Service Manual2004 REPAIR INSTRUCTION

Tacuma-Rezzo

REPAIR INSTRUCTION

ON-VEHICLE SERVICE

TRANSAXLE FLUID LEVEL CHECKING PROCEDURE

Tools Required

DW260-070 Oil Drain Plug

Checking Procedure

Start the engine and allow the engine to idle for approximately 5 minutes(850±25rpm), or if possible, drive the vehicle for a few miles to warm the transaxle fluid. Check the fluid level when the transaxle is under 30°C(86°F).
Park the vehicle on a hoist, inspection pit, or similar raised-level surface. The vehicle must be level to obtain a correct fluid level measurement.
Place a fluid container below the fluid level plug.

Notice : You must know fluid level plug and fluid drain plug.

Depress the brake pedal and move the shift lever through the gear ranges, pushing a few seconds in each range. Return the shift lever to the PARK posi- tion. ((left-hand Drive Shown, right-hand Drive Similar)

Caution : Do not remove the fluid level plug if the transaxle fluid is hot. This may cause injury if the fluid drains from the plug hole

Remove the fluid level plug with DW260-070. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the plug hole when the plug is removed.
If fluid drains through the plug hole a little bit it is normal. If fluid does not drain through the plug hole, the transaxle was either under filled or the transaxle is leaking fluid. Fix any leaks before setting the transaxle fluid level.

Installation Notice

Tightening Torque

45N•m(33lb-ft)

When the fluid level checking procedure is completed, wipe any fluid from the transaxle case with a rag or shop towel. Also, check that the fluid fill cap and the vent tube are properly installed.

Adjustment Notice:

Before checking fluid level, it is necessary to fill oil through the plug hole. Refer to below:

– Oil pan removal : 4L (4.2 quarts)

– Torque converter removal : 2L (2.1 quarts)

– Overhaul : 6.9±0.2L (7.3±0.2 quarts)

– Oil drain plug removal : 4L (4.2 quarts)

– Oil : ESSO LT 71141 or TOTAL ATF H50235

CHANGING THE FLUID

Disconnect the negative battery cable.
Remove the fluid drain plug with DW260-070.
Add transaxle fluid. Refer to "Transaxle Fluid Level Checking Procedure" in this Section.

Installation Notice

Tightening Torque

45N•m(33lb-ft)

When the fluid level checking procedure is completed, wipe any fluid from the transaxle case with a rag or shop towel. Also, check that the fluid fill cap and the vent tube are properly installed.

REPARING FLUID LEAKS

Locating leaks

General Method

Verify that the leak is transaxle fluid.
Thoroughly clean the suspected leak area.
Operate the vehicle for about 15 miles or until the transaxle reaches normal operating temperatures, 88°C( 190°F).
Park the vehicle over clean paper or cardboard.
Shut the engine OFF and look for fluid spots on the paper.
Make the necessary repairs of correct the leak.

Powder method

Thoroughly clean the suspected leak area.
Apply an aerosol-type powder (foot powder).
Operate the vehicle for about 15 miles or until the transaxle reaches normal operating temperatures, 88°C(190°F).
Shut the engine OFF.
Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak.
Make the necessary repairs.

Repairing the Fluid Leak

The following are potential causes for fluid leaks. Check these and repair as necessary.
Fasteners are not tightened to specification.
Fastener threads and tapped holes are dirty or corroded.
Gaskets, seals or sleeves are misaligned, damaged, or worn.
The seal bore or the gasket surface is damaged, warped, or scratched.
The manual shaft is nicked or damaged.
There is loose or worn bearing causing excess seal or sleeve wear.
Case or component porosity.
The fluid level is too high.
There is a plugged vent or a damaged vent tube.
There is water or coolant in the fluid.
Fluid drain back holes are plugged.

CASE POROSITY REPAIR

Caution : Epoxy adhesive may cause skin irritations and eye damage. Read and follow all information on the container label as provided by the manufacturer.

Thoroughly clean the area to be repaired with a cleaning solvent. Air dry the area.
Using instructions from the manufacturer, mix a sufficient amount of epoxy make the repair.
While the transaxle case is still hot, apply the epoxy. You can use a clean, dry soldering acid brush to clean the area and also apply the epoxy cement. Make certain that the area to be repaired is fully covered.
Allow the epoxy cement to cure for 3 hours before starting the engine.
Repeat the fluid leak diagnosis procedures. Refer to "fluid leak diagnosis and repair" in this Section.

