ETH Lue WEL ee ry ary nf NY POWER FLOW GEAR SHIFT CONTROLLER MAINTENANCE DIAGNOSIS TROUBLE SHOOTING ON VEHICLE SERVICE TEARDOWN. COMPONENT VALVE BODY ASSEMBLY SPECIFICATIONS. INDEX PAGESTechnical Service Information INTRODUCTION SPRINT SUZUKI The SPRINT SUZUKI 3 SPEED automatic transaxle is electrically controlled, fully automatic transmission, it utilized a regular non lock-up hydraulic torque converter, two planetary gear sets, two multidisc clutch packs in drums, one multidisc clutch in the case and a one way clutch assembly. We have included the latest information on the Geo Metro full electric control for this transmission on the final pages of this manual We thank AISIN SEIKI for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY TECHNICAL DIRECTOR DALE ENGLAND WAYNE COLONNA FIELD SERVICE CONSULTANT TECHNICAL SUPERVISOR ED KRUSE PETE LUBAN TECHNICAL CONSULTANT TECHNICAL CONSULTANT JIM DIAL GREGORY LIPNICK TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT JERRY GOTT DAVID CHALKER TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (308) 670-4161| 4 ATSG Technical Service Information CONSTRUCTION AND FUNCTIONATSG] Technical Service Information PLANETARY GEAA UNITSGENERAL DESCRIPTION ‘The automatic vansale consist of the hydraulic toraue converter, elactonialy contlled 3 pees automatic tans mission, countersnatt ane diteentt ‘The wanemision const of 2 planetary gers, 2 dik dutch ‘1 band brake, 7 dik beake and 1 oneway chute Hs ‘operation is convolied By selecting a position trom 6 pos one PR "0.2" and") manually by means of the selector lever ingle on the compartment Inthe "D” or "2" range, the gear ratio is changed forthe Tt, {nd ox 3 speed ("D" range en] automaticly by eect. ie com Technical Service Information TORQUE CONVERTER ‘The torque converter it of elemant hydraulic type and comet ofthe pum, turbine and rato in # unit incapable of diastembly. The pum ie mount tothe crankset the Turbine tothe input shaft and the ator to the tranemistion ce by wa of the oneay cuter ‘The torque converter, which increases torque when sartog, scelerating and uphill diving, functions as a fuld euch jamal fy UYDIRECT CLUTCH ‘The iret clutch connects the input shaft and the sun gear Ieommon to both front and rew planetary gear units) It operates a the 3 gear in the "D" range and in th Technical Service Information range. At the ame time, the forward cuteh operate in the former and the Tetrevrse rake inthe ate, Direct Clute Crom SectionTechnical Service Information ea“aTsGTechnical Service Information SECOND BRAKE “The second brake of band type, Itholde the sun gear ofthe the 2nd gear in “D" oF "2" range simultaneously with the front and var planetary gear unis stationary I gperates at forward clutch ‘Second Brake Pron Grom SectionFIRST & REVERSE BRAKE Technical Se nary operates in "L" of "Range At the same time, he rvice Information orwars cluteh operates in “L range and the direct cltch nF rage, Ud First & Reverse Brake Cras Section ONE: WAY CLUTCH ‘The sprag type oneway clutch is vied tween the rear Dlanetary eariae and the Wanemision cae, Ir consits of & Coney clutch race, sprags and 2 retaine” andthe one-wsy planetary carir inn mation to turn to arr mark side at ‘he frst gear in "D” oF °2" range, the sprog stick between farrier and ‘304, and. prevent the planetary cartier Wom turning revesly it arrow mar sce. — / GneWiay CuiehJATSG Technical Service Information POWER FLOW 188 Gear in “D" oF "2" Range {mak anc the font planetary ring gexy are engaged. This allows the clockwise revolution of the inaut sate to be transmiciea aiecty 10 the ving geat and then through the front bianetary crit tothe autout salt (On the oxher hand, the aun ger whichis engaged with the turn counterclockwise. However, Deng held by the one-way fluteh, it cannot twin. Consequenty, the pinions turn Clockwise on ther axes and this caver the rng geae of the Power Faw ot Tet Gearin Dor °F” Range 2) 102nd Gear in "D” of 2" Range [A oll prestre it applied to the forward clutch, the input ‘aftand the ring gar of the front planetary ger ae nga fd. This sllowe the revolution of the input shat to Be Teramitted Grectly to the fing gear, casing te front Blaneury eavtier turn clockwise In ths state, the sun ‘eaaged wih the pinions of the Hon planetary Technical Service Information ra, would twin counterclockwise, However, he second Drake i in operation and prevents it from turning. AS & fesult, the prions of the Tone planetary gear turn around the wun gear, Therefore, the front planetary rng geet an then the outout shat tun clockwise Power Flow of and Gear in Dor °F” Range (i) Power Fw of Bnd Gear in Bor °F Range) n3d Gear in “D” Range As ol sressure is applied to the forward clutch and the direc cute, the input shaft i engaged with the ng gar and the sun gear of the font planetary gta. In other words, the input sat ie recy connected to the planetary gear Technical Service Information unit eet As 2 ratlt, the pions of the planetary gear 1a locked and thus the input shaft revolution a wanamited rectly tote output sate. ower Faw of trd Gaara *B” Rage TT Power Flow of rd Gear O° Range (2) 12“L" Range ‘The toraue flow from the engin isthe same as atthe Tet ger in "D" oF "2" rang, But in thi ange, the Tatreverse rake & put into operation to prevent te ar planetary brake i applied In other words, when arving in "0" 9 "2" range, the counterclockwise revlution ofthe rea lanetary Technical Service Information exriat i stopped by manne of the oneavay clutch, but when the engine brake i applied, the torque (lockwize from the output shat ats fo prevent fhe one-way clutch from operat reverse brake int operation #0 a {0 Mold the rer planetary ain stationary. Thur a engine braking foro Is provi, =U" Range Power Flow 2) 13Technical Service Information “R” Range [As cl resave it applied to the det eutch, the input shat Ss engiged with the wun gear of the planetary gear. This AMiows the torgue to be tranamites diecty from the input sun gear but turn around counterclockwise on cause the rng gear to turn caunterelockise tana pine Hite to the tee planetary rng {hatte the son gear, On the ether hand, the Neteeverse a it also Tors counterclockwise thereby the car moves rate i alt at work snd therefore the rear planetary caret feat, Hy ai 5] fs "BH Barge Power Flow (1) "A Range Power Flow 12)Technical Service Information NT of "P Range [As the forward cluteh and rect clutch te reegsed, the with the parking lock gear whieh 1 ineorgoratea with the fngine torqce it ot tranrmited from the int shaft to the drive oer of the output sate and thu the fant wheels ae "F Range Components Operation Chart Forward | Direct second [lst & Reverse | One-way Parking Lock [ | Parking = | = - 0 _ oS Rene an = o = eet = ° me | O =_] a = =| 2 ie = t =) - . ° I = 0: Operates + To event overevlution of engine, hs 2nd gers operated only when aletor seri shied 82" range at the bee ol rave ther 53 ken (23 ue 15Technical Service | OIL PRESSURE CONTROL SYSTEM “The il pressure cont aye fundamentally const of tives art: (1 0 pressure proaueing syst which consis of an ol pum to araduce ol pressure and egulato ave 0 fagulete the preswre, (2) oi creuit to feed oil ito the nformation torque converts, the ol cooler and the tranamision compe: rents to be lubieates, and (3) contol system to shit he far of the planetary pear unt by eting on each cluten and rake ‘ir Presare Control Sytem Diagram4ATSG Technical Service InformationTechnical Service Information Manual Valve ‘Throttle Valve ‘The manual valve ie hmctly connected with the selector A the throm valve i inked withthe accelerator pedal by lever by mire It opens and clones theo pasage mechanical wie, it produces the throttle pretsure corresponding tothe Iy 40 a8 to form resect oi presure cveut far "L"."2", extent to which the accelerator pedal ie deoretand WG 'N", "Ror "Prange according 10 the wiecto’ inother wards, the engine outbut levee movement Wher the pedal is depressed, the Wwotle cam pushes the shite plug which then compreses tw soring® #o ‘move the throttle