For3 Trans 2-2

SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
AUTOMATIC TRANSMISSION
18.Shift Solenoids, Duty Sole- 7) Remove the solenoids, duty solenoids and ATF
temperature sensor.
noids and ATF Temperature
Sensor
A: REMOVAL
1) Lift-up the vehicle.
2) Clean the transmission exterior.
3) Replace the gasket with a new one, and tighten
the drain plug.
4) Drain the ATF completely.
Tightening torque:
AT-00066
25 N·m (2.5 kgf-m, 18.1 ft-lb)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
AT-00080 B: INSTALLATION
1) Insert the sensor, solenoid, duty solenoid to
(A) Oil pan specified position.
(B) Drain plug
5) Remove the oil pan.

6) Disconnect the solenoid and sensor connectors.
Remove the connectors from clip and disconnect
the connectors.
AT-00066

AT-00081
(I) Transfer duty solenoid (Brown)
AT-64
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
2) Tighten the bolts and nuts. 4) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb) Fluid packing:
THREE BOND 1217B (Part No. K0877YA020)
E
E E
D
D D
A
C B
C
AT-00079
AT-00051
Bolt length mm (in)
5) Apply liquid gasket fully to three holes other than
(A) 12 (0.47)
screw holes on transmission case.
(B) 40 (1.57)
(C) 45 (1.77) Fluid packing:
(D) 62 (2.44) THREE BOND 1217B (Part No. K0877YA020)
(E) 73 (2.87)
3) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.
AT-00052
6) Install the oil pan.

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
AT-00081
7) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole. <Ref. to AT-
(A) Lock-up duty solenoid (Blue) 29, Automatic Transmission Fluid.>
(B) Low clutch timing solenoid (Gray) 8) Check the ATF level. <Ref. to AT-29, Automatic
(C) Line pressure duty solenoid (Red) Transmission Fluid.>
(I) Transfer duty solenoid (Brown)
AT-65
TRANSFER DUTY SOLENOID AND VALVE BODY
19.Transfer Duty Solenoid and (1) Support the transmission using a transmis-
sion jack and raise slightly.
Valve Body (2) Remove the bolts and nuts as shown in the
A: REMOVAL figure.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(SOHC)-6, INSTALLATION, Air Cleaner
Case.>
4) Remove the intercooler. (Turbo model) <Ref. to
IN(TURBO)-10, REMOVAL, Intercooler.>
5) Remove the pitching stopper.
AT-00024
13) Remove the rear vehicle speed sensor.
AT-00023
6) Remove the front exhaust pipe with center ex-

haust pipe. (Non-turbo model) <Ref. to EX(SOHC)-
7, REMOVAL, Front Exhaust Pipe.>
AT-00082
7) Remove the rear exhaust pipe and muffler.
(Non-turbo model) <Ref. to EX(SOHC)-11, RE- 14) Remove the select cable nut.
MOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SO-
HC)-13, REMOVAL, Muffler.>
8) Remove the center, rear exhaust pipes and muf-
fler. (Turbo model) <Ref. to EX(TURBO)-7, RE-
MOVAL, Center Exhaust Pipe.>, <Ref. to
EX(TURBO)-12, REMOVAL, Rear Exhaust Pipe.>
and <Ref. to EX(TURBO)-14, REMOVAL, Muffler.>
9) Raise the vehicle and drain the ATF.
AT-00083
15) Move the gear select cable so that extension

bolts can be removed.
16) Remove the bolts.
AT-00016
(A) Oil pan

(B) Drain plug
(C) Differential oil drain plug
10) Remove the heat shield cover.

11) Remove the propeller shaft. <Ref. to DS-14,
REMOVAL, Propeller Shaft.>
12) Remove the transmission rear crossmember.
AT-66
17) Remove the extension case. B: INSTALLATION

NOTE: 1) Install the transfer duty solenoid and transfer
Use a container to catch oil flowing from extension. valve body.
(1) Install the transfer duty solenoid and trans-
fer valve body.
Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
AT-00084
18) Disconnect the transfer duty solenoid connec-

tor.
19) Remove the transfer duty solenoid and transfer
valve body.
AT-00086
(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
2) Install a new gasket and the extension case to

transmission case.
(1) Tighten eleven bolts.
AT-00085
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
(A) Transfer valve body
(2) Adjust the select cable. <Ref. to CS-10, AD-
(B) Transfer duty solenoid connector
JUSTMENT, Select Cable.>
(C) Transfer duty solenoid
3) Install the rear vehicle speed sensor.
Tightening torque:
T: 7 N·m (0.7 kgf-m, 5.1 ft-lb)
AT-00087
AT-67
4) Install the transmission rear crossmember. 9) Install the pitching stopper.

(1) Tighten the bolts.
Tightening torque:
Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T1: 35 N·m (3.6 kgf-m, 26 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
T2: 70 N·m (7.1 kgf-m, 51 ft-lb)
T2
T1
AT-00025
AT-00088
10) Install the air cleaner case. (Non-turbo model)
(2) Remove the transmission jack. <Ref. to IN(SOHC)-6, INSTALLATION, Air Cleaner
5) Install the propeller shaft. <Ref. to DS-15, IN- Case.>
STALLATION, Propeller Shaft.> 11) Install the intercooler. (Turbo model) <Ref. to
6) Install the front, center rear exhaust pipe and IN(TURBO)-11, INSTALLATION, Intercooler.>
muffler. (Non-turbo model) <Ref. to EX(SOHC)-8, 12) Fill ATF up to the middle of the “COLD” side on
INSTALLATION, Front Exhaust Pipe.>, <Ref. to level gauge by using the gauge hole. <Ref. to AT-
EX(SOHC)-11, INSTALLATION, Rear Exhaust 29, Automatic Transmission Fluid.>
Pipe.> and <Ref. to EX(SOHC)-13, INSTALLA- 13) Check the ATF level. <Ref. to AT-29, Automat-
TION, Muffler.> ic Transmission Fluid.>
7) Install the center, rear exhaust pipes and muf-
fler. (Turbo model) <Ref. to EX(TURBO)-8, IN-
STALLATION, Center Exhaust Pipe.>, <Ref. to
EX(TURBO)-12, INSTALLATION, Rear Exhaust
Pipe.> and <Ref. to EX(TURBO)-14, INSTALLA-
TION, Muffler.>
8) Connect the transmission harness connector.
AT-00089
AT-68
ATF FILTER
20.ATF Filter 5) Inspect the level of ATF. <Ref. to AT-29, Auto-

