124361534 daewoo-8140le-repair

[ RM-1 ]

DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)© All Rights Copyright AISIN AW CO., LTD.

FOREWORD

This REPAIR MANUAL covers Disassembly, Inspection and Assemblyprocedures for the following Automatic Transmission:

All information contained in this manual is the most up-to-date at the timeof publication. However, specifications and procedures are subject tochange without notice.

QUALITY ASSURANCE DEPT.

All rights reserved. This book may not bereproduced or copied, in whole or in part,without the written permission of AISIN AWCO., LTD.First Printing: Jul, 2003

© 2003

Automotic Transmission Engine Type REF No.

81-40LEDAEWOO: 96 484 421

AW: 30510-81C008

FAN I1.5L SOHC DW-01M-MRM002

[ RM-2 ]


ABBREVIATIONS

ASSY ............................................................ AssemblyA/T .......................................... Automatic TransmissionATF ................................ Automatic Transmission FluidB1 ........................................... O/D & 2nd Coast BrakeB2 .................................................................2nd BrakeB3 ................................................ 1st & Reverse BrakeC1 .........................................................Forward ClutchC2 ............................................................ Direct ClutchC3 ........................................................ Reverse ClutchF1.................................................... 1 Way Clutch No.1F2.................................................... 1 Way Clutch No.2O/D ............................................................. Over DriveV/B .............................................................. Valve BodyFIPG ...................................... Formed In Place GasketSST ...............................................Service Special ToolTT .................................................... Tightening TorqueT/M........................................................... TransmissionT/C .................................................... Torque ConverterFR .........................................................................FrontRR......................................................................... RearMID .................................................................... MiddleDIA ................................................................. DiameterB/G....................................................................Bearing

[ RM-3 ]


ABBREVIATIONS

SLT ........................ Throttle Pressure Control SolenoidS1,S2 .....................................Shift Solenoid No.1,No.2ST ....................................................... Timing SolenoidSL ................................................... Lock-Up SolenoidTh.................................................................. ThicknessL ......................................................................... LengthV........................................................................... ValveAcum......................................................... AccumulatorCont. ................................................................. ControlReg. .............................................................. RegulatorPress...............................................................PressureMod. .............................................................. ModulatorPla.................................................................. PlanetarySTD................................................................ StandardLUB. ...................................................................... LubeHSG ................................................................. HousingDiff ............................................................... Differential

[ RM-4 ]


BLANK

[ RM-5 ]


TABLE OF CONTENTS

FOREWORD ........................................................................................ RM-1ABBREVIATIONS ................................................................................ RM-2DESCRIPTION ..................................................................................... RM-6OPERATION ........................................................................................ RM-7REPAIR PROCEDURES...................................................................... RM-9GENERAL REPAIR INSTRUCTIONS................................................. RM-9REMOVAL OF COMPONENT PARTS............................................... RM-10ASSEMBLY AND DISASSEMBLY OF CONPONENTS .................... RM-321. OIL PUMP .......................................................................................................... RM-322. DIRECT CLUTCH (C2) ...................................................................................... RM-363. PLANETARY RING GEAR ................................................................................ RM-434. 1 WAY CLUTCH................................................................................................. RM-455. FORWARD AND REVERSE CLUTCH (C1,C3) ................................................. RM-486. COUNTER DRIVEN GEAR................................................................................ RM-567. VALVE BODY .................................................................................................... RM-598. DIFFERENTIAL ................................................................................................. RM-60INSTALLATION OF COMPONENT PARTS....................................... RM-61SERVICE SPECIFICATIONS ............................................................. RM-87

[ RM-6 ]


DESCRIPTION

The new automatic transmission AW 81-40LE is an electronically controlled4-speed automatic transmission with Lock-up mechanism.The transmission is mainly composed of the torque converter with lock upclutch, newly developed 4-speed planetary gear unit, the hydraulic controlsystem and the electric control system.

SECTIONAL VIEW

AW 81-40LE

[ RM-7 ]


OPERATION

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C 2B3B 2

B1

C 1

C 3

F1 F2

Differen tial Gear Assy

Counter Dr ive G ear Assy

C ounter Dr iven G ear Assy

FROM T /C

[ RM-8 ]


OPERATION

S1 S2 ST C1 C2 C3 B1 B2 B3 F1 F2ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

V<9 ON ON OFF OFF OFF ON OFF OFF ON OFF OFFV>=11 ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF

ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON2nd ON OFF OFF ON OFF OFF OFF ON OFF ON OFF3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF

3<=>4 OFF ON ON ON<=>OFF ON OFF OFF<=>ON ON OFF OFF OFF4th OFF ON OFF OFF ON OFF ON ON OFF OFF OFF1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF1st ON ON OFF ON OFF OFF OFF OFF ON OFF ON2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF

D

2

L

Brake 1 Way Clutch

R

N

POSITION

P

Solenoid Clutch

[ RM-9 ]


REPAIR PROCEDURES

GENERAL REPAIR INSTRUCTIONS

1. Most repair operations begin with an overview illustration.2. It identifies the components and shows how the parts fit together.3. The procedures are presented in a step-by-step format:

(1) The illustration shows what to do and where to do it.(2) The task heading tells what to do.(3) The detailed text tells how to perform the task and gives other

information such as specifications and warnings.You never have to leave the procedure to look up your specs.

1. During disassembly, keep parts in order to facilitate reassembly.2.(1) Always replace gaskets, O-rings and oil seals etc. with new ones.

(2) Parts which cannot be reused are indicated by the symbol “ ”.3. When necessary, use a sealer on gaskets to prevent leaks.4. Carefully observe all specification for bolt tightening torque.

Always use a torque wrench.5. Use of SST may be required, depending on the nature of the repair.