valve. Thus the line pressure pasa is pened and the totlepresute is gradu, The Dota premure we ako applied 19 he back of the tote vale 10 push back the vale, The Bottle presi x determines DY ‘he tensile fore of the springs (postion of the shit plug) and applied to the primary and secondary regulator valves 12 tone Throne Vaive 18Primary Regulator Valve “hie salve regulate the ol presre produced by the oi fume Uline presse) £0 corespand 0 each ondition of use reverand the won. Secondary Regulator Valve and hbriating i seswre to each part of the Varumission By mens of the thatte pressure an the sing __ ‘Secondary Regular Vale Technical Service Information B; Contra! Valve When nL ange, thie valve controle the ine resure sting fon the Tseveran brake fo reduce nok Bi Conte) Vale Cooler By-pass Valve “This wale i provided to keep the il pressure in the torque { | | | i | (Cooler Bypass Vale1-2 shift Valve This vave carries out the gear shite Between Ist and 2nd gear, When the 2nd brake solenoid operates. the line Dressure applied to the auth vale and the vale moves ‘the tanimason shifted inte 2rd gear rest 10 the 2nd Drake soni i relives feturn by means of the spring Force and the fed tothe Te gear, In “Lor "R* range, se ol pessre it appli tothe Ta: reverie brake whan te 2nd rake solenoid ooerates 1=2Shh waive 2-3 Shift Valve This valve avis out the gearshift Between 2nd and Jed ear, Wnen the direct eluten folenoid operates, the line Dresure i apoled tothe wif vale and the valve moves to ‘hur te evansmisson is ahitted from the 2nd ger tothe re lethen the oi seuiute tothe solenoid! i relieved, the ahi Hon is antag to he Bnd gear Technical Service Information Accumulator ‘ A Direct Cluteh and 2nd Brake Solenoids “Tete solenoids tuinON and OFF by the electric nina trom the controler (computer). They sere to control the gear ‘hile by operating the t= Zand 2 3 aft vas. Dect ute solenoid operates the 2 3 dle ave, ad 2nd brake felenoid dot the 12 shift valve When the soleneid vale {5 ON, the vale moves up te relieve the line presure and then OFF, the waive moves down and therefore the line Dreture applied tothe shit wave[Saatsc Oil Circuit in “N” Range ie i started and the 0 pump stars to operate, In this ange the Technical Service Information 3 applied to any elch or regulator vale is stopped auit Cireuit in "OD" oF "2" Range (1st Geard “The line aressure which has passe trough the manu valve Technical Service Information ‘lect tal from the contcer, thats, they are turned (ON. they slit the line esse. Therefore, nether the T= 4. Ue oremure Gi irae nD" or "B™ Range Ist Gow) 2Technical Servi: Oil Circuit in “D” or "2" Range (2nd Gear) [AS the ex seed it accalaated atte 1 2nd gear anit point, the 2nd brake x nd closes te elit eeu This eautes te line presure D fact on te 1 2anftvahe, Then the valve moves to allow the line pressure @ tobe applied to the 2nd brake and the ce Information 2nd gears attained. At this tne, he tne pressure @ ie also spplied tothe accumulator to redien «shock geeutring when ©. @. B: Line preme Bil Great in “Bor” Range (nd Gear) 23(Oil Cicuit in “D" Range (3rd Gear) ‘As the car speed is further aceelratea in the nd ger and teaches the 316 gear shift point the diect elute solenoid ‘urns OFF and closes the reliet ereuit. This eaves the ine pressure D to be apatig tothe 2 3 shift valve, Then the fl prere it apolieg to te ect clutch to make iengape [At the same time, the oil pressure see, at 8 Back presnie, on ‘he 2nd brake piston. Thur the 2nd brake paton is pushed back, the nd bra ie elated pod the Sd ea i attained, Technical Service Information In this sat, as the 2nd brake solenoid is OFF, the 1 — 2 shift valve is at work and opens the oil passage tothe 2nd brake but the 2nd brake dore not operate, It because the ll pressure to the 2nd brake ie Balanced with the above mentioned back pressure and the return spring force uses back the piston to prevent the 2nd brake from operating. (i Grau nO” Rage (id Gear) 28 B,D: ine reneTechnical Service Information L” Range after pusing through the manual valve, from the contaliet, the line presture Dit applied to the comer out atthe line pressures) anai@). The line pressure 1 ~ 2 aft valve. Then the in pressure i applied to the 1 Dis applied to te forward euteh. In Dia stte asthe nd reverse brake, Consequently the It geri ataned brake solenoid ie OFF teenute i no lactrcaly chaane Gil Great °C” Range 2826ATSG] Technical Service Information GEAR SHIFT CONTROL SYSTEM controller Gears and te 29g andres Eouioped a5 conwole sued parameter are the accserator seth. vacuum swtcres (No.1, 2 & 3, ait lever switch Conta [ - ] 1 | | | Tara | | | jo j | contra | | J — . Gew Sa Convo Syne ~ ~ Automatic shift speed LT snitponten noe se aenng I = | telew % ne oo 18 2) 10 6am 2-8 [asa we 5150 2-32 me 18-20 | 132-37) | cs ~701 woo “3-471 aoa a7 2-25 | 6338) (a oe si-59 | 96 toe 5159 oo (323) | 065) 2-39 | aan 26)TSG Technical Service Information Vacuum Switeh “The vacuum swith contact point is tuned ON o OFF by the carburetar vacuum and agnals the carburetor theotle valve opening fngine load to the controler "There are thew vacuum switcher and each of them hast ‘own ringe for ON/OFF operation. By means a these vacuum fitch ngnale and carburetor thot valve opening sinas the conollar renee the twotle valve opening and the engin oes Vacoom Swit eR nt | Sabureter Vacuum (mm Ha) or woe erow a0 ere then 300 x x x oo 30 - 200 3 x x eo 80 700-100 © ° x ‘bow 89 Les than 100 © ° ° 7 Switch “ON” Xs Switeh “OFF Shift Lever Switeh Being linked with the selector lever, mis ewitch changes ‘lector lever positions ioto electri gal and snd them fo ‘te conwalier The contact points of thisswith for "Pang °N ranges are aso connected with the starter mote ecu ‘So wan the snlactor levers shifted to vie "P" oF 'N ealton, the contact points or “BN range ae co rected and use thé starter motor to operate By turning the starter switeh “ON. When the selector Iver 1 i any ther pasition than “P” and Nth switch remains "OFF and tierefore the starter motor cannot be operated, that i, ‘Also, aft eoneact point for“ ange is connected with he ‘eee up light cra, only when the selector lever is hited to." A range, the contact point contact 10 light the back UB ih Si Lave Sach 28ATSG Technical Service Information Direet Clutch and 2nd Brake Solenoids ‘Theat solenoids ae mounted on the val Body. They are turned ON ane OFF by she signal rom the controler and actuate exch shit valve (1 2 and 2 ~ 2 valet) 29221 onerol eanemision gear aie 2nd brake solenoid operates 1 — 2 shift vale, and direct does 23 htt va Operation of Direct Clutch and 2nd Brake Solenoids foe 3 2 v Le? ca | mw [os [a | mw [aw | me | a |= [oe tae | o | o |x |x |o |x |x > Pavaescinos] oO | x [| x | 0 | x | x [0] x © = Operae Slecid Va Oot 3% Unopersnd Solenad Vanes Gow) ‘The speed senior consisting ofthe lead switch and magnet The acs fo Switch is mounted on the accelerator peal ls mult in the sonedoreter. As the magnet tums with the bracket When the activator pedals deoteueg mare tan speedometer cable its magnetic force causes the lad witch SOK of itt stoke, the switch tures ON and siras caruretoe to tum ON and OFF. Such ON/OFF tequency incest or thottlevlve opening tothe controler, rcreses in proportion withthe car speed and ewe tothe convater as bute signee 3 Saeco a Aeswertar Switch 29 Speed Sensor Accelerator Switch Tite IATSG] Technical Service Information MAINTENANCE TRANSAXLE FLUID LEVEL Checking Level (Transaxle at Normal Operating Temperature) Be sre to ook lid eel at ery engine change As the ng temoeratue 20°C ~ BOC, 158°F ~ 176°) 9f fle tature 10 re 170°C 80°, Ser 3. Wim selector ever" Boston start engine. DO NOT 5 move 0 lee! gauge trom i filer ty0e anc wpe ot eel gruge with clea cloth o Fo uever cause | cae | 6. Remsert ot ie 9 01 tler ube, moreushy should be etween "FULL HOT” and “LOW MH Bring shelve! t2°FULL HOT” mark, mark 49 "FULL HO) Un DERRON 30 nonice ‘und Bough the vent Then slippage and wansanle fore Checking Level (Transaxle at Room