matic Transmission Fluid.>
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
ST 18332AA000 OIL FILTER WRENCH
AT-00091
(A) ATF filter
B: INSTALLATION
1) Use a new ATF filter and apply a thin coat of ATF
to the oil seal.
2) Install the ATF filter. Turn it by hand, being care-
ful not to damage the oil seal.
3) Using the ST, tighten the ATF filter to transmis-
sion case.
ST 498545400 OIL FILTER WRENCH
ST 18332AA000 OIL FILTER WRENCH
• When using ST 18332AA000, tighten the ATF fil-
ter to 14 N·m (1.4 kgf-m, 10.1 ft-lb).
• When using ST 49854500, calculate the ATF fil-
ter torque specifications using the following formu-
la.
T2 = L2/(L1 + L2) × T1
T1: 14 N·m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 0.078 m (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length Tightening torque
mm (in) N·m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.2)
NOTE:
Align the ST with torque wrench while tightening
ATF filter.
4) Add ATF.
AT-69
TRANSMISSION CONTROL MODULE (TCM)
21.Transmission Control Mod- B: INSTALLATION

ule (TCM) 1) Install the transmission control module.
• LHD MODEL
A: REMOVAL Tightening torque:
1) Disconnect the ground cable from battery. 25 N·m (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00041 (B)
AT-00748
2) Remove the lower cover and then disconnect
the connector. (A) Transmission control module
3) Disconnect the connectors from transmission (B) Brake pedal
control module.
• LHD MODEL • RHD MODEL
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) (B)
(A)
(B)
AT-00748
(A) Transmission control module

AT-00749
(B) Brake pedal
• RHD MODEL (A) Transmission control module

(B) Steering column
2) Connect the connectors to transmission control

module.
3) Install in the reverse order of removal.
(B)
(A)
AT-00749
(A) Transmission control module

(B) Steering column
4) Remove the transmission control module.
AT-70
ATF COOLER PIPE AND HOSE
22.ATF Cooler Pipe and Hose 8) Disconnect the ATF cooler pipe from frame.
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the battery and washer tank.
3) Disconnect the ATF cooler hose from radiator.
(Turbo model)
(1) Remove the radiator. <Ref. to CO(SOHC)-
28, TURBO MODEL, REMOVAL, Radiator.>
(2) Remove the radiator under cover.
(3) Disconnect the ATF cooler hose from radia-
tor.
5) Remove the under cover.
6) Disconnect the ATF cooler hose from radiator.
NOTE:
• Do not remove with a screwdriver or other point-
ed tools.
• When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pli-
ers, and then pull directly out with your hand.
AT-00456
9) Disconnect the oil cooler inlet and outlet pipes.

NOTE:
When disconnecting the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
AT-00455
7) Disconnect the ATF cooler hoses from pipes.

NOTE:
• Do not remove with a screwdriver or other point-
ed tools.
• When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pli-
AT-00097
ers, and then pull directly out with your hand.
(A) Inlet pipe
(B) Outlet pipe
AT-00450
AT-71
B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

1) Install the oil cooler outlet and inlet pipes with sion side.
new washer. NOTE:
Tightening torque: • Install so that the hose is not folded over, exces-
T1: 25 N·m (2.5 kgf-m, 18.1 ft-lb) sively bent, or twisted.
T2: 44 N·m (4.5 kgf-m, 32.5 ft-lb) • Be careful to insert the hose to the specified po-
sition.
T1
T2
T1
AT-00566
AT-00450
2) Install the ATF cooler pipe to frame.
4) Connect the ATF cooler hose to the pipe of radi-
ator side. (Non-turbo model)
NOTE:
• Install so that the hose is not folded over, exces-
sively bent, or twisted.
• Be careful to insert the hose to the specified po-
sition.
AT-00455
5) Connect the ATF cooler hose to radiator. (Turbo

model)
(1) Connect the ATF cooler hose to radiator.
AT-00456 (2) Install the radiator under cover.
(3) Install the radiator. <Ref. to CO(SOHC)-31,
TURBO MODEL, INSTALLATION, Radiator.>
6) Install the under cover.
7) Install the battery and washer tank.
8) Fill ATF. <Ref. to AT-29, Automatic Transmis-
sion Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes and hoses.
AT-72
C: INSPECTION
Repair or replace any defective hoses, pipes,
clamps, and washers found from the inspection be-
low.
1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was by pressing with your
fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
AT-73
AIR BREATHER HOSE
23.Air Breather Hose B: INSTALLATION

1) Install the air breather hoses.
A: REMOVAL • NON-TURBO MODEL
<Ref. to IN(SOHC)-6, REMOVAL, Air Cleaner
Case.>
3) Disconnect the air breather hoses.
• NON-TURBO MODEL
AT-00099
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
• TURBO MODEL
AT-00099

• TURBO MODEL
AT-00098


AT-00098 Case.>
3) Install the intercooler. (Turbo model)
(A) Air breather hose (Transmission case) <Ref. to IN(TURBO)-11, INSTALLATION, Inter-
(B) Air breather hose (Oil pump housing) cooler.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
AT-74
OIL CHARGER PIPE
24.Oil Charger Pipe

A: REMOVAL
<Ref. to IN(SOHC)-6, REMOVAL, Air Cleaner
Case.>
3) Remove the oil charger pipe, and remove the O-
ring from flange face.
AT-00100
(A) Oil level gauge

(B) Oil charger pipe
B: INSTALLATION
1) Install the oil charger pipe with new O-ring.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
AT-00100
(A) Oil level gauge

(B) Oil charger pipe

Case.>
3) Install the intercooler. (Turbo model) <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
C: INSPECTION
Make sure the oil charger pipe is not deformed or
otherwise damaged.
AT-75
TORQUE CONVERTER CLUTCH ASSEMBLY
25.Torque Converter Clutch As- 3) Insert the input shaft while turning lightly by
hand.
sembly
Normal protrusion A:
A: REMOVAL 50 — 55 mm (1.97 — 2.17 in)
1) Remove the transmission assembly from vehi-
cle. <Ref. to AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Extract the torque converter clutch horizontally.
NOTE:
• Be careful not to scratch the bushing inside oil
pump shaft.
• Note that oil pump shaft also comes out.
AT-00291
4) Holding the torque converter clutch assembly by

hand, carefully install it to the torque converter
clutch case. Be careful not to damage the bushing.
Also avoid undue contact between the oil pump
shaft bushing and stator shaft portion of the oil
pump cover.
5) Rotate the shaft lightly by hand to engage the
AT-00113 splines securely.
3) Remove the input shaft. Dimension A:
NOTE: Non-turbo model
When the torque converter clutch assembly is re- −1.3 — −1.1 mm (−0.051 — −0.043 in)
moved, the input shaft will come out. Turbo model
2.7 — 2.9 mm (0.106 — 0.114 in)
AT-00114
AT-00311
4) Extract the oil pump shaft from torque converter
clutch. (A) Dimension A
5) Remove the clip from torque converter clutch.
B: INSTALLATION 6) Install the transmission assembly to vehicle.
<Ref. to AT-40, INSTALLATION, Automatic Trans-
1) Install the clip to torque converter clutch. mission Assembly.>
2) Install the oil pump shaft to torque converter
clutch, and then check the clip fits securely in its C: INSPECTION
groove. Make sure the ring gear is not damaged and that
protrusion on the edge of torque converter clutch is
not deformed or otherwise damaged.
AT-76
EXTENSION CASE
26.Extension Case 4) Tighten the bolts to secure extension case.
A: REMOVAL Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)
1) Remove the transmission assembly. <Ref. to
AT-38, REMOVAL, Automatic Transmission As-
sembly.>
AT-00118
5) Install the rear vehicle speed sensor.