OIL COOLER PIPE/HOSE

Disassembly and Assembly Procedure

Remove the oil cooler outlet pipe union bolt from the radiator upper side.
Remove the pipe bracket bolt.

Remove the oil cooler outlet pipe union bolt from the transaxle.

Installation Notice

Tightening Torque

32.5N•m(24lb-ft)

Disconnect oil cooler outlet pipe assembly.

Remove the oil cooler inlet pipe union bolt from the radiator lower side.
Remove the oil cooler inlet pipe union bolt from the transaxle.

Installation Notice

Tightening Torque

32.5N•m(24lb-ft)

Disconnect oil cooler outlet pipe assembly.
Installation should follow the removal procedure in the reverse order.

SHIFT CONTROL LEVER

(Left-hand Drive Shown, right-hand Drive Similar)

Removal and Installation Procedure

Remove the right and the left floor panels, the shift control panel, and the floor console, Refer to Section 9G, Interior Trim.
Disconnect the switch connectors

Remove the shift control cable from the selector lever. Refer to "Shift Control Cable" in this Section.
Remove the nuts from the shift control cable mounting bracket at the front of the shift control assembly.
Remove the bolts and the selector lever assembly.

Installation Notice

Tightening Torque

7.5N•m(66.5lb-in)

Make sure the slot in the Park/Neutral Position switch is all the way forward and the shift control lever is in the P position. Failure to do so may damage to the Park/Neutral Position switch and produce a false gear indication.

SHIFT CONTROL CABLE

Removal and Installation Procedure

Remove the battery and disconnect the battery cables.
Drain the transaxle fluid. Refer to "Changing the Fluid" in this Section.
Disconnect the shift control cable from the selector lever.
Disconnect the shift control cable from the bracket.

Remove the right and the left front lower trim panels, the shift control panel and the floor console. Refer to Section 9G, Interior Trim.
Loosen the pinch bolt, nut on the shift control lever.

Installation Notice

Tightening Torque

6N•m(53lb-in)

Remove the shift control cable from the shift control assembly by holding one nut while loosening the other one.

Installation Notice

Tightening Torque

8N•m(71lb-in)

Insert the shift control cable into the connecting slot on the shift control lever and secure it with the pinch bolt and nut.

Pull the shift cable through the firewall of the vehicle, bringing the rubber grommet with it.

Installation Notice

Push the shift control cable through the firewall of the vehicle and install the rubber grommet.

Install shift control cable onto the selector lever and secure with the clip.

Installation Notice

Perform a control cable adjustment. Refer to "Control Cable Adjustment" in this Section.
Install the floor console, the shift control panel and the right and the left lower trim panels. Refer to Section 9G, Interior Trim.
Connect the negative battery cable.

SHIFT CONTROL CABLE ADJUSTMENT

Disconnect the negative battery cable.
Move the selector lever to the PARK position.
Make sure the range selector lever on the transaxle is in the PARK position.

Remove the right and the left front lower trim panels, the shift control panel, and the floor console. Refer to Section 9G, Interior Trim.
Loosen the shift control cable adjustment pinch bolt.
Pull the shifter control cable until it is tight.

Installation Notice

Tightening Torque

8N•m(71lb-in)

Install the floor console, the shift control panel, and the right and the left lower trim panels. Refer to Section 9G, Interior Trim.
Connect the negative battery cable.

PARK/NEUTRAL POSITION SWITCH

Tools Required

DW260-050 Park/Neutral Position Switch setting gauge

Removal and Installation Procedure

Disconnect the negative battery cable.
Disconnect the shift control cable. Refer to "Shift Control Cable" in this Section.
Disconnect the Park/Neutral Position Switch electrical connector.

Remove the shift lever nut and the shift lever.

Remove the Park/Neutral Position Switch bolts.
Remove the Park/Neutral Position Switch.

Install the Park/Neutral Position Switch onto the selector shaft.
Tight the bolts a little bit. Set the Park/Neutral Position Switch using the setting gauge.

Installation Notice

Tightening Torque

10N•m(89lb-in)

Install the shift lever.

Installation Notice

Tightening Torque

10N•m(89lb-in)

Connect the Park/Neutral Position Switch electrical connector.
Connect the negative battery cable.