Temperature fof About 25°C (77°F) 2. Apply parking brake and block ar whale 2. Wit selector lever in "P” poution, start engine and un efor § minus, OO NOT RACE ENGINE 5. Wits engine sunning at ile, check Hid lee! on oil lve nus Fluid nue) should be betwnen "FULL COLO™ ard" LOW COLD” marks on the oi vel gauge It towel ig below "LOW COLD" mark, add fad to bring the lee! Qeiween "LOW COLO” and "FULL COLD™ marks Ui DEXRON=Ilo” equivalent automat tant ration fui, 00 NOT OVER wre 170° — 80°C. SEF W76'FICHANGING FLUID Fluid Change Procedure 1, Rai cx. 2. With eransante cool, remove dain pug and drain Hu, 3. Install rain luy gasket and grain plug to oil pan, and tighten drain pug tothe soreificavon 18-2Nm 18-23k9m 135165 be Tightening toraue for rain pus, | 15 liters (3.18264 US/imp. pt) of new flud from oi filmy tube, Use OEXRON-i or equiaiene automate orice: 1 Yihensetiling wansane with thd ater ts overhauled, our about 3.5 tne {about 2.7/3.1 US/imp. a assum Ing that torque converter is eused When filing dry torque converter and tantnle any wth thi, that, after Both of Siem were replaced, ‘our about 45 nes about 47/29 US! Imp ath 5. Check fluid level with tansanle at room temperature Technical Service Information Checking Transaxle Fluid Leakage (Check the vansanle (ineuaing ol Rott) for Hid Yeah {Check the oil noses (inlet ad outlet) for loos connection Aeteviorstion oF damage. It any detective, reise it ‘Oil nie and Outs Howes 31ATSG] Technical Service Information DIAGNOSIS AUTOMATIC TRANSAXLE UNIT Systematic trouble shooting 1 Engine coolant temperature ita normal operating tempe- 5, Elcte irc of gear sit contol system i fre from i break, couple iscannecion ane pooe contac. 2. Engin ile sped is 850 vom, 6. Vacuum nose of vacuum pateh securely connecte 3. Tranaace tu let is between “FULL HOT" and "LOW HOT" on oil level gauge at normal operating emparture Disconnect solenoid wre coupler and pevform corte | [Ruoninteom ireanipoune LYS a amivare sia] | |L# zn bene solenow sticks | 2 dni wave wicks [sees 32‘om wine pmo 21m pousot jo j09 wouenndo ous eau sessg oe au0 |x| wus aun 00 | sod 98091004 Boer ve wre s01) [oie a 100 140 | S081 uA vB oo i « 2 3 € S € 2 2 2 o o 3 & € £ oO o fad way wtun | Diagnosis Chat (8)< 2 3 € ° © 2 g & o o 3 2 e £ ry o ec Diagnosis Chart (0) 34Line pressure test This test to check oll arene system for operation by 0 Transaxle tug level between “FULL HOT” and "LOW HOT” marks on ei level gauge (at normal operating temperature offi). Transaxle tae of ol eakape. 1 Wie engine at sta9, remove plug at shown in figure and connect oi pessue gauge tothe vacates threaded hole Bo Bi Pressre Gauge Se (OBB2E IBID) — Technical Service Information 2. Insalt aeroreter 53. oply parking brake ad block car wheels 44 Wan selector ever ened 40.°P™ pos ton, srt engine 5. Depress trae pel fly 6, Shift selector lever to "D" range andl check oil rexure 7. Repeat the same check at instep 6 with elector iver nee 0."R" rege nonice. Dont rum engine a tll mare than 5 seconds continuously, for ol temperature may rte excestnaly high 8. If ine pressure mestred is within espetve speciation in the following «abe, oi pressure syste itn ood Croneped | rama ange Tang weed 2a tgiem™ | SS Bxgiem? (850'em) | 285 568—n | 782-113. pi 200 4004Fs | $50 - 860 KPs ‘Sal speed 10s ~ 18 kgien™ (21100 ~ 2,200 149.3 ~ 190.1 pu ‘imin) |. 500-700." | 10s0~ 1400 xP 9, Pouble causes for out-tpeifiction line pres ate at follows. Check each part which i suspected to be the 10, Reinstall pig and tighten 0.0.6 — 09 bpm (6 — 9 NmaS65IDK v | Wigher tan eification in "0" & "Ranger owe tan penticsionin D&A anger (it pump sees ower than specification only mR ange Forward clutch 0 pressure system 0 eakage “pan ut reverse brake oi oresture syst leakage 35Stall test ‘This tert ito check the overall prtormance ofthe automatic teansave and engine by meaning wal peed 9 "0" and nonice: 1. Be sure to perform the test only when wansonle ld is st nermal operating temperate 2. Don't ran engine at sll more than § seconds continu 3. Stall speed means maxanum engine rpm 3 °D" OF ‘ange with diving whale hed stationary, ee Test procedure 2. Apoly parking bake aa block car wheels 3: Start engine with elector lever sifted 19 "Prange 4, Depees brake ped 5 Shit aslector lever to "D" range and deoress accelerator eda fully while watching tachometer. ead auckly the Release accelerator pedal mmeciately alter Hall sped it cnackea 6. lathe same way, check sal speed at "Range 1. Sul speed shouldbe within te following epeiiaton Stal mee 2,100 — 2.300 r/min rom) 8, Possible causes for outof specification stl peed are at follows. Cneck each part which it supected to be the Technical Service Information 2. Diconnect waeuum switch coupler, Vacuum ite i 3. Wien engine running at le, vf elector leer to "D range 4. Rezeleate car speed by depressing accelerator pel half 5, Check i pnt taker poe from Yet t9 2nd at about 15 (9 mie) 5, Stop ear and htt sector lever t0 Connect vacua switeh cover 1. Wien wiecor iver sted to "D" range, art car and scunlerate by deprestingacelerator orga fly ‘55 enh (34 mien) and fom 2nd to 3 at 100 km {62 mile 8. Stop car again 130.Startex and keep i running 9 26 km (16 mile) and then felete scclerator pedal all the way Sack. 1 or 2 cond ater, depress Secelerator pe fully and cheek oweahit fom 2na to st takes place Keep eat running at 75 kh (7 meh) and in the same way at 0 step 10, check if downshift fom 3d Yo 20 takes pice 1 fellows, Check each part which i utpected tobe the Tulearemed [Poe cs Tonehaneeieaton | # Eni utat tS [Lica comer ae “Te Forward Gutch slippepe * Ommoy uth atemre = Divect eluth sippase 1st reverse bake sips Road test Ths test to obec if upsnite and downshitt take place at pected sponse ale actualy drng nonice. Barry ov the esti very i secigent 2, The txt aquies2perions, driver and tester 36 Conan Ponible caer No upanfctrom Veto | ® 12 dit valve defective os 1 2na brake solenoid detective Controle detective, oF 2 — Ssh wave aelectve Dieer clutch steroid etectve [= Accelerator switch defective 1 Contratier setectve, oF ‘iconnection or poor No upshitt from 2nd to ae [No cownahih trom aneMansi road test This test checks the gears being Wse0 in "LY, "2" or “DO range when crven with unoperated gear sift control sytem. ‘Couper of Solenoid Wire 3. With selector lever in "L” range, star the car ad accel ate 1030 kmin (18 milih). Cheek sn thie sae tat Tat ir being ure, 4, ACO kev (18 mile), Shift selector lever to “2” ange tng acerlerate 10 60 kmh (37 mili). Check in ins Stace that 2nd gear is being use 5. AL 60 kmh (37 mile), shit elector Iver 100" ange and check that 3rd gear used when sed higher than 0 kmim (37 mer 8, Afar above check, stop the car, then engine and connect folenoid wi coupe Engine brake test nonice: ‘Before tha txt, make ate that ther no ca Behind 1 #10 Tes: procedure rT whte ring cat in Jee gear of “O” range, shite lector 2. in the same way ae in ep 1, check engine brake for peration when aztector lever it pufted dows fb" 2, Hanging brake fis o operate in the above tet, posible caures for such tere ae at follows, Check each part hic is suspected 1 be the cause 7 Technical Service Information Condition Pouibe caure Fails operate when sited down t0-°2" range smited down to" range Second brake detective ge test 1. Stop the car on slope, sit selector lever to “Prange {anda the ame time apply parking brake 2. After stopping ermine, release parking brake lever gralATSG] Technical Service Information GEAR SHIFT CONTROL SYSTEM Systematic trouble shooting: fi ertorm speed | NotOK [e Spe (eeu “Srawmane Trouble Shocting (7),Technical Service Information creecnreonie ao eS mane Siemon [> [[Pertorm solenoid check "C™ “Tor ee Conwell detective “Syaerave Trouble Shooting 2)Technical Service Information Gear i shifted to 2nd or 3rd gear while diving in “Lrange notice: Gear shit wo 2nd may occur when wast lever eshitted from "0" or "2" range 19 "L", tat tha ie ora. Pertorm “A~3" check FESPA shite lever witch detective Jo 4 — Perform wolenoid ex “CJM * [ect ten solenoid o 2nd brake solenoid detective Conwaler detective ‘Sytematie Trouble Shooting (2) Car does nat move backward in “A” range Perform “A~8" eneck [NEON | ‘Shite lever swe Perform salen oveck Direct cuteh sae “ eid or 2nd ora Controle detective ‘Syawmate Trouble Sroating A) 40Technical Service Information Color of wires connected to shift ever switch cover Biack/Fed [Black/Vellow | Yellow 1 | 1 {— ‘Accelerator switch ‘Acealaratorswiteheiteut check Wan ignition switch turned "OFF", diconneet conwller coupler Wi accelerator pedal fully depressed, check fo continuity berween coupe terinal@andf, Refer to page TALS for termnals® an, [Accalestor switch unit check 1. Disconnect coupler of accelerator switch mounted on 2. Connect ohmmeser 19 acowerstor switen coupler anc hack esitance ith acesarator site turned "ON" and "OFF" respectively fy moving switch lever by Nand ‘carersor switch | _Onmmeter reading [enatanel oN. Bere OFF Totinisy Red | Black [Green/Red | Green 3. 