AT-00116
Tightening torque:
7 N·m (0.7 kgf-m, 5.1 ft-lb)
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
3) Separate the transmission case and extension

case sections.
AT-00116
(A) Rear vehicle speed sensor

AT-00118 6) Install the transmission assembly. <Ref. to AT-

40, INSTALLATION, Automatic Transmission As-
B: INSTALLATION sembly.>
1) Attach the selected thrust needle bearing to the
end surface of reduction drive gear with vaseline.
C: DISASSEMBLY
1) Take out the transfer clutch by lightly tapping the
NOTE: end of rear drive shaft.
Install the thrust needle bearing in correct direction.
NOTE:
2) Install a new gasket.
Be careful not to damage the oil seal in extension.
3) Install the extension case to transmission case.
AT-00119
(A) Extension case

(B) Transfer clutch
AT-77
EXTENSION CASE
2) Remove the transmission clutch pipe without 4) Install the transfer clutch assembly to extension
bending pipe. case.
NOTE:
• Be careful not to damage the seal rings.
• Insert the clutch assembly fully into position until
the bearing shoulder bottoms.
AT-00120
(A) Extension case

(B) Transfer clutch pipe
3) Remove the dust cover from extension case. AT-00125
4) Remove the oil seal from extension case.

(A) Transfer clutch
D: ASSEMBLY (B) Extension case
1) Using the ST and a press, press in a new oil
seal. E: INSPECTION
ST 498057300 INSTALLER • Use forced air to make sure the transfer pipe and
2) Press in the dust cover. extension case routes are not clogged and do not
3) Install the transfer clutch pipe to extension case leak.
without bending pipe. • Measure the extension end play and adjust it to
within specifications. <Ref. to AT-83, ADJUST-
MENT, Transfer Clutch.>
AT-00120
(A) Extension case

(B) Transfer clutch pipe
AT-78
TRANSFER CLUTCH
27.Transfer Clutch B: INSTALLATION

1) Select the thrust needle bearing.
A: REMOVAL 2) Install the transfer clutch assembly to extension
1) Remove the transmission assembly from vehi- case.
mission Assembly.>
AT-00125
(A) Transfer clutch

AT-00116
(B) Extension case
(A) Rear vehicle speed sensor 3) Tighten the bolts to secure extension case.
Tightening torque:
3) Separate the transmission case and extension 25 N·m (2.5 kgf-m, 18.1 ft-lb)
case sections.
AT-00118
AT-00118
4) Install the transmission assembly to vehicle.
4) Take out the transfer clutch by lightly tapping the <Ref. to AT-40, INSTALLATION, Automatic Trans-
end of rear drive shaft. mission Assembly.>
C: DISASSEMBLY
1) Remove the seal ring.
AT-00119
(A) Transfer clutch

AT-00127
(B) Extension case
(A) Seal ring
(B) Transfer clutch
AT-79
TRANSFER CLUTCH
2) Using a press and ST, remove the ball bearing. 5) Apply compressed air to rear drive shaft to re-
ST 498077600 REMOVER move the piston.
AT-00128 AT-00131
3) Remove the snap ring, and take out the pressure D: ASSEMBLY
plate, drive plates and driven plates. 1) Install the transfer clutch piston.
AT-00129
AT-00132
(A) Snap ring (A) Transfer clutch piston

(B) Transfer clutch (B) Rear drive shaft
4) Remove the snap ring with ST1, ST2 and ST3, 2) Install the return spring to transfer piston.
and take out the return spring and transfer clutch
piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
AT-00133
(A) Return spring

(B) Rear drive shaft
AT-00130
(A) Snap ring

(B) Transfer piston seal
AT-80
TRANSFER CLUTCH
3) Install the transfer clutch piston seal. 6) Using the ST1 and ST2, install the snap ring to
rear drive shaft.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
AT-00134
(A) Transfer clutch piston seal

(B) Rear drive shaft AT-00137
4) Install the ST to rear drive shaft. (A) Snap ring

ST 499257300 SNAP RING OUTER GUIDE (B) Transfer clutch
7) Install the driven plates, drive plates, pressure

plate and snap ring.
AT-00135
(A) Transfer clutch

AT-00138
5) Install the snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE (A) Snap ring
8) Apply compressed air to see if the assembled

parts move smoothly.
AT-00136
(A) Snap ring

(B) Transfer clutch AT-00139
9) Check the clearance between snap ring and

pressure plate. <Ref. to AT-82, INSPECTION,
Transfer Clutch.>
AT-81
TRANSFER CLUTCH
10) Press-fit a new ball bearing with ST. E: INSPECTION

ST 899580100 INSTALLER • Check the drive plate facing for wear and dam-
age.
• Check the snap ring for wear, the return spring
for permanent set, breakage and deformation.
• Check the lathe cut ring for damage.
• Measure the extension end play and adjust it
within specifications. <Ref. to AT-83, ADJUST-
1) Inspect the clearance between snap ring and
pressure plate.
2) Before measuring the clearance, place the same
AT-00140
thickness of shim on both sides to prevent pressure
plate from tilting.
(A) Ball bearing
3) If the clearance is not within specification, adjust
11) Coat a new seal ring with vaseline, and install it it by selecting a suitable pressure plate on the
in the seal ring groove of shaft. transfer clutch piston side.
NOTE: Standard value:
Do not expand the seal ring excessively when in- 0.7 — 1.1 mm (0.028 — 0.043 in)
stalling. Allowable limit:
1.6 mm (0.063 in)
AT-00141
AT-00142
(A) Snap ring
(B) Transfer clutch Available pressure plates
12) Install the transfer clutch assembly without Part No. Thickness mm (in)
damaging seal ring. 31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
4) Check if the tight corner braking does not occur

when the vehicle is started with steering wheel held
at fully turned position. If the tight corner braking
occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
AT-00125 vehicle speed at approx. 5 km/h (3 mph) in both
clockwise and counterclockwise directions for
(A) Transfer clutch approx. ten times each, while repeating acceler-
(B) Extension case ation and braking intermittently.
(2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
AT-82
TRANSFER CLUTCH
F: ADJUSTMENT 0.45 mm (0.0177 in): Gasket thickness