PAN, GASKET

Removal and Installation Procedure

Disconnect the negative battery cable.
Raise and suitably support the vehicle.
Place a fluid container below the oil pan.
Remove left under cover. Refer to the section 9M Exterior Trim.
Drain the transaxle fluid.
Remove the two oil cooler pipe. Refer to "Oil Cooler Pipe/Hose" in this Section.
Remove the transaxle oil pan bolts and the pan.
Remove the transaxle oil pan gasket. The gasket is reusable.

Installation Notice

Tightening Torque

6N•m(53lb-in)

Inspect the gasket and the pan for cracks, dents, or cuts. Install the transaxle pan and the gasket.
Refill the transaxle fluid. Refer to "transaxle fluid level checking procedure" in this Section.
Connect the negative battery cable.

VALVE BODY/ TRANSAXLE WIRING HARNESS CONNECTOR

Removal Procedure

Remove the negative battery and disconnect the battery cables.
Disconnect the transaxle wiring harness connector by turning to the counter clock wise direction.
Remove the clip from wiring harness connector.

Drain the transaxle fluid. Refer to "Transaxle Fluid Checking Procedure" in this Section.

Remove the transaxle oil pan and gasket. Refer to "Pan, Gasket" in this Section.
Remove the valve body assembly bolts.
Remove the transaxle input speed sensor bolts and sensor.

Remove the transaxle output speed sensor bolts by tilting the valve body assembly.
Remove the transaxle output speed sensor.

Notice : Be careful not to loose washer when removing the transaxle output speed sensor.

Remove the valve body assembly.

Notice : Be careful hurt when removing the valve body assembly.

Installation Procedure

Install the transaxle output speed sensor by tilting the valve body assembly.

Installation Notice

Tightening Torque

6N•m(53lb-in)

Install the valve body assembly.

Notice : Push the transaxle wiring harness connector from the inside of transaxle housing to the outside.

Installation Notice

Tightening Torque

8N•m(71lb-in)

Install the transaxle oil pan and gasket. Refer to "Pan, Gasket" in this Section.
Connect the transaxle wiring harness connector by turning to the clock wise direction.
Install the retainer clip to the wiring harness connector.

TCM (TRNASAXLE CONTROL MODULE)

Removal and Installation Procedure

Remove the right A pillar trim. Refer to Section 9G, Inner Trim.
Disconnect the three TCM connector.
Remove the TCM.

Installation Notice

Tightening Torque

7.5N•m(66.5lb-in)

DRIVE AXLE OIL SEAL

Tools Required

DW 260-030 Axle Seal Installer

Removal and Installation Procedure

Disconnect the negative battery cable.
Remove the drive axle. Refer to Section 3A, Automatic Transaxle Drive Axle.

Notice : Be careful not to damage the bore of the trans-axle case.

Remove the transaxle drive seal using a screwdriver if necessary, crush the seal first with the screwdriver in order to loosen the seal from the case.

Install the transaxle drive seal using the axle seal installer DW 260-030.
Install the drive axle. Refer to Section 3A, Automatic Transaxle Drive Axle.
Connect the negative battery cable.

TRANSAXLE MOUNT

Tools Required

DW 110-060 Engine Support Fixture

DW 260-010 Transaxle Support Fixture

Removal and Installation Procedure

Install the engine support fixture DW 110-060. ((left-hand Drive Shown, right-hand Drive Similar)

Raise and suitably support the vehicle.
Install the transaxle support fixture DW 260-010. ((left-hand Drive Shown, right-hand Drive Similar)

Remove the transaxle mount bracket bolts.

Remove the bolts from the transaxle mount bracket cage.
Remove the transaxle mount bracket cage.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tightening Torque

Transaxle mount bracket cage bolts to 65N•m(48Lb-Ft)

Transaxle mount bolts to 81N•m(60Lb-Ft)

TRANSAXLE ASSEMBLY

Tools Required

DW 110-060 Engine Support Fixture

DW 260-010 Transaxle Support Fixture

Removal Procedure

Install the engine support fixture DW 110-060. ((lefthand Drive Shown, right-hand Drive Similar)
Disconnect the negative battery.

Locate the selector lever P position.
Disconnect the transaxle wiring harness.

Remove the air breather hose.

Disconnect the Park/Neutral Position Switch electrical connector.
Disconnect the shift cable from the shift lever and the shift cable mounting bracket.

Remove the Park/Neutral Position Switch. Refer to "Park/Neutral Position Switch" in this Section.
Remove the transaxle mount bracket bolts.

Remove the upper transaxle-to-engine bolts.

Remove the lower transaxle-to-engine bolts.

