4 ATSGEI. 5 i karte TRANSMISSION SERVICE © os INDEX Sectional Cross Sections. Hydraulics. Specifications.. Diagnosis and Testing.. Trouble Shooting. Fault Codes... Central Systems. System Components. Oil Pressure Testing. Components F4A3. Teardown.. Components W4A3. Reassembly.. Component Teardown and Assembly.. ValveBody. Center Differential-Transfer Case 4WD. Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami FL 33156 (305) 670-4161 2 15 19 23 104MITSUBISHI i ATSG F4A3 W4A3 INTRODUCTION There are two model versions of this transaxle. The F4A3 is the two wheel, front wheel drive version and the W4A3 is the all wheel or 4 wheel drive model. The teardown and assembly of these units are similiar. We have high lighted the differences so that the technican will have the information necessary to service both of these units. The component rebuilding sections shows the differences in these units. This manual contains the information needed in diagnosing both the mechanical, hydraulic and electronic complaints with the units. Each of these models have two versions. The F4A33 with a converter clutch, The F4A33 without a converter clutch, The W4A32 with a converter clutch’ and the W4A33 without a converter clutch. We have covered the the changes in the unit. The wire schematics for the units up to 1992 and the 1993 ; and up, along with updates in both the parts and diagnosing both systems. We thank Mitsubishi Corporation for the illustrations and information contained in this manual. DALE ENGLAND ROBERT D. CHERRNAY FIELD SERVICE CONSULTANT TECHNICAL DIRECTOR WAYNE COLONNA FRANK MIETUS TECHNICAL CONSULTANT ee PETE LUBAN ED KRUSE G ECE HICRI'CONGHL TANT] TECHNICAL CONSULTANT JIM DIAL TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (305) 670-4161c a & : 5 scteatommmaseesanee : A aD o ~— —_ | 8 es = ; B <= | {_] = oO manos en, eo mn C2 S ---_E—E ~~ > : = “oat Sm \ 3 KE “ = uo wt] fades | S un mag OL 5 fe oo LE wha age a ‘ems seyenuos enbioy mowpim Eeyed — MGI TWNOLLDAS ‘yeunp seuenuos onbion Qu EEvPd ~ MBIA TNOUDISSECTIONAL VIEW - W4A22 with torque convertar clutch eso 7 c Tore, 2 — 3% E 3 som Some ® 8 = 3 3 UD . s 2 £ om) ° (— Ly; oe a Tne4ATSG Technical Service Information HYDRAULIC CONTROL SYSTEM (Without torque converter clutch) HYDRAULIC CONTROL SYSTEM (With torque converter clutch)ATSGI Technical Service Information SPECIFICATIONS TRANSAXLE MODEL TABLE - MODEL 1992 Transaxle Gear ratio | Speedometer | Final gear | Veniciemodel | Engine mode! mode! type ‘gear ratio ratio Faag3-1-UP61* A [2996 4376/0228 4G63-DOHC TIC MNP2 A | 2836 3958) Z1ia 8G72-DOHE MNN3 A 2836 3958 | Figs 6672 MNNA nN 26136 3958 | FI6A 8G72-DOHC MNNS*? A 28136 3.958 | FGA 6G72-DOHC W4A32-1-UNN 4 2836 4422 | Naaw 4664 WNA, 8 28136 |} 4750 | Naw 4693 uoa2 8 30336 | 4422. | ESea 4G83-.D0HC. Wana3-1-UP6"" A 29836 [4422 | b27a 4G63-D0HC TIC TRANSAXLE MODEL TABLE - MODEL 1993 Transaxle Gear rato | Speedometer | Final gear | Vehicle mode! | Engine model model type gear rato ratio FAA33.1-UP61"* rn 4376 | 02a 4G63-:DOHC TIC MNPS rN 2036 3358 | 211A 6G72-00HC | MNeg A 28136 3988 | Fiea 6672 MNPC, A 28136 | 3958 | Fi6a 6G72-D0HC | MINPE* A 28136 358 | Fiea 6G72-D0HC W4A32-1-UNQ. A 281368 4.422 | N2aw,Naaw | aG64 WNFI 8 2838 4750 | NZIW 4g93 Weag3--UP6I"" | A 29936 4az2___| 027A 4G63-DOHC TIC NOTE *T; Mode! without torque converter clutch (TCC) "2: Model with 4-wheel steering oil pump drive gear TRANSAXLE MODEL TABLE — MODEL 1994 [ Transaxie Gear ratio | Speedometer | Final gear | Vehicle model | Engine mode! model ‘wpe ‘gear ratio ratio F4A33.1-UP63* A 29736 4376 | Daza 4G63-DOHC TIC uPa? 4 2936 4376 | E56 4G64-DOHC MNo2 4a 28°36 3958 | 211A 8G72.D0HC MNOS a 28°36 3958 | Fiea 6672 MNoa a 28736 4376 | Fi6a 6G72.D0HC waa32-1-UNQ A 2336 4422 | N2aW.Naaw | aG64 WAR33.1-UP61* A 2936 4422 [D27A 4G53.00HC TIC NOTE "1. Model without torque converter clutch (TCC! GEAR RATIO TABLE A B 1st 2551 2.846 2nd 1.438 1581 3d 1.000 1900 atm 0.685, 0835 Reverse 2176 2178 zATSG] Technical Service Information DIAGNOSIS AND TEST connector | YY « @6 ¥® ec ELCaAT ‘%. Diagnosis contol "Ground FLUID LEVEL AND CONDITION 1. Drive until the fluid temperature reaches the usual tempera- ture [70 - 80°C (160 — 180°F)] 2. Place vehicle on level floor 3. Move selector lever sequentially to every position to fil torque converter and hydraulic circuit with fluid, then piace lever in “N" Neutral position. This operation is necessary to be sure that fluid level check is accurate. CONTROL CABLE Whether control cable is property adjusted can be confirmed by checking whether park/neutral position switch is performing well ‘Apply parking brakes and service brakes securely. Place selector lever to "R” range. Set ignition key to “ST” position. Slowly move the selector lever upward until it clicks as it fits in notch of “P” range. If starter motor operates when lever makes a click, "P” position is correct. 5. Then slowly move selector lever to “N” range by the same procedure as in foregoing paragraph. If starter motor ‘operates when selector lever fits in “N", “N” position is correct. 6. Aiso check to be sure the vehicle doesn’t begin to move and the lever doesn’t stop between P-R-N-D. 7. The control cable is property adjusted if, as described above, the starter motor starts at both the “P” range and the “N" range. OBTAINING FAULT CODES (1) Connect the voltmeter or scan tool to the connector for diagnosis, (2) Read the output fault codes. Then follow the remedy procedures according to the “FAULT CODE DESCRIPTION” on the following page. NOTE © As many as a maximum of ten fault codes, in the sequence of occurrence, can be stored in the Random ‘Access Memory (RAM) incorporated within the control unit, © If the number of stored fault codes or fault patterns exceeds ten, already stored fault codes will be erased, in sequence beginning with the oldest. * Do not disconnect the battery until all fault codes or fault patterns have been read out, because all stored fault codes or fault patterns will be canceled when the battery is disconnected, (3) If the fail-safe system is activated and the transaxle is locked in 3rd gear, the fault code in the FailSafe Code Description will be stored in the RAM. Three of these fault codes can be stored. (4) The cancellation will occur if, with the transaxle locked in 3rd gear, the ignition key is turned to the OFF position, but the fault code is stored in the RAM. 74 ATSG Technical Service Information COMPONENT LOCATION Name Symbol Name ‘Symbol ‘AT fd temperature sensor A_ [Engine