friction components rotating parts and sliding parts before installation A new clutch disc should be immersed in ATF for at least two hours before installation Do not apply sealer or adhesive to gaskets When a bushing must be replaced replace the assembly in which it is incorporated If the transaxle main unit is damaged also disassemble and clean the cooler system TSB Revision SECTIONAL VIEW F4A33 with torque converter clutch T
96. gnment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plates and disc TFAO498 Clutch di 2 Install the clutch reaction plate with its shear droop directed Shear droop as shown in the illustration Ser Wave spring Pressure plate Clutch reaction late Return spring P Clutch plate 0501 ALA SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 5 kg 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value F4A22 F4A23 0 4 0 6 mm 016 024 in F4A21 0 3 0 5 mm 012 020 in TSB Revision F4A2 Rear Clutch 23B 63 9 INPUT SHAFT INSTALLATION 1 Install the input shaft with its oil groove aligned with the oil hole in the rear clutch retainer in TSB Revision 23B 64 F4A2 End Clutch END CLUTCH DISASSEMBLY AND REASSEMBLY No of Clutch Discs and Plates Model FAA2 1 F4A22 3 3 F4A23 4 4 TFA0607 Disassembly steps 1 Seal ring B 2 Snap ring 3 Clutch reaction plate 4 Clutch disc 5 Clutch plate pA 6 Snap ring 7 Washer 8 Return spring GAD 9 End clutch piston 10 Oil seal 11 D ring 12 End clutch retainer 13 Oil seal
97. gs and transfer drive gear attached from the inside of the transaxle case 13JInstall the snap ring in the groove of the output flange bearing TSB Revision F4A2 Transaxle 23B 37 14 Apply petrolatum jelly to the spacer and attach the spacer to the case 15 install the bearing outer race and inner races in the transfer idler gear Inner race Outer race Transfer idler gear 1770054 16 Place the transfer idler gear in the case and insert and screw the idler shaft into position 17 Screw in and tighten the idler shaft by using the special tool 18 Insert the special tool into the output flange and measure the preload using a low reading torque wrench Adjust the preload to the standard value by tightening or loosening the transfer idler shaft Standard value F4A21 F4A22 0 8 Nm 6 ft Ibs F4A23 1 5 Nm 1 1 ft Ibs TSB Revision F4A2 Transaxle 19 After completing the preload adjustment install the idler shaft lock plate The clearance between the idler shaft and the lock plate should be closed in the direction that will prevent idler shaft looseness and then tighten the lock plate bolt to the specified torque Tightening torque 54 Nm 40 ft Ibs 20 Install the bearing retainer 21 Tighten the screw to specified torque Caution The screw should not be reused Tightening torque 20 Nm 15 ft Ibs 22 Lock the screw head in place using a chisel 2
98. h mounting bolts and then remove the special tool E SOLENOID VALVE ASSEMBLY INSTALLATION 1 Install the solenoid valves as shown Solenoid valve Wire color Shift control solenoid valve A SCSV A Orange Shift control solenoid valve SCSV B Yellow Torque converter clutch solenoid TCC solenoid SCSV B sCSV A solenoid TFA028 Pressure control solenoid valve 5 TSB Revision F4A3 W4A3 Transfer Shaft FWD 23C 113 TRANSFER SHAFT FWD DISASSEMBLY AND REASSEMBLY TFAO322 Disassembly steps 4 98 1 Taper roller bearing 2 Transfer shaft 9A 3 Taper roller bearing DISASSEMBLY SERVICE POINT TAPER ROLLER BEARING REMOVAL MD998348 01 e 1 sel 777 032 REASSEMBLY SERVICE POINTS 4 TAPER ROLLER BEARING INSTALLATION TSB Revision 23 114 F4A3 W4A3 Transfer Shaft FWD 84 TAPER ROLLER BEARING INSTALLATION Revision F4A3 W4A3 Center Differential 4WD 23C 115 CENTER DIFFERENTIAL 4WD DISASSEMBLY AND REASSEMBLY 74 Nm 54 ft Ibs Disassembly steps GAD 1 Transfer driven gear Bd 904 2 Taper roller bearing AC 04 Taper roller bearing 084 4 Bolt 5 Center differential flange 6 Spacer 7 Side gear front 8 Pinion shaft 9 Pinion 10 Washer 1 Side gear rear Clip 13 Spacer 14 Center differential case 0261 DISASSEMBLY SERVICE POINTS
99. haft Move the input shaft in and out with pliers to obtain the end play reading Be careful not to scratch the input shaft Record the indicator reading for reference when reassem bling the transaxle 5 Remove the cover holder and remove the cover 6 Attach the dial indicator on the transaxle case with the special tool Measure the transfer shaft end play and record the indicator reading 7 Remove the pulse generator A and B MODEL 1992 only TSB Revision 23 18 F3A2 Transaxle 8 Remove the manual control lever and then remove the park neutral position switch PNP switch MODEL 1992 Park neutral position switch NONN N 9 Remove the oil pan and oil pan gasket IO Remove the oil filter 1 1 Remove the clip of the solenoid valve connector MODEL 1992 only TSB Revision 17001 2 Accumulator ziston 1750431 F3A2 Transaxle 23A 19 12 5 catches and remove the solenoid valve connector lt MODEL 1992 only gt 13 Disconnect the throttle cable from the throttle cam 14 Remove the valve body mounting bolts indicated by arrows and remove the valve body from the transaxle case 15 Remove the two accumulator springs then remove the accumulator piston from the transaxle case 16 Remove the 14 bolts indicated by arrows and remove the converter housing and gasket 17 Remove the six oil pump m
100. hat it fits correctly in the spot faced portion of the carrier 2 Apply vaseline unsparingly to the inside surface of the short pinion and attach the 17 rollers on the surface 1750291 3 Line up the holes of the rear thrust washer and front thrust washer A with the shaft hole of the carrier 4 Install the short pinion spacer bushing and front thrust washer and align the holes Use care not to allow the rollers to get out of position Front thrust Rear thrust washer washer A 170266 TSB Revision F4A3 W4A3 Planetary Gear 23C 99 5b Insert the pinion shaft Make sure that the flattened end of pinion shaft is correctly fitted in the hole of the rear thrust plate when the pinion shafts is inserted B4 ONE WAY CLUTCH INSTALLATION 1 Push the one way clutch into the outer race Make sure that arrow on the outside circumference of cage is directed upward as shown in the illustration when the one way clutch is pushed in ALA WAVE WASHER INSTALLATION 1 Install the wave washer to the rivet so that its indentation is placed on the outer race side TFAO5Ot D4 RIVET INSTALLATION 1 Stake the rivet using a punch and press NOTE 1 Use a punch with a 60 tip angle 2 Stake the rivet with a load of 11 000 13 000 N 2 425 2 866 Ibs TSB Revision eee 23 100 F4A3 W4A3 Annulus Gear and Transfer Drive Gear Set ANNULUS GEAR AND TRANSFER DRIVE GEAR SET DISASSEMBLY AND
101. he center bearing retainer and outer race 55 Remove the center bearing retainer stopper bolt t n aa 2 5 20 ail ENS 718665 SE 2 154 TSB Revision 23 64 4 W4A3 Transaxle 4WD 56 First remove the stopper ring and then put a bearing puller or similar tool in the viscous coupling groove and pull out the viscous coupling 57 Remove the front bearing retainer mounting bolt M10 Then screw a bolt M12 into the threaded hole of the front bearing retainer and holding that bolt remove the front bearing retainer and outer race 58 Remove the front output shaft 59 Using a sliding hammer or similar tool remove the outer race 60 Remove the oil seals Quter race TFAO158l REASSEMBLY 1 Using the special tool install the oil seals to the differential bearing retainer and transaxle case MD998325 01 TSB Revision F4A3 W4A3 Transaxle 4WD 23C 65 2 Using the special tool install the rear output shaft oil seal MD998200 01 Oil seal 0161 3 Using the special tool press fit the outer race in the MB990938 01 transaxle case MB990934 01 4 Install the front output shaft assembly 5 Position the solder approx 10 mm 40 in long by 1 6 mm 06 in in diameter in the front bearing retainer in the position shown in the figure and then install the
102. he kickdown band attach the ends of the band to the ends of the anchor rod and servo piston rod 38 When putting the kickdown drum in the kickdown band engage the splines of the kickdown drum with those of the reverse sun gear 39 Apply petrolatum jelly to thrust bearing 8 and attach the thrust bearing to the kickdown drum 40 Apply petrolatum jelly to thrust race 7 and attach the thrust race to the rear clutch hub TSB Revision 23 36 2 Transaxle 41 Install the rear clutch hub engaging it with the forward sun gear splines 42 Apply petrolatum jelly to thrust bearing 7 6 and attach it to the clutch hub 43 Apply petrolatum jelly to thrust washer 2 and thrust bearing 4 and attach the washer and bearing to the rear clutch assembly 44 Mate the rear clutch assembly with the front clutch assembly Front clutch Rear clutch TFAO026 45 Install the clutch assembly TSB Revision 2 Transaxle 23A 37 46 Install the differential 47 Attach thrust race 3 and thrust washer 21 the rear end face of the oil pump with petrolatum jelly 48 Attach the special tool to the transaxle case Using the tool as a guide first install a new oil pump gasket and then the oil pump in the case 49 Remove the special tool bO Tighten the oil pump bolts to the specified torque 51 Measure the end play of the input shaft If the measure ment is out of specification