1f found tauty in step 2 check, replace gcelratr switch, 4, nen replacing acenleator awit, itll anew Switch 0 pedal bracket aezorcing othe following procedure 1) Innit aecleratorswiten to pedal racket. In this soe, Lighten 2 swten mounting sarews only temporal, nat 2) Connect ohmmeter to siten couple. 531 Depress acnlerator ped fully ane checkin thir tate that switeh "ON", tat it, ohmmaterregirters 20 ohm 4) Relate acelerator peda! 10% of peda stoke away trom fully sepeeted postin as shown. MolGing pedal i this oiton,acjust switch by moving i 0 tat switch Turns from “ON” to “OFF”, thats, ohmmeter pointer moves from zero to infnsty, Tiger ? zwten mounting tere 5, Connect swish coupe. : eowiatar Switch a “Recearatar switch raTationTechnical Service Information Checking procedures for A checks, noriee Bo the following before carrying out A, 8, C and D checks gi 1. Turn sniionswiteh “OFF” al«X{slelrfe | 2 Aftrtening anton witch “OFF”, eiconnact contol: | : “The gute [ght home terminal numbers ofthe coupler as econnecied from controler viewed from wire harness sie. For each check, bring ahmmeter arog in touch with tem ras from wire harness ie of coupler connected ‘Gaupie Terminal Nombert *A-1" check procedure Wewed trom Wire Harness Sie) ‘Shit selector ever 10D range | Gnack weminae (O° range) for contnuty (Check ermine ukOP™ | Canty ON ranger for acontnuity ni GN and] Abe nev heck the wovape Between ies je 22Y_| mnaegb inde CR ge) Tourn | Sricieeonichneood) [Siw en coaton | soecte 42Technical Service Information check procedure ‘Shit selector lever to "2 [eck cermin (0° range for eon oo Check FB "Lange tor |_Cominaey | | aiscontinuiey | acer “SSR sae! — (heck iE 7 1" angel for | _Oiconwiny Shit ever swith in good Shit ever awit censition detecive “A-2" check procedure (heck BGC" renge for |_Dtcontey | [Sartre [Star 43Technical Service Information "AA" check procedure [ Shitesector ever to (heck — Di" range) for = 7] ‘Shit ever awit in 008 eandition __J Ana” Check "B check procedure ‘Sed reraor check Speed vnsor in|ATSG Technical Service Information check procedure [ Diver autem wienoid and 2nd bake (Sora ne | _. J} — lL 2 : 4 Siomactmemase FQ , Teaciick need rom 2nd brake solenoid] wo ‘nun 12 volap¢ sapped 2 yellow |} Lee rermins of counter? | nd tre "O° Check Direct clutch and 2nd brake olen ‘iver Clutch and 2nd Brake Solenoid “D" check procedure nonce: ‘Apply psrking brake and block car wheel Pace selector lever nto “B” range whem accelerator 1 Checks with asterisk mark +] should be caied out within a short period of time and each continuity test nan instant. tong time [gine a igh revolution speed) can cause wansaxle id temperature fie excesiney igh in lene 5Technical Service Information sand cenerator switch check (°O" ehec Disconnect convraller coupler with ignition switch turned “OFF™ Star ang warm up engine ake sre aceleratr pedal on [Gres B= i or eacontmny —_éeonimiey_| | [Gent Bierce — cent ee [ex @-Gterdcontnuty Ss”~=~“*‘“*S*S*éié = | + [[oeore sccrieraor pel fly nd'ceck = Dor continuity} ‘Vacuum swith] aconteuey_| | eee etectve « [Besse accierator pedal fly and check) — BD for continu + [Deore scelerator pedal fully and check D — @ for continuity +[[Deores scelerator peda fully and check @ — @ for continuity site — detec ——————__™ [ Wscsnum enitches and accelerator wit in good conetion Wicing diagram of gear shift control system Page 7A‘-45 shows elec cult of gee enift control ays, For electric cuit check of each part, hold prods of oh Retering to this crcuit diagram, check each cuit of wiles, solenoids and senior for daconnection and poor 1 Make sure to urn "OFF" lgnition switch before checking sch ore ‘© Wien nition switch turned “OF, daconneet coupler of eter in touch with wire connected side wrminals of the uconnected couple [on wiring harness ise) ‘The numbers soweach terminal numberof the disconnected couple [on witing harness sce) vewe trom wite connected 46Technical Service Information ‘Wg Dragram of Gear Sots Cone Sytem a7Shift lever switch Shit ever switch circu chack HPA ON", “DM, OF "L" range 1 check for continuity Benween the following mals of the disconnected controller couse fon Wiring harness side) respectively We check in blow tble, tum ignition ewiteh ON" and check the voltage between taminas QD and ‘Tha voltage soul be about 12V. Technical Service Information [Alter checks instep 2, shift elector lever to "0", “2, (UT and"'R one ater another. In eath of thee ‘ange lt talre isnot corected even after etightening 2 nut ae eserves in stp 2 or found faulty im step 4 check, ‘ooten sit lver snitch mounting bolt and then, with selector lever shied to °N" range, move sit lever fiteh by Rand 35 showin below figure. Stop the sft lever switen at the postion where "Click heard fom Shit ever switch unit check 1 Apply parking Brake and block car whee 2. Shit selector lever a4 desribed inthe following steps With mactor Invern "Por N range depending om eh step, tur sarterswrtch “ON” and check that this uses sarer moter to operat, i other orcs, engine to start 1 Shite selector lever to "P" range and turn starter teh “ON 21 Shit elector lever trom 23) Shit walectr lever trom “N" so appr and turn starter ouiteh “ON, 4) Shit slector lever from "N™ back to “P” and turn starter swith "ON", 3. W found faulty n any one of D,@. @ and @ checks in the above step 2,2 nuts of manval sit lever may poss. Iy be loose. So retghten thea 2 ute and then perform checks in step 2 2gan to-°N" and sun starter ‘Wonca Shi Lever Rae 48 soe | Seimn ‘eto pinche in ap Zand ep date reat 7 T oo imemouninn bore a I @ ~ @ vorr meters ~ ; 5 ~ N oe | ° < l 2 @-@ | L LT e-e ‘Ajuting Shift Lever Switch Postion 1 faulty condition stil exe even after agating sit lever switen position ax derribad in step 5, there may Disconnect 2 coupes of shit ever sch, Shift selector lever to each range, In each range, check 2|ATSG Technical Service Information ses | SatSemce = | [ vowmono | Soe eme ee Tres eansh o- 8 ut Dad brake | =® Wo? wae 5 Bitte iene tem sews 2, Remove vacuum stch om dash pane. 53. Check vacuum swtenes (No. 1,No. 2 & No.2} for proper ‘operat by using vacaurn pump sn onmater inciates 0 2 when no vacuum appind and it moves from 0 2 to 2 when specie vacmm a given Below He Reinstall vacuum switen 40 dash panel and conneet vacuum nose and coupler — ‘Solenand Cousins ove body an meses olen sesstonee It soeu8 13 Fesstance exit, solard win gand condition 5. Conneet porsioe terminal of 12V battery 20 solenoid inal and negative Yerminsl to elenow body. Check hee introns | notice: Make sure not to reverse positive and negative terminal of meary hen connecting them to leno 6. if found tat in step dor creck, replace solenoid Orme 8. After nsaling ov an. rane ‘hecking Vacuum Switanes with Vacuum 49Technical Service Information Vacuum anton vwrerto const Tsu to apy immo) | Ohmmeterponteindetion Nor ‘Yellow wire and Black o on a ve 30-300 Fonda waa ° on j No? Green ina Blak wire " i From Of to= 2 Speed sentor 2. Remove instrument cluster any fom instrament panel 2. Remove speedometer {, Using ommmete, check speed senor Connect ohmmater to 2 termina of speed sensoc which is installed onthe back of speedometer, Obmmeter pointer incicates enher O02 or fn ti sa ‘Checking Speed Sensor 50 5. lo the sume sate a in stp &, torn speedometer cable joint one full turn clockwise raually. During this tum heck that obmmeter pointer detlects toward © fof OD times, I ohmmeter pointer wat a 0 M before turning speedometer cable joint, delet toward timer doring one ten, and if was at = £2 it deflects toward 02 4 times. 