Raise and suitably support the vehicle.
Drain transaxle fluid. Refer to "Transaxle Fluid Level Checking" in this Section.
Install the transaxle support fixture DW 260-010, and transaxle support jack (left-hand Drive Shown, right-hand Drive Similar)

Remover the oil cooler pipes from transaxle case. Refer to "Oil Cooler Pipe/Hose" in this Section.

Remove the lower transaxle to-engine bolts.

Remove the drive axles. Refer to Section 3A Automatic Transaxle Drive Axle.
Remove the service hall cover.

Remove the torque converter bolt.

Remove the transaxle assembly from the vehicle.

Installation Procedure

Installation should follow the removal procedure in the reverse order.
Install the torque converter bolt.

Installation Notice

Tightening Torque

45N•m(33lb-ft)

Install the transaxle mounting bracket.

Installation Notice

Tightening Torque

90N•m(66lb-ft)

Install the drive axle. Refer to Section 3A Automatic Transaxle Drive Axle.
Install the lower transaxle-to-engine bolts.

Installation Notice

Tightening Torque

The large lower transaxle-toengine bolts 31N•m(23Lb-Ft).

The small the lower transaxle-to-engine bolts to 21N•m(15Lb-Ft)

Install the upper transaxle-to-engine bolts.

Installation Notice

Tightening Torque

75N•m(55lb-ft)

Add transaxle fluid. Refer to "Transaxle Fluid Checking Procedure" in this Section.
Install the under cover bolts.
Adjust the shift control cable. Refer to "Shift Control Cable" in this Section.
Installation should follow the removal procedure in the reverse order.

UNIT REPAIR

TORQUE CONVERTER

Remove the torque converter assembly.
Installation should follow the removal procedure in the reverse order.

TRANSAXLE HOLDING FIXTURE ASSEMBLY

Tools Required

DW 260-020 Transaxle Support Fixture

Caution : To reduce the possibility of personal injury or transaxle damage, make sure, when doing the next step, that all of the bolts for the support fixture are installed as shown, and that the bolts are tightened to 11N•m(98lb-ft).

Install the DW 260-020 transaxle support fixture onto the transaxle.
Torque the support fixture bolts to 11N•m(98lb-ft).
Position the transaxle with the rear cover facing up.

VALVE BODY

Disassembly and Assembly Procedure

Remove the oil pan bolts and oil pan.
Remove the oil pan gasket.

Installation Notice

Tightening Torque

6N•m(53lb-in)

Remove valve body fixing bolts and transaxle input speed sensor bolt on the valve body.
Remove the holder for the transaxle input speed sensor.

Installation Notice

Tightening Torque

8N•m(71lb-in)

Tilt the valve body.
Remove the fastening screw for the output speed sensor under the valve body assembly.
Lever the cable out of the retaining clip and pull out the output speed sensor.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tightening Torque

6N•m(53lb-in)

REAR COVER

Disassembly and Assembly Procedure

Removal the valve body assembly. Refer to "valve body removal" in this Section.
Pull out sealing sleeve(brake C) with a kind of nail.
Turn transaxle by 90°.

Remove the rear cover bolts.
Hit the rear cover rightly.
Remove the cover.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tightening Torque

23N•m(17lb-ft)

CLUTCH B/E

Disassembly and Assembly Procedure

Tools Required

DW 260-140 Clutch B Stop Ring Remover/Installer

DW 260-150 Clutch B Stop Ring Remover/Installer

Remove the rear cover. Refer to "rear cover removal" in this Section.
Remove the two sealing rings(clutch B/E)

Take out input shaft with clutch B/E.

Remove needle bearing and thrust washer.
Remove shim.

Take out the retaining snap ring

Take out the piston B.

Remove disc set B.

Take out the piston rings.

Removal Notice

Remove the rectangular-section ring for the input shaft and the retaining ring.

Remove inner disc carrier E and needle roller thrust bearing.

Take out the snap ring.

Remove Disc set E.

Press down cup spring(clutch E) with cup spring press fixture.
Remove the split stop ring.

Remove the oil dam and cup spring.
Pull the O-ring off the oil dam.

Press down cup spring(clutch B)with cup spring press fixture.
Remove the split stop ring.

Remove the cup spring.
Installation should follow the removal procedure in the reverse order.

Adjustment Notice

Before assembling clutch B/E, setting discs(clutch B/E) have to measured by below measurement procedure.