contiol module o ‘AT solenoid valve assembly (valve body 8 __| Kickdown servo switch A ‘Auto-ruise contol unit F__[Puise generator A Datalink connector 0 _| Trratie position sensor c ELC-4 AT control module e 7 = Datalink connector c Le ~~ Auro-cruise pi controlunt S833ATSG Technical Service Information TROUBLESHOOTING GUIDE aha pm ah egies le Career one naa 12 reorsiee o bes ara waa nar 72] ences eh or nerve wong Sepstensereeantseatberen ne morn A germans art arn arses srountemstereang ome PES aonagedo Gace wing ono PS cenaedo' oncaeid han ERE ears | i ez T FE @ndcaes tame ol poety aurrgpecton PSch esaittontal sone ae -atbroesong. TPS = Toe oson cena S551 5 Butcorwolsaeroavane cic TTomecomenncachsaaes BOO °c a 3 € 2 € o fo 2 ® oO 3 & € £ oO ® FE 10Technical Service Information i tp : [earner ao] [e] f | ee a (@3NNLLNOD) (13GOW Z661) LINDUIO Lv O73 L_.Technical Service Information A ATSG (@3NNUNOd) (T3GOW 7661) UNDO Lv Ta (W3G0W zest) LINDHID Lv 97aTechnical Service Information (PaAATSE 8 (a3nNuNoo) (siepou sexe, pur £661 YO) INDIO LY 9713 ln SURE (sjpou 408) pue E661 UO) LINDUID LV 7-973Technical Service Information (aAaTsc (aanNUNOd) (stepow Jere pue Es61 WO) LIND WY KOTRFAULT CODE DESCRIPTION Technical Service Information Code Display Pattern Item Remedial Action " Excessively large tote ~ Chock throttle position sensor position sensor output connector. SUL m + Check throttle position sensor ‘on bench. ‘Aajust throttle position sensor. 2 Excessively small throttle Check accelerator switch n position sensor output {whether code number 24s being LL output) 13 Defective or impropeiy adjusted throttle position UL sensor 14 Improperly adjusted throttie Tui position sensor 18 ‘*Open circuited low-oiF- ~ Check oil temperature sensor temperature sensor ort an Pn ‘=1992 model> 1¢ Check ol temperature sensor on ‘*Open-ctcuited oll temperatura | bench. sensor <1993 model> 16 Shor -ircuited high oF temperature sensor TU <1992 model only> 7 ‘Open-circuited high-oi- temperature sensor or short- UL circuited low-oil-temperature sensor <1892 madel only> 2 ‘Open-circuited kickdawn servo | @ Check kickdown servo switch m switch sonnector. 1 Chack kickdown servo switch on bench 2 Short-ciruited kickdown servo TT. ‘switch 23 ‘Open-circuitedignition pulse | @ Check ignition pulse signal ine. Ara pickup cable 2a Opencircuited orimproperly | © Check accelerator switch connector, ru usted accelerator switch Check accelerator switch on bench. Jon. 1992 model only> {Adjust accelerator switchTechnical Service Information cece Display Pattern em Remedial Acton a ‘Open cruited pulse generator A | © Check pulse generator Aor on Boneh TU © Check vehicle-speed reed switch (chattering). 2 Oper-ciruited pulse generator 8 OTL 41 Open-circuited shift control © Check solenoid valve: Freee solenoid valve A Chock sn contol soled vave on a 2 Shortreuited shift conta nonrut solenoid valve A 3 Open-auted shit coril | » Check slenad vate connector sdiencidvave * Check sft convol solenoid vaive on Bonbench “4 Short-circuited shift control nr solenoid valve 8 rr Open-cicuited pressure contol | © Check solenoid valve connector one sdenodvalve Check pressure contol solenod ‘ale on bench 6 Short-circuited pressure “remo contol solenat vaio 47 Qpen-crcuited torque ‘converter cee ‘solenoid valve connector. Sitch soianok hock orque converter utch Tia solenoid on bench. @ Shortereuted torque converter _ elute goienodd 8 Detectveorque converter | Check torque converter catch clutch system hyarauie creat TOT nero © Cheek torque convener clutch solenoid on bench. @ Replace control unitTechnical Service Information Code No. Display Pattern Item Remedial Action 51 my Ist gear incorrect ratio © Check connectors of pulse eneratorsAand 8. Bhreck pulse generators A and B on Bench «Rear ciutenstpping 82 aT, ‘2nd gear incorrect ratio © Check connectors of pulse enerators A and 8. Bhreck pulse generators A and B on Bench Rearelutch sipping Kekdown brake sipping 83 3rd gear incorrect ratio | Check connectors of pulse enerators A and 8. heck pulse generators A and B on Bench « Front euten sipping Rear cuteh sipping ‘Ath gear incorrect ratio ‘© Check connectors of pulse apnerators A and 8 heck pulse generators A and B on Dench. End clutch slipping Kickdown brake sipping 61 Shortcircuited torque reduction request signal ine of open-circutted torque reduction execution signal ine ‘© Check torque reduction request signal line. © Check torque reduction execution signal line. 62 Open-circuited torque reduction request signal line ‘© Check torque reduction request signal line, Short-cireutted torque reduction execution signal ine ‘© Check torque reduction execution signal line. Teas 7Technical Service Information FAIL-SAFE CODE DESCRIPTION cose Display Paster item Faisafe Related No. Self Siagnosis a | Open-circuited pulse | Fixed at Sra (0) 31 | generator or 2nd'(2: 1) NANA 82 Opencircuited pulse [Fixed at Sra 0) 2 generator or 2nd(2, 38 Open- oF shorecrcvited| Fixed at a ana shit control solenoid OANA vavea 38 Open-orshortcicuited|Fixedatard——*d a3. a shiftcontrolsolenoxd ANA sa, valves 85 Open- or short-crcuited| Fixed at (0) 45.46 pressure control | or and (2) AANA sa Solenoid valve 86 Incorrect gear ratio [Fixed at Sra (0) 51.52 or2nd 2,1) 53,54 Ann 72.096 18Technical Service Information INSPECTION OF CONTROL SYSTEM Check the control system by using the scan tool and following the procedure given below. CONTROL SYSTEM INSPECTION TABLE Description Possible Cause of Co cane cea Trouble (or Remedy) ‘Throtle position ‘Accelerator pedal fully 04-10V | © TPSisimpropery adjusted sensor 1S) feleased, voltage s high when accelerator Pedals fully depressed or ‘Accelerator pedal siowly Varies with Felessed, Drange, 31d speed. driven 2150 kmin 3) mph 1,600 ~ 2,000 rpm ‘Drange. 