Be sure to use SST where specified and follow the proper workprocedure.

[ RM-10 ] REMOVAL OF COMPONENT PARTS


REMOVAL OF COMPONENT PARTS

SS-01-81A

Breather Hose

Clip

No.1 Breather Plug

Bracket

Union

Transaxle RevolutionSensor

"O" Ring

"O" Ring

"O" Ring

Non Reusable Part

"O" Ring

Gasket

Speed Sensor

Union

Screw Plug



Gasket

Valve BodyAssembly

Gasket

Oil Seal

Torque Converter

Oil Seal

Newtral StartSwitch

Spacer

"O" ring

"O" ring

"O" ring

"O" ring

Brake DrumGasket

ApplyGasket

"O" ring

SS-01-01ANon Reusable Part



SS-01-02A

"O" Ring

"O" RingO/D BrakePiston

2nd BrakePiston

1st & ReverseBrake Piston

Forward Clutch Hub

Apply Gasket Transaxle RearCover

Forward Clutch & ReverseClutch Assembly

One-Way ClutchAssembly

Rear PlanetarySun Gear

Front PlanetarySun Gear

Planetary Gear

Planetary RingGear

"O" Ring

"O" Ring

Non Reusable Part



SS-01-03A

Oil SealDifferential Gear

Oil Pump

Counter Driven Gear

Counter DriveGear

Nut

Apply Gasket

Non Reusable Part

Direct ClutchAssembly

Direct Clutch Hub



3. REMOVE UNION(1) Remove the 2 unions.(2) Remove the 2 “O” rings from the unions.

4. REMOVE SCREW PLUG(1) Remove the screw plug from the transaxle

case.(2) Remove the “O” ring from the screw plug.

6. REMOVE INPUT SPEED SENSOR AND NO.1BREATHER PLUG

(1) Remove the 1 bolt and input speed sensor.(2) Remove the clip and breather hose.(3) Remove the No.1 breather plug.(4) Remove the “O” ring from the No.1 breather

plug.

5. REMOVE BRACKET(1) Remove the 1 bolt and bracket.

SEPARATE EXTERNAL PARTS1. REMOVE TORQUE CONVERTER2. REMOVE NEUTRAL START SWITCH(1) Remove the nut, washer and control lever.(2) Using a screwdriver, unstake the lock washer.(3) Remove the 2 bolts and nut, and pull out the

neutral start switch.

SS-01-04A

SS-01-05A

SS-01-06A

SS-01-80A

SS-01-07A



8. REMOVE OIL PAN AND GASKET(1) Remove the 18 bolts.(2) Remove the oil pan and gasket.(3) Remove the gasket and drain plug from the

oil pan.

9. EXAMINE PARTICLES IN PAN(1) Remove the magnets and use them to

collect any steel chips. Examine the chipsand particles in the pan and on the magnetto determine what type of wear has occurredin the transaxle:

Steel (magnetic)..... bearing, gear and plateware

Brass (non-magnetic)..... bushing wear10. REMOVE OIL STRAINER(1) Remove the 3 bolts and oil strainer.

(2) Remove the gasket from the oil strainer.

7. PLACE TRANSAXLE ON WOODENBLOCKS

SS-01-08A

SS-01-09A

SS-01-10A

SS-01-11A

SS-01-12A



(3) Support the valve body assembly andremove the 14 bolts.

(4) Disconnect the manual valve control rodfrom the manual valve lever, then removethe valve body assembly.

12. REMOVE CHECK VALVE(1) Remove the check valve and spring.

13. REMOVE BRAKE DRUM GASKET(1) Remove the brake drum gasket.

14. REMOVE APPLY GASKET

11. REMOVE VALVE BODY ASSEMBLY(1) Remove the bolt and ATF temperature

sensor with clamp.(2) Disconnect the 5 connectors.

SS-01-13A

SS-01-14A

SS-01-15A

SS-01-16A

SS-01-17A



(3) Remove the 2 “O” rings from the C2accumulator piston.

(6) Remove the 2 “O” rings from the C1accumulator piston.

(4) Apply compressed air (4.0 kgf/cm2) to the oilhole and remove the C1 accumulator pistonand spring.

(5) Remove the spring.CAUTION: Blowing off the air may cause the

piston's jump-out. When removingthe piston, hold it with your handusing a waste cloth. Take care notto splash ATF when air-blowing.

15. REMOVE ACCUMULATOR SPRING ANDPISTON

(1) Apply compressed air (4.0 kgf/cm2) to the oilhole and remove the C2 accumulator pistonand spring.

(2) Remove the spring.CAUTION: Blowing off the air may cause the

piston's jump-out. When removingthe piston, hold it with your handusing a waste cloth. Take care notto splash ATF when air-blowing.

SS-01-18A

SS-01-19A

SS-01-20A

SS-01-21A



16. REMOVE TRANSAXLE WIRE(1) Remove the 1 bolt.(2) Remove the transaxle wire from the

transaxle case.

(3) Remove the “O” ring from the transaxle wire.

(7) Apply compressed air (4.0 kgf/cm2) to theoil hole and remove the B1 accumulatorpiston and spring.

CAUTION: Blowing off the air may cause thepiston's jump-out. When removingthe piston, hold it with your handusing a waste cloth. Take care notto splash ATF when air-blowing.

(8) Remove the 2 “O” rings from the B1accumulator piston.

SS-01-22A

SS-01-23A

SS-01-24A

SS-01-25A



21. REMOVE DIFFERENTIAL GEARASSEMBLY

18. REMOVE TRANSAXLE HOUSING(1) Remove the 16 bolts.(2) Tap on the circumference of the transaxle

housing with a plastic hammer to remove thetransaxle housing from the transaxle case.

CAUTION: Differential gear assembly may beaccidentally removed when thetransaxle housing is removed.