CLUTCH B/E MEASUREMENT PROCEDURE

Determine snap ring play

Tools Required

DW 260-090 Clutch B/E(snap ring play, installation space) Measuring Fixture

Put the dial gauge sensor on the clutch B adjusting ring.
Feed compressed air to clutch B via control valves.
Set dial gauge to o.
Pressurize clutch E via the control valve and read measurement value.
Repeat measurement twice with disc set turned by 1203.
Average measurement values M1, M2, M3.(measurement value is S)

CALCULATION

S = (M1+M2+M3)/3

EXAMPLE

– M1 = 0.27mm, M2 = 0.23mm, M3 = 0.25mm

– S = 0.25mm

Measuring installation space, clutch B(E)

Tools Required

DW 260-090 Clutch B/E(snap ring play, installation space) Measuring Fixture

Put the dial gauge's sensor on the clutch B adjusting ring.
Feed compressed air to clutch E via control valves.
Set dial gauge to o.
Lift measurement ring B by hand until it touches the cup and read the measurement value.
Repeat measurement twice with the set turned by 120°.
Average measurement values M4, M5, M6. (measurement value is M B)

The minimum installation space E B is equal to the height of the ring R B (specification value ; 11.99mm) plus measurement value M B
CALCULATION

M B = (M4+M5+M6)/3

E B = R B + M B

EXAMPLE

M 4 = 2.36mm

M 5 = 2.40mm

M 6 = 2.38mm

So, M B = (2.36+2.40+2.38) / 3 = 2.38mm

E B = 11.99 + 2.38

= 14.37mm

Measuring installation space, clutch E(E)

Tools Required

DW 260-090 Clutch B/E(snap ring play, installation space) Measuring Fixture

Put the dial gauge's sensor on the clutch E adjusting ring.
Set dial gauge to o.
Feed compressed air to clutch E via control valves.
Read off the measured value.
Repeat measurement twice with the set turned by 120°.
Average measurement values M7, M8, M9. (measurement value is M E)

The minimum installation space B E is equals ring height R E (specification value ; 20.98mm) plus M E - minus snap ring play S.
CALCULATION

M E = (M7+M8+M9)/3

E E = R E + M E − S

EXAMPLE

M 7 = 2.6mm

M 8 = 2.55mm

M 9 = 2.54mm

So, M E = (2.6+2.55+2.54) / 3 = 2.56mm

E E = 20.98+2.56−0.25

= 23.29mm

Determining adjusting disc B(P)

Tools Required

DW 260-100 Brake B/E Disc Thickness Measuring Fixture

Using disc thickness gauge, determine thickness M E for the disc set for clutch B(without adjusting disc, which located in second highest plate).
Calculate the test dimension P B(P B = E B - M B)

E B = installation space

M B = disc set thickness

EXAMPLE

E B = 14.37mm

M B = 11.3mm

P B = 3.07mm

Find the disc set's thickness. Refer to the below table.

P B	Disc set's Thickness
2.83~3.39mm	1.8mm
3.40~3.68mm	2.1mm
3.69~4.08mm	2.5mm
4.09~4.54mm	3.0mm

P B IS 3.08mm so, the disc set's thickness is 1.8mm.

Replace clutch B's setting disc.(1.8mm)

Determining adjusting disc B(P)

Tools Required

DW 260-100 Brake B/E Disc Thickness Measuring Fixture

Using disc thickness gauge, determine thickness MB for the disc set for clutch E(without adjusting disc, which located in the lowest plate).
Calculate the test dimension P E(P E = E E - M E)

E E = installation space

M E = disc set thickness

EXAMPLE

E E = 23.29mm

M E = 16.70mm

P E = 6.59mm

Find the disc set's thickness. Refer to the below table.

P E	Disc set's Thickness
5.41~6.00mm	3.9mm
6.01~6.48mm	4.4mm
6.49~6.98mm	5.0mm

P B IS 3.08mm so, the disc set's thickness is 5.0mm.

Replace clutch B's setting disc.(5.0mm)

PLANETARY GEAR SET

Disassembly and Assembly Procedure

Remove the clutch B/E. refer to "clutch B/E" in this Section.
Remove the rear sun gear.

Remove the planetary gear set.

Remove snap ring from front ring gear.

Take out rear planetary gear set.

Remove the axial needle bearing.

Take out front gear set with rear ring gear, front sun gear and oil trays.

Take oil trays and front sun gear off the planetary gear set.
Installation should follow the removal procedure in the reverse order.