1) Measure the distance “L” from end of extension 2: Distance from the end of transmission case to
case and rear drive shaft with ST. end of reduction drive gear
ST 398643600 GAUGE H: Shim clearance
L = Measured value − 15 mm 0.05 — 0.25 mm (0.0020 — 0.0098 in)
(L = Measured value − 0.59 in) Example:
When, L = 18.60 mm (0.7323 in), 2 = 15.05 mm
(0.5925 in)
Calculation when the clearance is 0.05 mm
(0.0020 in)
ST H = (18.60 + 0.45) − 15.05 − 0.05 = 3.95
[H = (0.7323 + 0.0177) − 0.5925 − 0.0020 =
0.1555]
B Calculation when the clearance is 0.25 mm
(0.0098 in)
L
A H = (18.60 + 0.45) − 15.05 − 0.25 = 3.75
AT-00143 [H = (0.7323 + 0.0177) − 0.5925 − 0.0098 =
0.1476]
A: Measured value
After calculation, the value of “H” becomes be-
B: ST thickness [15 mm (0.59 in)]
tween 3.75 and 3.95, therefore select the bearing
L: Distance from the end of extension case to end
thickness of 3.8.
of rear drive shaft
2) Measure the distance “2” from the transmission Thrust needle bearing
case mating surface to the reduction drive gear end Part No. Thickness mm (in)
surface with ST1 and ST2. 806536020 3.8 (0.150)
2 = Measured value − 50 mm 806535030 4.0 (0.157)
(2 = Measured value − 1.97 in) 806535040 4.2 (0.165)
ST1 398643600 GAUGE 806535050 4.4 (0.173)
ST2 499577000 GAUGE 806535060 4.6 (0.181)
806535070 4.8 (0.189)
ST2 ST1 806535090 5.0 (0.197)
A B
AT-00144
A: Measured value
B: ST thickness [50 mm (1.97 in)]
2: Distance from the end of transmission case to
end of reduction drive gear
3) Calculation equation:
NOTE:
Calculate “H”:
When the clearance is at 0.05 mm (0.0020 in) and
0.25 mm (0.0098 in), then select a suitable thrust
needle bearing from the table.
H = (L + 0.45 mm) − 2 − T
[H = (L + 0.0177 in) − 2 − T]
T: Thrust needle bearing thickness
L: Distance from the end of extension case to end
of rear drive shaft
AT-83
REDUCTION DRIVEN GEAR
28.Reduction Driven Gear Tightening torque:

100 N·m (10.2 kgf-m, 73.8 ft-lb)
A: REMOVAL
mission Assembly.>
2) Remove the rear vehicle speed sensor, and sep-
arate the transmission case and extension case.
<Ref. to AT-77, REMOVAL, Extension Case.>
3) Set the select lever to “P” range.
4) Straighten the staked portion, and remove the
lock nut.
AT-00153
(A) Reduction driven gear

(B) Reduction drive gear
3) After tightening, stake the lock nut securely.

4) Combine the transmission case with extension
case, and install the rear vehicle speed sensor.
<Ref. to AT-77, Installation.>
AT-00153 <Ref. to AT-40, INSTALLATION, Automatic Trans-
mission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
5) Using the ST1 and ST2, extract the reduction gear.
driven gear.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
AT-00156
(A) Snap ring

AT-00154
2) Using the ST, remove the ball bearing from re-
duction driven gear.
ST 498077600 REMOVER
B: INSTALLATION
1) Set the select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
a new drive pinion lock nut.
AT-00157
(A) Ball bearing
AT-84
REDUCTION DRIVEN GEAR
D: ASSEMBLY
1) Using a press, install a new ball bearing to re-
duction driven gear.
AT-00158
(A) Ball bearing
2) Install the snap ring to reduction driven gear.
AT-00156
(A) Snap ring
E: INSPECTION
Check the ball bearing and gear for dents or dam-
age.
AT-85
REDUCTION DRIVE GEAR
29.Reduction Drive Gear C: DISASSEMBLY

1) Take out the seal rings.
A: REMOVAL
mission Assembly.>
2) Remove the rear vehicle speed sensor, and sep-
arate the transmission case and extension case.
<Ref. to AT-77, REMOVAL, Extension Case.>
3) Remove the reduction driven gear. <Ref. to AT-
84, REMOVAL, Reduction Driven Gear.>
4) Using ST, extract the reduction drive gear.
ST1 499737100 PULLER AT-00161
ST2 899524100 PULLER SET
(A) Seal rings
(B) Reduction drive shaft
2) Using the ST, remove the ball bearing.

ST 498077600 REMOVER
AT-00159
(A) Reduction drive gear
B: INSTALLATION
1) Install the reduction drive gear assembly. AT-00162
NOTE:
(A) Ball bearing
Insert it fully into position until the bearing shoulder
bottoms. (B) Reduction drive gear
3) Using a press, remove the reduction drive gear.
AT-00160
AT-00163
2) Install the reduction driven gear. <Ref. to AT-84,
INSTALLATION, Reduction Driven Gear.> D: ASSEMBLY
3) Combine the transmission case with extension 1) Press-fit the reduction drive gear to shaft.
case, and install the rear vehicle speed sensor.
2) Press-fit the a new ball bearing to reduction drive
<Ref. to AT-77, Installation.>
gear.
3) Apply vaseline to the outer surface of seal ring
and shaft groove.
mission Assembly.>
AT-86
REDUCTION DRIVE GEAR
4) Attach new seal rings.
AT-00161
(A) Seal rings

(B) Reduction drive shaft
E: INSPECTION
• Rotate the bearing by hand, make sure it rotates
smoothly.
• Make sure that each component is free of harm-
ful gouges, cuts, or dust.
• Measure the extension end play and adjust it to
within specifications.<Ref. to AT-83, ADJUST-
AT-87
PARKING PAWL
30.Parking Pawl C: INSPECTION

Make sure that the tab of packing pole on the re-
A: REMOVAL duction gear is not worn or otherwise damaged.
mission Assembly.>
2) Remove the rear vehicle speed sensor and sep-
arate the transmission case and extension case
sections. <Ref. to AT-77, REMOVAL, Extension
Case.>
3) Remove the reduction drive gear. <Ref. to AT-
86, REMOVAL, Reduction Drive Gear.>
4) Remove the parking pawl, return spring and
shaft.
AT-00171
(A) Return spring

(B) Parking pawl
B: INSTALLATION
1) Install the parking pawl, shaft and return spring.
AT-00171
(A) Return spring

(B) Parking pawl
2) Install the reduction drive gear. <Ref. to AT-86,

INSTALLATION, Reduction Drive Gear.>
3) Install the rear vehicle speed sensor and exten-
sion case. <Ref. to AT-77, INSTALLATION, Exten-
sion Case.>
mission Assembly.>
AT-88
TORQUE CONVERTER CLUTCH CASE
31.Torque Converter Clutch 8) Remove the oil charger pipe. <Ref. to AT-75,
REMOVAL, Oil Charger Pipe.>
Case 9) Remove the oil cooler inlet and outlet pipes.
A: REMOVAL <Ref. to AT-71, REMOVAL, ATF Cooler Pipe and
1) Remove the transmission assembly from vehi- Hose.>
cle. <Ref. to AT-38, REMOVAL, Automatic Trans- 10) Lightly tapping the torque converter clutch case
mission Assembly.> with plastic hammer, separate the transmission
2) Extract the torque converter clutch assembly. case and torque converter clutch case.
<Ref. to AT-76, REMOVAL, Torque Converter NOTE:
Clutch Assembly.> • Be careful not to damage the oil seal and bush-
3) Remove the input shaft. ing inside the torque converter clutch case by oil
pump cover.
• Be careful not to lose the rubber seal.
AT-00114
4) Remove the air breather hose. <Ref. to AT-74,