19. INSPECT INPUT SHAFT END PLAY(1) Using a dial indicator, measure the input

shaft end play.

20. REMOVE OIL PUMP(1) Remove the 6 bolts and oil pump.

17. REMOVE VEHICLE SPEED SENSOR(1) Remove the 1 bolt and the vehicle speed

sensor.

SS-01-26A

SS-01-27A

SS-01-28A

SS-01-29A

SS-01-82A



25. REMOVE COUNTER DRIVEN GEARASSEMBLY

23. REMOVE DIRECT CLUTCH ASSEMBLY

(1) Remove the direct clutch assembly fromthe transaxle case.

(2) Remove the thrust needle roller bearingfrom the direct clutch assembly.

24. REMOVE DIRECT CLUTCH HUB(1) Remove the direct clutch hub, thrust needle

roller bearing and thrust bearing race fromthe transaxle case.

22. REMOVE APPLY GASKET

SS-01-30A

SS-01-31A

SS-01-32A

SS-01-33A

SS-01-34A



(2) Remove the thrust needle roller bearing andthrust bearing race from the forward &reverse clutch assembly.

26. REMOVE TRANSAXLE REAR COVER(1) Remove the 9 bolts.(2) Tap on the circumference of the transaxle

rear cover with a plastic hammer to removethe transaxle rear cover from the transaxlecase.

27. REMOVE 4 APPLY GASKETS

28. REMOVE 2ND COAST & O/D BRAKEFLANGE, DISC AND PLATE

(1) Remove the flange, 2 discs and 2 platesfrom the transaxle case.

29. REMOVE FORWARD & REVERSE CLUTCHASSEMBLY

(1) Remove the thrust needle roller bearing andforward & reverse clutch assembly.

SS-01-35A

SS-01-36A

SS-01-37A

SS-01-38A

SS-01-39A



(3) Remove the thrust needle roller bearing andplanetary carrier thrust washer from the rearplanetary sun gear and 1 way clutchassembly.

(2) Remove the thrust bearing race and thrustneedle roller bearing from the forward clutchhub.

31. REMOVE REAR PLANETARY SUN GEARAND 1 WAY CLUTCH ASSEMBLY

(1) Remove the rear planetary sun gear and 1way clutch assembly.

30. REMOVE FORWARD CLUTCH HUB(1) Remove the forward clutch hub from the

transaxle case.

SS-01-40A

SS-01-41A

SS-01-42A

SS-01-43A

SS-01-44A

(2) Remove the thrust bearing race from therear planetary sun gear and 1 way clutchassembly.



(3) Remove the 2 “O” rings from the 2nd brakepiston.

32. REMOVE FRONT PLANETARY SUN GEAR(1) Remove the front planetary sun gear from

the transaxle case.(2) Remove the thrust bearing race from the

front planetary sun gear.

33. REMOVE 2ND BRAKE(1) Using SST and a press, remove the 2 snap

rings, 2ND brake and 2ND brake pistonreturn spring.

CAUTION: Stop the press when the 2nd brakeis lowered 1 - 2 mm from the snapring groove, preventing the 2ndbrake from being deformed.

(2) Apply compressed air (4.0 kgf/cm2) to the2nd brake to remove the 2nd brake pistonfrom the 2nd brake clutch cylinder.


(4) Remove the 1 way clutch assembly andthrust washer from the rear planetary sungear.

SS-01-45A

SS-01-46A

SS-01-47A

SS-01-48A

SS-01-83A

SST



(2) Remove the No.2 one-way clutch from theplanetary gear.

(3) Remove the anti-rattle clip.

35. REMOVE COUNTER DRIVE GEAR ANDPLANETARY RING GEAR

(1) Fix the counter drive gear with the parkinglock pawl.

34. REMOVE NO.2 1 WAY CLUTCH ANDPLANETARY GEAR

(1) Remove the No.2 1 way clutch and planetarygear from the transaxle case.

(4) Remove the 2 plates, 2 discs and flange.

SS-01-49A

SS-01-50A

SS-01-51A

SS-01-52A



(4) Remove the nut.CAUTION: Remove the nut without unstaking

the planetary ring gear. If chisel orother tool is used to unstake theplanetary ring gear, such impactmay damage the bearing.

(3) Using SST and a hammer, unstake thecounter drive gear nut.

SS-01-53A

SS-01-84A

SST

SST

SS-01-86C

(2) Using SST, lift the transaxle case.



SS-01-54A

SS-01-55A

(5) Install the 3 bolts to the counter drove gear.Bolt (M6):L = 40 - 80 mmPitch = 1.0 mm(6) Rotate 3 bolts in order and remove the

counter drive gear and planetary ring gear.

36. REMOVE PARKING LOCK PAWL(1) Remove the 2 bolts and parking lock pawl

bracket.

(2) Remove the parking lock pawl shaft, torsionspring and parking lock pawl.

SS-01-62A

SS-01-63C

SST



(5) Remove the parking lock rod from themanual valve lever.

(3) Using a pin punch and hammer, drive out thepin.

(4) Remove the manual valve lever shaft andmanual valve lever.

(2) Using a chisel and hammer, unstake andremove the spacer.

37. REMOVE MANUAL VALVE LEVER SHAFT(1) Remove the 1 bolt and manual detent spring.

SS-01-56A

SS-01-57A

SS-01-58A

SS-01-59A

SS-01-60A



(4) Remove the 2 “O” rings from the 1st &reverse brake piston.

38. REMOVE 1ST & REVERSE BRAKE(1) Using SST and a press, remove the snap

ring.

(2) Remove the flange, 4 plates, 4 discs andreturn spring.

(3) Apply compressed air (4.0 kgf/cm2) to thetransaxle case to remove the 1st & reversebrake piston.

