General
A: PrecautionWhen disassembling or assembling the automatic transmission, observe the following instructions.
1. Workshop
Provide a place that is clean and free from dust. Principally the conventional workshop is suitable except for a dusty place. In a workshop where grinding work, etc. which produces fine particles is done, make independent place divided by the vinyl curtain or the equivalent.
2. Work table
The size of 1 x 1.5 m (40 x 60 inch) is large enough to work, and it is more desirable that its surface be covered with flat plate like iron plate which is not rusted too much.
3. Cleaning of exterior
1. Clean the exterior surface of transmission with steam and/or kerosene prior to disassembly, however it should be noted that vinyl tape be placed on the air breather or oil level gauge to prevent infiltration of the steam into the transmission and also the cleaning job be done away from the place of disassembly and assembly.
2. Partial cleaning will do, depending on the extent of disassembly (such as when disassembly is limited to some certain parts).
4. Disassembly, assembly and cleaning
1. Disassemble and assemble the transmission while inspecting the parts in accordance with the Diagnostics.
2. During job, do not use gloves. Do not clean the parts with rags: Use chamois or nylon cloth.
3. Pay special attention to the air to be used for cleaning. Get the moisture and the dust rid of the air as much as possible. Be careful not to scratch or dent any part while checking for proper operation with an air gun.
4. Complete the job from cleaning to completion of assembly as continuously and speedily as possible in order to avoid occurrence of secondary troubles caused by dust. When stopping the job unavoidably cover the parts with clean chamois or nylon cloth to keep them away from any dust.
5. Use kerosene, white gasoline or the equivalent as washing fluid. Use always new fluid for cleaning the automatic transmission parts and never reuse. The used fluid is usable in disassemble and assemble work of engine and manual transmission.
6. Although the cleaning should be done by dipping into the washing fluid or blowing of the pressurized washing fluid, the dipping is more desirable. (Do not rub with a brush.) Assemble the parts immediately after the cleaning without exposure to the air for a while. Besides in case of washing rubber parts, perform the job quickly not to dip them into the washing fluid for long time.
7. Apply the Automatic Transmission Fluid (ATF) onto the parts immediately prior to assembly, and the specified tightening torque should be observed carefully.
8. Use Vaseline if it is necessary to hold parts in the position when assembling.
9. Drain ATF and differential gear oil into a saucer so that the conditions of fluid and oil can be inspected.
10. Do not support axle drive shaft, stator shaft, input shaft or various pipes when moving transmission from one place to another.
11. Always discard old oil seals and O-ring, and install new ones.
12. Always discard old oil seals and O-ring, and install new ones.
13. Be sure to replace parts which are damaged, worn, scratched, discolored, etc.
B: Inspection
1. ATF Level
1. Raise ATF temperature to 60 to 80°C (140 to 176°F) from 40 to 60°C (104 to 140°F) (when cold) by driving a distance of 5 to 10 km (3 to 6 miles).
Note: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking oil level.
2. Make sure the vehicle is level. After selecting all positions (P, R, N, D, 3, 2, 1), set the selector lever in "P" range. Measure fluid level with the engine idling.
Note: After running, idle the engine for one or two minutes before measurement.
3. If the fluid level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found within the specified range (above the center between upper and lower marks). When the transmission is hot, the level should be above the center of upper and lower marks, and when it is cold, the level should be found below the center of these two marks.
Caution:
^ Use care not to exceed the upper limit level.
^ ATF level varies with temperature. Remember that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of fluid.
4. Fluid temperature rising speed
By idling the engine
Time for temperature rise to 60°C (140°F) with atmospheric temperature of 0°C (32°F): More than 25 minutes
Time for temperature rise to 30°C (86°F) with atmospheric temperature of 0°C (32°F): Approx. 8 minutes
^ By running the vehicle
Time for temperature rise to 60°C (140°F) with atmospheric temperature of 0°C (32°F): More than 10 minutes
5. Method for checking fluid level upon delivery or at periodic inspection
Check fluid level after a warm-up run of approx. 10 minutes. During the warm-up period, the automatic transmission functions can also be checked.
2. Differential Gear Oil Level
1. Ensure the vehicle is in safe condition.
Note: Do not check the oil level nor add oil to the case with the front end of the vehicle jacked-up; this will result in an incorrect reading of the oil level.
2. Check whether the oil level is between the upper (F) and lower (L) marks. If it is below the lower limit mark, add oil until the level reaches the upper mark.
3. Oil Leakage
It is difficult to accurately determine the precise position of a oil leak, since the surrounding area also becomes wet with oil. The places where oil seals and gaskets are used are as follows:
1. Jointing portion of the case
^ Transmission case and oil pump housing jointing portion
^ Torque converter clutch case and oil pump housing jointing portion
^ Transmission case and extension case jointing portion
2. Torque converter clutch case
^ Engine crankshaft oil seal
^ Torque converter clutch impeller sleeve oil seal
^ ATE cooler pipe connector
^ Torque converter clutch
^ Torque converter clutch case
^ Axle shaft oil seal
^ O-ring on the outside diameter of axle shaft oil seal holder
^ O-ring on the differential oil gauge
^ Differential oil drain plug
^ Location of steel balls
3. Oil pump housing
^ Oil pump housing (Defective casting)
^ O-ring on the test plugs
^ Differential gear breather
^ Location of steels balls.
4. Automatic transmission case
^ Transmission case (Defective casting)
^ Mating surface of oil pan
^ O-ring on the test plugs
^ Oil supply pipe connector
^ ATF cooler pipe connector and gasket
^ Oil pan drain plug
^ O-ring on the transmission harness holder
^ Oil pump plugs
^ ATF breather
^ Shift lever oil seal
^ O-ring on the vehicle speed sensor 2 (Front)
^ O-ring on the turbine revolution sensor
^ ATF filter oil seal
5. Extension case
^ Extension case (Defective casting)
^ O-ring on the vehicle speed sensor 1 (Rear)
^ Rear drive shaft oil seal
^ O-ring on the test plugs