AT-00175
REMOVAL, Air Breather Hose.>
5) Remove the pitching stopper bracket. 11) Remove the seal pipe if it is attached. (Reusing
is not allowed.)
AT-00173
AT-00176
6) Lift-up the lever behind connector and discon-
nect it from stay.
(A) Seal pipe
7) Disconnect the inhibitor switch connector from
stay. 12) Remove the differential assembly. <Ref. to AT-
103, REMOVAL, Front Differential.>
13) Remove the oil seal from torque converter
clutch case.
B: INSTALLATION
1) Check the appearance of each component and
clean it.
AT-00174
(A) Transmission harness

(B) Inhibitor switch harness
AT-89
2) Force-fit the oil seal to torque converter clutch Liquid gasket:

case with ST. THREE BOND 1215 (Part No. 004403007)
ST 398437700 DRIFT
AT-00179
AT-00177
3) Install the differential assembly to torque con- (A) THREE BOND 1215
verter clutch case. <Ref. to AT-103, INSTALLA- (B) Rubber seal
TION, Front Differential.> 8) Install the torque converter clutch case assem-
4) Install the left and right side retainers. <Ref. to bly without damaging bush and oil seal and secure
AT-107, ADJUSTMENT, Front Differential.> it with six bolts and four nuts.
5) Install a new seal pipe to torque converter clutch
case. Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
AT-00176
AT-00175
(A) Seal pipe
9) Install the pitching stopper bracket and transmis-
6) Install the rubber seal to torque converter clutch sion ground cable.
case. Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
AT-00178
AT-00173
(A) Rubber seal
10) Insert the inhibitor switch and transmission
7) Apply proper amount of liquid gasket to the en- connector into stay.
tire torque converter clutch case mating surface.
11) Install the air breather hose. <Ref. to AT-74, IN-
STALLATION, Air Breather Hose.>
12) Install the the oil cooler pipes. <Ref. to AT-72,
INSTALLATION, ATF Cooler Pipe and Hose.>
AT-90
13) Install the oil charger pipe with O-ring. <Ref. to

AT-75, INSTALLATION, Oil Charger Pipe.>
14) Insert the input shaft while turning lightly by
hand. At this time, not to damage the bushing.
50 — 55 mm (1.97 — 2.17 in)
AT-00291
15) Install the torque converter clutch assembly.

<Ref. to AT-76, INSTALLATION, Torque Converter
Clutch Assembly.>
mission Assembly.>
C: INSPECTION
Measure the backlash and adjust within specifica-
tions. <Ref. to AT-100, ADJUSTMENT, Drive Pin-
ion Shaft.>
AT-91
OIL PUMP
32.Oil Pump 13) Place two wooden blocks on the workbench,

and stand the transmission case with its rear end
A: REMOVAL facing down.
1) Remove the transmission assembly from vehi- NOTE:
cle. <Ref. to AT-38, REMOVAL, Automatic Trans- • Be careful not to scratch the rear mating surface
mission Assembly.> of transmission case.
2) Extract the torque converter clutch assembly. • Note that the parking rod and drive pinion pro-
<Ref. to AT-76, REMOVAL, Torque Converter trude from mating surface.
Clutch Assembly.>
3) Remove the input shaft.
AT-00181
AT-00114 14) Remove the oil pump housing and adjusting

thrust washer.
4) Lift-up the lever behind the transmission harness
connector and disconnect it from stay.
5) Disconnect the inhibitor switch connector from
stay.
6) Disconnect the air breather hose. <Ref. to AT-
74, REMOVAL, Air Breather Hose.>
7) Remove the oil charger pipe. <Ref. to AT-75,
8) Remove the oil cooler inlet and outlet pipes.
<Ref. to AT-71, REMOVAL, ATF Cooler Pipe and
Hose.> AT-00182
9) Separate the torque converter clutch case and
transmission case sections <Ref. to AT-89, RE- (A) Oil pump housing
MOVAL, Torque Converter Clutch Case.>
10) Separate the transmission case and extension 15) Remove the oil seal retainer.
case sections. <Ref. to AT-77, REMOVAL, Exten- Also remove the O-ring and oil seal (air breather).
sion Case.>
84, REMOVAL, REMOVAL, Reduction Driven
Gear.>
12) Loosen the taper roller bearing mounting bolts.
AT-00183
(A) Oil seal retainer

(B) Drive pinion shaft
AT-00180 16) Remove the O-rings from oil pump housing.

17) Remove the drive pinion assembly.
AT-92
OIL PUMP
B: INSTALLATION 5) Install the oil seal retainer taking care not to

1) Assemble the drive pinion assembly to oil pump damage oil seal lips. Then secure it with three
housing. bolts.
NOTE: Tightening torque:
• Be careful not to bend the shims. 7 N·m (0.7 kgf-m, 5.1 ft-lb)
• Be careful not to force the pinion against housing
bore.
2) Tighten the four bolts to secure roller bearing.
Tightening torque:
40 N·m (4.1 kgf-m, 30 ft-lb)
AT-00187
(A) Oil seal retainer

(B) Drive pinion shaft
6) Make sure the O-ring is fitted correctly in posi-

AT-00184 tion.
7) Secure the housing with two nuts and bolt.
3) Paying attention to the orientation of oil seals, in-
stall two new oil seals to oil seal retainer using ST. Tightening torque:
ST 499247300 INSTALLER 42 N·m (4.3 kgf-m, 31 ft-lb)
AT-00185 AT-00188
(A) Oil seal (A) Oil pump housing

(B) Oil seal retainer
8) Install the torque converter clutch case assem-
4) Attach a new O-ring to oil seal retainer with va- bly to transmission case assembly. <Ref. to AT-76,
seline. Install the seal to oil pump housing bore. INSTALLATION, Torque Converter Clutch Assem-
bly.>
9) Install the reduction driven gear. <Ref. to AT-84,
INSTALLATION, Reduction Driven Gear.>
10) Combine the extension case with transmission
case, and install the vehicle speed sensor 1 (rear).
<Ref. to AT-77, INSTALLATION, Extension Case.>
AT-00186
(A) O-ring
AT-93
OIL PUMP
11) Insert inhibitor switch and transmission con- C: DISASSEMBLY

nector into stay. 1) Remove the four seal rings.
AT-00174
AT-00189
(A) Transmission harness (A) Seal rings