103. ing 7 in the kickdown drum 47 Install the clutch assembly in the kickdown drum 48 Install the clutch assembly and kickdown drum into the transaxle case at the same time 49 Adhere thrust race 3 and thrust washer 1 to the back of the oil pump with petrolatum 50 Use the special tool to install a new oil pump gasket and oil pump assembly Oil pump assembly mounting bolts 21 Nm 16 ft Ibs TSB Revision F4A3 W4A3 Transaxle 4WD 23C 77 0116 2200048 61 62 63 64 65 66 Install the end clutch cover and tighten the bolts to the specified torque End clutch cover mounting bolts 11 Nm 8 165 Install the differential assembly Place solder with a length of approximately 10 mm 39 in and diameter of 1 6 mm 06 in on the differential rear bearing retainer at the position shown in the diagram and install the outer race Install the differential rear bearing retainer and tighten the bolts to the specified torque Loosen the bolts remove the differential rear bearing retainer and remove the solder If the solder is not crushed repeat steps 51 53 using the solder with the diameter of 3 mm Differential rear bearing retainer mounting bolts 35 Nm 26 ft ibs Measure the thickness of the crushed solder with a micrometer and adjust by selecting a spacer with a thickness that will provide the standard value for the end play and preload Standard value 0
104. install 2 new O rings and push into the transaxle case Caution 1 Coat the O rings with automatic transmission fluid and align the oil holes 2 Do not move the wave spring out of position when installing 34 Install the snap ring 35 Use a thickness gauge and measure the end play of the low reverse brake Adjust to the standard value by selecting the proper pressure plate Standard value 1 0 1 2 mm 039 047 TSB Revision EE EE 23 72 W4A3 Transaxle AWD 36 Install the air exhaust plug and then install the plug Air exhaust plug 33 Nm 24 ft lbs Pre 37 Install the anchor rod Anchor rod 0140 38 Install the kickdown servo spring piston and sleeve Caution The seal ring alignment hole of the kickdown servo piston must not overlap the oil filler port indicated by the arrow in the diagram 39 Use the special tool to push in the kickdown servo piston and sleeve and then install a snap ring d Ow 40 Install the kickdown band Caution Install so the arrow mark is facing toward the front TSB Revision W4A3 Transaxle AWD 23C 73 41 Install thrust bearing 4 and thrust washer 2 on the rear Thrust washer 2 clutch Thrust bearing 4 42 Combine the rear clutch assembly and the front clutch assembly 43 Install thrust bearing 5 on the rear clutch hub 44 Install the r
105. ions amp in the illustration in alignment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plate and disc TFAO498 Shear i 2 Install the innermost the reaction plate with their shear Clutch plates droops directed as shown in the illustration Clutch reaction plate Clutch disc CA SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value 0 7 0 9 mm 028 035 in TSB Revision 23 48 F3A2 Rear Clutch REAR CLUTCH DISASSEMBLY AND REASSEMBLY 6 15 TFAO704 Disassembly steps 1 Seal ring 904 2 Input shaft 3 O ring 4 Snap ring 5 Thrust race 6 Seal ring 7 Snap ring 984 8 Clutch reaction plate 9 Clutch disc 98410 Clutch plate B4 11 Clutch pressure plate GAD 12 Wave spring 18 Return spring 14 Rear clutch piston 15 Rear clutch retainer 16 D ring 17 D ring TFA0011 TSB Revision MD998337 01 MD998338 Screwdriver 1750274 Z 1750274 TFA0498 Wave spring Pressure plate Clutch reaction plate Return spring F3A2 Rear Clutch 23A 49 DISASSEMBLY SERVICE POINT GAD WAVE SPRING REMOVAL 1 C
106. ity between terminals with the manual control lever at each position Serer The continuity between terminals should be as shown the table below MODEL 1992 Internal Connection in the Inhibitor Switch MODEL 1992 Termin P R N Connected circuits No JE ne C O switch ON terminal a r te O 1750149 O MODEL 1993 Lack of continuity indicates a poorly adjusted switch or faulty switch Readjust the switch If still without continuity replace the switch Approx 12 mm 47 in 80 Measure the distance between the ring gear end and the converter housing end The torque converter has been properly installed if the measurement is approx 12 mm 47 in TSB Revision 23A 44 F3A2 Oil Pump OIL PUMP DISASSEMBLY AND REASSEMBLY Disassembly steps ME4 1 O ring 04 2 Reaction shaft support 4 3 Steel ball 3 984 4 Drivegear QA 984 5 Driven gear 6 Seal ring 47 Cil seal 8 Oil pump housing 9 Snap ring 10 Oil seal 1750261 DISASSEMBLY SERVICE POINT AD DRIVE GEAR DRIVEN GEAR REMOVAL 1 Make reassembly alignment marks on the drive and driven gears REASSEMBLY SERVICE POINTS 4 OIL SEAL INSTALLATION MD998334 01 Tt TSB Revision 2 OU 23 45 amp B4 DRIVEN GEAR DRIVE GEAR SIDE CLEARANCE MEASUREMENT Standard val
107. justing spacer and the drive bevel gear mount adjusting spacer as described below and then adjust tooth contact again e When the driven bevel gear height is too small even if the thinnest driven bevel gear mount adjusting spacer 0 13 mm 0051 in is used Replace the drive bevel gear mount adjusting spacer Driven bevel that is in use with one that is one rank thicker and gear mount replace the drive bevel preload adjusting spacer that is adjusting in use with one that is one rank thinner spacer e When the driven bevel gear height is too large even if the thickest driven bevel gear mount adjusting spacer 0 52 025 in is used SE Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thinner adjusting replace the drive bevel gear preload adjusting spacer spacer that is in use with one that is one rank thicker Repeat above steps until the tooth contact pattern equal or close to the standard pattern is obtained 2 If the tooth contact pattern cannot be adjusted close to the standard pattern by above adjustment replace the drive bevel gear and driven bevel gear as a set and readjust the tooth contact 221012 TSB Revision 23 124 FAA3 W4A3 Transfer Case Adapter 4WD TRANSFER CASE ADAPTER AWD DISASSEMBLY AND REASSEMBLY 150 Nm 109 ft ibs Disassembly steps GAD 98 1 Locknut 4B 04 2 Driven bevel gear 64
108. l filler plug Transfer case adapter mounting bolt Transfer cover mounting bolt TSB Revision F4A3 W4A3 Special Tools 23C 19 SPECIAL TOOLS Tool Number and Replaced by OTC Application tool name tool number MB990934 MB990934 01 Installation of bearing out race Installer adapter MB990936 990936 01 Installer adapter MB990938 990938 01 Installer bar MB991013 MIT307098 Removal and installation of transfer driven Special spanner bevel gear lock nut lt 4WD gt MB991144 MB991144 Measurement of transfer drive and driven Side gear holding bevel gears drive torque lt 4WD gt tool MD998200 MD998200 01 Installation of rear output shaft and transfer Oil seal installer case oil seal lt 4WD gt MD998266 MD998266 01 Alignment of intermediate plate and valve Guide pin bodies MD998303 MD998341 01 Installation and removal of kickdown servo Valve spring compressor MD998316 MIT209038 Measurement of input shaft end play Dial gauge support TSB Revision 23 20 F4A3 W4A3 Special Tools Tool Number and tool name MD998333 Removers Replaced by OTC tool number MD998333 01 MD998334 MD998334 01 Oil pump oil seal installer Application Removal and installation of oil pump assembly center differential Installation of oil pump oil seal MD998335 MD998335 01 Oil pump band MD998336 MD998336 01 Guide pin
109. l gear teeth both sides using a brush TSB Revision 23 120 F4A3 W4A3 Transfer 4WD B4 SPACER INSTALLATION 1 Install the spacer that has been used Ce TRANSFER CASE SUB ASSEMBLY INSTALLATION 1 With the matching marks in alignment install the transfer case adapter sub assembly to the transfer case sub assembly 2 Tighten the transfer case adapter sub assembly to the transfer case sub assembly to specified torque Transfer case adapter mounting bolt 39 Nm 28 ft Ibs 3 Using the special tool turn the drive bevel gear shaft one turn in normal direction one turn in reverse direction NOTE Do not give the drive bevel gear shaft more than one turn in either direction as this causes unclear tooth contact pattern 4 Make sure that the driven bevel gear and transfer case Matching mark matching marks are in alignment Matching mark TSB Revision Apply sealant both sides F4A3 W4A3 Transfer 4WD 23C 121 5 Check to see if the drive bevel gear tooth contact is normal NOTE Refer to the TOOTH CONTACT ADJUSTMENT PROCE DURES on next page below for the standard tooth contact 6 Check to see if the drive bevel gear and driven bevel backlash is as specified Standard value Bevel gear set backlash 0 08 0 13 0031 0051 in D4 EXTENSION HOUSING INSTALLATION 1 Apply sealant to the adapter flange surface and install the extension housing Specified seal
110. l the band with the arrow mark foward oil pump side 4 23 42 When putting the kickdown drum in the kickdown band engage the splines of the kickdown drum with those of the reverse sun gear Place the kickdown band on the kickdown drum and tighten the kickdown servo adjusting screw to keep the band in position 43 Apply petrolatum jelly to thrust bearing 8 and attach the thrust bearing to the kickdown drum f Thrust bearing 8 CS O V 1750196 TSB Revision 23 44 F4A2 Transaxle 44 Apply petrolatum jelly to thrust race 7 and attach the thrust race to the rear clutch hub 45 Install clutch hub engaging it with the forward sun gear splines 46 Apply petrolatum jelly to thrust bearing 6 and attach it to the clutch hub 47 Apply petrolatum jelly to thrust washer 2 and thrust bearing 7 4 and attach the washer and bearing to the rear clutch assembly 1750200 48 Mate the rear clutch assembly with the front clutch assembly Rear clutch Front clutch 17502011 TSB Revision F4A2 Transaxle 23 45 49 Install the clutch assembly 50 Install the differential b1 Attach thrust race 3 and thrust washer 1 the rear end face of the oil pump with petrolatum jelly 52 Install the special tool on the transaxle case Using the special tool as a guide install a new oil pump gasket and the oil pump in the case 53 Remove the special tool 54 Tighten the oil pump bolts t