BRAKE C/D

Disassembly and Assembly Procedure

Tools Required

DW 260-160 Brake C/D Snap Ring Remover/Installer

Take snap ring out of transaxle housing.

Release cylinder with piston C by applying compressed air to the feed bore .

Remove cylinder with piston C.

Take disc carrier C/D and spring disc out of transaxle housing.

Release cylinder with piston D by applying compressed air to the feed bore.

Remove cylinder with piston C.

Separate between piston C and cylinder C.

Take snap ring out of brake C.

Remove the disc set C.

Installation Notice

Transaxle has two lined clutch discs and one steel clutch disc. The lined discs must be installed in such a way that the lining faces the steel disc.
Insert the fitting keys into the appropriate grooves.

Turn the disc carrier C/D by 180°.
Using assembly bracket Press down cup spring and take out the snap ring.

Remove the disc set D.
Installation should follow the removal procedure in the reverse order.

DIFFERENTIAL

Disassembly and Assembly Procedure

Remove the torque converter housing. Refer to "torque converter" in this Section.
Lift out the differential.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Don't disassemble the differential to avoid incorrect operation.

SIDE SHAFT

Disassembly and Assembly Procedure

Remove the differential. Refer to "differential" in this Section.
Tilt and remove the side shaft.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Don't disassemble the differential to avoid incorrect operation.

BRAKE F

Disassembly and Assembly Procedure

Tools Required

DW 260-060 Brake F Split Stop Ring Remover

Remove the side shaft. Refer to "side shaft" in this Section.
Take OFF the disc set and the brake F inner disc carrier.

Mount fixture and remove the brake F split stop ring.

Remove the fixture and take off the cup spring.

Release the piston F by applying compressed air to the bore.

Remove piston F. and bearing plate with spur gear.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Since the bearing set is tight, press the bearing plate upward from underneath to remove it.

Measuring installation space F

Tools Required

DW 260-110 Brake F Disc Clearance Measuring Bar

Using a depth gauge, measuring from the transaxle housing sealing surfaces to the piston's disc support surface at two opposing points = M 1, M 2
Average the measurement values M 1, M 2 = B F

CALCULATION

B F = (M 1+M 2)/2

CALCULATION

M 1 = 18.6mm

M 2 = 18.8mm

B F = 18.7mm

Determining adjusting disc F

Calculate the test dimension P F(P F = B F - M F)

B F = installation space

M F = disc set thickness(assume 14.50mm)

EXAMPLE

B F = 18.70mm

M F = 14.50mm

P E = 4.2mm

Find the disc set's thickness. Refer to the below table.

P F	Disc set's Thickness
3.01~3.19mm	1.8mm
3.20~3.48mm	2.1mm
3.49~3.88mm	2.5mm
3.89~4.08mm	2.7mm
4.09~4.30mm	3.0mm

P E IS 4.20mm so, the disc set's thickness is 3.0mm.

Replace clutch B's setting disc.(3.0mm)

TORQUE CONVERTER HOUSING

Disassembly and Assembly Procedure

Remove the torque converter bolts.
Hit the torque converter housing lightly.
Remove the torque converter housing.

Installation Notice

First pre-tighten the bolts in the following order.

(7,20) ˃ (12,23) ˃ (16,4)

Tightening Torque

15N•m(11lb-ft)

Then, tighten the bolts in the following order.

(15,3) --> (16,4) --> (14,5) --> (13,23) --> (12,22) --> (11,21) --> (10,20) --> (9,19) --> (8,18) --> (7,17) --> (6) --> (1,2)

Last, in numerical order, tighten the bolts all the way.(1 --> 23)

Tightening Torque

23N•m(17lb-ft)

Take out the metal gasket.
Take out the paper gasket.
Remove the oil filter bolt and oil filter.

Installation Notice

Tightening Torque

10N•m(89lb-in)

Remove the baffle plate bolts and baffle plate.

Installation Notice

Tightening Torque

10N•m(89lb-in)

Remove the line pressure measurement plug.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tightening Torque

20N•m(15lb-ft)

SHIFT MECHANISM

Disassembly and Assembly Procedure

Take out the select shaft clamping sleeve.

Remove the shift mechanism.

Shift mechanism is consist of select shaft, detent disc, connecting bar, stop bush.

Installation should follow the removal procedure in the reverse order.

PARKING LOCK SYSTEM

Disassembly and Assembly Procedure

Remove the parking lock assembly.

Parking lock system is consist of parking pawl, leg spring, support bolt.