CAUTION: Blowing off the air may cause thepiston's jump-out. When removingthee piston, hold it with your handusing a waste cloth. Take care notto splash ATF when air-blowing.

(6) Using a screwdriver, remove the oil seal.

SS-01-61A

SS-01-65A

SS-01-66A

SS-01-83A

SST

SS-01-64A



41. REMOVE OIL RESERVOIR LOCK PLATE(1) Remove the 3 bolts and oil reservoir lock

plate from the transxle housing.

42. REMOVE APPLY PIPE(1) Remove the 1 bolt and No.1 transaxle apply

pipe clamp from the transaxle housing.(2) Remove the transaxle lube apply pipe and

differential gear lube apply pipe from thetransaxle housing.

43. REMOVE OIL SEAL(1) Using SST and a hammer, remove the oil

seal from the transaxle housing.

40. REMOVE OUTER TAPERED ROLLERBEARING RACE AND SHIM FROMTRANSAXLE CASE

(1) Using SST, remove the outer tapered rollerbearing race and shim.

39. REMOVE NO.1 TRANSAXLE CASE PLATE(1) Remove the 1 bolt and No.1 transaxle case

plate from the transaxle case.

SS-01-67A

SS-01-70A

SS-01-71A

SST

SS-01-72A

SST

SS-01-68A



44. REMOVE OIL SEAL OF TRANSAXLEHOUSING

(1) Using SST and a hammer, remove the oilseal.

SS-01-73ASST

SS-01-75A

SS-01-85A

SST

(2) Remove the O/D brake return spring.

45. REMOVE O/D BRAKE PISTON(1) Using SST and a press, remove the snap

ring.CAUTION: Stop the press when the O/D

brake piston is lowered 1 - 2 mmfrom the snap ring grove,preventing the O/D brake pistonfrom being deformed.

SS-01-76A

SS-01-77A

(3) Apply compressed air (4.0 kgf/cm2) to thetransaxle rear cover to remove the O/Dbrake piston.


(4) Remove the 2 “O” rings from the O/D brakepiston.



46. DISASSEMBLE TRANSAXLE REARCOVER

(1) Remove the 2 seal rings from the transaxlerear cover.

CAUTION: Do not expand the seal ringexcessively.

(2) Remove the 4 screw plugs and 4 “O” ringsfrom the transaxle rear cover.

SS-01-78A

SS-01-79A

[ RM-32 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS


ASSEMBLY AND DISASSEMBLY OFCOMPONENT PARTS

1. OIL PUMP

SS-02-01A

Oil Pump Body

Oil Pump Drive Gear

Oil Pump Drive Gear

Stator Shaft



DISASSEMBLY OF OIL PUMP1. CHECK OIL PUMP DRIVE GEAR ROTATION(1) Turn the drive gear with the 2 screwdrivers

and make sure it rotates smoothly.CAUTION: Be careful not to damage the oil lip.

2. REMOVE STATOR SHAFT(1) Remove the 8 bolts and stator shaft.CAUTION: Be careful not to let the drive gear

drop as it might come off attachedto the stator shaft.

3. REMOVE OIL PUMP DRiVE GEAR ANDDRIVEN GEAR

2. CHECK TIP CLEARANCE OF DRIVEN GEAR(1) Measure the tip clearance between the

driven gear teeth and drive gear teeth.

INSPECTION OF OIL PUMP1. CHECK BODY CLEARANCE OF DRIVEN

GEAR(1) Push the driven gear to one side of the body.

Using a feeler gauge, measure theclearance.

SS-02-02A

SS-02-03A

SS-02-04A

SS-02-05A

SS-02-06A

Body Clearance STD. 0.10-0.17 mmMAX 0.22 mm

Tip Clearance Driven STD. 0.07-0.15 mmMAX 0.20 mm



3. CHECK SIDE CLEARANCE OF BOTH GEAR(1) Using a steel straight edge and feeler gauge,

measure the side clearance of both gears. Ifthe side clearance is greater the themaximum, select the drive and driven gear.

4. CHECK OIL PUMP BODY BUSHING(1) Using a dial indicator, measure the inside

diameter of the oil pump body bushing.

5. CHECK STATOR SHAFT BUSHING(1) Using a dial indicator, measure the inside

diameter of the stator shaft bushings.

SS-02-07A

SS-02-08A

SS-02-09A

Side Clearance of STD. 0.02-0.05 mmDrive and Driven Gear MAX 0.10 mm

Gear Thickness Mark Drive GearType 1 Th= 8.440-8.449 mm

2 Th= 8.450-8.459 mm3 Th= 8.460-8.470 mm4 Th= 8.471-8.480 mm5 Th= 8.481-8.490 mm

Mark Driven Gear1 Th= 8.440-8.449 mm2 Th= 8.450-8.459 mm3 Th= 8.460-8.470 mm4 Th= 8.471-8.480 mm5 Th= 8.481-8.490 mm

Body Bush STD. 38.113-38.138 mmMAX 38.188 mm

Stator Shaft Bush STD. 18.424-18.450 mmMAX 18.50 mm



3. CHECK PUMP DRIVE GEAR ROTATION(1) Turn the drive gear with 2 screwdrivers and

make sure it rotates smoothly.CAUTION: Be careful not to damage the oil lip.