111. lts to the specified torque in the sequence shown in the illustration 16003C TSB Revision 23B 74 F4A2 Low Reverse Brake LOW REVERSE BRAKE DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Low reverse brake piston 2 D ring 3 D ring 4 Center support TFA0386 TSB Revision 4 2 Kickdown Servo 23B 75 KICKDOWN SERVO DISASSEMBLY AND REASSEMBLY Disassembly steps 1 O ring 2 Kickdown servo sleeve 3 4 Sed D ring ring 5 Locknut 6 Kickdown servo rod 7 Kickdown servo piston 1750299 TSB Revision NI 23B 76 F4A2 Speedometer Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Disassembly steps 1 O ring Ha 2 Spring pin riven gear 1 Oil seal 5 Sleeve 201078 REASSEMBLY SERVICE POINT SEET Aq SPRING PIN INSTALLATION 1 Drive a new spring pin into the sleeve Make sure that the slit in the spring pin does not face the gear Driven gear Oil seal Slit Spring pin TSB Revision F4A2 Drive Shaft Oil Seal 23 77 DRIVE SHAFT OIL DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Converter housing 2 Transmission case pA 3 Oil seal 1750298 REASSEMBLY SERVICE POINT OIL SEAL INSTALLATION MD998325 01 TSB Revision 23B 78 F4A2 Transfer Shaft TRANSFER SHAFT DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Bearing 2 Transfer shaft 0656 DISASSEMBLY S
112. mber MD998904 MD998904 Pull out idler shaft Wrench adapter MD998916 1 01 MD998916 MD998916 2 01 Socket wrench MD998916 3 01 wu Bolt MD998905 MD998905 01 Removal and installation of center support SES Handle MD998907 MD998907 01 Disassembly and reassembly of front clutch Spring com and rear clutch pressor MD998915 MD998916 01 Adjustment of kickdown servo MD99891 7 MD99891 7 Disassembly and reassembly of transfer Bearing remover driven gear bearing MD998918 MD99891 8 Adjustment of kickdown servo Kickdown servo wrench MD998919 MD998919 Reassembly of end clutch Snap ring installer TSB Revision 4A3 W4A3 Transaxle F W D TRANSAXLE FWD COMFONENTS SO OP a 21 Nm 1 16 ft lbs Torque converter Oil pump assembly Gasket Thrust washer 1 Front clutch assembly Thrust race 3 Thrust bearing 4 Thrust washer 2 Rear clutch assembly Thrust bearing 5 Rear clutch hub Thrust race 6 Thrust bearing 7 Kickdown band Kickdown drum 16 Snap ring TSB Revision Center support Wave spring Return spring Pressure plate Brake disc Brake plate Reaction plate Reverse sun gear Thrust bearing 8 Thrust race 9 Forward sun gear Planetary carrier assembly Thrust bearing 10 Output flange Oil level gauge Oil filler tube Snap ring
113. mm 006 in to T 0 38 mm 015 in 0 mm 0 in Transfer shaft preload 0 1 0 15 mm 004 006 in Differential case end play 0 0 15 mm 0 006 in 58 Place the spacer for the transfer shaft which was selected in Step 57 in the transfer shaft bearing hole in the converter housing and insert the bearing outer race in the case TSB Revision F3A2 Transaxle 23A 39 b9 Place the spacer for the differential case which was selected in Step 57 on the bearing outer race Spacer ELS 60 Coat the gasket surface of the transaxle case with silicone grease 61 Install a new gasket on the transaxle case Caution Do not reuse the gasket which was previously re moved 62 Install the converter housing with the 14 bolts Tighten the bolts to the specified torque Specified torque 21 Nm 16 ft lbs 63 Install the parking sprag rod to the manual control shaft Then insert the shaft in the transaxle as shown in the illustration In doing this work do not install O ring in the O ring groove 1770053 64 After installing a new O ring on the manual control shaft assembly draw the shaft back into the case then install the set screw and gasket Also install the detent steel ball seat and spring at the same time 65 Place the case with the oil pan mounting surface up 66 Install the sprag rod support and tighten the two bolts to the specified torque Specified torque 2
114. mounting bolts Then demount the special tools OIL FILTER STEEL BALL RELIEF SPRING LOCATION D LOWER VALVE BODY SUB ASSEMBLY INSTALLATION 1 Mount the special tools on the intermediate plate N 3 Q 2 Install the separating plate TSB Revision 23 84 SCSV B TSB Revision SCSV A TCC solenoid TFAO28C F4A2 Valve Body 3 Secure the lower valve body with the bolts Then remove the special tools EA SOLENOID VALVE ASSEMBLY INSTALLATION 1 Install each solenoid valve in the position shown in the figure Solenoid valve Wiring color Shift control solenoid valve Orange SCSV A Shift control solenoid valve Yellow SCSV B Torque converter clutch solenoid TCC solenoid Red lt MODEL 1992 and MODEL 1993 E33A D21A D22A gt Red Black MODEL 1993 CB5A N11W N14W N34W gt Pressure control solenoid valve PCSV Blue 23 1 AUTOMATIC TRANSAXLE F4A33 W4A32 W4A33 CONTENTS ANNULUS GEAR AND TRANSFER SPECIFICATIONS 2 2 2 2 0 20420201 9 DRIVE GEAR SET nin net 100 Adjustment Pressure Plate CENTER DIFFERENTIAL 4WD 115 Snap Rings and Spacers 11 DIFFERENTIAL inneren 102 Gear Ratio Table 9 END CLUTCH 94 Sealant
115. n the outside circumference of cage is directed upward as shown in the illustration when the one way clutch is pushed in TSB Revision 23 54 F3A2 Annulus Gear and Transfer Drive Gear Set ANNULUS GEAR AND TRANSFER DRIVE GEAR SET DISASSEMBLY AND REASSEMBLY Disassembly steps 0 1 Snap ring GAD 904 2 Bearing Bp 98 3 Transfer drive gear 16 A 4 4 Bearing 5 Snap ring 6 Output flange 7 Annulus gear 170178 DISASSEMBLY SERVICE POINTS 4A BEARING REMOVAL iB TRANSFER DRIVE GEAR REMOVAL MD998348 01 O cr BEARING REMOVAL 70115 TSB Revision 2 Annulus Gear and Transfer Drive Gear Set 23A 55 REASSEMBLY SERVICE POINTS BEARING INSTALLATION DA TRANSFER DRIVE GEAR INSTALLATION 1 Install the transfer drive gear in proper direction The direction can be identified by the groove provided in one of the pinion side surfaces Caution Replace the output flange and transfer drive gear as a set TFAO503 LA BEARING INSTALLATION TFAO384 D SNAP RING SELECTION 1 Select a snap ring which should be the thickest one that can be installed in groove Standard value 0 0 06 mm 0 0024 in TSB Revision 23 56 DIFFERENTIAL DISASSEMBLY AND REASSEMBLY F3A2 Differential 135 Nm 98 ft Ibs Disassembly steps 041 Bolt 2 Differential drive gear GAD 96 Ball bearing 98 4 Lock pin 4 5 Pinion shaf
116. nd 76 Clean the gasket surfaces of both the transaxle case and oil pan Using a new oil pan gasket install the oil pan by tightening the 12 bolts to the specified torque 77 Install the park neutral position switch PNP switch and manual control lever and tighten the manual control lever nut to the specified torque ay Park neutral _ position switch dd S TFA0805 TSB Revision 23A 42 F3A2 Transaxle MODEL 1992 12mm 78 Adjust the park neutral position switch by the following 47 in Manual procedure control ch p fever a Place the manual control lever in the N neutral position b Turn the park neutral position switch body until the 12 m 47 in wide end of the manual control lever aligns Pe Lia with the switch body flange 12 mm 47 in wide 20 in hole portion Alternatively turn the switch body until the 5 mm 20 in hole in manual control lever aligns with the 12 5 mm 20 in hole in the switch in 175133 Gg 47 c Tighten the attaching bolts to specified torque taking Section care that switch body is not displaced Tightening torque 11 Nm 8 ft Ibs sie Switch body Attaching bolts MODEL 1993 12mm 47 Switch bod 5 mm dia 20 in hole 12mm 47 in Section A A Manual control lever TFAO79 TSB Revision 2 Transaxle 23A 43 79 Check the continu
117. nd MD998336 MD998336 01 Alignment of oil pump housing and reaction Guide pin shaft support MD998337 MD998337 01 Use with MD998338 MD998907 Spring compressor TSB Revision F3A2 Special Tools 23A 13 ool Number and Replaced by OTC Application tool name tool number MD998338 MD998338 Disassembly of rear clutch Spring compressor MD998343 MD998343 01 Preload measurement of transfer idler shaft lt Wrench adapter MD998344 MD998344 01 Removal and installation of transfer idler Wrench adapter shaft B MD998348 MD998348 01 Removal of bearing Bearing puller MD998365 General service tool Removal of kickdown servo cover Kickdown servo cover remover MD998301 MD998348 01 AS Bearing remover Removal of bearing 1 MD998812 General service tool Use with installer and installer adapter Installer cap MD998813 General service tool Use with installer cap and installer adapter Installer I 00 TSB Revision 23 14 F3A2 Special Tools Number and Replaced by OTC Application tool name tool number MD998815 General service tool Installation of each bearing Installer adapter 26 MD998818 Installer adapter MD998819 Installer adapter 40 MD998820 Installer adapter 42 MD998905 MD998905 01 Removal and installation of center support Handle MD998907 0998907 01 Disassembly reassembly o
118. ndard value 0 6 0 85 mm 024 031 in TSB Revision 23 96 F4A3 W4A3 Planetary Gear PLANETARY GEAR DISASSEMBLY AND REASSEMBLY W4A32 Disassembly steps 1 Bolt 2 One way clutch outer race 3 End plate 84 4 One way clutch 5 End plate 6 Pinion shaft 1 Front thrust washer 8 Spacer bushing 9 Short pinion 10 Roller GAD 411 Thrust bearing 12 Planetary carrier TFA0713 TSB Revision F4A3 W4A3 Planetary Gear 23C 97 DISASSEMBLY AND REASSEMBLY 4 33 W4A33 Disassembly steps 1 Thrust bearing Bo D4 2 Rivet 64 3 Wave washer 4 One way clutch outer race 5 End plate B4 6 One way clutch 7 End plate 8 Planetary carrier TFAO491 DISASSEMBLY SERVICE POINTS THRUST BEARING REMOVAL 1 Remove the only one short pinion Use care not to drop and lose the 17 rollers in the short pinion Do not remove the other short pinions 2 Remove the thrust bearing TSB Revision 23 98 F4A3 W4A3 Planetary Gear RIVET REMOVAL 1 Shift the stopper plate to ensure that the rivet head does not hit it NOTE Make sure that the stopper plate claw is not located at the groove in the one way clutch outer race Stopper plate ang 0492 2 Using pin punch drive out the rivet REASSEMBLY SERVICE POINTS Aq THRUST BEARING INSTALLATION 1 Install a new thrust bearing on the carrier Make sure t