(B) Inhibitor switch harness
2) Lightly tap the end of stator shaft to remove the
12) Install the air breather hose. <Ref. to AT-74, IN- cover.
13) Install the oil cooler pipe. <Ref. to AT-72, IN-
STALLATION, ATF Cooler Pipe and Hose.>
14) Install the oil charger pipe with O-ring. <Ref. to
50 — 55 mm (1.97 — 2.17 in)
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) Remove the inner and outer rotor.
AT-00291

Clutch Assembly.>
AT-00191
mission Assembly.>
(A) Inner rotor
(B) Outer rotor
AT-94
OIL PUMP
D: ASSEMBLY 4) Install the oil seal retainer and new seal rings.
1) Install the oil pump rotor assembly to oil pump After adjusting the drive pinion backlash and tooth
housing. contact. <Ref. to AT-96, ADJUSTMENT, Oil
Pump.>
AT-00191
AT-00189
(A) Inner rotor

(A) Seal rings
(B) Outer rotor
2) Align both pivots with the pivot holes of cover, E: INSPECTION

and install the oil pump cover being careful not to 1) Check the seal ring and O-ring oil seal for breaks
apply undue force to pivots. or damage.
2) Check other parts for dents or abnormalities.
Tightening torque:
3) Selection of oil pump rotor assembly
25 N·m (2.5 kgf-m, 18.1 ft-lb)
(1) Tip clearance
Install the inner rotor and outer rotor to oil pump.
With the rotor gears facing each other, measure
the crest-to-crest clearance.
Tip clearance:
0.02 — 0.15 mm (0.0008 — 0.0059 in)
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) After assembling, turn the oil pump shaft to

check for smooth rotation of rotor. AT-00192
(A) Thickness gauge

(B) Inner rotor
(C) Outer rotor
AT-95
OIL PUMP
(2) Side clearance 2) Using the ST, measure the distance from oil
Set a depth gauge to oil pump housing, then pump housing mating surface to top surface of oil
measure oil pump housing-to-rotor clearances. pump cover with thrust needle bearing.
ST 398643600 GAUGE
Side clearance:
0.02 — 0.04 mm (0.0008 — 0.0016 in)
AT-00195
AT-00193 3) Calculation of total end play

Select the suitable bearing race among those listed
(A) Depth gauge in this table so that the clearance C is in 0.25 to
(B) Inner rotor 0.55 mm (0.0098 to 0.0217 in) range.
(C) Outer rotor C = (L + G) − 2
Clearance between concave portion of high clutch
(3) If depth and/or side clearances are outside C
and end of clutch drum support
specifications, replace the rotor assembly.
Length from case mating surface to concave portion
L
Oil pump rotor assembly of high clutch
Part No. Thickness mm (in) G Gasket thickness [0.28 mm (0.0110 in)]
15008AA060 11.37 — 11.38 (0.4476 — 0.4480) Height from housing mating surface to upper surface
2
15008AA070 11.38 — 11.39 (0.4480 — 0.4484) of clutch drum support
15008AA080 11.39 — 11.40 (0.4484 — 0.4488)
• Measure the total end play and adjust within

specifications.<Ref. to AT-96, ADJUSTMENT, Oil
Pump.>
F: ADJUSTMENT
1) Using the ST, measure the distance from trans-
mission case mating surface to recessed portion of
high clutch drum “L”.
ST 398643600 GAUGE
AT-00196
Thrust needle bearing

Part No. Thickness mm (in)
806528050 4.1 (0.161)
806528060 4.3 (0.169)
806528070 4.5 (0.177)
806528080 4.7 (0.185)
806528090 4.9 (0.193)
806528100 5.1 (0.201)
AT-00194
4) After completing end play adjustment, insert the

bearing race in recess of high clutch. Attach the
thrust needle bearing to oil pump cover with vase-
line.
AT-96
OIL PUMP
5) After correctly installing the new gasket to case

mating surface, carefully install the oil pump hous-
ing assembly. Be careful to avoid hitting the drive
pinion against inside of case.
6) Install both parts with dowel pins aligned. Make
sure no clearance exists at mating surface.
AT-97
DRIVE PINION SHAFT
33.Drive Pinion Shaft B: INSTALLATION

1) Assemble the drive pinion assembly to oil pump
A: REMOVAL housing. <Ref. to AT-93, INSTALLATION, Oil
1) Remove the transmission assembly from vehi- Pump.>
cle. <Ref. to AT-38, REMOVAL, Automatic Trans- 2) Install the oil pump housing to transmission
mission Assembly.> case. <Ref. to AT-93, INSTALLATION, Oil Pump.>
2) Extract the torque converter clutch assembly. 3) Combine the torque converter case with trans-
<Ref. to AT-76, REMOVAL, Torque Converter mission case. <Ref. to AT-89, INSTALLATION,
Clutch Assembly.> Torque Converter Clutch Case.>
3) Remove the input shaft. 4) Install the reduction driven gear. <Ref. to AT-84,
INSTALLATION, Reduction Driven Gear.>
5) Combine the extension case with transmission
case, and install the vehicle speed sensor 1 (rear).
<Ref. to AT-77, INSTALLATION, Extension Case.>
6) Insert the inhibitor switch and transmission con-
nector into stay.
7) Install the air breather hose. <Ref. to AT-74, IN-
8) Install the oil cooler inlet and outlet pipes. <Ref.
to AT-72, INSTALLATION, ATF Cooler Pipe and
AT-00114
Hose.>
4) Lift-up the lever behind transmission harness 9) Install the oil charger pipe with O-ring. <Ref. to
connector and disconnect it from stay. AT-75, INSTALLATION, Oil Charger Pipe.>
5) Disconnect the inhibitor switch connector from 10) Insert the input shaft while turning lightly by
stay. hand. At this time, not to damage the bushing.
6) Disconnect the air breather hose. <Ref. to AT- Normal protrusion A:
74, REMOVAL, Air Breather Hose.> 50 — 55 mm (1.97 — 2.17 in)
7) Remove the oil charger pipe. <Ref. to AT-75,
Hose.>
transmission case sections <Ref. to AT-89, RE-
MOVAL, Torque Converter Clutch Case.>
10) Separate the transmission case and extension
case sections. <Ref. to AT-77, REMOVAL, Exten-
sion Case.> AT-00291
84, REMOVAL, Reduction Driven Gear.> 11) Install the torque converter clutch assembly.
12) Separate the drive pinion shaft and oil pump <Ref. to AT-76, INSTALLATION, Torque Converter
housing <Ref. to AT-92, REMOVAL, Oil Pump.> Clutch Assembly.>
mission Assembly.>
AT-00180
AT-98
DRIVE PINION SHAFT
C: DISASSEMBLY D: ASSEMBLY
1) Straighten the staked portion of lock nut, and re- 1) Measure the dimension “A” of drive pinion shaft.
move the lock nut while locking rear spline portion ST 398643600 GAUGE
of shaft with ST1 and ST2. Then pull off the drive
pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
A AT-00200
2) Using a press, force-fit a new roller bearing in

position.
NOTE:
AT-00197 If too much pressure is applied, the roller bearing
will not turn easily.
2) Remove the O-ring.
3) Using a press, separate the rear roller bearing
and outer race from shaft.
AT-00201
(A) Drive pinion shaft