4th speed, arven at 50 rh (31 mph 1.100 — 1,400 ram Gepressed throttle opening | « TPSorcreuit haess is detective degree itthere sno change. + TPSoraccoleratr pedal cabo is ‘Accelerator peda tally 45 -80V efectve changes not smooth epressed Oltemperatre Cod engin before star) Equvaient | © Detective ol temperature sensor Sensor to outsde orareut hamess temperature Engine warming up | Graduaty After engine warming up a - 10% Keksown servo range, le oN Impropery ajusted Kickdown servo swten Detectwe bckdown servo smitchor Drange, 1st or Sid speed on eeu hares. ‘+ Detective ckdown servo Drange, nd or ath speed OFF Ignition signal Nrange, ide 150 - 900 tam | © Detective ignition system tne Detective ignition tre! pickup N range, 2500 rom 2.400 — 2.600 rom |” creuthamess ttachometer reading) ‘Accelerator pedal | Accelero: pedal uly ON © Improperly adjusted accelerator Swen released pods Switch £21882 mode only> «Detective scceleratorpedal switch orcrcut harness ‘Accelerator pedal sighty OFF depressed hosed throwte| “Accelerator pedal fly ON Impropery adjusted TPS postion switch feleased Defective 7PS or ercuit harness ‘Accelerator pedal sightly OFF Gepressed ‘rcondiioning Drange. air condoning on * Detective a condoning compressor compressor autch | idle-up clutch relay ON signal detection eveur ‘ey signal a = = amoss ‘ange. er conditions idle OFF 7 “Transaxle gear Drange. ile ce Defective Tom position Detective accelerator peda switch range ile 1st ereut + Befective parknoutal poston switch 2range: 2nd speed 2ND greut «# Beteste TPS creut Drange, O10 OFF. ard speed RD Drange, O10. ih speed aH Pulse goneraiorA | Drange, stop [om ‘© Detectve pulse generator Aor ‘reuit harness '# Defective pulse generator A ‘shielded wire ‘© External nove interference 9TSG Technical Service Information a Description Possible Cause of Condition Criteria ‘Trouble tor Remedy) lse generator® | Drange, stop Oop . Drange, rdspeed driven | 1,600 2.000 wpm | « x50 vn (3 mph External noise interference Drange. 4 speed, ariven | 1/600 — 2.000 rpm mxsokrn (ot mph) | Oversrve swatch | Overive awitehin ON oD ® Detective overdrive swten or positon ‘rout hemess Overdrive switch in OFF ‘OD-0FF postion Powerleconomy | Power patiem selected Power * Defective powereconomy select Select swteh {ncding economy pttom Saitoh or Grout harness Eontrol with iow ot temperaturel | Economy patemselecied | ___Ecanomy Parkineutral posinen | Shifted to Prange | Pp © Improperly adjusted parkneutral position Sone eaten [Shifted to Rrange i a + Betectve parkneuttal poston switch or ‘reatramess | ShitedtoN range N «+ Betective manual conto cable 5 It Seiscto: ever does not move ([Britedto Drange ° check shit osk mechan Shited to 2 range 2 Shitted to Lange I u Vehicle peed | Weticie stationary [__oikmm (0 mph) _| © Vehicie-speed reed owichis ‘eed evnten detective igh speed signalis DrvenatSokrh(19meh) | 30 krvh (19 mph) | | outputwhere vehicles sistonay. «# Gtherwto,vehicle-speed reed switch Divenst60 kmh i moh) | 60 km/h (31 mph) |" orcreuthamessis efecine PSV duty Drange. le 50 — 70% __| © Dutyshouldinecome 100% when acceler — — or ph depressed wren at range, 1st speed orb range die conditons Detective Text Drange gearbeing sifted | Depends on condition © Detecuve TPS circuit Defective accelerator pedal switch sreuit aE | Pag asiges oon | wom am |; Beecnongnanere ue ‘ear Pane es Beier apie pasrenaard Se anon tess nave | van |» RORSSTaoa cranve pares taseentp > Sommerer TeEmmoasn | Penge suspension | oe |» tone To {tachometer eading! * © Defective TPS circuit Drage age. 20m | Deprds ov Ea tachometer reading) 20ATSG Technical Service Information TRANSAXLE CONTROL UNIT ‘The connector has 42 pins to accommodate the increased number of sensor inputs. Here are the pin assignments. <1992 model> Torque converter clutch solenoid Shift control solenoid vaive A Power source Ground Pressure control solenoid valve ‘Shift control solenoid valve B Engine communication signal Power source Ground Ground ‘Accelerator switch On-board diagnostic output Air conditioning compressor clutch relay signal Engine communication signal Diagnostic test mode control terminal Engine communication signal Power source {backup} Kickdown servo switch Closed throttle position switch Git temperature sensor (Low temperature side) Giltemperature sensor (High temperature side) Throtle positon sensor Sensor ground Vehicle-speed reed switch Parkineutral position switch (PI Parneutral positon switen (R) Pariineuttal positon switch (N) Parkineutral position switch (D) Parkineutral position switch (2) Park/neutral position switch (L) Overdrive switch Pulse generator B Pulse g Pulse ger Ground Ignition pulse fer mode signal 20Technical Service Information <1993 model> Torque converter clutch solenoid 1 2 Shit contro solenoid valve (SCSV-A) 4 Engine communication signal & = 7. Kickdown serve switch & Airconditioning relay signal 8. On-board diagnostic output terminal 10. Pulse generator B (PG-B) output 11. Diagnostic test mode contro! terminal 12, Power source 13. Ground 14 Pressure control solenoid valve (CSV) 18. Shift control solenoid valve B (SCSV-B) 6 = 17, Engine communication signal 18, Engine communication signal 19, 20. Closed throtte position switch 21. Throttle position sensor (TPS) 23. Oiltemperature sensor 24, Sensor ground 25. Power source 26. — Ground 31. Parkineutral position switch (P) 32. Parkineutral position switch (R) 33. Park/neutral position switch (N) 34. Park/neutral position switch (D) 36. Park/neutral position switch (2) 36. Parkineutral position switch (L) 37. Overdrive switch 3B Power mode signa 39. Power source (backup) 40. Vehicle-speed reed switch 41. Pulse generator B (PG-B) 42, Pulse generator 8 (PG-8) 43, Pulse generator A(PG-A) 44, Pulse generator A (PG-A) 45, Ground 46. Ignition puise 2Technical Service Information ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER Selector || Overdrive | Shifting Engine Parking Clutch Brake lever ‘control gear | Gear ratio | start | mechanism position | __ switch 1 | c2] ca fowc] a1 | 62 Pp = Neutral = Possible ° R - Reverse | 2.176 ° ° N = Neutral = Possible 1st 2.551 ° ° 2nd 1.488 ° ° D ON ‘3rd 1.000 ele[s oD 0.685 . . ist 2551 | iz ° D OFF 2nd 1488 | Le ° ‘rd 1.000 | elele Ist 2.851 ° ° 2 5 2nd 1.488 ° ° L = Ist 2.581 ° ° NOTE Ct. Frontclutch C2 Rear clutch 3. End clutch 81 |” Low reverse brake 82... Kickdown brake OWG.... One way clutch SHIFT PATTERNS ‘Two shift patterns are pre-stored in the control unit of this transaxle. One is the power pattern [for more powerful performance), and the other is the economy pattem (for improved fuel consumption and quieter operation), ‘The driver can select and switch to the desired pattern by using the power/economy select switch on the center console. The solid lines shown in these shift patterns indicate up-shifts. and the broken lines indicate dowr-shifts. The reason why there is a difference between the shift points for up-shifts and for downshifts is so that up-shifts and down-shifts will not ‘occur frequently when driving at @ speed in the vicinity of the shift point. When the vehicle is stopped, there is a shift to 2nd gear in order to obtain a suitable “creeping”. but when the accelerator pedal is then depressed the vehicie