1 found faulty, replace speedometer. 2. Reinstall removed parts and connect couplersTechnical Service Information ON VEHICLE SERVICE OIL PAN GASKET Remove of Disconnect With some car, oll an can be smooth in th sate. 60. HeBE 2, pertorme. Feowog Ov Pan Gasket Install oF Connect(i Cleaner Magne nsalavion 4. There a8 18 oll pan suring Bolts in all and two of them have crore goo in ther Meads Mount thew ‘ort grooves Bolt im wich portions a8 shown in figure ter applying sealant to ther threads, However, do not doply sels to other 13 bots. Be ure not to overghten, a eNm 04-08 kam 0 pan doit Technical Service Information 15, Tighten transaxle mounting member Bolts, mounting nut ana stabilizer shaft mount bots te speitetions Sater | Tonanng rae ‘le mounts SO SON nonberban 50-60kam ss_ down <0-50Nm | sorbet iizer shaft mount 20> Sohn Sabin 20 sake no-sebn 6, Upon completion of instalation, warm up transenle and check fro ea kage OIL STRAINER Remove or Disconnect 1. Drain transl fig 2, Remove oil pan (0:1 an Bole reaanion Oi Strainer Install or Connect 2. Oi seine to lower valve body. Tighten ol ssine bolts to5-BNmi05~O6kgm.37~43 BI 3. Reinstall es pan and etl transaae fd 44 Upon completion of inealaion, warm up tanta ang 52DIRECT CLUTCH AND 2ND BRAKE SOLE- NOIDS, AND SOLENOID WIRE HARNESS Remove or Disconnect 1 Drain ansae fuis anc rove oil pan 2. Couplers trom direct cluten nd 2nd Brake solenoids, and ‘hon solenoids thems “Solenoae 13, Solenoic wie harness with gommes ram voper side “Selena Wire Hames Install or Connect 1 Solenoid wire harness to transane cae. IF gramme sal (Oring! 6 damaged, replace i. Se above figure for srommet and ws! ("O° ring Direct eter and 2nd brake soloide to lower vale body. solenc ea 0" ring) damaged, reac Solenoid wire to ech wlenoit (ii panto ranean an then rfl rasan Hud Solenosd wire harness coupler {Upon completion of instalation, warm up tansale and 53 TSG Technical Service Information OIL PRESSURE CONTROL CABLE Remove or Disconnect 1. Olt presure contol cable ftom accelerator cable after removing cable cover. ‘Oi Presta Contra Cable 2. Oran sransane hia 3. O1oan 4. Oi presaire contrat cable trom whromi valve cam, '. Ol pressure contrat cable trom vansasle cave, Throttle Vave Cam Install or ConnectTSG Technical Service Information Checking and Adjusting Oil Pressure Control Cable ind at By turning them If attempt By tuthingaajusting ing nuts B. Tighten 1. Check accelerator eabl for play and aust if ncestary, 4, 2, Warm up engine and run tat ale Then check to ensure 2. Alter rem cover, ewe ‘thickness gaune ‘Checking wd Aduating Ol Pressive Control Cable PayATSG Technical Service Information MANUAL SELECTOR Install of Connect Rlemove or Disconnect ‘© Anply grease to the postions indicated as Ain below 1, Selector knob serew and then elector knob by turning 2. Gomote ton 2. Seer ndetor a’ % ut Tiare trae Se aie ram ttt ae Fain acamovi urn Secor eer shat ut 18-22 kgm 5. Lee tounng mh sets wer wom ~ Tone ee | 10-16Nem Lever houtng mts 101.649 75-118 “Manual Selector Components 55Technical Service Information SELECT CABLE ‘Seiet Cable Compares Flemove or Disconnect fr and ten from for. 5. Rate car 6, Select cable rom tront pareTechnical Service Information SHIFT LEVER SWITCH novice. (Do not oveshal shite ever switch Remove or Disconnect 1. Shit lever switen couples. 2, Shit lever saith from transanie Install or Connect Shit manual ahitt lever 40 °N" range, that is, to hit elector Iver 0°” range “anal Sec Cae Teint and Maal SE 10.With selector lever sfted to "N™ range, turn nut B® in figure by hand tilt contacts manual wlect cable joints | ‘Than tighten nut B oeith wrench A sl Sect Cwvienuai B&B) I Manual ShifeLovarin "8 Range 2. Using tat hess sarwdriver, tue sity lever switch joint lockasse or sounterciockise to the positon shown in figure and check that 2 "cick is heard from joint at Baler select cable heck forthe following 1 Pus car with selector lever ated to “Prange Cr should not move fF Gat can be deen in "0", 2" and "U"ranae ‘Sh Lever Switoh Jone 873. After instaling shift lever mitch to manual sift shat, move shift lever seiteh by hand in arom direction at shown in igure. Stop atthe positon where a “lek rom Joint is heavdor fle by hand and then secuce it by ghten ing bolt 19 13 = 23m (1.3 23 kgm, 95 — 165 lo torave “Adjusting Shite Lever Switch Postion 4, Coupler and clam. 5. Upon completion of shitt lever switch intallaion, heck for its proper inealation according tothe following 1 Apply parking brake ana block car wh, 2) Wien 'sleror lever shifted to "P" range, turn starter switch "ON" and check that this ener Harter motor 31 Shite selector lever from P" to °N range, turn Starter switch "ON" an chek that this causes trier ‘motor © operate, 4) Shite sletor lever from °N to "L” and then back to NT range, turm Harter itch "ON" and check thet 5} Shite selector lever from "N" to "P” range and check starter motor for operation 4 instep 4, 61 Check to make sure that in any other range than “P and °N", narter motor dores't operate even when ‘arer switch turnee "0 7) Turn gniion switch “ON (without sartng engine and shite seletor lever to. "R™ range. Than check ‘hat backup lamps ba. It any check result wae unetistactory in sep 5, remove 58 Technical Service Information ‘TRANSAXLE ASSEMBLY Remove or Disconnect 1. Disconnect nepitive cable frm battery. 2. To take down engine with wansanin rom ear body. 43. Disconnect drive axle (LI from oitfrentil side gears of Uwansonle ac rive ae [A from dive axle inne shot For encine and tratesle removal. its not necessary to remove the orive ale trom steering knuckle 4, tna iting device, orice: Before lifting engine with wansane, recheck to scertain all hoses, electric wtes and eables ae disconnected from engine and transi 5. Take down engine with transaue 6. Remove vanmasie cae hong tower plate 7 Remove si (6) drive plate bolts To lock drive pate, ‘engage 2 minus secewarver with the drive pate geer ‘through the notch provided at under sie of transaxle cae. “Removing Orive Plate Bate 8. Remove bolts and nut fastening engine and transane, and remove transeale from engine, orice: '¢ When removing transaxle as'y from engine, move it in prllel with crankshaft and use care 30 44 0% to soy ‘+ After ramoring transane sy, be sure to keep It 40 that fit pan is atthe bottom, Hf transaid thd initInstall or Connect 1 Betore mounting wansace assembly converter (Refer 0 below figure) 1) Meauce the catance A shown in below figure. The distance snould be more than 21.4 mm (0.85 in), ft fe ie than. 21 mm (O85 sn), means that the tecaue converte i improperly nsaie. Theretor, in reinstall for aroper nrtaliaton, Tongue Converter istalaion Tuten sic (6) aren plate bolts 1.8 = 1.9 kgm (18 19 Nim, 130 ~ 140 14) © Lower engine with tranaxle into car body and tighten engine and trenaxle mounting nuts and Blt, and remove © After instaling dive axles (R & L) into difereca side fea of transaxle ane ceive axle inner shaft, Ughten ball ‘ug bolts and stabilizer bar mount bracket Bolts 0 spec [Adit accelerator cable play necessary a previously desribed Inval sla cable ae describes Aefl engine coolant to pectin eve 1 Rit aman an check the Hi eve 59 Technical Service Information 1 Before starting engine, check agsin to emure that all parts once diatiembled or connected ae back in placeTechnical Service Information UNIT REPAIR DISASSEMBLY OF TRANSAXLE pan, tap around lghty 1 not force tof by Using a sereTechnical Service Information 7.011 presare contol cable trom thot vale cam and 5 Semen Femovig Beas Poe ‘Removing Ot Presse Control Cale 10, Second brake band cover and gatket, 8. OW strainer ana tower valve body brake piston sake a flows For removal of lower valve body, remove the 11 bolts 1 Serbe mark on piston rd a shown i below igre sown in gure. 2) Blow at into ol Mole and measure rod evoke | [Second ak pisos oa 15- 30mm roke [_@06— 0.71 im 3) Hf out of specication, replace aston roe with the one 2nd brake pinion vod of 2 diferent lngihese valle | Penton rod ienath | ldenacaion mark Available [121.3 mm (6.77 in) | Unmarked 1227 mm (6 83 9) pistons. Taree lowprenure comprestes air (1 kgm" 1S pus, 100 KPa, max) into holes down, and pop each orice: Do not attempt to depress atcumulator pistons before removing therm Octane, Huid may be ected from the ‘ak and Paton Rod Stroke | !OT Hote “Mark on Paton Rad (kengih = 122.7 mm) 12, Second brake piston (Removal isnot requires if econ brake pinton and rod aren go0d candi.) Remove snap ting with screwdriver or the lke while pushing in pinion cover and remove cover and piston ‘Second Brake Pon Technical Service Information 13, Solem wie hacnes. 