119. ne way clutch 6 End plate 7 Pinion shaft 8 Front thrust washer 9 Spacer bushing 10 Short pinion 11 Roller QAD 12 Thrust bearing 13 Planet carrier TFA0524 TSB Revision 23A 52 F3A2 Planetary Gear DISASSEMBLY SERVICE POINT THRUST BEARING REMOVAL 1 Remove the only one short pinion Use care not to drop and lose the 17 rollers in the short pinion Do not remove the other short pinions 170255 2 Remove the thrust bearing REASSEMBLY SERVICE POINTS THRUST BEARING INSTALLATION 1 Install a new thrust bearing on the carrier Make sure that it fits correctly in the spot faced portion of the carrier 2 Apply vaseline unsparingly to the inside surface of the short pinion and attach the 17 rollers on the surface 3 Line up the holes of the rear thrust washer and front thrust washer A with the shaft hole of the carrier 4 Install the short pinion spacer bushing and front thrust washer and align the holes Use care not to allow the rollers to get out of position Front thrust washer A Rear thrust washer TSB Revision 17026 2 Planetary Gear 5 Insert the pinion shaft Make sure that the flattened end of pinion shaft is correctly fitted in the hole of the rear thrust plate when the pinion shafts is inserted 2 Notch 1702611 B4 ONE WAY CLUTCH INSTALLATION 1 Push the one way clutch into the outer race Make sure that arrow o
120. nsaxle FWD 2200048 TFAO16 23C 35 3 Install the transfer shaft 4 Place solder with a length of approximately 10 mm 39 in and diameter of 1 6 mm 06 in on the output bearing retainer at the position shown in the diagram and install the outer race 5 Install the output bearing retainer and tighten the bolts to the specified torque Output bearing retainer mounting bolts 24 Nm 18 ft Ibs 6 Loosen the bolts and remove the output bearing retainer 7 Remove the outer race from the output bearing retainer and remove the solder If the solder is not crushed repeat steps 4 6 using the solder with diameter of mm 12 in Measure the thickness of the crushed solder with a micrometer and select a spacer with a thickness that will provide the standard value for the preload Standard value 0 075 0 135 mm 003 0053 in 8 Install the spacer selected in the previous item and the outer race on the output bearing retainer 9 Install a new O ring around the outer circumference of the outer bearing retainer 10 Coat the O ring with automatic transmission fluid and tighten the output bearing retainer mounting bolts to the specified torque Output bearing retainer mounting bolts 24 Nm 18 165 TSB Revision 23 36 F4A3 W4A3 Transaxle FWD 11 Insert the output flange into the case and install a snap ring around the bearing 12 Install the bearing retainer using new b
121. nstall the differential cover and a new gasket Differential cover mounting bolts 11 Nm 8 ft Ibs Install the detent assembly Install a new O ring on the manual control shaft assembly coat the O ring with automatic transaxle fluid and then insert into the transaxle case Align the groove in the manual control shaft and the set screw hole then install the set screw Manual control shaft set screw 9 Nm 7 ft Ibs Install the parking roller support Parking roller support bolts 24 Nm 18 ft Ibs F4A3 W4A3 Transaxle FWD 23C 47 Oil temperature TFAO71 TSB Revision 63 64 65 66 67 62 Insert the oil temperature sensor into the case Install an O ring in the O ring groove at the top of the valve body assembly Replace the solenoid valve harness grommet O ring with a new one Pass the solenoid valve connector through the transaxle case hole from the inside Push the solenoid valve harness grommet into the case hole Insert the knock pin of the valve body into the case keeping the detent plate pin in the manual valve groove Temporarily install the valve body install the oil temperature sensor and holder then tighten the mounting bolts to the specified torque A bolt 1 8 mm 709 in B bolt 25 mm 984 in C bolt 40 mm 1 575 in Valve body assembly mounting bolts 11 Nm 8 ft Ibs Caution Firmly fasten the solenoid valve and oil temperatur
122. nual control shaft 1750441 TSB Revision j rod t Spragrod support Ee ER e M E ws h A 2 Parking sprag rod gt OI 2 9 2 7 175017 mounting surface 1750431 F4A2 Transaxle 74 Place the case with the oil pan mounting surface up 75 Install the sprag rod support and tighten the two bolts to specified torque Tightening torque 24 Nm 18 ft Ibs 76 Install the O ring at the top of the valve body 77 Replace the O ring of the solenoid valve connector with a new one 78 When installing the valve body insert the solenoid valve connector in the case while making sure that cut of connector is positioned as shown in the illustration F4A21 F4A22 79 install the valve body in the transaxle case while fitting the detent plate pin in the gap between the lands of the manual valve 80 Tighten the valve body mounting bolts 10 pieces to the specified torque Abolt 18 mm 709 in long Bbolt 25 mm 984 in long Cbolt 40 mm 1 575 in long TSB Revision F4A2 Transaxle 81 Install the oil filter and tighten the four oil filter mounting bolts to the specified torque 82 Install five magnets in the five depressions provided inside the oil pan Be sure to remove metal particles from the magnets and clean the inside of the oil pan beforehand 83 Clean the gasket surfaces of the transaxle case and oil pan Install
123. o the specified torque 55 Measure the end play of the input shaft If the measure ment is out of specification replace thrust race 3 and thrust washer 1 to meet the specification Standard value 0 3 1 0 mm 012 039 in TSB Revision 4 2 Transaxle b6 Place approx 10 mm 394 in long and 2 5 mm 10 in dia pieces of solder at the locations shown on the differential assembly 57 Install the converter housing directly to the transmission case without installing the rubber coated metal gasket b8 Tighten the bolts to the specification 59 Loosen the bolts and remove the converter housing and remove the pieces of flattened solder 60 Measure the thickness of the flattened solder using a micrometer Add the measured solder thickness T to the value 0 38 mm 015 in which corresponds to the gasket thickness Then subtract from that sum a value corresponding to the specified end play The result obtained is the thickness of the spacer to be selected Select a spacer whose thickness falls within the range determined by the formulas below T 0 38 mm 015 in 0 15 mm 006 in to I 0 38 mm 015 in 0 mm 0 in 61 Place the spacer which was selected in Step 60 on the outer race of the differential bearing 62 Apply silicone grease to all gasket surfaces of the transaxle case 1750021 TSB Revision F4A2 T
124. ol to install a new oil pump gasket and oil pump assembly Oil pump assembly mounting bolts 21 Nm 16 ft Ibs TSB Revision F4A3 W4A3 Transaxle FWD 23C 43 39 Measure the end play of the input shaft If not the standard value replace thrust race 3 and thrust washer 1 and adjust to the standard value Standard value 0 3 1 0 mm 012 039 in 40 Install the spacer idler gear and bearing and then insert the idler shaft Caution Assemble so that the identification groove on the idler gear faces the rear 41 Tighten the idler shaft lock bolt together with the new lock plat to the specified torque Bend the three fingers of the lock plate to prevent turning Idler shaft lock bolt 38 Nm 28 ft Ibs 42 Install the idler gear cover and a new gasket Idler gear cover mounting bolt 11 Nm 8 ft Ibs 43 Insert the end clutch shaft from the end with the long spline lt 1 TSB Revision 23C 44 F4A3 W4A3 Transaxle FWD 44 Fit the thrust washer on the return spring of the end clutch 45 Install the end clutch hub on the end clutch assembly 46 Adhere thrust bearing 1to the end of the clutch hub with petrolatum 47 Install end clutch assembly 48 Attach a new O ring to the end clutch cover TSB Revision F4A3 W4A3 Transaxle FWD 23C 45 49 Install the end clutch cover and tighten the bolts to the specified torque End clutch cov
125. olts Bearing retainer mounting bolts 20 Nm 15 ft Ibs 13 Caulk the heads of the bolts 14 Apply a coating of petrolatum to thrust bearing 10 and attach to the planetary carrier 15 Assemble the planetary carrier TSB Revision F4A3 W4A3 Transaxle FWD 23C 37 16 Assemble the forward sun gear thrust race 9 thrust bearing 8 and reverse sun gear 17 Install both sun gears assembled in the previous item into the planetary carrier 18 Assemble the reaction plate brake disc and brake plate TSB Revision 23 38 F4A3 W4A3 Transaxle FWD 0243 Identification of thrust bearings thrust races and thrust washers Unit mm in D d t Part No D d Part No 70 2 76 55 7 2 193 1 4 055 zi 48 1 1 894 34 4 1 354 MD707271 70 2 76 55 7 2 193 1 8 071 2 42 6 1 677 28 1 10 MD720753 41 70 2 76 55 7 2 193 1 1 087 54 2 13 38 7 1 524 1 6 063 MD704936 70 2 76 55 1 2 193 2 6 102 4 52 2 05 36 4 1 433 0720010 66 2 60 54 1 13 1 8 071 MD731212 2 45 1 77 28 1 10 MD735062 48 9 1 925 37 1 46 1 0 039 MD997854 incl 1 46 1 81 31 1 22 MD735063 48 9 1 925 31 1 46 1 2 047 MD997847 incl 1 48 9 1 925 37 1 4 1 4 055 MD997848 incl 2 52 2 05 364 1 433 MD720010 48 9 1 925 31 1 46 1 6 063