starts off in 1st gear. 2BTSG Technical Service Information INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS Improper connection of connector, damaged or disconnected harness, for incorrect wining con- ection. ft Reconnect the connec- tor; repair or replace the hamess. Based on the wiring diagram, ‘check whether the continuity and 1. Wiring ‘Grounding of each harness is OK. Nary the thermo-sensitive part "oivtemperature | __/ ftom low temperature ta igh <~\_[osuasniarancomeaed ? Sensor For oe aeratrekmnevesist- )o( NOcontiuity, 4} Damaged or disconnect ee madet> | \ sresbotween th terminals and Replace he oi formperture sensor NZ OG 2 3) 1 Low temperature side 2. Grouna’ ° High temperature side \ary the thermo-sensitive part ll 43. Oitemperature temperature and check the resist. No continuity \_,| Damaged or disconnected ‘sensor ance between the terminals 1 and (resistance: =) wiring <1993 model> 2. Changes of the resistance con- Replace the oit tinuous and smooth. temperature sensor Normal : fe sensor 2 Ground 24Technical Service Information “4. Throttle- Check the resistance between Resistance: Damaged or discon Fantonsaneor Lok Sree tcc TS fepserari. >} amagelen TPSterminal 35-65 KN2OC (68°F) Feplace the TPS. STON KAP [creatine sitar between = Check ersten Resinangs: . came wgumnatad gndz wun neering -o{ more ss = Closed throttle m-up. 20°C (68°F) Teast ne TFSi eee Semi Resistance: approx. 0.4 k 20°C (68°F) Check for changes of the resist: ance between terminals 4 and 2 when the throttle valve ‘operated from the idling position to the fully open position. Replace the TPS, Changes of the resistance con- smooth Normal 255. Pulse generator ‘AorB nulse generator terminals rs Po oo : = 6. Pulse generator ‘Aor B (checking by anoscillo- scope) )selloscope waveform Noise smn Technical Service Information Check the resistance between terminals 1 and 2 oF 3 and 4. 215-276 0/20°C (68) Connect the pulse generator and ‘body hamess, and connect an ‘oscilloscope. Check with the chassis on a dynamo or with the front wheels raised. With the selactor lever at the “L” position and the engine running at 4,000 rpm, check the voltage viayatorm between terminals 1 positior running at 1,000 rpm, check the voltage waveform between terminals 3 and 4, BOOmVEp or higher 26 Noise in the waveform Resistance: Shor -creut, or dam. foolowor +4) agedordisconnected feo mgh wang Replace the pulse generator Incorrect installation of the pulse generator, or ‘malfunction of the pulse ‘ganerator. —s Correct the installation Condition, or replace the pulse generator. Improper grounding of the pulse generator cir- cuit's shielded wiring. —i Replace the pulse generator. Incorrect installation of the pulse generator, or ‘malfunction of the pulse generator. a Correct the installation ‘condition, or replace the pulse generator. Improper grounding of the pulse generator cr- cuit's shielded wiring. eee Replace the pulse generator.Technical Service Information 7. Pressure- control sole- ‘noid valve (ecsv) TaTosa CREA Replace the POSV Connect 12 between se rae) aaa aa SRean anatemal rae BARGRON and OFF ana check tor Sermon the vate ad Sood vane Sheraton ‘connector terminals ee 2 Fee” Replace the PCSV. 00 hatin a CT); Se i es a Check me regmienceDeween ee {Srna ord of te selon Saeceeinas Sedov dacsoreteg salen wae amectr nie rene meee Shor-crrourt, or dam- ‘aged or disconnected wring: Check the resistance between terminal 1 of the solenoid valve connector and the transaxle case. Resistance: 100 low oF too high case. 22.3 1.50/20°C (68°F) as Replace the SCSV. Connect 12V between the trans: axle case and terminal 3 or 4: switch ON and OFF and check for ‘operation noise of the solenoid valve, and check the valve stroke, Residue accumulated in valve and core. Seeaeesane eer Replace the SCSV. 27Technical Service Information ‘9. Torque converter: clutch system ull the parking brake to setit securely. Set the selector lever to “P” or *N", and start the engine. With the engine ial Press the foot brake my I < he selector lever to the ‘or “D" range. Let the engine continue idling, Norma 28 Stop the engine, Improper adustment ofiding Readjust the idling Poor closure (sticking) of the torque conver- ter clutch solenoid, Replace the torque converter clutch solenoid. ‘Sticking of the clutch control valve q ‘Overhaul the valve body. ‘Sticking (seizure) of the torque conver- were i Replace the torque converter assembly.ATSG Technical Service Information 10. Torque converter ‘Check the resistance between Resistance: clutch solenoid terminal 2 of the solenoid valve too low or too Connector and the transmission igh Short-crcuit, or dam- aged or disconnected wiring, (TCC solenoid) ‘Standard value: 3 0/20% Solenois valve ‘connector terminals ac Tey Senos Tio operation OY): 4 [Connect 12 Vberwesn the trans poise, Check, msion case and terminal 2 fo suck Switch ON end OFF and check (Wave srke: in) or less) “Sticking is {for operation noise. Replace the TCC. solenoid. Foreign terminal ‘caught between the valve and guide Replace the TCC usually at the eo) wananessclrepateloot \_,(Nosentouy sez model [> sepesses cee eset (seins Continuity exists (resistance: O) Ee solenoid ‘Check the installation of the accelerator switch; adjust it necessary. not shed Replace the accelerator switch, With the accelerator pedal ve- pressed slightly (about 5%). ‘check the resistance between ter- minals 1 and 2 No continuity resistance: =) Normal Continuity exists (resistance: 0} 2972, Park/neutral position switch ©1992 model> Technical Service Information inthe “P* range, check for con- tihuity between terminals 3 and 4, and terminals 8 and 9. 