1) Remove wire hala plate securing mut 2) Remove 2 wire clampron trancaxle and pull out rlenoid 18, Ot pump 1) Remove 6 ol ume secring bolt 2) Remove oil pump by wing special too! (Oil pump remover, 09918-48210). notice: Be careful not to loose baaing and bearing races which may sometimes sick tf! pump. FRemoving 01 Pumpbots orice: Be careful not to loose ring gar rae ad Beating which may sometimes suck 9 mput sha Technical Service Information 19. Second brake band nonice Be caret no 1 give damage or ben to second brake bane 20, Front planetary 1ing ger anc ring gee bearing ‘Removing Front Planetary Ring Gear & Bearing 63| ATSG Technical Service Information 21, Front planetary gear ae 2, One way cluten and rear planetary gee Front Pareiary Gear Assy ‘Gne-way Clutch & Rear Planetary Gear 22, Planetary sun gtr and tront planetary gear bearing 25, Fea planetary ring gearing gear bearing and washer. Planetary Sun Gear Tear Pavetary Ring Gear, Bearing & Wathors Toetween Emap ring ana flange with 2 23, One may euten snap ring by using seremciver orice: Ue care not to damage tansanle cue when removing sap Gneway Guich Sha Fig Checking Tvvevara Brake Cesrance27, Zamaprings by using a minus sremesive: Removing? Shap Ringe 28. tsvreverse bei ge, dice, plates ane damper pate, "Removing Flange, Duce and Plates, et 29, Ditterenta ger any 30, Transoele rear cove 1) Remove 10 bolts and 2 nut 2) Remove rear cover by tapping lightly with » plane Technical Service Information 31. Reduction driven ges nut 1) Free tne nut from eating by utng chisel 2 itt manual shtt lever to parking postion ("P™ range to that output shalt i locked and cannot turn 13) Loosen the reduction rien gear nut Notice: {Loosen the aut earfully by ui Do not aurea shock such as by hammering wranch a1 parking lock pew and output shat wil be damaged, “Reduction Driven Gear not 2 Poll out reduction driven gear ‘Removing Rear Cover Removing Reduction Driven Gear 23, Drive counter sutt out with a plamic hammer.66Technical Service Information — xt “Removing return Spring Rasy Removing Tereven Brake Pon by Blowing 67Technical Service Information ‘COMPONENT GROUP OVERHAUL "Component Grouse General Description Cleaning Notice 1 Before veaemby. bePump Body Oil Seal 692. Baay clesrance of sien see Puan deven gear to one de of boay. Using a fser gauge, resuie clearance between driven eat and body, 4, Sie ae Technical Service Information Using a steel staighcedge and 2 felr gauge, measure the sige eearance between dive! driven gear and pump body. (007 — 0118mm Standard boar clearance | OQ oSmm 02 = 005 mm Stancardideclesrance | (g 0029.05 mem Lie 0.30 men (0011) (0.3 mem 10.0099 i) the cnarance exceed he lit, replace ariven ger (Checking Boay Clearance 3. Tip cearance of both ive and driven gears. Measure (racial cnorance between gc teth ard crescent. IW ine clearance excend he bn replace the gat Dit 018mm Standar vpclexance | gous” yuneeay 1 Install or Connect Driven gear and drive gear to pump body ater apslving ATF to ort, Pump cover to pump bedy and tighten 11 pump cover e-aNm Pump cove bolt o8—t2k3m tightening toraue 60-e5ibtt mit 1.30 mm (0011 ‘Checking Tp Clearance Fianing Pomp Cover als 70 “wo (2) 0 pump cove se ngs. Apply ATE to oi Bump Bushing and two (2) a ngs Ort puma cover sal (Oris) {Check drive gear for smooth rationTechnical Service InformationTetum sonngh and remove snap sng ot (eh ring comprenotl on return TW piston return sorings are compreniad at far down 35 12 allow snap ing to move, ncugh. M compressed farther ‘down spring ant may get detormed Removing Soap Ring 44, Soring seat and return spring a8 55 Dect cuten piston Blow comarered aie through drum ol hole to remove swith neate nose pters Technical Service Information 6, tener seat fom aru 1 Outer eal trom puto. Inspect 1. Check valve (tel ball for free movernent in piston. 2, Check vive for lakage by using low pressure ai, ‘Removing Discs Clutch Pinon by Blowing Air ‘Checking Check Ball Leakage Install or Connect Inner sel ("0° rr). [Apply ATF to inner sel and fit tin drum, Use new inner Outer sat (“0° ring ‘Apply ATF 40 outer tal and fi to piston, Use new Piston ito drum Be careful so thot seals ("O" ring) doesnot get twisted ar eauTtaling Piston to Brum 4. Clutch eturn spring ay 5. Spring sexe, Thataing Soring Seat 6. Snapsing ‘Compre return spring and install pring set snap ring in ‘groove. Place special toa! (clutch saving compressor] oh soring seat and compress sorings with press, and then, Install rap ring using a sreweiver. for usage of special too Clutch soring compressor. 4 projection of axing 1+ Do not compres return spring more than neces. i ap ving is socray fitted in notice: Ww EN discs are 10 be stalled, they mutt be soaked ‘in mitomatie vanamision Thuid for at Inst 2 hours before sisembly. 8. Clteh plate snap ving Technical Service Information 9, Alter installing cluteh plate snap cing, measure the Meight between napringand clutch flange as peviouly outlined, | 249305 mm Hee | @09e— 0120 im) 1 gut of specification even when new clutch discs ang plates are stale, install lange of citferent thickness Following 2 types of clutch flanges are avaiable at epare Thickness [Available lute flange 3.00 men (0.178 5), 32.37 mm (0.192 in), Ghecking Direct Cah Clearance 10. check piston for movement by blowing ai trough ol ‘Checking Piston Yor MovementATSC Technical Service Information FORWARDTechnical Servic: 13. Sing sat sao rig CCompeass piston return sings and remove snap ng Place special tool (clutch spring compressor] on sprig notice: 'Do ot push down return spring more than necesary “Removing Spring Seat Shap Ring ‘Soving satan springs Forward clutch piston. Blow comprened air through input daft oll hole to reasle nowe ert e Information Install or Connect {ane and outer ls (“O" ings 1 elute piston, Apply ATF to them and fit to piston, Use new seals 2. Piston ino input shaft drum. Use cares that seis donot get ested or enh. 3. 8 pinton return springs ana sbrng sea. Thali Piston Return Saringe Spring eat snap ing Comores return sorngs and instal snap rng in groove by Place soeci) tool (itch spring compreszoe) on sing feat and compres: springs with a press. Se figute (lft ‘hort for rage of spa oo eluteh pring compresr) orice: Shack to make sure thet nap rng curly fitted i rejections of sting sa © Demet comprens turn spring more than necesury Bs Insal ite, plats snd ange Instal them i following ord maw D owen ae D Pe B Sina aw @ Connon © Fe Clute pate sap ring, [Alter isang elvt plate snap ring, measure she height between snapring and cute flange a revousy outlines. 201-268 mm Hee (0.079— 0.105.) Cation, inatall flange of eitlerent Uicknnt. Following 2 “Removing Cutch Paton by Blowing Air 6, Inner and outer was (°° singe trom piston Inspect 1 Check valve (ball for tre movement in etch piste. 