2. INSTALL STATOR SHAFT(1) Align the stator shaft with each bolt hole.(2) Install the 8 bolts.

TT = 7.8-11.8 N.m (80-120 kgf.cm)

ASSEMBLY OF OIL PUMP1. INSTALL OIL PUMP DRIVE GEAR AND

DRIVEN GEAR

SS-02-04A

SS-02-03A

SS-02-02A



2. DIRECT CLUTCH

SS-03-01A

Seal Ring

Input ShaftSub-assembly

Return Spring

Snap Ring

"O" Ring

Non Reusable Part

"O" Ring

Piston

Snap Ring

Flange

Plate

Disc



2. REMOVE SNAP RING(1) Using a screwdriver, remove the snap ring.

3. REMOVE FLANGE, DISC AND PLATE(1) Remove the flange, 2 discs and 2 plates.

DISASSEMBLY OF DIRECT CLUTCH1. CHECK PISTON STROKE OF DIRECT

CLUTCH(1) Install the direct clutch and thrust needle

roller bearing on the oil pump.(2) Using a dial indicator, measure the direct

clutch piston stroke while applying andreleasing compressed air (4.0 kgf/cm2).SS-03-02A

SS-03-03A

SS-03-04A

Piston Stroke 0.40-0.70 mm



4. REMOVE DIRECT CLUTCH RETURNSPRING

(1) Place SST on the return spring andcompress.

(2) Using a snap ring expander, remove thesnap ring.

CAUTION: Stop the press when the pistonreturn spring is lowered to the place1-2 mm from the snap ring groove,preventing the piston return springfrom being deformed. Do notexpand the snap ring excessively.

(3) Remove the direct clutch return spring.

5. REMOVE DIRECT CLUTCH PISTON(1) Install the direct clutch on the oil pump.(2) Apply compressed air (4.0 kgf/cm2) to the oil

pump to remove the direct clutch piston.CAUTION: Blowing off the air may cause the

piston' jump-put. When removingthe piston, hold it with your handusing a waste cloth. Take care notto splash ATF when air-blowing.

HINT: When the piston cannot be removed as it isslanted, either blow the air again with theprotruding side pushed or remove thepiston using needle nose pliers with vinyltape on the tip.

SS-03-05A

SST

SS-03-06A

SS-03-07A



6. REMOVE “O” RING(1) Using a small screwdriver, remove the “O”

ring from the direct clutch piston.

(2) Remove the “O” ring from the input shaft.

7. REMOVE SEAL RING(1) Remove the 2 seal rings from the input shaft.CAUTION: Do not expand the ring ends

excessively.

2. CHECK DIRECT CLUTCH RETURN SPRING(1) Using vernier calipers, measure the free

length of the spring together with the springsheet.

SS-03-09A

SS-03-10A

INSPECTION OF DIRECT CLUTCH1. INSPECT DISC AND FLANGE(1) Check to see if the sliding surface of the

disc, plate and flange are worm or burnt.HINT: If the lining of the disc is peeling off or

discolored, or even if a part of the printednumber is defaced, replace all discs.Before assembling new discs, soak them inATF for at least 15 minutes.

SS-03-11A

SS-03-12A

SS-03-08A

STD36.04 mm

Piston ReturnSpring Free Length



3. CHECK DIRECT CLUTCH PISTON(1) Check that the check ball is free by shaking

the piston.(2) Check that the valve does not leak by

applying low-pressure compressed air.

2. INSTALL O-RING(1) Coat a new “O” ring with ATF, and install the

“O” ring to the input shaft.

(2) Coat a new “O” ring with ATF, and install the“O” ring to the direct clutch piston.

3. INSTALL DIRECT CLUTCH PISTON(1) Coat the direct clutch piston with ATF, install

it to the direct clutch drum.CAUTION: Be careful no to damage the lip seal

of direct clutch piston.

SS-03-13A

ASSEMBLY OF DIRECT CLUTCH1. INSTALL SEAL RING(1) Install the 2 seal rings to the input shaft.CAUTION: Do not expand the ring ends

excessively.

SS-03-10A

SS-03-09A

SS-03-14A

SS-03-08A



4. INSTALL DIRECT CLUTCH RETURNSPRING.

(1) Install the direct clutch return spring.

(2) Place SST on the return spring andcompress.

(3) Using a snap ring expander, install the snapring.

CAUTION: Stop the press when the pistonreturn spring is lowered to the place1 - 2 mm from the snap ring groove,preventing the piston return springfrom being deformed. Do notexpand the snap ring excessively.

(2) Using a screwdriver, remove the snap ring.(3) Check that the end gap of the snap ring is

not aligned with one of the cutouts.

SS-03-06A

SS-03-05A

SST

SS-03-03A

SS-03-15A

F

P

D

5. INSTALL PLATE, DISC AND FLANGE(1) Install the 2 plates, 2 discs and flange.

HINT: Before installing the discs, coat them withATF.



6. CHECK PISTON STROKE OF DIRECTCLUTCH

(1) Install the direct clutch on the oil pump.(2) Using a dial indicator, measure the direct

clutch piston stroke while applying andreleasing compressed air (4.0kgf/cm2).

SS-03-02AHINT: If the piston stroke is out of standards,

select another flange.


Flange Thickness Th= 3.0 mmType Th= 3.2 mm

Th= 3.4 mm



3. PLANETARY RING GEAR

DISASSEMBLY OF PLANETARY RING GEAR

2. REMOVE PLANETARY RING GEARFLANGE

(1) Remove the planetary ring gear flange fromthe planetary ring gear.

DISASSEMBLY OF PLANETARY RING GEAR1. REMOVE SNAP RING(1) Using a screwdriver, remove the snap ring.

SS-04-01A

Planetary Ring Gear Flange

Non Reusable Part

Snap Ring

Planetary Ring Gear

SS-04-02A

SS-04-03A



2. INSTALL SNAP RING(2) Using a screwdriver, install the snap ring.

SS-04-03A

ASSEMBLY OF PLANETARY RING GEAR1. INSTALL PLANETARY RING GEAR FLANGE(1) Install a new planetary ring gear flange to

the planetary ring gear.