000000 no Continuity exists ‘In the “R” range. check for con- tinuity between terminals 4 and 7 and terminals 10 and 11 Continuity exists ‘In the “N" range, check for con- tinuity between terminals 2 and 4, and terminals 8 and 9, in the “D" range. check for con- tinuity between terminals 4 and 6. Continuity exists in the 2” range, check for con- tinuity between terminals 1 and 4 Continuity exists inthe “L” range, check for con- tinuity between terminals 4 and 5. Continuity exists Normal 30 Pons cos ai |, Gecoanam) + wording wiring, ae Replace the park neutral position switchTechnical Service Information 13, Park/neutral position switch ‘<1993 model> Inthe "P* range, check for con- tinuity between terminals 3 and 4, ‘and terminals 7 and 8. J ‘in the “R" range, check for con- tinuity between terminals 2 and 3, and terminals § and 6, Continuity exists ° ‘Inthe “R” range, check for con- tinuity between terminals 2 and 3, and terminals 5 and 6. Continuity exists ‘nthe “D* range, check for con- tinuity between terminals 3 and 10, Continuity exists ‘nthe “2* range, check for con- tunuity between terminals 3 and 11 Continuity exists ‘nthe “L* range, check for con- tinuity between terminals 3 and 8 Continuity exists ) Normal 31 No continuity | Poor contact, or dam- ‘aged or disconnected wring, Replace the park/ neutral position switch74. Kickdown (10D) servo switch -<1982 madel> 15. Transaxle con- ‘trol modul (Tem) Technical Service Information ‘Check for continuity between the kickdown servo switch terminal and the transaxle case. [Poor contact, or dam- Leo ___ ‘aged or disconnected wring Replace the K/D servo ‘Start the engine, setto the “D” Tange, and let the engine idle; ‘check far continuity between the kickdown servo switch terminal and the transaxle ca: Continuity ex- ists. Poor contact (sticking) NOTE: Be sure the brakes are zy applied during this check Normal Disconnect the hamess (both A Replace the K/D servo switch, Ber Sieerecters Hom te vere ae ate er troneowec ean The pri Oe Nona Ronee chee does ‘Malfunction of the ori- ginal TCM ing, a new TCM to this harness Lt and make a road test. Consider the original TCM to be normal, and again check the sen- sors, wiring, etc. ‘Same problem (as before TCM ‘exchange) occurs, 2 Install anew TCM.ORear eee, presse Ohesueng @rorue Pressure comener_ Ls |\ —_pressur ‘Dkeckdown brake es Low-reverse: brake BE ‘\ @xickdown brah End ciut pressure pressure a greene v4 Technical Service Information OIL PRESSURE TESTS 1. Completely warm up the transaxle. 2. Raise the vehicle by using a jack so that the front wheels can be rotated, Connect an engine tachometer and place it in a position where it's easy to see. Attach the special oilpressure gauge _(MD998330 or MD999563) and the adaptor (MD998332) to each oil pressure outlet port ‘When the reverse position pressure is to be tested, the 3,000 kPa (400 psi) type of gauge should be used, 3 4. Measure the oil pressure under various conditions, and check to be sure that the measured results are within the standard value range shown in the “Standard oil pressure table” below. If the oil pressure is not within the specified range, check and repair as described in the section “Remedial steps if oil Pressure is not normal” on the next page. Stall Speed Below Specification in “D” and “R” If stall speed is lower than specification, insufficient engine output or faulty torque converter is sus- pected. Check for engine misfiring, ignition timing, valve clearance, etc. If these are good, torque converter is faulty. ‘STANDARD OIL PRESSURE TABLE Stall speed: 2,200 - 3,200 rpm Consors Sean ol pressure Wa oe) wo | Seee | Engr S A @ 6 © 5 se [eee | ae | ote lee] B] SS) Se peion | “Eon | pottn | ossund | ‘Stasi’ | ‘Gossow’ | dusts | San | curtn | wvetse | camer obscatsny | Geass | ptetsre | otessre | presume | ‘Since | Stsaue v |W | ving | wewwar| aep- aa] = | 7 5 5 S = i | Sh oer 2] © | ware | ane [60-490] 100-10) [729 636 - * ter = 66 | tt8 = Sor (oe Ho) 2] <5, |pue | «* | 260- ag0| 930 - 900) 7 = |e-eel - |. go csatonw_| "$858 ter = ee | (ne - 18 oe = ‘ea: =] 0 [appx | at | 960 ago | a0 — goo | ean - 00 ao] - | 450 eso isaiores | "853 ter = 66 | 18 - 128) ie > See 2% SS = | 2 [arom | ant [60 ago] 690 - ooo} — woo | — [aso — ego ity teh oer ‘% ¥28) ‘ee © [© [Avo | im | 380- 4g] : | ax9- 500 - | ae- asf 868 ec 8) 1: Toor [Revere | 260 - ego, ‘(ge -2auch sao aaa — — [igi = 2240) «a0 — eso a] on E88 ie [ae = reas = BA ais = 31S) fet = Sa Topix |Revene | 360-490] | voon ian] v0.0 naa] ~ 900-142 | 450 680 ers ist > seine | Smo | Semone” | ea = St note OP ndeates nessun slow TOP 88 (2) SWON Golavienmn ON poanon {3 SBiOFr Gb'sanenmn Fe poston (a) 2 ressweis nox sansa 33Technical Service Information REMEDIAL ACTION TO TAKE FOR INADEQUATE OIL PRESSURE NOTE Line pressures are @.9.O.0.0 and @>) shown on the Standard Oil Pressure Table cn the preceding page. valve line pressure Detective valve body assembly Valve body left loose €. Improper oil pump delivery pressure” ‘Symptom Possible cause Remedy 1. Allline pressures | a. Plugged oil fter ‘2, Visually check ol filter and replace tif plugged are low lor high). | b. Improperiy adjusted regulator b. Measure line pressure 2) (K/D brake pres: sure} and readjust line pressure if tis ut of specifications Or, replace vaive body assembly cc. Replace valve body assembly. 6. Torque vaive body clamp bolt and mounting bolt to specification e. Check oll pump gear side clearance and replace oll pump assembly as necessary. 2. Improper reducing pressure ‘2. Plugged reducing pressure circuit filter (L-shaped) b. Improperly adjusted reducing pressure ¢. Defective valve body assembly a. Disassemble valve body assembly to check filter and replace filter ifitis plugged. b. Measure reducing pressure) and readjust as necessary c. Replace valve body assembly, 3. Improper K/D brake pressure (application) @, Defective searing @and D-rn oLeD sens piston end seline of sieeve b, Sefecive valve body assembly a. Disassemble KD servo and check seal ning and D-ring for damage. Replace seal ring (9r D-ring if damaged or scratched, b. Replace valve body assembly. 4, Improper K/D brake pressure (release) 2, Defective seal ring @ and Dring @ of WD servo piston and seal ing of sleeve b. Defective valve body assembly ‘a. Disassemble K/D servo and check seal ring and D-ring for damage. Replace eal ring ‘r D-ring t damaged or scratched. b, Replace valve body assembly. 5. Improper front clutch pressure «a. Defective seal ring @ and D-ing @ of KD servo piston and seal ring of sieeve jefective valve body assembly Worn front clutch piston and retainer or defective D-ring ® or seal ring @ ‘a, Disassemble K/D servo and check seal ring and D-ring for damage. Replace seal ring ‘9r D-ring if damaged or scratched. Replace vaive body assembly. Disassemble transaxle and check front clutch piston and retainer for wear and D-ring and Seal ring for damage. Replace piston, retainer, D-nng, or seal ring as necessary. brake pressure b. Defective valve body assembly . Defective D-ring €@ of piston oF O-ring @) of center support 6. Improper 2. Defective D-ring ® of piston, a. Disassemble rear clutch and check input shaft rear clutch seal ring @ of retainer D-ring, center support seal ring, and piston pressure and seal ing @ and D-ring @ D-ring: replace if damaged or scratched of input shaft b. Defective valve body assembly _| b. Replace valve body assembly 7. Improper 4. Defective sealsing@, D-ring®, | a. Disassemble the end clutch and check piston oll end clutch and oil seal © of end clutch seal, D-ring, and center support seal ring | pressure replace if damage or scratches are evident b. Defective valve body assembly _| b, Replace valve body assembly. 