AT-00198
(B) Roller bearing
(A) Outer race 3) After fitting a new O-ring to shaft, attach the drive
pinion collar to shaft.
4) Using a press and ST, separate the front roller
bearing from shaft. 4) Install the lock washer to drive pinion shaft in
proper direction.
ST 498517000 REPLACER
5) Tighten a new lock nut with ST1, ST2 and ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/(L1 + L2) × T1
T1: 116 N·m (11.8 kgf-m, 85.3 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
AT-00199
Torque wrench length Tightening torque
m (in) N·m (kgf-m, ft-lb)
(A) Front roller bearing
0.4 (15.75) 98 (10.0, 72)
0.45 (17.72) 100 (10.2, 73.8)
0.5 (19.69) 101 (10.3, 74.5)
0.55 (21.65) 102 (10.4, 75)
AT-99
DRIVE PINION SHAFT
ST1 498937110 HOLDER 10) Select three or less shims from following table.
Available drive pinion shims
ST3 499787500 ADAPTER
NOTE: 31451AA050 0.150 (0.0059)
Install the ST2 to torque wrench as straight as pos- 31451AA060 0.175 (0.0069)
sible.
31451AA070 0.200 (0.0079)
31451AA080 0.225 (0.0089)
31451AA090 0.250 (0.0098)
31451AA100 0.275 (0.0108)
E: INSPECTION
• Make sure that all component parts are free of
harmful cuts, gouges and other faults.
• Adjust the teeth alignment. <Ref. to AT-100, AD-
JUSTMENT, Drive Pinion Shaft.>
AT-00202 F: ADJUSTMENT
6) Measure the starting torque of bearing. Make 1) Thoroughly remove the liquid gasket from case
sure the starting torque is within specified range. If mating surface beforehand.
out of allowable range, replace the roller bearing. 2) Install the oil pump housing assembly to torque
converter clutch case, and secure it evenly by tight-
Starting torque: ening four bolts.
7.6 — 38.1 N (0.776 — 3.88 kgf, 5.6 — 28.1 lb)
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
AT-00203
7) Stake the lock nut securely at two places.

8) Measure the dimension “B” of drive pinion shaft.
ST 398643600 GAUGE
AT-00205
3) Rotate the drive pinion several times with ST1

and ST2.
B
AT-00204
9) The thickness “t” (mm) of drive pinion shim.

t = 6.5±0.0625 − (B − A)
AT-00206
AT-100
DRIVE PINION SHAFT
4) Adjust the backlash between drive pinion and Corrective action: Increase the thickness of drive
crown gear. <Ref. to AT-107, ADJUSTMENT, pinion height adjusting shim in order to bring drive
Front Differential.> pinion close to crown gear.
5) Apply red lead evenly to the surfaces of three or
four teeth of crown gear. Rotate the drive pinion in
forward and reverse directions several times. Then
remove the oil pump housing, and check the tooth
contact pattern.
If tooth contact is improper, readjust the backlash
or shim thickness.<Ref. to AT-107, ADJUSTMENT,
Front Differential.>
• Tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward toe side under no-load rotation. AT-00212
[When loaded, contact pattern moves toward • Flank contact
heel.]
Checking item: Backlash is too small.
Contact pattern
(A)
(B)
AT-00207
AT-00209
(A) Toe side
(B) Heel side Corrective action: Reduce the thickness of drive
pinion height adjusting shim in order to move drive
• Face contact pinion away from crown gear.
Checking item: Backlash is too large.
Contact pattern
AT-00213
AT-00208
AT-101
DRIVE PINION SHAFT
• Toe contact (Inside end contact) Corrective action: Reduce the thickness of drive
Checking item: Contact areas is small. pinion height adjusting shim in order to move drive
Contact pattern pinion away from crown gear.
AT-00210 AT-00212
Corrective action: Increase the thickness of drive 6) If tooth contact is correct, mark the retainer posi-
pinion height adjusting shim in order to bring drive tion and loosen it. After fitting a new O-ring, screw
pinion close to crown gear. in the retainer to marked position. Then tighten the
lock plate to specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
AT-00213
• Heel contact (Outside end contact)

Checking item: Contact areas is small.
Contact pattern AT-00214
(A) Lock plate
AT-00211
AT-102
FRONT DIFFERENTIAL
34.Front Differential B: INSTALLATION

1) Install the differential assembly to case, paying
A: REMOVAL special attention not to damage the inside of case
1) Remove the transmission assembly from vehi- (particularly, differential side retainer contact sur-
cle. <Ref. to AT-38, REMOVAL, Automatic Trans- face).
mission Assembly.>
2) Extract the torque converter clutch assembly.
<Ref. to AT-76, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.
AT-00215
(A) Differential assembly
2) Remove the O-rings from left and right side re-

AT-00114 tainer.
3) Using the ST, install the side retainers. <Ref. to
4) Disconnect the air breather hose. <Ref. to AT- AT-103, REMOVAL, Front Differential.>
74, REMOVAL, Air Breather Hose.> ST 499787000 WRENCH ASSY
5) Lift-up the lever behind transmission harness 4) Install the lock plate.
connector and disconnect it from stay.
6) Disconnect the inhibitor switch from stay. Tightening torque:
7) Remove the oil charger pipe. <Ref. to AT-74, 25 N·m (2.5 kgf-m, 18.1 ft-lb)
REMOVAL, Air Breather Hose.>
Hose.>
transmission case.<Ref. to AT-89, REMOVAL,
Torque Converter Clutch Case.>
10) Remove the seal pipe if it is attached.
11) Remove the differential side retainer with ST.
NOTE:
AT-00214
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of torque
(A) Lock plate
converter clutch case.
ST 499787000 WRENCH ASSY 5) Install the new seal pipe to torque converter
12) Remove the differential assembly without dam- clutch case.
aging installation part of retainer.
AT-00176
(A) Seal pipe
AT-103
FRONT DIFFERENTIAL
6) Install the torque converter clutch case to trans- C: DISASSEMBLY

mission case. <Ref. to AT-89, INSTALLATION,
Torque Converter Clutch Case.> 1. DIFFERENTIAL CASE ASSEMBLY
7) Install the air breather hose. 1) Using a press and ST, remove the taper roller
8) Insert the inhibitor switch and transmission con- bearing.
nector into stay. ST 498077000 REMOVER
AT-00174 AT-00216
(A) Transmission harness 2) Secure the case in a vise and remove the crown
(B) Inhibitor switch harness gear tightening bolts, then separate the crown
gear, case (RH) and case (LH).
9) Install the oil cooler pipes. <Ref. to AT-72, IN-
STALLATION, ATF Cooler Pipe and Hose.>
10) Install the oil charger pipe with O-ring <Ref. to
50 — 55 mm (1.97 — 2.17 in)
AT-00217
(A) Crown gear

(B) Differential case (RH)
(C) Differential case (LH)
3) Pull out the straight pin and shaft, and remove

the differential bevel gear, washer, and differential
bevel pinion.
AT-00291

Clutch Assembly.>
mission Assembly.>
AT-00218
(A) Differential case (RH)
AT-104
FRONT DIFFERENTIAL
2. SIDE RETAINER 4) Securely attach the two claws to outer race, set
ST to side retainer.
NOTE: ST 398527700 PULLER ASSY
Remove and install the oil seal and O-ring after ad-
justing drive pinion backlash and tooth contact.
1) Remove the O-ring.
AT-00222
(A) Shaft
AT-00219
(B) Claw
2) Remove the oil seal. 5) Return the removed claw to original position,
and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
ST 398527700 PULLER ASSY
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
AT-00220
3) Take out either split pin, remove the claw.