2. Check valve for leakage by uring low pressure a. If found faulty; replace eluch pon 78 Thickness Avaiabie cute thoge [3.00 mm (01 3.37 mm (0.1329) =r {check Glut piston for movement by Blowing a through Input shat i hte.C4 ATSG Technical Service Information UPPER AND LOWER VALVE BODIES ‘Uooer Vave Body ComponentsImportant Steps in Disassembly and Reassembly of Valve Bodies 1 nan lssseing valve Sod, be sure to keep ech valve together wits its corepondig "rng ‘+ When removing upper valve body fom lower one, be Careful not to fallout & pt of sel Ball shown inure, When assembing, install thew four (4) ste! balls the otitions in upper valve body a shown in figure. ‘Four (a Stoel Bale Irsilavion 1 Replace auch guiket with new one, Make sre tht new tvtket i the tae a the old one befor inslltion. '¢ When inaling sch valve to valve body, ue special care ‘© Several of tvottie valve rings are uted a the throttle valve in upoee vale booy, Be sure to inkall the same umber of throtte waive ring as those wed before diss Technical Service Information © Wnen installing upper vale body to lower one, instal sixteen (16) upper valve Body bolts flows. us 7 en per valve body bolt of eeem ‘iantening toreue 95706 1am 11 Install two (2) reamer bolts (positioning bolts) at the postions shown af "D" in balow figure, Do not tighten these Bolts to spaifiation a this time, Fingeright only 2 Insult other 14 bots shown in igus 3) Tighten four () bolts @ to mecitantion 4) Tighten eh (9) bolts @ to section. 5) Tighten two {2} bolts and two reamer bol Dro fambiy. 1 Viner insulin lower valve body cover and gasket to lower Bort | __tenath | Bolthead shape | Pieowe sae cy, gen he lore Bey Bl sen a eee Bere 5 | 38mm (149 5) | Orepreme | 6 Tower vive body a7 6Nm © | 44mmt78inl | Deepreces | 2 owt bots 04-08%9m | Reamer bolt (ermal recess | ‘aening torque 30-401 cl x 2 1 Tighten thro vlve cam bol to speciation, Throne wave | ean cam belt 08-09kem tighening tore 45-6518 18 Upper Vale Body Bolts InvaationS4ATSG Technical Service Information COUNTER SHAFT AND OUTPUT SHAFT BEARINGS ‘Counter Shaft and Outaut Shaft Counter Shaft Bearings 2 (cea cover se. Remove or daconnect 3 1 counter nat earings 1 Sap rings By using a server ie (Gearing remo ‘Removing BearingTechnical Service Information Inal or connect 2 Snapring Counter shat bearing (Roller bearing) to cae 3. Counter shat space 0 case Use spect tools Bearing installer attachment and instal: 4, Another counter shaft tworing (bat bearing] to cae, Use ler mane, Special tool (Bearing installer attachment and invallee The bearing incall attachment hat two tides used for han) insulation of counter sate bearings 3nd output att bearing See Below figure for deta Ttaling Counter Shah Spacer St cane oat aia 5, Bearing backing plate and snap ring, ‘Specia! Tools (Bearing Iataler ‘Attachment and Handle! Output Shaft Bearings Wnen cepacing ovtout shaft bearing, remove the damaged ‘bearing and instal new braing a follow Output sate beating trom output shaft by uting two tre lever, Do not rete the removed earn. New output sate bearing to transaxle cae, Use speci ‘ool (Gearing installer attachment andinstalier Mant, ‘natal Counter Sart Bowing ‘rataing Out Shalt Bearing to raneanATSG| Technical Service Information = New outour sate bearing to outout shalt Use woecal ASSEMBLY OF TRANSAXLE teal (Bearing near GENERAL ASSEMBLY NOTICE ven flaw in a small part ty caute of leakage oF 2. Bene to torave each bolt and mut to aeciiation. 4. Getove auembling new cluah dacs and brake band, 19k them in automatic trantmisin fluid for a last 2 hows 5. Do not ure adhesive cement on gaskets an sila ars 16. When assembling rantanl, be sure 10 ue new gskets an ‘O° ge "a9 for cleaning. 8. Be sure to install theust bearings and races in corect, DIFFERENTIAL ASS'Y Disasemaiy and stiembly sracedures for diferent! ai'y alTechnical Service Information Thus Bearings a0 Races aration 82Technical Service Information 1. Ring gear race 2. Ring gear bearing 3. Ring gear race 4. Snap ring 5, Ring gear flange 6. Ring gear race 7. Front planetary ring gear 8. Front planetary gear ass'y 9, Front planetary gear race 10. Front planetary gear bearing 11 Input drum snap ring 12. Sun gear 418, Sun gear input drum 14, Snap ring 18, Planetary thrust washer 16. Rear planetary thrust washer 17. Sun gear pin 18, Oneway clutch race snap ring 49. Onesway clutch snap ring 20, Oneway clutch 2 2 2, 27. 28. 30. 31 22, 33, 35, 36, 37 - One-way clutch race Rear planetary gear ass'y Rear planetary ring gear Rear ring gear race Ring gear bearing Rear ring gear race Ring gear flange Ring gear snap ring ‘et eeverse brake flange and snap ring etreverse brake dise Istreverse brake plate atreverse brake damper plate Return spring snap ring ‘eteeverse brake return spring Piston inner seal Istreverse beake piston Piston outer seal () Planetary Gear and Relamea Pars4aTSG Technical Service Information ‘Second Brave ComporensTechnical Service Information 2, Manual sift shaft and petking lock pa Ss | —S Mr a! wa So Og © “Manual Shit Shalt, Parking Look Paw! and Rewted Pars 1) tnsall ower washer and parking lek fod to manual sift 2) Manual sife sft into transaxle cate, and then, manual Setent spring, Torque bolt and nut of manual detent spring 1008 ~ 1.2 pm (8~ 12 Nim, BO 85 lb (Une special care 0 thet manual Bit haf wil ot mage cil sal lio wren passing through i 13) Shite watt upper washer and then manual site lever to manual att shaft. Tighen 2 ruts (Upper and lower 8) a fetiow. 1 Tighten lower nut 19.27 = 23 kp (27 — 33. Nm, 200 ~ 735 pt) torque by, Tighten upper nut to 27 — 3:3 kgm (27 ~ 33 Nem, 200235 1b) torque 4) Attar tgtnning nit, check manual sift shaft for moot Totaling Marae Shite Detent Spring 86TSG Technical Service Information 5) Resritor pin and snap rng to parking lock pawl sleeve Thstaling Parking Lock Paw Seve 65) Parking lock pa lock pat scing, an the, ing ant anf lever 87Technical Service Information “staing Snap Ring 4. Counter nae Using a spect too! (Gearing instalie) and hammer, When inerting counter att into case, check to make sure that spacer in the poston ay shown in figure 1p not hammer shalt exeesvely hard, oF map ring and cae will be damage, Tnatating Outout Safe 6, Reduction driven gear on counter sat 1) Shit manual shift lever to "parking position 40 that ‘output shat i locked andeannat ttn 2) Tighten orwen gear mut to specication Tring Counter Shaft 5. Output sae 1) Shite manual shift lever te «poston other than parking 2) Using» seca too! (Bearing installer) and hammer, inal cutout hat. To= oN 11 1S kgm 200 108.0 tte Driven ger nut tightening toraue Tighten nat by turning wrench by hand. “iahtening rut by hammering wrench may cause demage to parking lock pawl and output shat. 2) Using ache! and a hammer, eau driven grar nut a two places EN Tightening Driven Gear NutTechnical Service Information 8, Using special tools (Output shaft remover and Bearing remover Mandl}, push output shaft against rear cover fie 1) Fit projections of speci! tol (Output shaft remover 12 ‘ote of eae, 2} Push beuing and output shat agsint rea cover sie by tapping soeclal tool [Bearing remover handle) with theme ighly, Make size to use special ool Do net ap output ‘shaft cireeiy witha hammer © Becaretul not 1 hammer too hard Caulking Driven Gear Mae cover gue ‘Ghack that output shale bearing enters rear cove bearing hole smoothly. Check for abnatmal gat sound by rota ing outou att 2) Ine 10 bolts ane 2 nus “Toraue bole and mut fo following seeiieations. 