Installation should follow the removal procedure in the reverse order.

BEARING PLATE(WITH SPUR GEAR) ASSEMBLY

Disassembly and Assembly Procedure

Remove the piston F. refer to "brake F" in this Section.
Remove the bearing plate bolts. And bearing plate.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tightening Torque

27N•m(17lb-ft)

OIL PUMP ASSEMBLY

Disassembly and Assembly Procedure

Remove the oil pump housing bolts.
Using the plastic hammer. Take out the oil pump housing.

Installation Notice

Tightening Torque

10N•m(89lb-in)

Remove the stator shaft bolts.

Dismantle the oil pump gear, ring gear
Installation should follow the removal procedure in the reverse order.

DIFFERENTIAL/SIDE SHAFT OUTER RACE, BEARING SHIM

Disassembly and Assembly Procedure

Take out the outer race of the transaxle housing side.
Remove the bearing shim.
Take out the outer race of the torque converter housing side.

Installation Notice

Heat the bearing seats well and insert bearing outer rings with shim for differential and side shaft into the transaxle housing.

IMPORTANT MEASUREMENT/ADJUSTMENT

Adjusting axial play, input shaft

Tools Required

DW 260-080 Clutch B/E Shim Setting Gauge

Important : After assembling the rear cover. You must measure the axial play spec'. if the measured data is not satisfied the specification. Replace the clutch B/E's shim.

Incorrect axial play may cause the vibration or noise. The specification of the axial play is 0.18 to 0.42mm.

Clamp fixture on the input shaft so that the measuring base rests on the stator shaft.
Set dial gauge to 0.
Measure axial play by pulling and pressing on the handle(repeat measurement)

Calculate the measurement values.(average)

EXAMPLE

M 1 = 0.51mm
M 2 = 0.49mm
M = (0.51+0.49)/2 = 0.5mm
S( specification) = 0.18~0.42mm
D(adjustment value) = 0.5mm (0.18~0.42)mm
So, D is 0.08 to 0.32mm
Calculate the average, so D is 0.2mm

Replace shim.

Disc thickness must be between 0.08 and 0.32mm thicker. It is sensible to select one with a disc that average 0.2mm thicker than the one that was installed.

SPECIFICATIONS

GENERAL SPECIFICATIONS

.	Definition
Transaxle Type	4-speed with four-wheel drive and transverse engine
Input Torque	240N•m
Transaxle Weight	76kg
Torque Converter Capacity	9.72kg
Transaxle Fluid Type(manufacture company)	ESSO LT 71141 or TOTAL ATF H50235
Transaxle Fluid Capacity	7.3±0.2qt (6.9±0.2L)

TRANSAXLE GEAR RATIO

Gear	Ratio
First	2.719
Second	1.487
Third	1.000
Fourth	0.717
Reverse	2.529
Final	3,945 (2.0DOHC)

FLUID CAPACITY

.	Litres	Quarts
Bottom Pan Removal	4	4.2
Complete Overhaul	6.9±0.2	7.3±0.2
Torque Converter Removal	2	2.1
(Measurements are approximate)

FASTENER TIGHTENING SPECIFICATIONS

Application	N•m	Lb-Ft	Lb-In
Bearing Plate Bolts	23.5	17.5	-
Slotted Nut	220	-	-
Rear Cover Attachment Bolts	23.5	17.5	-
Baffle Plate Attachment Bolts	10	-	89
Park/Neutral Position Switch	10	-	89
Fluid Pump Connecting Bolts	10	-	89
Fluid Filter Housing Cover Attachment Bolts	10	-	89
Input Speed sensor Attachment Bolts	8	-	71
Output Speed sensor Attachment Bolts	8	-	71
Valve Body Bolts	8	-	71
Valve Body Upper Lower Fixing Bolts	6	-	53
Fluid Pan Connecting Bolts	6	-	53
Fluid Pan Drain Plug	45	33	-
Fluid Level Plug	45	33	-
Line Pleasure Plugs	20	15	-
Valve Housing 1 Cover Attachment Bolts	6	-	53
Solenoid Valve Attachment Bolts	6	-	53
Pressure Control Regulator(EDS) Attachment Bolts	6	-	53
Cooler Pipe Attachment Bolts	32.5	24	-
Shift Control Cable Adjuster Pinch Nut	8	-	71
Shift Control Cable Attachment Nut	8	-	71
Shift Control Cable Bracket Attachment Nut	25	18	-
Shift Control Lever Bracket Attachment Bolt	8	-	71
Transaxle Upper Attachment Bolts	72.5	53	-
Transaxle Lower Attachment Bolts(Long Bolts)	31	23	-
Transaxle Lower Attachment Bolts(Short Bolts)	21	15	-
Selector Lever(On Transaxle Case)	15	11	-
TCM Attachment Bolts	7	-	62
TCM Bracket Attachment Bolts	7	-	62
Transaxle Center Mounting Bracket Attachment Bolts	61	44	-
Transaxle Center Mounting Bracket Attachment Nuts	100	74	-
Transaxle Left Mount-to-Connecting Bolts	48	35	-
Transaxle Left Mount-to-Connecting Nuts	48	35	-
Transaxle Rear Mount Bracket Attachment Bolts	75	55	-
Torque Converter Attachment Bolts	45	33	-