8 Improper ‘2, Damaged O-nng between valve | a, Remove valve body assembly and check O-ing low-reverse body and transmission (on top of upper valve body, replace if damage or scratches are evident Replace valve body assembly. Disassemble transaxle and check O-ring and O-nng: replace if damage or scratches are evigent. 9. Improper torque converter pressure 2, Sticking torque converter clutch Solenoid (TCC solenoid) or torque Converter clutch control valve b. Plugged or leaky oil cooler and pipings cc. Damaged seal ring @ of input shaft 4d. Defective torque converter ‘@. Check torque converter clutch system and TCC solenoid for operation, b. Repair or replace cooler or pipings. ¢. Disassemble transaxle and check seal ring; replace if tis damaged. d. Replace torque converter. 34ATSG Technical Service Information Seal ong iF @Seirng } @Sealeng Dung | @D-«ing rf OD+ing @O-1ng © seat \, @o0me { @Seatring | Rear clutch Front clutch seus Borng Endlutch Low-toverse brake @seatnng KD brakeTechnical Service Information TRANSAXLE - FWD COMPONENTS Berets atirteral parts wath automatic transmission fluid unng reassembly, 21Nm 1 ttle. Kickdown servo piston Spring Anchor rod Detent assembly Manual control shaft Parking roller support Oilpan 18, Kickdown drum Gasket 18. Snap ring 44. Oil temperature sensor 17. Center support 45. Oilscreen 18 Wave spring 46. Valve body assembly 19. Retum spring 47. Manual control lever 20 Pressure plate ‘48. Park/neutral position switch 21. Brake disc (PNP switch) 1. Torque converter 22. Brake plate 49, End clutch shaft 2. Oilpump assembly 23. Reaction plate 50. Bearing retainer 3. Gasket, 24. Reverse sun gear 51. Thrust bearing #11 4 Thrust washer #1 25. Thrust bearing #8 52, End clutch hub’ 5. Front clutch assembly 26. Thrust race # 53. Thrust washer 6 Thrustrace #3, 27. Forward sun gear 54. End clutch assembly 7 Thwust bearing #4 28, Planetary cartier assembly 55. O-ring & Thrust washer #2 29. Thrust bearing #10 56. End clutch cover 9. Rear clutch assembly 30. Output flange 57. Pulse generator 10. Thrust bearing #5 31. Oillevel gauge 58. Lock bolt 11. Rear clutch hub, 32. Oilfiller tube 59. Idler shaft 12. Thrust race #6 33. Snap ring 60. Idler gear 13. Thrust bearing #7 34. Kickdown servo switch 61. Spacer 14 Kickdown band) 35, Snapring 62. Gasket 36ATSG Technical Service Information 56 Nm —_ Lubricate all internal parts with automatic transmission fluid during reassembly. 63. Idler gear cover 64. Differential bearing retainer 85, Quter race 68. Differential front bearing cap 67. Differential assembly nore ter bearing ta OTB and subsequent adel, “marked pans Transter shat rece ebacecer recy attaches, nt wo ohamess 72. Transaxle case 37Technical Service Information 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 the special tool to mount the dial gauge on the transmission case and measure the end play of the input shaft 5. Remove the pulse generator “A” and “B” 6 Remove manual control lever then remove park/neutral position switch (PNP switch]Technical Service Information 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 il temperature sensor harness from the clamp. Fi tertperatu sensor) © 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. 39Technical Service Information 13. Remove the parking roller support. 14, Remove the set screw of the manual control shaft and Temove the manual control shaft assembly, 15. Remove the detent assembly. 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 40Technical Service Information 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. aTechnical Service Information 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. NAD “se YA; W 30. Remove oil pump installation bolts aTechnical Service Information 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.Z PRN ‘Thrust bearing #7, Technical Service Information 36, Remove the thrust bearing #7. 37. Remave 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.Technical Service Information 41, Remove the kickdown servo piston 42. Remove the anchor rod. 43, Remove the plug, then remove the air exhaust plug. 44, Remove the snap ring. 45, Using the special tool, remove the center support. 45TSG Technical Service Information 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. 46Technical Service Information 51. Remove the output bearing retainer mounting bolts and then remove the output bearing retainer and outer race. 52. Remove the transfer shaft. 53. Use a sliding hammer, etc., to remove the outer race. 54. Remove all oil seals. 47ATSG] Technical Service Information TRANSAXLE (4WD) COMPONENTS Aeraieene its with automatic tansmission uid | during reassembly 2 21Nm Tere. Kickdown servo piston Spring ‘Anchor rod Detent assembly Manual contrl shat Parking roller support il pan Gasket 44, Oil temperature sensor Center support 45. Oil fter Wave spring 46, Valve body assembly 19. Return spring 447. Manual control lever 1. Torque converter 20. Pressure plate ‘48. Park/neutral position switch 2 Oil pump assembly 21. Brake dise (PNP switch) 3 Gasket 22. Brake plate 449. End clutch shaft 4. Thrust washer #1 23. Reaction piate 50. Bearing retainer 5. Front clutch assembly 24. Reverse sun gear 51. Thrust bearing #11 6. Thrust race #3 25. Thrust bearing #8 2. End clutch hut 7. Thrust bearing #4 26. Thrust race #: 53, Thrust washer & Thrust washer #2 27. Forward sun gear 54. End clutch assembly 9. Rear clutch assembly 28, Planetary carrier assembly 55. Oving 10. Thrust bearing #8 28. Thrustbearing #10 56. End clutch cover 11. Rearclutch hub 30. Output flange 57, Pulse generator 12. Thrust bearing #7 31. Oillevel gauge 58. Lock bolt 13. Thrust race #6 32. Oilfiler tube 59. Idler shaft 14. Kickdown band 33. Snap ring 60. Idler gear 16. Kickdown drum 34. Kickdown servo switch 61. Spacer 16. Snap ring 35. Snap ring 62, Gasket 48ATSG Technical Service Information ‘ete mie = ee an ie ftibs. aie ey 57 2 | | te a4 “ ‘ rs Le * Tie, 1 oo ° “ ® fo acd sim 11Nm aNm ibe. wp Bheibs, ee. Bri Lubricate all intemal 63, Idler gear cover 71. Center differential assembly parts with automatic 64 Differential bearing retainer 72. Center bearing retainer transmission flu 5. Spacer 73. Stopper ring during reassembly 66. Differential front bearing cap 74. Viscous coupling unit 67. Differential assembly 28, Centerbearingretsiner NOTE. sasket 76, Front output shaft Gn 1993 and subsequent models, *-marked parts 69. Differential cover 7? lear output shaft have the connecter cirectly attached. not via aharness, 70. Ourputbearing retainer 78, Transaxle case 49i ue {i | RD ie Technical Service Information W4A3 51. Remove the output bearing retainer mounting bolts and then remove the output bearing retainer and outer race. 52. Insert a rod 8 mm (.31 in.) in diameter and 200 mm (7.87 in.) in length from the hole shown in the figure and punch out the rear output shaft. 