SS-04-02A



4. 1 WAY CLUTCH

1. CHECK OPERATION OF 1 WAY CLUTCH(1) Install the 1 way clutch and thrust washer to

the rear planetary sun gear.(2) Hold the rear planetary sun gear and turn

the 1 way clutch. The 1 way clutch shouldturn freely clockwise and should lockcounterclockwise.


DISASSEMBLY OF 1 WAY CLUTCHFreely

Lock SS-05-02A

SS-05-03A

SS-05-01A

Snap Ring

Retainer2nd Brake Hub

1 Way Clutch



3. REMOVE 1 WAY CLUTCH

4. REMOVE RETAINER(1) Using a small screwdriver, remove the

retainer.

2. INSTALL 1 WAY CLUTCH

3. INSTALL SNAP RING(1) Using a screwdriver, install the snap ring.

ASSEMBLY OF 1 WAY CLUTCH1. INSTALL RETAINER(1) Install the retainer to the 2nd brake hub.

HINT: Install the retainer closely.

SS-05-04A

SS-05-05A

SS-05-04A

SS-05-03A



4. CHECK OPERATION OF 1 WAY CLUTCH(1) Install the 1 way clutch and thrust washer to

the rear planetary sun gear.(2) Hold the rear planetary sun gear and turn

the 1 way clutch. The 1 way clutch shouldturn freely clockwise and should lockcounterclockwise.

Freely

LockSS-05-02A



5. FORWARD AND REVERSE CLUTCH

SS-06-01C

"O" Ring

Forward Clutch Drum"O" Ring

Non Reusable Part

IntermediateShaft Sub-assembly

Forward Clutch Piston

Forward Clutch Return Spring

Clutch Balancer

Snap Ring

Snap Ring

Snap Ring

Flange

Flange

Disc

Disc

Plate

Plate

Flange

Seal Ring



2. CHECK PISTON STROKE OF FORWARDCLUTCH

(1) Install the forward and reverse clutch andthrust needle roller bearing on the transaxlerear cover.

(2) Using a dial indicator and measuringterminal (SST), measure the forward clutchpiston stroke while applying and releasingcompressed air (4.0 kgf/cm2).

HINT: The forward and reverse clutch will comeout as you apply the compressed air.Therefore, while the checking is beingdone, press on the input shaft of theforward and reverse clutch using stampingmachine or alike so that the pressure is notapplied on the forward and reverse clutch.


SS-06-02A

SS-06-03A

SST

SST

SS-06-04A

DISASSEMBLY OF FORWARD ANDREVERSE CLUTCH1. CHECK PISTON STROKE OF REVERSE

CLUTCH(1) Install the forward and reverse clutch and

thrust needle roller bearing on the transaxlerear cover.

(2) Using a dial indicator, measure the reverseclutch piston stroke while applying andreleasing compressed air (4.0 kgf/cm2).





4. REMOVE FLANGE, DISC AND PLATE(1) Remove the 2 flanges, 2 discs and plate

from the reverse clutch drum.


6. REMOVE FLANGE, DISC AND PLATE(1) Remove the flange, 4 discs and 4 plates

from the forward clutch drum.

7. REMOVE FORWARD CLUTCH RETURNSPRING

(1) Place SST on the clutch balancer andcompress the springs with a press.

(2) Using a snap ring expander, remove thesnap ring.

CAUTION: Stop the press when the clutchbalancer is lowered to the place 1 -2 mm from the snap ring groove,preventing the clutch balancer frombeing deformed. Do not expand thesnap ring excessively.

(3) Remove the clutch balancer and forwardclutch return spring.

SS-06-05A

SS-06-06A

SS-06-07A

SS-06-08A

SST

SS-06-19A



8. REMOVE FORWARD CLUTCH PISTON(1) Install the forward and reverse multiple disc

clutch on the transaxle rear cover.(2) Apply compressed air (4.0 kgf/cm2) to the

transaxle rear cover to remove the forwardclutch piston.


HINT: When the piston cannot be removed as it isslanted, either blow the air again with theprotruding side pushed or remove thepiston using a needle nose pliers with vinyltape on the tip.

9. REMOVE FORWARD CLUTCH DRUM(1) Apply compressed air (4.0 kgf/cm2) to the

transaxle rear cover to remove the forwardclutch drum.

CAUTION: Blowing off the air may cause thedrum's jump-out. When removingthe drum, hold it with your handusing a waster cloth. Take care notto splash ATF when air-blowing.

HINT: When the drum cannot be removed as it isslanted, either blow the air again with theprotruding side pushed or remove the drumusing a needle nose pliers with vinyl tapeon the tip.

10. REMOVE “O” RING(1) Using a small screwdriver, remove the “O”

ring from the forward clutch drum.

SS-06-09A

SS-06-10A

SS-06-11A



(2) Using a small screwdriver, remove the “O”ring from the intermediate shaft sub-assembly.

(2) Coat a new “O” ring with ATF, and install it tothe forward clutch drum.

ASSEMBLY OF FORWARD AND REVERSECLUTCH1. INSTALL “O” RING(1) Coat a new “O” ring with ATF, and install it to

the intermediate shaft sub-assembly.

SS-06-12A

SS-06-13A

SS-06-14A

SS-06-12A

SS-06-11A

INSPECTION OF FORWARD AND REVERSECLUTCH1. INSPECT DISC AND FLANGE(1) Check to see if the sliding surface of the

disc, plate and flange are worn or burnt.HINT: If the lining of the disc is peeling off or

discolored, or even if a part of the printednumber is defaced, replace all discs.Before assembling new discs, soak them inATF for at least 15 minutes.

2. CHECK FORWARD CLUTCH RETURNSPRING

(1) Using vernier calipers, measure the freelength of the spring together with the springseat.