126. ompress the return spring with the special tool 2 Using a screwdriver remove the wave spring REASSEMBLY SERVICE POINTS WAVE SPRING INSTALLATION 1 Compress clutch reaction plate with the special tool 2 Install the wave spring BA CLUTCH PRESSURE PLATE CLUTCH PLATE CLUTCH REACTION PLATE INSTALLATION 1 Install the clutch pressure plate clutch plates and clutch reaction plate with their missing tooth portions in the illustration in alignment NOTE This design is to facilitate escape of automatic transmission fluid and improve the cooling efficiency of the plates and disc 2 Install the clutch reaction plate with its shear droop directed as shown in the illustration C SNAP RING SELECTION 1 Check clearance between the snap ring and clutch reaction plate To check the clearance hold entire circumference of the clutch reaction plate down with 50 N 11 Ibs force If clearance is out of standard value select a snap ring to obtain the standard value Standard value 0 4 0 6 mm 016 024 in TSB Revision F3A2 Rear Clutch INPUT SHAFT INSTALLATION 1 Install the input shaft with its oil groove aligned with the oil hole in the rear clutch retainer TSB Revision 2 Gear PLANETARY GEAR DISASSEMBLY AND REASSEMBLY TFA0522 Disassembly steps 1 Bolt 2 Lock plate 3 One way clutch outer race Di 40 Nm 4 End plate 29 ft Ibs 9845 O
127. orque converter Kickdown Planetary Oil pump brake gear Transfer Low reverse idler gear brake Front clutch Rear clutch T IL T A J AM A CC AN Y 2248 S a d Io te eem Eeer mJ Les Transfer drive gear EE e KZ S JK Ip 3 Ell pre ee I E l FEES lt a UE e so End clutch D em D Hu S Transfer shaft clutc Za Differential 1 TN 4 wheel steering oil pump drive gear Vehicles with 4 wheel steering system TFA0547 TSB Revision 23C 4 F4A3 W4A3 General Information SECTIONAL VIEW F4A33 without torque converter clutch Oil pump Low reverse idler gear Kickdown Planetary gear Rear clutch converter ZH GE Transfer i B drive gear nd clutch Z SOU Y ii pp R Transfer shaft Differential L Z M o H TFA0101 TSB Revision F4A3 W4A3 General Information SECTIONAL VIEW W4A32 with torque converter clutch Torque converter Rear output Y shaft p M 0 Sab i P She L Liat CA cif CH Differential ront utput shaft TSB Revision Viscous coupl Kickdown Low reverse Tr Oil pump brake brake
128. ough the location shown and at the same time read the dial indicator and select a pressure plate to obtain the specified end play Standard value F4A21 0 7 0 9 mm 028 035 in F4A22 F4A23 1 0 1 2 mm 039 047 in j After a pressure plate of the appropriate thickness has been selected remove all the mounted parts 2 Using the special tools drive the transfer shaft bearing outer races into position TSB Revision F4A2 Transaxle 3 Insert the transfer shaft in the case 4 Mount the special tool on the transaxle case to support the transfer shaft D MD998319 01 1750182 b Install the thickest spacer 1 80 mm 071 in 6 Install the transfer driven gear on the transfer shaft Le 2E WE gt 2 By OO Y do 7 Remove the special tool and secure the transfer shaft in position TSB Revision F4A2 Transaxle 8 Put on the lock nut and tighten it to specified torque Caution The lock nut is a left handed screw Tightening torque 215 Nm 156 ft ibs 9 Measure the end play while sliding the transfer shaft in and out and select a spacer to obtain the specified end play Standard value 0 0 025 mm 0 001 in 10 Bend the locking tab of the lock nut 11 Place the transmission case on the workbench with the oil pan mounting surface up 12 Insert the output flange in position with two ball bearin
129. ounting bolts indicated by arrows 18 Screw the special tools MD998333 01 into the bolt holes marked TSB Revision 23 20 F3A2 Transaxle 19 Grasping the special tools remove the oil pump Then remove the gasket 20 Remove the spacer and differential from the transaxle case 21 Remove fiber thrust washer 1 177001 22 Grasp and raise the input shaft to remove both the front and rear clutch assemblies together _ 23 Remove thrust bearing 6 s TSB Revision 2 23 21 24 Remove the clutch hub 25 Remove thrust race 7 and thrust bearing 8 26 Remove the kickdown drum 27 Remove the kickdown band ex pech 2p NM Tib SN Kickdown servo cover 28 Remove the snap ring 29 Set the special tools as shown in the illustration and use them to remove the kickdown servo cover LT TSB Revision 23A 22 F3A2 Transaxle 30 Remove the kickdown servo piston and spring D 6 n ist ickdown servo piston 17200 31 Remove the anchor rod 32 Remove the snap ring 33 Set the special tool on the center support and remove the center support from the case Reverse sun gear 34 Remove reverse sun gear thrust bearing 9 thrust race 10 and forward sun gear together 175017 TSB Revision KEEN 2 Transaxle 23 23 35 Remove the planetary ge
130. outer race TSB Revision 23 66 F4A3 W4A3 Transaxle 4WD bearing retainer Cao TFA0156 2200048 990938 01 990936 01 TFAO1E 6 Install the front bearing retainer and tighten the bolt with the specified torque Front bearing retainer mounting bolts 49 Nm 35 ft Ibs 7 Loosen the bolts and remove the front bearing retainer 8 Remove the outer race from the front bearing retainer and remove the solder If the solder does not break perform the work in steps 5 8 with large diameter solder Measure the thickness of the crushed solder with a micrometer and select a spacer with the correct thickness so the preload reaches the standard value Standard value 0 055 0 115 mm 0022 0045 9 Install the spacer selected in the previous step and the outer race in the front bearing retainer 10 First install the front bearing retainer and apply sealant to the bolts and then tighten with the specified torque Specified sealant 3M Stud Locking Part No 4170 or equivalent Front bearing retainer mounting bolts 49 Nm 35 ft Ibs 11 Using a bearing puller support the viscous coupling and insert in the case Then install the stopper ring 12 Using the special tool install the outer race in the center bearing retainer 13 Install the center bearing retainer stopper bolt Center bearing retainer stopper bolt 5 Nm 4 165 TSB Revision FAA3
131. ove the spacer and differential from the transaxle case 1750337 TSB Revision Fiber thrust washer 1 TSB Revision 4 2 Transaxle 24 Remove fiber thrust washer 1 25 Grasp and raise the input shaft to remove both the front and rear clutch assemblies together 26 Remove thrust bearing 6 27 Remove the clutch hub 28 Remove thrust race 7 and thrust bearing 8 F4A2 Transaxle 29 Remove the kickdown drum 30 Remove the kickdown band 31 Using the special tools push in the kickdown servo and remove the snap ring p 1770028 32 Remove the special tools and then remove the kickdown servo piston sleeve and spring 33 Remove the anchor rod 1750170 SB Revision 23 28 F4A2 Transaxle 34 Remove the snap ring 35 Set the special tool on the center support and remove the center support from the case 36 Remove reverse sun gear thrust bearing 9 thrust race 10 and forward sun gear together NS CO Forward sun gear lt lt lt Real 37 Remove the planetary gear set and thrust bearing 12 Thrust bearing 12 f 38 Remove the wave spring return spring reaction plate brake discs and brake plates TSB Revision F4A2 Transaxle 23B 29 39 Sealant has been applied to the threads of the screws on the bearing retainer Tap the screw heads so the screws
132. p of the snap ring approx 180 away from that of the return spring mounting snap ring TSB Revision 23 90 F4A3 W4A3 Rear Clutch REAR CLUTCH DISASSEMBLY AND REASSEMBLY W4A32 Disassembly steps 1 Seal ring 4 2 Input shaft 3 O ring 4 Snap ring 5 Thrust race 6 Seal ring D 7 Snap ring 64 8 Clutch reaction plate 9 Clutch disc 7 9 C410 Clutch plate 64 11 Clutch pressure plate OAD amp A 12 Wave spring 13 Return spring 14 Rear clutch piston 15 Rear clutch retainer 16 D ring 17 D ring TFAO 621 TSB Revision 1750215 4 W4A3 Rear Clutch 23C 91 DISASSEMBLY AND REASSEMBLY F4A33 W4A33 0418 The number of seal rings varies with the transaxle model Models with torque converter clutch 3 Models without torque converter clutch TF A0490 Disassembly steps 1 Seal ring 960410 Clutch plate bE 2 Input shaft 11 Wave spring 3 O ring Bd 9 4 12 Snap ring 4 Snap ring 13 Return spring 5 Thrust race 14 Rear clutch piston 6 Seal ring 15 D ring 0 7 Snap ring 16 D ring pC 8 Clutch reaction plate 17 Rear clutch retainer 9 Clutch disc C TSB Revision 23 92 F4A3 W4A3 Rear Clutch DISASSEMBLY SERVICE POINTS WAVE SPRING REMOVAL 1 Compress the return spring with the special tool 2 Using a screwdriver remove the wave spring MD998337 01 BD SNAP RING REMOVAL
133. place the solenoid valve harness grommet O ring with a new one Pass the solenoid valve connector through the transaxle case hole from the inside Push the solenoid valve harness grommet into the case hole Insert the knock pin of the valve body into the case keeping the detent plate pin in the manual valve groove Temporarily install the valve body install the oil temperature sensor and holder then tighten the mounting bolts to the specified torque A bolt 18 mm 709 in B bolt 25 mm 984 in C bolt 40 mm 1 575 in Valve body assembly mounting bolts 11 Nm 8 ft Ibs Caution Firmly fasten the solenoid valve and oil temperature sensor harness at the position shown in the diagram Especially be sure to route the pressure control solenoid valve PCSV harness which is separated from other harness as shown in the diagram and fasten the harness with a clamp Failure to fasten it may result in contact with the detent plate or parking rod F4A3 W4A3 Transaxle 4WD 80 Install the oil screen filter mounting bolts 6 Nm 5 ft Ibs 81 Install the magnets in the oil pan and install the oil pan Oil pan mounting bolts 11 Nm 8 ft Ibs 82 Install park neutral position switch PNP switch and manual control lever Park neutral position switch mounting bolts 11 Nm 8 ft lbs Manual control lever mounting bolt 19 Nm 14 ft Ibs 83 Install the speedometer gear assembly Speedome