53. Using the special tool, remove the center differential. 54, Put a bolt (M6) into the center bearing retainer and, holding that bolt, remove the center bearing retainer and outer race. 55. Remove the center bearing retainer stopper bolt.Technical i it) outer race Service Information W4A3 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. 68. Remove the front output shaft. 58. Using @ sliding hammer or similar tool, remove the outer race. 60. Remove the oil seals. REASSEMBLY 1. Using the special tool, install the oil seats to the differential bearing retainer and transaxle case. 51Technical Service Information W4A3 ip990998-01 igago94.01 2. Using the special tool, install the rear output shaft oil seal 3. Using the special tool, press-fit the outer race in the transaxle case. 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 outer race. 32Technical Service Information W4A3 WES 6. Install the front bearing retainer and tighten the bolt with \ (po the specified torque. Front bearing retainer mounting bolts: 49 Nm (35 ftlbs.) 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 in.) 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.lbs.) 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 ft.lbs.) 53Technical Service Information W4A3 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. 16. Place solder with a length 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. 17. Install the output bearing retainer and tighten the bolts to the specified torque. Output bearing retainer mounting botts: 24 Nm (18 ftlbs.) 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 in.) 20. Install the spacer selected in the previous item and the outer race on the output bearing retainer. 34.Technical Service Information W4A3 21. Install @ 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 the specified torque. Output bearing retainer mounting bolts: 24.Nm (18 ftibs.) 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 botts: 20 Nm (15 ftlbs.) 25. Caulk the heads of the bolts. 26. Apply a coating of petrolatum to thrust bearing #10 and attach to the planetary carrier. 35Technical Service Information W4A3 27. Assemble the planetary carrier. 28. Assemble the forward sun gear, thrust race #9, thrust bearing #8 and reverse sun gear. 29. Install both sun gears assembled in the previous item into the planetary carrier. 30. Assemble the reaction plate, brake disc and brake plate.Technical Service Information REASSEMBLY MD998325-01 4. Using the special tool, install the oil seals to the differential Dtterenat bearing retainer and transaxle case rane T Speci! tool (i sea for aiferenia 088632501 Beating retainer (Oil seal for wensaxle case | _MD996925-01 (MD998803") +: Vehicles with 4-wheel steering oil pump Use the special too! to press fit the outer race into the i 399093801 transaxle case. \ sas AUTOMATIC TRANSMISSION SERVICE GROUP3. 10. Technical Service Information Install the transfer shaft Place solder with a length of approximately 10 mm (.389 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. Install the output bearing retainer and tighten the bolts to the specified torque Output bearing retainer mounting bolts: 24. Nm (18 ft.lbs.) Loosen the bolts and remove the output bearing retainer. Remove the outer race from the output bearing retainer and remove the solder. If the solder is not crushed, repeat steps (4) — (@),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 in.) Install the spacer selected in the previous item and the outer race on the output bearing retainer. Install a new O-ring around the outer circumference of the outer bearing retainer. Coat the O-ting with automatic transmission fluid and tighten the output bearing retainer mounting bolts to the specified torque. Output bearing retainer mounting bolts: 24 Nm (18 ft.lbs.) 58Technical Service Information 11. Insert the output flange into the case and install a snap ring around the bearing, 12. Install the bearing retainer using new bolts. Bearing retainer mounting bolts: 20 Nm (15 ft.lbs.) 13. Caulk the heads of the bolts. 14, Apply a coating of petrolatum to thrust bearing #10 and attach to the planetary carrier. 18. Assemble the planetary carrier 59Technical Service Information 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. 60.ATSG] Technical Service Information Identification of thrust bearings, thrust Unt: mm in) . d 1 a i) ele Pato, | Sr razr 557 aia0 | 14 (os) 7 381 (a0 [sea ci36H | Moron | 70.278) |557 2195) 18107) 2 zene] 010 | | woro7ss | #6 70.276) | 557 2.193) 22 (087 3 «| se i219 [987 (1524 | 16 (06% | MO7oHe36 | #6 70276 | 557 12.199) | 261102) 4 182205) [sea asa | Mo720010 | #7 eo | seta | recom | Morse | oz sam | wit | - o7asce2 | #6 4gg (1925) | 37.40 | 1.0 (036) wDs97e6¢ inc =] ase | 312 | 08 cas | moron | 49 | as (1928) | 37 46) | 12 (047) 0987647 incl *1) ae (19 | 37 thae) | 14 (oes) Moaerede me 2]; sz aos jaan | _— wo720010 | #10 a2 (1905) | 37 tae, | 18 (063) Dasreds fect <2) 42 ag9 11320) | 37 (148) | 18 (071) WDsereso int <3) “se @20 | aetcy | (| wo7ae06 | @n #69 323) | 37 (a6) | 20 (079) WOsE7@5% inet $3] fe 11995) | 37 1.45) | 22 (067 Mbge?es2 tne TAPER ROLLER BEARING REMOVAL (1) Using the special tool, remove the taper roller bearing from the center differential flange. REASSEMBLY SERVICE POINTS ‘#A¢ 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 bot: 75 Nm (54 ft.lbs.) (4) Using the front output shaft, rotate the side gear front and select the thickest spacer to gently rotate the side gear front. 