Range	Park/Neutral	Reverse	D				3			2		1
Gear	N	R	1st	2nd	3rd	4th	1st	2nd	3rd	1st	2nd	1st
Solenoid Valve 1	ON	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF	ON/OFF
Solenoid Valve 2	ON	ON	ON	OFF	OFF	OFF	ON	OFF	OFF	ON	OFF	ON
Line Pressure Control Solenoid Valve 3 (EDS 3)	OFF	OFF	OFF	ON	ON/OFF	ON/OFF	OFF	ON	ON/OFF	OFF	ON	ON/OFF
Line Pressure Control Solenoid Valve 4 (EDS 4)	ON	OFF	ON	ON	ON	OFF	ON	ON	ON	ON	ON	ON
Line Pressure Control Solenoid Valve 5 (EDS 5)	OFF	OFF	ON	ON	OFF	OFF	ON	ON	OFF	ON	ON	ON
Line Pressure Control Solenoid Valve 6 (EDS 6)	ON	OFF	ON	ON	ON	OFF	ON	ON	ON	ON	ON	ON
Brake B	A	A	A	.	A	.	A	.	A	A	.	A
Brake C	.	.	.	.	.	H	.	.	.	.	.	.
Brake D	.	H	.	.	.	.	.	.	.	.	.	.
Clutch E	.	.	.	A	A	A	.	A	A	.	A	.
Brake F	.	.	H	H	.	.	H	H	.	H	H	H
Lock-up Clutch	.	.	.	.	.	A	.	.	.	.	.	.
A = Applied H = Holding ON = The solenoid is energized. OFF = The solenoid is de-energized. = Manual Second-Third gear is only available above approximately 100 km/h (62 mph). * = Manual First-Second gear is only available above approximately 100 km/h (62 mph). NOTE: Manual First-Third gear is also possible at high vehicle speed as a safety feature.

SHIFT SPEED CHART

Up Shift Speed

MODEL	First-Second gear (34.8km/h)				Second-Third gear (36.4km/h)				Third-Fourth gear (38km/h)
.	10% TPS	25% TPS	50% TPS	100% TPS	10% TPS	25% TPS	50% TPS	100% TPS	10% TPS	25% TPS	50% TPS	100% TPS
2.0 DOHC EOBD	20	20	27	57	37	38	49	108	50	53	74	168

Down Shift Speed

MODEL	Down Shift (36.4km/h)			Lock Up Clutch Applied (Fourth)		Lock Up Clutch Released (Fourth)
.	Fourth-Third (Coast)	Third-Second (Coast)	Second-First (Coast)	10%	25%	10%	25%
2.0 DOHC EOBD	43	22	12	70	70	65	65

LINE PRESSURE

Gear Range	Solenoid	Line Pressure	B Port	E Port
Park/Neutral	ON	LOW	6.2~8.6 bar	.
Park/Neutral	OFF	HIGH	15.3~17.4 bar	.
Reverse	ON	LOW	6.2~8.6 bar	.
Reverse	OFF	HIGH	15.3~17.4 bar	.
Drive	ON	LOW	.	6.2~8.6 bar
Drive	OFF	HIGH	.	9.5~11.2 bar
3	ON	LOW	6.2~8.6 bar	6.2~8.6 bar
3	OFF	HIGH	15.3~17.4 bar	9.5~11.2 bar
2	ON	LOW	.	6.2~8.6 bar
2	OFF	HIGH	.	9.5~11.2 bar
1	ON	LOW	6.2~8.6 bar	.
1	OFF	HIGH	15.3~17.4 bar	.