134. prag rod support bolts 24 18 Idler shaft lock plate bolt 24 18 Bearing retainer bolts 19 14 Oilpaspembly mounting bolts 21 16 Converter housing bolts 21 16 Valve body assembly mounting bolts 11 8 Oil filter bolts 6 5 Oil pan bolts 11 8 Park neutral position switch bolts 11 8 Manual control lever nut 19 14 Pump housing to reaction shaft support bolts 11 8 Differential drigearbolts 135 98 One way clutch outer race lock plate bolts 40 29 Valve body bolts 5 Pressure check plug 9 7 Speedometer sleeve locking plate bolt 4 3 Drain plug 33 24 Throttle cam bolt 9 7 nd cover bolts 5 4 3overnor set screw 9 7 TSB Revision gt M I c 23 12 SPECIAL TOOLS F3A2 Special Tools Tool Number and Replaced by OTC Application tool name tool number MD998266 MD998266 01 Alignment of intermediate plate and valve Guide pins body MD998316 MIT209038 Measurement of low reverse brake end Dial gauge play support MD998319 MD998319 01 Installation of transfer shaft rear bearing Transfer shaft and gear retainer MD998325 MD998325 01 Installation of differential oil seal Differential oil seal installer MD998333 MD998333 01 Removal of oil pump BA Oil pump remover llu tasas MD998334 MD998334 01 Installation of oil pump oil seal Oil seal installer MD998335 MD998335 01 Installation of oil pump Oil pump ba
135. r separating plate MF4 12 Steel balls 13 Spring b 14 Steel ball E 15 Upper valve body sub assembly 04 16 Steel balls 17 Solenoid valve MODEL 1992 only 18 Stiffener plate 19 Upper separating plate 964 20 Steel ball 96 21 Spring 22 Spring guide 23 Intermediate plate TFA0705 00 4 Revision 2 3A 64 F3A2 Valve Bod 5 Nm 4 ft lbs Front end cover Front end cover gasket Front end plate Front end plate gasket Range control spring Range control valve Torque converter control spring Torque converter control valve Line pressure adjusting screw Regulator spring Regulator valve 1 2 shift spring 1 2 shift plug Filter TSB Revision Viewed from B Engine brake valve 2 8 control spring ring 2 8 control valve 2 8 shift spring 2 8 shift valve Stopper plate 45 Throttle valve Throttle spring Rear end cover Gasket 1 2 shift valve 2 8 shift plug Upper valve body TFA0512 F3A2 Valve Body 23A 65 52 End cover 53 Accumulator plug 54 Accumulator spring 55 Accumulator spring 456 Stopper plate 57 Accumulator valve 58 Sleeve 59 Clutch control valve MODEL 1992 only 60 Clutch control spring 61 Reducing spring 62 Reducing valve 63 Lower valve body 0706 REASSEMBLY SERVICE POINTS
136. ransaxle 23B 47 63 Install a new gasket on the transaxle case Caution Do not reuse the gasket which was previously re moved 64 install converter housing and tighten the 14 bolts indicated by arrows to specified torque Tightening torque 21 Nm 16 ft lbs 65 Install the end clutch shaft inserting the end that has the longer splines first 66 Install the thrust washer on the return spring at the end clutch side 67 Install the end clutch hub on the end clutch assembly 68 Attach thrust bearing 13 to the end clutch hub with petrolatum jelly TSB Revision 23B 48 F4A2 Transaxle 69 Install the end clutch assembly 70 Install new O ring the groove of the end clutch cover Check the bearing for smooth rotation and replace it if defects are evident Apply an ample amount of automatic transmission fluid to the bearing 71 Secure the end clutch cover by tightening its mounting bolts to specified torque Tightening torque 7 Nm 5 ft Ibs 72 Install the parking sprag rod to the manual control shaft Then insert the shaft in the transaxle as shown in the illustration In doing this work do not install O ring in the O ring groove 73 After installing a new O ring on the manual control shaft assembly draw the shaft back into the case then install the set screw and gasket Also install the detent steel ball seat Setscrew and spring at the same time Seat H Ma
137. roughly clean the exterior of the assembly preferably by steam 2 Place the transmission the workbench with the oil pan down 3 Remove the torque converter 4 Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required except when major parts are replaced Thrust washers are located between the reaction shaft support and rear clutch retainer and between the reaction shaft support and front clutch retainer Mount a dial indicator to the converter housing using the special tool with its plunger seated against the end of the input shaft Move the input shaft in and out with pliers to obtain the end play reading Be careful not to scratch the input shaft Record the indicator reading for reference when reassem bling the transaxle 5 Remove pulse generators A and B MODEL 1993 C N lt 2 27 I 4 a Pulse Pulse generator B Y NN 2 L 6 Remove the manual control lever and then remove the park neutral position switch TSB Revision 22 4 2 Transaxle MODEL 1992 7 Snap off the snap ring and remove the kickdown servo 7 switch A qes l BS Ve 211 2 S6 zii cf al NU VI ed je 4 b Jy Si E u UE SORA servo it mm S switc Reese Snap ring 1750160 MODEL 1993 u Kickdown servo switch D Z TFAO769 8 Remove the oil pan and oil p
138. rque converter clutch Differential Kickdown brake Low reverse brake Ge d Transfer md drive gear r WE x HER 7 driven gear 1 e gt Governor Transfer shaft 1710001 TSB Revision 23 4 F3A2 General Information SECTIONAL VIEW MODEL 1993 Transfer idler gear Converter housing Toraue converter Front clutch baba ue rse Oil pump b Kickdown Planetary Input brake gear set Rear clutch Rear cover Transfer drive gear Transfer driven gear Transaxle case Transfer shaft Governor Differential 1700014 TSB Revision uoisiMeHd 951 Kickdown Torque servo Kickdown converter KAP Front clutch Rear Low reverse brake 2 Ge Clutch control Anchor rod Ex Transaxle control unit valve Torque pa Lf converter E clutch solenoid Cooler DP Ins 0 To lubrication Front Ex LU NN AH 1 2 Reducing valve lator To lubrication rear Ex Torque converter Ex control valve 661 13GONW WALSAS 1OHLINOO kickdown M OT vale ELI 1 2 shift valve
139. rt TSB Revision 23 16 F4A2 Special Tools Tool Number and Replaced by OTC Application too name tool number MD998337 MD998337 01 Use with MD998338 MD998907 Spring compressor MD998338 MD998338 Disassembly of rear clutch Spring compressor EXERCERE MD998341 MD998341 01 Removal and installation of kickdown servo Kickdown servo gt amp adapter set MD998344 MD998344 01 Removal and installation of transfer idler Wrench adapter shaft B MD998348 Bearing puller MD998348 0 1 Removal of bearing MD998367 Snap ring OSD installer MD998812 Installer cap MD998813 Installer 100 MD998301 Bearing remover MD998367 01 Assembly of the end clutch MD998348 01 Removal of bearing General service tool Use with installer and installer adapter TSB Revision General service tool Use with installer and installer adapter Number tool name MD998814 Installer 200 MD998818 Installer adapter 38 F4A2 Special Tools 23B 17 Replaced by OTC Application tool number MIT3041 80 Use with installer cap and installer adapter General service tool Installation of each bearing MD998819 Installer adapter 40 MD998824 Installer adapter 50 M 0998905 Handle MD998906 MD998905 01 Removal and installation of center support MD9989
140. s and Adhesives 17 EXTENSION HOUSING 4WD 130 Service Specifications de omes 10 FRONT CLUTCH u T y 86 Torque Specifications 18 FRONT OUTPUT SHAFT 4WD 118 Transaxle Model Table aA uan aha cut 9 GENERAL INFORMATION 2 Valve Body Spring Identification Chart 10 KICKDOWN SERVO 105 SPEEDOMETER GEAR 107 LOW REVERSE BRAKE 106 TRANSAXLE 4WD 52 OIL PUMP 84 TRANSAXLE FWD 23 OIL PUMP DRIVE GEAR TRANSFER 4WD 119 F4A 33 1 MNNS MNPE 131 TRANSFER CASE 4WD 127 PLANETARY GEAR 96 TRANSFER CASE ADAPTER 4WD 124 REAR 90 TRANSFER SHAFT FWD 113 SPECIAL TOOLS en 19 VALVE BODY EE 108 23 2 F4A3 W4A3 General Information GENERAL INFORMATION Precautions to be taken when disassembling and reassembling the transaxle e Because the automatic transaxle is composed of component parts of an especially hi
141. saxle 4WD 23C 57 20 Take out the end clutch cover installation bolts then remove the cover holder and end clutch cover 21 Remove the end clutch assembly 22 Remove the thrust plate 23 Remove the end clutch hub 24 Remove the thrust bearing 11 NOTE It may be stuck to the end clutch hub 25 Pull out the end clutch shaft TSB Revision MD998904 3 te TSB Revision F4A3 W4A3 Transaxle 4WD 26 Remove the idler gear cover mounting bolts then remove the idler gear cover and gasket 27 Disengage the bolt stopper and remove the bolt 28 Using the special tool pull out the idler shaft and then remove the idler gear and bearing inner race 29 Remove the spacer 30 Remove oil pump installation bolts F4A3 W4A3 Transaxle 4WD 23C 59 Vis A MD998333 01 TSB Revision 31 Use the special tool and remove the oil pump 32 Remove thrust washer 1 and thrust race 3 33 Hold the input shaft and remove the front clutch assembly and rear clutch assembly together 34 Remove the thrust bearing 5 35 Remove the clutch hub NOTE The thrust race may be stuck to the clutch hub WAAG Transaxle AWD 36 Remove the thrust bearing 7 37 Remove the kickdown drum 38 Remove the kickdown band 39 Remove the kickdown servo cover snap ring Then remove the kickdown servo switch 40
142. servo piston 42 Remove the anchor rod a J Anchor rod SN 43 Remove the plug then remove the air exhaust plug 44 Remove the snap ring 45 Using the special tool remove the center support TSB Revision W4A3 Transaxle FWD 23C 33 46 Remove reverse sun gear and forward sun gear together 47 Remove planet carrier assembly 48 Remove the wave spring return spring reaction plate brake discs and brake plates 49 Remove the screws and the rear bearing retainer 50 Remove the snap ring and then remove the output flange assembly TSB Revision 23 34 F4A3 W4A3 Transaxle FWD 51 Remove the output bearing retainer mounting bolts and then remove the output bearing retainer and outer race 52 Remove the transfer shaft 0150 53 Use a sliding hammer etc to remove the outer race 54 Remove all oil seals TFA0478 MD998325 01 REASSEMBLY 1 Using the special tool install the oil seals to the differential Differential bearing retainer and transaxle case bearing retainer Special tool Oil seal for differential MD998325 01 bearing retainer Oil seal for transaxle case MD998325 01 MD998803 Vehicles with 4 wheel steering oil pump 2 Use the special tool to press fit the outer race into the 990938 0 1 transaxle case 990934 01 poc cce 7 TFA0479 TSB Revision F4A3 W4A3 Tra