9B¢ 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.lbs.] Specified adhesiv ‘3M Stud Locking Part No, 4170 or equivalent 105Technical Service Information 9C@ TAPER ROLLER BEARING INSTALLATION (1) Using the special tool, install the taper roller bearing on the center differential flange. §D¢ TAPER ROLLER BEARING INSTALLATION (1) Using the special tool, install the taper roller bearing on the transfer driven 106TSG Technical Service Information FRONT OUTPUT SHAFT - 4WD DISASSEMBLY AND REASSEMBLY Disassembly steps ‘8 04 1. Taper roller bearing ‘QO OMG 2. Taper roller bearing 3. Front output shaft DISASSEMBLY SERVICE POINT QA TAPER ROLLER BEARINGS REMOVAL (1) Using the special tool, remove the taper roller bearings on both ends of the front output shaft. M9680), REASSEMBLY SERVICE POINT 9A¢ TAPER ROLLER BEARINGS INSTALLATION (1) Using the special tool, press-fit the taper roller bearings on both ends of the front output shaft. 107ATSG Technical Service Information TRANSFER - 4WD DISASSEMBLY AND REASSEMBLY 5Nm —@ afelbs, Disassembly steps 1. Cover £4 2. Cover gasket 06 3. Extenstonhousing assombiy i gu cate al ce 5, Tranter case sub assembly Wirtemal sons O84 spacer vith gear ol ving luring reasser #A¢ 8. Transfer case adapter sub assembly CET eel REASSEMBLY SERVICE POINTS 9A¢) TRANSFER CASE ADAPTER SUB ASSEMBLY INSTALLATION (1) Apply a light and uniform coat of machine blue or red lead to the driven bevel gear teeth (both sides) using @ brush. 108Technical Service Information 9B¢ SPACER INSTALLATION (1) Install the spacer that has been used. 9C¢ 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.\bs.) (3) Using the special tool, turn the drive bevel gear shaft (one tum in normai direction, one tum 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 marks are in alignment. 109Technical Service Information (6) 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.) 9D¢ EXTENSION HOUSING INSTALLATION (1) Apply sealant to the adapter flange surface and install the extension housing ‘Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent NOTE Squeeze out sealant from the tube uniformly and con- tinuously in adequante amount. 9E@ SEALANT TO COVER GASKET APPLICATION Specified sealant: 10Technical Service Information ‘TOOTH CONTACT ADJUSTING PROCEDURES 1. Standard tooth contact pattern Small end side Drive side tooth face (Side on which force acts when running forward) Big end side Coast side tooth face (Side on which force acts when reversing) 00 o> 2. 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. 3. Tooth contact pattern produced when driven bevel gear height is too sm: 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.Technical Service Information NOTE (1) If correct tooth contact cannot be obtained even by change of the driven bevel gear mount adjusting spacer, Drive bevel gear eee increase or decrease the drive bevel gear preload rount adjusting spacer oe eee ote cacer adjusting spacer and the drive bevel gear mount adjusting spacer as described below and then adjust tooth contact again. ‘© 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 el in use with one that is one rank thinner. ‘© 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: Replace the drive bevel gear mount adjusting spacer cea precad that is in use with one that is one rank thinner and SGustng replace the drive bevel gear preload adjusting spacer Spocer that is in use with one that is one rank thicker. Repeat above steps until the tooth contact pattem equal oF close to the standard pattem is obtained. (2) Ifthe tooth contact pattern cannot be adjusted close to the standard pattem by above adjustment, replace the drive bevel gear and driven bevel gear as a set and readjust the tooth contact. 2TRANSFER CASE ADAPTER - 4WD DISASSEMBLY AND REASSEMBLY Disassembly steps Lock nut Driven bevel gear ‘Taper roller bearing Spacer Collar Outer race Outer race Transfer case adapter Taper roller bearing, Sp Labrcate at SW irteral pars vat gear ol uring reassembly Technical Service Information OAD LOCKNUT REMOVAL tool, remove the lock nut. 13 DISASSEMBLY SERVICE POINTS (1) Unlock the lock nut. (Straighten the bent nut.) (2) Holding the driven bevel gear in a vice and using the specialTSG Technical Service Information [From November 1997 NOTE The nut size has been changed trom 55 to 50. (From November 1991) $B) DRIVEN BEVEL GEAR ASSEMBLY REMOVAL (1) Using 2 press, remove the driven bevel gear assembly. QC OUTER RACE REMOVAL (1) Remove the outer race, striking lightly with a screwdriver etc. QD) TAPER ROLLER BEARING REMOVAL uaTechnical Service Information REASSEMBLY SERVICE POINTS #A¢) TAPER ROLLER BEARING INSTALLATION 9B¢ 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 's within standard range. Standard value: 1.0 - 1.7 Nm (.72 - 1.23 ft.lbs.) (3) If the rotating drive torque is outside of the standard range, adjust using adjusting spacers. C4 TAPER ROLLER BEARING INSTALLATION 9D¢ DRIVEN BEVEL GEAR INSTALLATION (1) Attach the driven bevel gear to the transfer case adapter and then align their matching marks. nsATSG Technical Service Information (Up to October 1997 9£@ 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.lbs) NOTE The nut size has been changed from §5 to 50. (From November 1991) (2) Lock the lock nut at two positions. 16ATSG Technical Service Information TRANSFER CASE - 4WD DISASSEMBLY AND REASSEMBLY sm j Disassembly steps 1. Transfer cover 04 3 Spach car © Guter rece 90¢ 5. Drive bevel gear shaft . Outer race pacer tt 8: Oise ransfer case #84 10: Dive bevel gear SW itema pars ho GAS 11. Taper roller Beating with gear ol 3 0N4 12, Teper roller bearing ‘uring reassembly u7ATSG Technical Service Information TT DISASSEMBLY SERVICE POINT AQ TAPER ROLLER BEARINGS REMOVAL Mogese0t REASSEMBLY SERVICE POINTS i A4@ TAPER ROLLER BEARING INSTALLATION 9B@ DRIVE BEVEL GEAR INSTALLATION (1) Install the drive bevel gear to the drive bevel gear shaft with their matching marks in alignment. Matching mark Matching mark nsTechnical Service Information 9C¢ = OL SEAL INSTALLATION 90¢ DRIVE BEVEL GEAR SHAFT INSTALLATION (1) Install the drive bevel gear shaft to the transfer case and align the matching mark on the transfer case with that on the drivé bevel gear shaft. 9E¢ 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 ftibs.) (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. 19Technical Service Information EXTENSION HOUSING - 4WD wy DISASSEMBLY AND REASSEMBLY 4 oseeezz01 tJ REASSEMBLY SERVICE POINTS M6 OW SEAL INSTALLATION = t #86 Aum BLEEDER INSTALLATION OIL PUMP DRIVE GEAR ~ F4A33-' 1-MINNS, MNPE (1) Install the air bleeder anpiving sealant to the inserting DISASSEMBLY AND REASSEMBLY Sova ¥ Nalaaieanied No. 8001 or equivalent v a ee DISASSEMBLY SERVICE POINT ‘ORO BEARING REMOVAL, Diasserbty ape [ZI ¢ Gone iy GH apeiy 3 SS Y ZB 3 Ope aive i om dive gear 8: Sug REASSEMBLY SERVICE POINT AMG BEARING INSTALLATION 120