STD24.04 mm




2. INSTALL FORWARD CLUTCH DRUM(1) Coat the forward clutch drum with ATF,

install the forward clutch drum.CAUTION: Be careful not to damage the “O”

ring and lip seal of forward clutchdrum.

3. INSTALL FORWARD CLUTCH PISTON(1) Coat the forward clutch piston with ATF,

install the forward clutch piston.CAUTION: Be careful not to damage the lip

seal of forward clutch piston.

4. INSTALL FORWARD CLUTCH RETURNSPRING

(1) Install thee forward clutch return spring andclutch balancer.

CAUTION: Be careful not to damage the lipseal of forward clutch return spring.

(2) Place SST, on the clutch balancer andcompress the piston return spring with apress.

(3) Using a snap ring expander, install the snapring.

CAUTION: Stop the press when the clutchbalancer is lowered to the place 1 -2 mm from the snap ring groove,preventing the clutch balancer formbeing deformed. Do not expand thesnap ring excessively.

SS-06-15A

SS-06-16A

SS-06-08A

SST

SS-06-19A



5. INSTALL PLATE, DISC AND FLANGE(1) Install the 4 plates, 4 discs and flange.

6. INSTALL SNAP RING(1) Using a screwdriver, install the snap ring.(2) Check that the end gap of the snap ring is


7. INSTALL PLATE, DISC AND FLANGE(1) Install the plate, 2 discs and 2 flanges.

8. INSTALL SNAP RING(1) Using a screwdriver, install the snap ring.(2) Check that the end gap of the snap ring is


SS-06-06A

SS-06-04A

SS-06-17A

F

P

D

F

D

SS-06-18A

FP

D



9. CHECK PISTON STROKE OF REVERSECLUTCH


(2) Using a dial indicator, measure the reverseclutch piston stroke while applying andreleasing compressed air (4.0 kgf/cm2).

10. CHECK PISTON STROKE OF FORWARDCLUTCH


(2) Using a dial indicator and measuringterminal (SST), measure the forward clutchpiston stroke while applying and releasingcompressed air (4.0 kgf/cm2).

SS-06-03A

SST

SST

SS-06-02A

HINT: If the piston stroke is out of standards,select another flange.

HINT: The forward and reverse clutch will comeout as you apply the compressed air.Therefore, while the checking is beingdone, press on the input shaft of theforward and reverse clutch using stampingmachine or alike so that the pressure is notapplied on the forward and reverse clutch.

HINT: If the piston stroke is out of standards,select another flange.



Th= 3.4 mmTh= 3.6 mm



Th= 3.2 mmTh= 3.3 mmTh= 3.4 mmTh= 3.5 mmTh= 3.6 mm



6. COUNTER DRIVEN GEAR

SS-07-01A

Outer Tapered RollerBearing Race

Counter Driven Gear

Outer Tapered RollerBearing Race

SS-07-02C

SST

DISASSEMBLY OF COUNTER DRIVEN GEAR1. REMOVE FRONT DRIVE PINION REAR

TAPERED ROLLER BEARING(1) Using SST and a press, remove the front

drive pinion tapered roller bearing rear innerrace counter driven gear from the differentialdrive pinion.

(2) Using SST, remove the front drive piniontapered roller bearing rear outer race anddrive pinion washer from the transaxle case.

SS-07-03C



SS-07-04C

SST

SS-07-06C

SS-07-07C

SS-07-08C

SST

3. REMOVE SIFFERENTIAL DRIVEN PINIONPLUG

(1) Using extension bar and hammer, removethe differential drive pinion plug.

2. REMOVE FRONT DRIVE PINION FRONTTAPERED ROLLER BEARING

(1) Using SST and a press, remove the frontdrive pinion tapered roller bearing front innerrace from the differential drive pinion.

(2) Using SST, remove the front drive piniontapered roller bearing front outer race fromthe transaxle housing.

SS-07-05C

ASSEMBLY OF COUNTER DRIVEN GEAR1. INSTALL FRONT DRIVE PINION PLUG(1) Using a socket wrench (10 mm) and

hammer, install a new differential drivepinion plug to the differential drive pinion.

2.3-2.8 mmPinion plug

2. INSTALL FRONT DRIVE PINION FRONTTAPERED ROLLER BEARING

(1) Using SST and a press, install the front drivepinion tapered roller bearing front inner raceto the differential drive pinion.



SS-07-10C

SST

SS-07-11C

SST

SS-07-09CSST

SS-07-12C

SST

(2) Using SST and a hammer, install the frontdrive pinion tapered roller bearing front outerrace to the transaxle housing.

(2) Using SST and a hammer, install the pinionwasher and front drive pinion tapered rollerbearing rear outer race to the transaxlecase.

3. INSTALL COUNTER DRIVE GEAR(1) Using SST and a press, install the counter

drive gear to the differential drive pinion.

4. INSTALL FRONT DRIVE PINION REARTAPERED ROLLER BEARING

(1) Using SST and a press, install the front drivepinion tapered roller bearing rear inner raceto the differential drive pinion.



SS-08-17A

7. VALVE BODY

DISASSEMBLY OF VALVE BODY1. REMOVE SHIFT SOLENOID (NO.1, NO.2, ST,

SL)(1) Remove the each bolt and the solenoids.

SS-11-01AM

No.1 Solenoid

ST Solenoid

SL Solenoid

No.2 Solenoid

ASSEMBLY OF VALVE BODY1. INSTALL SHIFT SOLENOID (NO.1, NO.2, ST,

SL)(1) Replace the “O” ring of each solenoid and

install the solenoid.CAUTION: Make sure to use new “O” ring and

not to damage the “O” ring.(2) Tighten the 7 bolts.