ST 398527700 PULLER ASSY
AT-00223
(A) Shaft
(B) Side retainer
AT-00221
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
(A) Claw
1) Install the washer, differential bevel gear and dif-
(B) Split pin
ferential bevel pinion in differential case (RH). In-
(C) Pin sert pinion shaft.
AT-105
FRONT DIFFERENTIAL
2) Install the straight pin from reverse direction. NOTE:

• Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
• Fix the bevel pinion gear in place with a screw-
driver or similar tool when measuring.
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
AT-00218
(A) Differential case (RH)
3) Install the washer and differential bevel gear to

differential case (LH). Then put the case over differ-
ential case (RH), and connect both cases.
4) Install the crown gear and secure it by tightening AT-00224
the bolt.
(3) If backlash is not as specified, select a
Standard tightening torque: washer from table below.
62 N·m (6.3 kgf-m, 45.6 ft-lb)
Washer
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
6) Using the ST, install the taper roller bearing.

ST 398437700 DRIFT
AT-00217
(A) Crown gear

(B) Differential case (RH)
(C) Differential case (LH)
5) Measurement of backlash (Selection of washer)

(1) Install the axle shaft (Subaru genuine part)
AT-00225
to differential case.
Part No. 38415AA070 AXLE SHAFT
(2) Measure the gear backlash with ST1 and (A) Taper roller bearing
ST2, and insert ST2 through the access window
of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
AT-106
FRONT DIFFERENTIAL
2. SIDE RETAINER 3) Thoroughly remove the liquid gasket from case

mating surface beforehand.
1) Install the bearing outer race to side retainer.
4) Install the oil pump housing assembly to torque
2) Using the ST and hammer, install a new oil seal.
converter clutch case, and secure it evenly by tight-
ST 18675AA000 INSTALLER
ening four bolts.
NOTE:
ST Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
AT-00226
3) Install a new O-ring.
AT-00205
5) Rotate the drive pinion several times with ST1

and ST2.
AT-00219
E: INSPECTION
• Check each component for harmful cuts, dam-
age and other faults.
• Measure the backlash and adjust within specifi-
cations. <Ref. to AT-107, ADJUSTMENT, Front
Differential.>
F: ADJUSTMENT
1) Using ST, screw in the retainer until light contact AT-00206
is felt.
6) Tighten the LH retainer until contact is felt while
NOTE: rotating shaft. Then loosen the RH retainer. Keep
Screw in the RH side slightly deeper than the LH tightening the LH retainer and loosening the RH re-
side. tainer until pinion shaft can no longer be turned.
ST 499787000 WRENCH ASSY This is the “zero” state.
AT-00227 AT-00229
2) Remove the oil pump housing.

(A) Retainer
AT-107
FRONT DIFFERENTIAL
7) After the “zero” state is established, back off the 9) Turn the drive pinion several rotations with ST1
LH retainer 3 notches and secure it with the lock and check to see if the backlash is within the stan-
plate. Then back off the RH retainer and retighten dard value with ST2, ST3, ST4 and ST5.
until it stops. Rotate the drive pinion a few times. ST1 499787700 WRENCH
Tighten the RH retainer 1-3/4 notches further. This ST2 498247001 MAGNET BASE
sets the preload. Finally, secure the retainer with its ST3 498247100 DIAL GAUGE
lock plate. ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
AT-00214
(A) Lock plate
NOTE: AT-00231
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in). 10) Adjust the tooth contact between front differen-
tial and drive shaft. <Ref. to AT-100, ADJUST-
MENT, Drive Pinion Shaft.>
0.05 mm
(0.0020 in)
AT-00230
8) Insert the axle shaft (Subaru genuine part) to

both holes of side retainer.
Part No. 38415AA070 AXLE SHAFT
AT-108

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SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR

5) Remove the oil pan.

(A) Lock-up duty solenoid (Blue)

3) Connect the harness connectors.

6) Install the oil pan.

13) Remove the rear vehicle speed sensor.

6) Remove the front exhaust pipe with center ex-

15) Move the gear select cable so that extension

(A) Oil pan

10) Remove the heat shield cover.

17) Remove the extension case. B: INSTALLATION

18) Disconnect the transfer duty solenoid connec-

(A) Transfer valve body

2) Install a new gasket and the extension case to

4) Install the transmission rear crossmember. 9) Install the pitching stopper.

20.ATF Filter 5) Inspect the level of ATF. <Ref. to AT-29, Auto-

(A) ATF filter

21.Transmission Control Mod- B: INSTALLATION

(A) Transmission control module

• RHD MODEL (A) Transmission control module

2) Connect the connectors to transmission control

(A) Transmission control module

4) Remove the transmission control module.

9) Disconnect the oil cooler inlet and outlet pipes.

7) Disconnect the ATF cooler hoses from pipes.

B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

5) Connect the ATF cooler hose to radiator. (Turbo

23.Air Breather Hose B: INSTALLATION

(A) Air breather hose (Transmission case)

(A) Air breather hose (Transmission case)

(A) Air breather hose (Transmission case)

2) Install the air cleaner case. (Non-turbo model)

24.Oil Charger Pipe

(A) Oil level gauge

(A) Oil level gauge

2) Install the air cleaner case. (Non-turbo model)

4) Holding the torque converter clutch assembly by

26.Extension Case 4) Tighten the bolts to secure extension case.

A: REMOVAL Tightening torque:

5) Install the rear vehicle speed sensor.

3) Separate the transmission case and extension

(A) Rear vehicle speed sensor

AT-00118 6) Install the transmission assembly. <Ref. to AT-

(A) Extension case

(A) Extension case

3) Remove the dust cover from extension case. AT-00125

4) Remove the oil seal from extension case.

(A) Extension case

27.Transfer Clutch B: INSTALLATION

(A) Transfer clutch

(A) Transfer clutch

(A) Snap ring (A) Transfer clutch piston

(A) Return spring

(A) Snap ring

(A) Transfer clutch piston seal

4) Install the ST to rear drive shaft. (A) Snap ring

7) Install the driven plates, drive plates, pressure

(A) Transfer clutch

8) Apply compressed air to see if the assembled