16 2Nm Bor | 1.8 23k9m Rear cover bot and 120- 16510% nut tigtening tora TlisNe | nue 11 = 1.5 kom 80-105 ie Tasting Rear Comer ‘Pushing Ourout Shalt Agoiat Rear Cover 89“esalng Diss, Plates and Farge 23) natal sna rng. 1, aka cute elaranct ten sap Hing and Mange, | 058—182mm (0.023 0.076im)Technical Service Information (Checking Vetrevre Brake Piston Movement Thstaliog Rear Planetary Ring Gear aces tnd Bearing Engoe rin 18, Rear planttary thrust washers on rear planetary gear ‘Aoply grease to thrust washers and fit hem before and in gear as, one each ce sre that different lug apes match slots in gear Dee ange seTechnical Service Information Dlanetary gear as clockwise by hand, by hand. Visually cheek to ‘uly seated, Als, make mre tat Tnataling One-way Clutch Roce Srap Ring Trtaling One way Clutch 92Technical Service Information 20, Sun ger pin and thrust washr on sun ger at 22, Front planetary gear bearing and ace. ‘Aoply grees to thrust washer a0 that wil not alo, Inaalt nn gear in foloming ger eck to make sr hei is Fe st war O ewe @ Race Marg sie om Ge DON € wey ee Tali Sun Gone Ay Trataling Front Planetary Goer Aa'y€ 2 3 E g € @ 8 z 5 ao 3 8 z £ $ 3 & rect installing direton install brake ban too much o¢ Thing Ring Gear Races ond Bering ‘Gutaut Shalt Sea Ring Tastaling Front Planetary Ring Gear Assy 94Technical Service Information 28. toput shat sea sings on input sat vinen Tnsaling Ring Geor Races and Bearing Invaled.correcty. In such cate, remove diect dutch2. TSG Inout shatt and formariec clutch sa old input shat wth rect latch natal by hand and [ign teeth of forward clutch dice belore instalation, Wen instaling mput shat, be careful so tat its bearing face will aot al of ret nt to damage Output sal 8 [Alter intaling input shat, ener i fe peoper installa: tion by moving it up and down ighey by hand. If inout tate makes clear sound Ike "Chiek™ when moved up fd dove, neal pce. But iit does not intl in proper postion. So ty 2. Toataig Inout Shake (Check for covrct instalation ofeach component parts follow: Aver installing input shaft, check to make sure thet ach, component it insaliad properly aceording. {allowing exeroton Place ste! saghteage on ansaie cast end surface, rd measure the distance shown in figure by wing Terier, For the distance @ , subtract the wish of Suaightedge from verier reading. IW measured dance Bis within following specification, it means that component parts other than erect dutch finales propel. I out of speciation, duster 49.82 —51.06mm Distance | tr962— 20101 96 Technical Service Information Be en 4 eassring Distance Between Case End Surface tid gut Shalt Flange ‘Second brake band pi. ‘ign hole in second brake band with ese pin hole and insert brake band in. ‘Apply ATE to brake bond pin before instalation, “nstaling Second Brake Band PinTechnical Service Information 135. Cave gasket anc ranaue cate howting. Use new gasket. Intl! gasket using care 20 chat will ignten ease Routing Bote 0 Specification caw howtig bots rene vein ous cts “Tsang Another Input Shot Bearing Race (Case Housing Bolts inealation 97Technical Service Information 28 Direct lath watner ono pum. 442. Check input shat ene pay [Arch greied water ono pum ‘Apply ial gauge onto Input shaft end surace and Fitter Hang inte noteh of: pump body. ‘measure tus play of input hat. 03-05 am Inputaat ewustelay | gig o0xein) 1H out of above specification, remove olf pump and replace input shaft bearing race on ol pump side (Reler {pope TAI-96) with elther ofthe following Bewring race ickres (0.8 mm (0031 i 1.4 rm (0.055 i ‘Avaliable nur hats bearing race fl puro se) ‘Check to make sure thet input sate turnesmoethy. ‘stalling Dect Clutch Wher 40, New ol pump cove sal ("O" rng 100i pump Inetallgeated cover lon outer groove of ol pump. Make sre that cover tli not twisted or extrude 41. 0 pump to wansaxle case ‘Align a! pum bolt ole with case bolt hole and push in pump gently By hand unt i contacts eae, Use exe 20 ‘rat cect clits watner dort not fll off, and input ‘aft seal rngs and pump cover eal ngs will not come of or get damage. ‘Tighten 6 oll pum bolts gradually 10 specification i pump wom “esaring Troe Play of Tope Shae prening tore 49, Solenoid wire nares oon, 1) Inset solanaid wire Rol pate inthe groove in solencie Swite grommet and instal solanoid wire to stud bok of 2) Secure nol pate with lock washer and nut 2) natal 2 solenond wire clamp to roar cover. Stour them with ear cover bolts Tnstaing 01 Pome Tnataling Solenoid Wire HarnessTechnical Service Information Tnataling Solenoid Wire Hold Plate “44. Check for correct instalation of second brake band Looking through second brake band cove hole, check that second brake piston fed end i algned with the canta of recess in bake band 25 shown inure If od fend contacts outside of brake band rece, pull up cond brake band by inserting thin wie in brake band tinting s0 that band recess aligns with od end properly 11 Install new eal regs on pistons. Be sure to apply ATF to pistons an sel ings. 2 testa pnts in case Be careful s that sea rings wil not all off 3) Insert sing into second brake accumulator piston ‘Second Brake Piston Rod and Brake Band 45, Check second brake piston stroke ax previously deterib- Stands bacon |g? 88 Nts tightening torque 07-09 kas ses vanening | ss-esin Instaling Accumulator Pitors and Spring 49, Vate boay Att'y on cu ‘Align manual valve ith pia on manus shit lever and Tower the valve body into plten. Be careful to that sccurelatar spring wil 9 inctne Install 1 bots a lower valve body. Exch bolt length is give in blow figure. Fest, tghten two reumer bots (positioning bolt) and’ @ lightly, Then ght all bats in diagonal rd. oa Nm ome wane voy bt of tiohtening tore oe emTavaling Va Body 50, lnstal ot pressure contol ct Technical Service Information 51, i ae tower aie bo ‘them horizontally te valve body Tnstaling OW Tuber 52. 2 slencid wires; one to diveetchiteh solenoid and the ‘ote to econ brake solenoid eR “nstaling Oi Pressure Contl Cable 0 Thrace Valve Com 100TSG Technical Service Information 1 59, Oil maine and wolenod wie me Clamp solencié wire by festering slenoid wie camp with oi strainer Blt nthe postion as shown in Fue T aa 6Nm owas ee Spenimome | Settee Tasting Magnet 0 OVPon Tnstaing Ov Swaine 154, Magnet inci aan and ei pan with new gasket. ‘trata magne ino pam phe under ot strainer as shown below figure 2) Check to mae sue that oil tubes ae aot in contact 2) There ae 95 0 pan bolts mal and two of ther have crore groove in ther heads Mount thee two e038 ‘ooved bet in ach positions ae shown afer soins “Tighten 15 oi pan bolts weoteston Tastaing OV Pan Bos T 4-6Nm 0 pan bots voenmgrone | 04 OB Kam 55, Oil filer tube with “O" rng 30-a0um Tnvert it filler tube oy cae a8 far at i Hangs and aa eNm 04-06kam 30-408 wean (i tier tobe vote arin rightening toraue 135-165 Bh 0 pe drain ius 101ATSG] Technical Service Information 1990 GEO METRO COMPUTER CONTROL TRANSAXLE “The Geo Metro computer control transaxle looks ike and operates justlike a Chavy Sprint transaxe. However, there isa difference in the contro system. With the Chevy Sprint we have vacuum switches, an accelerator switch, a shift over switch, and a speed sensor (igure 1). Withthe Geo Metro, we see that the accelerator switch and the vacuum switches. have been replaced with a throtle position sensor (igure 2 & 3) CCELERATOR| SWiTcH ~ VACUUM SWITCHES: SHIFTLEVER ‘| ‘SWITCH ‘SPEED SENSOR CONTROLLER 2ND GEAR SOLENOID > | oineer ature [__sotenoio THROTTLE POSITION SENSOR NEUTRAL SAFETY CONTROL MODULE FIGURE 1 - CHEVY SPRINT GEAR SHIFT CONTROL SYSTEM (VACUUM) ‘2ND GEAR SOLENOID DIRECT CLUTCH — SOLENOID FIGURE 2 - GEO METRO GEAR SHIFT CONTROL SYSTEM (ELECTRICAL) AUTOMATIC TRANSMISSION SERVICE GROUP 102= GROUND ON/OFF SIGNAL (IDLE SIGNAL) (OUTPUT VOLTAGE (OPENING ANGLE SIGNAL) POWER SUPPLY FROM ECM (REFERENCE VOLTAGE) 1 THROTTLE POSITION SENSOR 2- THROTTLE BODY Technical Service Information FIGURE 3 - GEO METRO THROTTLE POSITION SENSOR ‘The throttle position sensor can be easily checked for proper operation at the sensor self using an ‘ohmmeter (figure 4 &5) CONDON fide Seen) leverte-stop jew Gaartoce ie SSimm ootain ES (038i) continuity | ea7-eKo Theorie valve e Risk postion 240.149 2 Throttle valves ily opened 3A7-66k2 (gure 4) (figure 5) The throttle position sensor can also be checked at the A/T control module harness plug with a voltmeter (figure 6 & 7) AUTOMATIC TRANSMISSION SERVICE GROUP 103Technical Service Information "TURN ON ignition swien t Measure change of votage ‘hack change h volage F lerinals 137 (figure 6) ted Discrepancy (Gheck change Fo volage terminus 16 trote | | we [om (Figure 7) AUTOMATIC TRANSMISSION SERVICE GROUP 104