Service Manual2005 AISIN AUTOMATIC TRANSAXLE

SECTION 5A2

AISIN AUTOMATIC TRANSAXLE

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

General Specifications

.	Definition
.	1.6 DOHC
Transaxle Fluid Type	ISU DEXRON III or ESSO JWS 3309
Transaxle Fluid Capacity	5.77 ± 0.2L (6.1 ± 0.2 qts)

Transaxle Gear Ratio

Gear	Ratio
Gear	1.6 DOHC
First	2.875
Second	1.568
Third	1.000
Fourth	0.697
Reverse	2.300
Counter	1.020
Differential	3.750

Fluid Capacity

.	Capacity
.	1.6 DOHC
Transaxle Fluid (dry fill)	5.77 ± 0.2L (6.1 ± 0.2 qts)
Transaxle Fluid (drain and refill)	2.1L (2.2 qts)

Notice : Fluid capacity (drain and refill) could be changed according to the some condition, therefore be sure to check the fluid using the oil stick guage.

Line Pressure Specification

Application	Idling	Stall
At "D" range	3.9-4.2 kg/cm² (55-60 psi)	11.3-12.5 kg/cm² (161-178 psi)
At "R" range	6.0-6.9 kg/cm² (85-98 psi)	16.2-18.6 kg/cm² (230-265 psi)

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Drain Plug	17	13	-
Control Cable Adjusting Nut	8	-	71
Shift Control Lever Assembly Mounting Bolts	8	-	71
Manual Valve Lever Shaft Nut	12	-	106
Transmission Range (TR) Switch Bolts	5.4	-	48
Input Speed Sensor Retaining Bolt	5.4	-	48
Output Speed Sensor Retaining Bolt	7.4	-	65
TCM Retaining Bolts	5	-	44
Fluid Cooler Inlet Pipe Fitting Nut	35	26	-
Fluid Cooler Inlet Pipe Bolt	9	-	80
Inlet Pipe Union Bolt	35	26	-
Fluid Cooler Rear Outlet Pipe Fitting Nut	35	26	-
Fluid Cooler Rear Outlet Pipe Clip Bolt	9	-	80
Front Outlet Pipe Union Bolt	35	26	-
Lower Transaxle-to-Engine Retaining Bolts (a)	73	54	-
Lower Transaxle-to-Engine Retaining Bolts (b)	31	23	-
Lower Transaxle-to-Engine Retaining Bolts (c)	21	15	-
Upper Transaxle-to-Engine Mounting Bolts	73	54	-
Upper Transaxle Mounting Bracket Bolts	60	44	-
Rear Mounting Bracket Bolts	60	44	-
Damping Block Connection Nut and Bolt	80	59	-
Torque Converter Bolts	45	43	-
Screw Plugs	7.4	-	65
Transaxle Apply Clamp Bolt	5.4	-	48
Oil Reservoir Lock Plate Bolts	5.4	-	48
Transaxle Case Plate Bolt	9.8	-	87
Transaxle Housing Bolts	29	22	-
Manual Detent Spring Bolt	9.8	-	87
Parking Lock Pawl Bracket Bolts	7.4	-	65
Planetary Ring Gear Nut (Standard)	9.8	-	87
Planetary Ring Gear Nut (Maximum)	29	22	-
Transaxle Rear Cover Bolts	25	18	-
Oil Pump Bolts	25	18	-
Valve Body Bolts	11	-	97
Oil Strainer Bolts	9.8	-	87
Oil Pan Bolts	7	-	62
Unions	25	18	-
Stator Shaft Bolts	25	18	-
Shift Solenoid Valve Bolts	11	-	97
Differential Case-to-Differential Ring Gear Bolt	102	75	-

SPECIAL TOOLS

Special Tools Table

	DW260-021-02 Automatic Transaxle Overhaul Fixture
	DW240-020 Brake/Clutch Spring Compressor
	DW240-030 Forward Clutch Adapter
	DW240-040 Direct Clutch Adapter
	DW240-050 Overdrive Brake Adapter
	DW240-060-01 Brake Spring Compressor Bolt/Nut
	DW240-060-02 Brake Spring Compressor Plate
	DW240-070 1st/Reverse Brake Adapter
	DW240-080 2nd Brake Adapter
	DW240-090 Planetary Ring Gear Remover
	DW240-100 Counter Drive Gear Installation Adapter
	DW260-041 Planetary Ring Gear Nut Removal/Installation Socket (52mm)
	DW260-031-01 Tranaxle Housing Oil Seal Installer
	DW260-031-02 Tranaxle Case Oil Seal Installer
	DW240-120 Measuring Terminal
	DW240-130 Differential Preload Adapter
	DW260-013 Transaxle Support Fixture
	DW240-140 Transaxle Housing Side Bearing Outer Race Adapter
	DW240-150 Transaxle Case Side Bearing Outer Race Adapter
	DW240-160 Transaxle Case Outer Tapered Roller Bearing Race Adapter