143. shaft and hit it with a plastic hammer or similar instrument to install it securely NOTE Apply ATF to the oil seal lip and do not scratch it 91 Coat the oil pump drive hub with automatic transmission fluid and install the torque converter Push in firmly so that dimension A in the diagram is the standard value Standard value W4A33 approx 16 3 mm 642 in W4A32 approx 12 4 mm 488 in TSB Revision hemm 23 84 F4A3 W4A3 Oil Pump OIL PUMP DISASSEMBLY AND REASSEMBLY Disassembly steps 4 1 O ring 90 2 Reaction shaft support C 3 Steel ball GAD 9B4 4 Drivegear GAD B 5 Driven gear 6 Seal ring Aa 7 Oil seal 8 Oil pump housing 9 Snap ring with torque converter clutch only 10 Oil seal with torque converter clutch only TFA0245 DISASSEMBLY SERVICE POINT AD DRIVE GEAR DRIVEN GEAR REMOVAL 1 Make reassembly alignment marks on the drive and driven gears REASSEMBLY SERVICE POINTS MD998334 01 Aq OIL SEAL INSTALLATION Oil pump housing TSB Revision SS F4A3 W4A3 Oil Pump 23C 85 DA DRIVEN GEAR DRIVE GEAR SIDE CLEARANCE MEASUREMENT Standard value 0 03 0 05 mm 001 002 in CA STEEL BALL LOCATION 04 REACTION SHAFT SUPPORT INSTALLATION 8 ft ibs 1 Assemble the reaction shaft support and the pump hous ing and tighten the five bolts by fingers 2 Insert the special tool Guide Pin MD998336 01 in the oil pump bolt hole and tighten the p
144. t Matching mark F C Matching mark lt bE SPACER SELECTION 1 Use the existing spacer to assemble the transfer case 2 Using the special tool check that the bevel gear rotating drive torque is within standard range Standard value 1 7 2 5 Nm 1 23 1 81 ft lbs 3 If the rotating drive torque is outside of the standard range adjust using adjusting spacers NOTE For adjustment use two spacers of which thickness is as close as possible to each other TSB Revision 23 130 F4A3 W4A3 Extension Housing 4WD EXTENSION HOUSING 4WD DISASSEMBLY AND REASSEMBLY Disassembly steps 841 Air breather 2 Dust seal guard 4 Cil seal 4 Extension housing REASSEMBLY SERVICE POINTS bA OIL SEAL INSTALLATION TFA0602 B AIR BLEEDER INSTALLATION 1 Install the air bleeder applying sealant to the inserting portion Specified sealant 3M SUPER WETHERSTRIP No 8001 or equivalent Apply sealant 74 TSB Revision F4A3 W4A3 Oil Pump Drive Gear F4A33 1 MNN5 MNPE 23C 131 OIL PUMP DRIVE GEAR F4A33 1 MNN5 MNPE DISASSEMBLY AND REASSEMBLY SE ES ANY TORT steps Front cover 2 Gasket GAD pAg Bearing GAD 4 4 Bearing 5 Oil pump drive gear 6 Snap ring TFA0667 DISASSEMBLY SERVICE POINT A BEARING REMOVAL MD998348 01 REASSEMBLY SERVICE POINT 22272727770 A BEAR
145. t AAA 6 Pinion 4 7 Washer AAA Side gear pA 9 Spacer 10 Differential case 160015 DISASSEMBLY SERVICE POINTS BALL BEARING REMOVAL Bb LOCK PIN REMOVAL 1 Drive out the lock pin with a punch inserted in hole A 2 Remove the pinion shaft from the case and remove the pinion gears and washers 3 Remove the side gears and spacers from the case Keep the removed gears and spacers for R H side use separated from those for L H side use 160017 TSB Revision Lock pin Differential case Protrusion lt Installation direction chamfered TFMOOOE F3A2 Differential TSB Revision 23A 57 REASSEMBLY SERVICE POINTS Aq SPACER SIDE GEAR WASHER PINION PINION SHAFT INSTALLATION ES 1 With the spacers installed on the back of the differential side gears install the gears in the differential case When reusing the removed parts install them in the original positions noted during disassembly When using new differential side gears install spacers of medium thickness 1 0 9 mm 039 os 2 Install the washers to the back of the pinion gears install the gears in the differential case and then insert the pinion shaft 3 Measure the backlash between the side gear and pinion gear The backlash should be 0 025 to 0 150 mm 0010 to 0059 in and the right and left gear pairs should have equal backlash If the
146. tall the brake pressure plate which was selected in Step 1 26 Install the return spring 27 Apply petrolatum jelly to the wave spring and attach the wave spring to the center support 28 Install the two new O rings on the hydraulic pressure holes of the center support Coat the O rings with automatic transmission fluid TSB Revision SC lt VA q 1750170 Kickdown servo piston 17200 TFAO493 TSB Revision F3A2 29 Attach the special tool to the center support and install the Transaxle support in the transaxle case Caution 1 2 Install the center support taking care that the waved spring is not out of position Install the two O rings in alignment with the oil holes provided in the transmission case 30 Remove the special tool from center support 31 Install the snap ring for the center support 32 Install the anchor rod in the transaxle case 33 Install new seal rings in the grooves of the kickdown servo piston and coat the rings with automatic transaxle fluid 34 Insert the kickdown servo spring and piston in the transaxle case 35 Install a new O ring and D ring on the kickdown servo sleeve and apply a very thin coat of automatic transaxle fluid to the rings F3A2 Transaxle 23A 35 36 Insert the kickdown servo sleeve in the transaxle case and install the snap ring 37 Install t
147. ter gear locking plate mounting bolt 5 Nm 4 165 F4A3 W4A3 Transaxle 4WD MODEL 1993 lt Ds 7 J Z Transparent tube iS 4 6 2 0 vi M 197 RS A IB 2 4 gt e 1 V groove Lock nut 23C 81 84 Install the pulse generator A and B Pulse generator mounting bolts 11 Nm 8 ft lbs Caution Install the black tube on the output gear side and the transparent tube on the end clutch side 85 Install the oil filler tube and insert the level gauge Oil filler tube mounting bolt 24 Nm 18 ft Ibs 86 Install the brackets Transaxle mounting bracket bolts 70 Nm 51 ft Ibs 87 Adjust the kickdown servo 88 Adjust the kickdown servo by the following procedure Fit the claw of the special tool in the notch of the piston to prevent the piston from turning and use adapter to secure it as illustrated at left Caution 1 Do not push in the piston With the special tool 2 When the adapter is installed to the transaxle case do not apply excessive torque but tighten with a hand b Loosen the lock nut until it is about to reach the V groove in the adjusting rod Tighten the special tool inner until it touches the lock nut 1750464 TSB Revision 23 82 F4A3 W4A3 Transaxle 4WD c Fit the special tool outer to the lock nut Turn the outer XO c p outer X cylinder counterclockwise and the inner cylinder clock
148. the wave spring drop which was applied in Step 30 2 Install the two O rings in alignment with the oil holes provided in the transaxle case 33 Remove the special tool from the center support A 34 Install the snap ring to secure the center support The snap ring ends should not interfere with the pulse generator mounting hole Pulse generator A mounting hole O Snap ring ends 35 Install the anchor rod in the transaxle case 1750170 36 Install a new teflon seal ring and a new D ring in the grooves of the kickdown servo piston and apply automatic transaxle fluid to the rings 37 Install a new O ring to the groove of kickdown servo sleeve and apply automatic transaxle fluid to the ring 38 Assemble the kickdown servo piston with the sleeve Kickdown Kickdown scrvo piston 175222 servo sleeve 1750017 TSB Revision F4A2 Transaxle 23B 43 39 Put the spring on the kickdown servo piston and sleeve assembly and insert them together in the transaxle case making sure that the end gap of the teflon seal ring of the kickdown servo piston does not interfere with the fluid apply hole provided in the servo bore of the transaxle case 40 Using the special tools push in the kickdown servo piston and sleeve assembly and then install the snap ring 41 Install the kickdown band attach the ends of the band to the ends of the anchor rod and servo piston rod NOTE Instal
149. tio Vehicle model Engine model gear ratio F3A21 2 ER18 22 1 3 3 600 CB2A 4615 GEAR RATIO TABLE Reverse SERVICE SPECIFICATIONS mm in Standard Transfer idler gear bearing preload Nm ft Ibs 0 8 6 Input shaft end play 0 3 1 0 012 039 Transfer shaft preload 0 1 0 15 004 006 Low reverse brake end play 0 8 1 0 031 039 Differential case end play 0 0 15 0 006 Oil pump gear side clearance 0 03 0 05 001 002 Front clutch snap ring clearance 0 4 0 6 016 023 Rear clutch snap ring clearance 0 3 0 5 012 020 Output flange bearing end play 0 0 06 0 002 Differential pinion backlash 0 025 0 150 001 006 TSB Revision 23A 8 VALVE BODY SPRING IDENTIFICATION F3A2 Specifications mm in Spring Free Outside Number of Wire height diameter loops diameter Throttle valve spring 32 05 9 5 12 1 0 1 262 374 039 Kickdown valve spring 26 14 6 4 19 0 5 1 029 252 020 Range control valve 23 44 8 4 11 1 0 spring 923 331 039 Torque converter control 26 4 8 8 12 1 1 valve spring 1 039 346 043 Regulator valve spring 51 4 15 4 12 14 2 024 606 055 1 2 shift valve spring 31 3 7 6 10 0 6 1 232 299 024 2 3 control valve spring 50 80 6 6 29 0 9 2 000 260 035 2 3 shift valve spring 23 71 7 2 14 0 9 933 283 035 Line relief spring 17
150. to the lock nut Turn the outer cylinder clockwise and the inner cylinder counterclockwise to unlock the lock nut and the special tool inner Caution When unlocking is carried out apply equal force to both special tools to loosen Tighten the lock nut with a hand until it touches the piston Then use torque wrench to tighten the lock nut to specified torque Lock nut 29 Nm 21 ft Ibs Caution The lock nut may turn with the adjusting rod if tightened quickly with socket wrench or torque wrench g Remove the special tool for securing the piston Install the plug to the Low Reverse pressure outlet and tighten to specified torque 23B 52 F4A2 Transaxle 85 Set a new D ring in the kickdown servo switch push the switch into the case and secure it with the snap ring MODEL 1992 41 FR 86 Install the park neutral position switch and manual control ALA 2 lever and tighten the manual control lever nut to the Q Park neutral E specified torque Mc C N AN Manual control lever 1750159 z Manual control SA lever PAN NM PX SS Park neutral position switch EE TSB Revision 4 2 Transaxle 23B 53 87 Adjust the park neutral position switch as follows a Place the manual control lever in the N neutral position b Turn the park neutral position switch body he mm 47 in wide end of the manual control aligns with the switch bod
151. ue 0 03 0 05 mm 001 002 in C4 STEEL BALL LOCATION 0 REACTION SHAFT SUPPORT INSTALLATION 1 Assemble the reaction shaft support and the pump hous ing and tighten the five bolts by fingers 2 Insert the special tool Guide Pin 0998336 in the oil pump bolt hole and tighten the peripheries of the support and housing with the special tool Band MD998335 to locate the support and housing 3 Tighten the five bolts to the specified torque 4 Make sure that the oil pump gear turns freely 175076 O RING INSTALLATION 1 Install a new O ring in the groove of the pump housing and apply petrolatum jelly to the O ring _ Revision 23 46 2 Front Clutch FRONT CLUTCH DISASSEMBLY AND REASSEMBLY Disassembly steps 64 1 Snap ring B 2 Clutch reaction plate 3 Clutch disc GAD 4 Snap ring 5 Return spring 6 Front clutch piston 7 D ring 8 D ring 9 Front clutch retainer 1750262 TFA0001 TSB Revision F3A2 Front Clutch MD998337 01 DISASSEMBLY SERVICE POINT MD998907 01 SNAP RING REMOVAL 1 Compress the return spring with the special tool 2 Remove the snap ring REASSEMBLY SERVICE POINTS 4 SNAP RING INSTALLATION 1 Compress the return spring with the special tool 2 Install the snap ring MD998337 01 MD998907 01 CLUTCH REACTION PLATE INSTALLATION 1 Install the clutch reaction plate with their missing tooth port
152. ug 33 Nm 24 165 25 Install the anchor rod 26 Install the kickdown servo spring piston and sleeve Caution The seal ring alignment hole of the kickdown servo piston must not overlap the oil filler port indicated by the arrow in the diagram 27 Use the special tool to push in the kickdown servo piston and sleeve and then install a snap ring 28 Install the kickdown band Caution Install so the arrow mark is facing toward the front TSB Revision F4A3 W4A3 Transaxle FWD 23C 41 29 Install thrust bearing 4 and thrust washer 2 on the rear Thrust washer 2 Thrust bearing 4 clutch qwe 0269 30 Combine the rear clutch assembly and the front clutch assembly 31 Install thrust bearing 5 on the rear clutch hub 32 Install the rear clutch hub on the rear clutch 33 Install thrust race 6 on the end of the rear clutch hub Thrust race 6 0273 TSB Revision 23 42 W4A3 Transaxle FWD Se OR 34 Install thrust bearing 7 in the kickdown drum foe Thrust bearing 7 5 e lt 2 TFA0274 35 Install the clutch assembly in the kickdown drum TFAO27E 36 Install the clutch assembly and kickdown drum into the transaxle case at the same time 17 TFA0276 37 Adhere thrust race 3 and thrust washer 1to the back of Thrust washer 1 Thrust race 3 i the oil pump with petrolatum 38 Use the special to
153. ure control solenoid valve 3 Torque converter clutch solenoid Models with torque converter clutch 4 Shift control solenoid valve 5 Shift control solenoid valve B 6 Plate Except models with torque converter 7 vy mm clutch Valve stopper N D control sleeve N D control valve D410 Lower valve body sub assembly 11 Lower separating plate 12 Nut 13 Jet 4 14 Relief spring 964 15 Steel ball B C4 16 Oil filter B4 17 Upper valve body sub assembly 4 18 Steel ball 19 Teflon ball pA 20 N D plate 21 Block 22 Upper separating plate 23 Intermediate plate TFA0523 TSB Revision F4A3 W4A3 Valve Bod 24 Disassembly steps Re 2 Shi Stopper plate 4 Shift control plug Rear clutch exhaust valve A Front end cover Pressure control spring Pressure control valve Torque converter control spring Torque converter control valve Adjusting screw Regulator spring quor valve t control spring TSB Revision Viewed from B TFA0518 36 Rear clutch exhaust valve B 37 Rear clutch exhaust spring 38 2 3 4 3 shift spring 39 2 3 4 3 shift valve 40 Rear end cover 41 Shift control plug B 9 4 42 SE 43 Shift control valve 44 1 2 shift spring 45 1 2 shift valve 46 Upper valve body 23C 109 23 110 F4A3 W4A3 Valve Body NE 59 47 48 Stopper 49 End clutch plug 50 End
154. utput flange bearing end play Front clutch end play FAA33 W4A33 FAA32 Rear clutch end play F4A33 W4A33 2 End clutch end play Transfer drive gear end play Front output shaft preload W4A32 WAA33 Center differential side gear end play W4A32 W4A33 Bevel gear set backlash W4A32 W4A33 Driven bevel gear turning drive torque WAA32 W4A33 Drive bevel gear shaft turning drive torque W4A32 W4A33 F4A3 W4A3 Specifications Nm ft Ibs Nm ft Ibs VALVE BODY SPRING IDENTIFICATION CHART Part name Wire diameter Outside diameter mm in Standard 0 075 0 135 0030 0053 1 0 1 2 0394 0472 0 3 1 0 0118 0394 0 075 0 135 0030 0053 0 045 0 165 0018 0065 0 025 0 150 0010 0059 0 03 0 05 0012 0020 0 0 09 0 0035 0 8 1 0 0315 0394 0 7 0 9 0276 0354 1 0 1 2 0394 0472 0 4 0 6 0157 0236 0 60 0 85 0236 0335 0 0 09 0 0035 0 055 0 115 0022 0045 0 01 0 03 0004 0012 0 08 0 13 0031 0051 1 0 17 72 1 23 1 7 2 5 1 23 1 81 mm in No of turns 1 4 055j 0 6 024 0 45 0177 0 7 028 0 6 024 0 8 031 0 7 028 1 2 047 1 0 039 1 3 051 0 5 020 Regular valve spring 1 2 shift valve spring Pressure control valve spring Rear clutch exhaust valve spring End clutch valve
155. way any sand mud etc adhered around the transaxle 2 Place the transaxle assembly on the workbench with the oil pan down 3 Remove the torque converter 4 Use the special tool to mount the dial gauge on the transaxle case and measure the end play of the input shaft 5 Remove the pulse generator A and B MODEL 1993 2 2 6 Remove manual control lever then remove park neutral position switch PNP switch TSB Revision F4A3 W4A3 Transaxle 4WD 23C 55 7 Remove the oil pan magnets and gasket 8 Remove the oil filter from the valve body 9 Remove the 10 valve body mounting bolts 10 Remove the oil temperature sensor holder and remove the oil temperature sensor harness from the clamp 11 Press the finger of the solenoid valve harness grommet push the grommet into the case and remove the valve body assembly 12 Pull out the oil temperature sensor 112 TSB Revision 23 56 F4A3 W4A3 Transaxle 4WD 13 Remove the parking roller support 14 Remove the set screw of the manual control shaft and Setrserew remove the manual control shaft assembly 15 Remove the detent assembly TFA0114 16 Remove the differential cover and gasket 17 Remove the differential front bearing cap 18 Remove the differential bearing retainer spacer and outer race 19 Remove the differential assembly TSB Revision F4A3 W4A3 Tran
156. y Use the following procedure a Install the brake reaction plate brake plates and brake discs in the transaxle case Caution Blow off automatic transmission fluid from the plates and discs with low pressure compressed air b Install the pressure plate and mount the return spring Return J spring B Pressure di plate rake Brake SC plate 1700052 TSB Revision F3A2 Transaxle Wave spring c Apply petrolatum jelly to the wave spring and attach the wave spring on the low reverse brake piston d Install the two O rings removed during disassembly and coat them with automatic transaxle fluid e Attach the special tool to the center support and install the support in the transaxle case Caution 1 Install the center support taking care that the waved spring is not out of position 2 Install the two O rings in alignment with the oil holes provided in the transaxle case f Remove the special tool g Install the snap ring h Mount the special tool and dial indicator on the rear side of the transaxle case Make sure that the dial indicator rod MD998913 01 is inserted into the transfer idler shaft hole contacting the brake reaction plate at a right angle Brake reaction plate 1750443 TSB Revision AJ sa FA 90 Vw KS lt 52 INS Torque converter side Groove Inner race Outer race Tr ranster idle gear
157. y flange 12 mm 47 in wide portion Alternatively turn the switch body until the 5 mm 20 in hole in the manual control lever aligns with the 5 mm 20 in hole in the switch body Tighten the attaching bolts to the specified torque 47 in Manual control lever 5mm dia 20 in hole taking care that switch body is not displaced in 17513 i Tightening torque 11 Nm 8 ft Ibs Section A A control lever Attaching bolts MODEL 1993 20 in hole TSB Revision 23 54 F4A2 Transaxle MODEL 1992 88 Check the continuity between terminals with the manual control lever at each position The continuity between terminals should be as shown in the table below Internal Connection in the Inhibitor Switch MODEL 1992 No O Transaxle control unit Transaxle control unit Transaxle control unit Ignition switch ON terminal Transaxle control unit Transaxle control unit Transaxle control unit ME Ignition switch ST terminal Starter motor S terminal Ignition switch ON terminal MODEL 1993 Connected circuits Transaxle control module Transaxle control module Transaxle control module Ignition switch ON terminal Ignition switch ST terminal Backup lamp Ignition switch ON terminal

Automatic Transmission Service

Contents

Download Pdf Manuals

Related Search

Related Contents