TT = 10.0-12.0 N.m (100-200 kgf.cm)SS-11-04AM

No.1 Solenoid(20 mm, 49 mm)

ST Solenoid(20 mm)

SL Solenoid(28 mm, 49mm)

No.2 Solenoid(20 mm, 49 mm)



8. DIFFERENTIAL

SS-10-01A

Differential Assembly

Side Bearing Outer Race

Side Bearing Outer Race

[ RM-61 ] INSTALLATION OF COMPONENT PARTS


INSTALLATION OF COMPONENT PARTS RACE AND BEARING SPECIFICATIONS

SS-09-01A

A

BC

D

E

FG

(mm) A B C D E F GRASE Outer Dia. --- 30.60 45.50 --- 29.00 --- ---(Front) Inner Dia. --- 19.30 34.95 --- 19.30 --- ---

BEARING Outer Dia. 62.00 29.60 46.50 57.50 --- 48.50 30.20Inner Dia. 43.20 18.10 33.30 42.50 --- 32.50 or 32.90 17.80

RACE Outer Dia. --- 28.20 --- --- --- --- 32.60(REAR) Inner Dia. --- 18.10 --- --- --- --- 20.50



1. ASSEMBLY TRANSAXLE TEAR COVER(1) Install 4 new “O” rings to the 4 screw plugs.(2) Install the 4 screw plugs with the “O” rings to

the transaxle rear cover.

TT = 5.9-8.8 N.m (60-90 kgf.cm)

(3) Install the 2 seal rings to the transaxle rearcover.

2. CHECK O/D & 2ND COAST BRAKE PISTONRETURN SPRING

(1) Using vernier calipers, measure the freelength of the spring together with the springseat.

3. INSTALL O/D & 2ND COAST BRAKEPISTON

(1) Coat 2 new “O” rings with ATF, install themto the O/D & 2nd coast brake piston.

(2) Coat the O/D & 2nd coast brake piston withATF, install it to the transaxle rear cover.

CAUTION: Be careful not to damage the “O”rings of the O/D & 2nd coast brakepiston.

SS-01-79A

SS-01-78A

SS-09-02A

SS-01-77A

SS-09-03A

STD18.99 mm




6. INSTALL APPLY PIPE(1) Install the transaxle lube apply pipe and

differential gear lube apply pipe to thetransaxle housing.

(2) Install the No.1 transaxle apply pipe clamp tothe transaxle housing with 1 bolt.

TT = 3.9-6.9 N.m (40-70 kgf.cm)

7. INSTALL OIL RESERVOIR LOCK PLATE(1) Install the oil reservoir lock plate to the

transaxle housing with the 3 bolts.

TT = 3.9-6.9 N.m (40-70 kgf.cm)

SS-01-71A

SS-01-70A

(3) Using SST and a press, install the O/D &2nd coast brake return spring and snap ringto transaxle rear cover.

CAUTION: Stop the press when the O/D & 2ndcoast brake piston is lowered 1 - 2mm from the snap ring groove,preventing the O/D & 2nd coastbrake piston from being deformed.

4. INSTALL TRANSAXLE HOUSING OIL SEAL(1) Using SST and a hammer, drive in a new oil

seal.

5. INSTALL OIL SEAL(1) Using SST and a hammer, drive in a new oil

seal.A = 0 mm(2) Coat the lip of oil seal with MP grease.

SS-01-85A

SST

SS-09-05A

SST

SST

Oil seal in depth 2.6-3.6 mm

SS-09-07A

A

SST



8. INSTALL TRANSAXLE CASE OIL SEAL(1) Using SST and a hammer, drive in a new oil

seal.

SS-09-09A

SST

SST


9. INSTALL NO.1 TRANSAXLE CASE PLATE(1) Install the No.1 transaxle case plate to the

transaxle case with the bolt.

TT = 7.8-11.8 N.m (80-120 kgf.cm)

10. ADJUST COUNTER DRIVEN GEAR PRELOAD(1) Install the differential gear to the transaxle

case.

(2) Install the transaxle housing and tighten the16 bolts of the transaxle housing temporarily.

(3) Tighten 8 or 9 bolts out of 16 bolts of thetransaxle housing completely.

TT = 23.5-35.5 N.m (240-360 kgf.cm)

(4) Using a SST, turn the differential gearassembly right and left 2 or 3 times to allowthe bearing settle.

SS-01-67A

SS-09-11A

SS-09-12A

SS-01-26A



SS-09-14A

SS-01-26A

SS-09-13A

SS-09-12A

(6) Remove the transaxle housing and installthe counter driven gear.

(7) Install the transaxle housing and tighten the16 bolts of the transaxle housing temporarily.

(8) Tighten the bolts of the transaxle housing inthe same manner as in step (3).

TT = 23.5-35.5 N.m (240-360 kgf.cm)

9) Using a SST, turn the differential gearassembly right and left 2 or 3 times to allowthe bearing settle.

(10) Using SST and a small torque wrench,measure the preload of the differential gear.From this valve deduct the value measuredin step (4). This is the preload of the counterdriven gear.

New Bearing 0.78-13.7 N.m (8.0-14.0 kgf.cm)Reused Bearing 0.39-0.69 N.m (4.0-7.0 kgf.cm)

(5) Using SST and small torque wrench,measure the preload of the differential gear.

HINT: Note down the measured valve.

SS-09-13A



HINT: When the preload is larger than thespecification, select a thinner adjuster shim.When the preload is smaller than thespecification, select a thicker adjuster shim.

11. CHECK 1ST & REVERSE BRAKE PISTONRETURN SPRING

(1) Using vernier calipers, measure the freelength of the spring together with springseat.

12. INSPECT DISC, PLATE AND FLANGE OF1ST & REVERSE BRAKE

(1) Check to see if the sliding surface of the disc,plate and flange are worn or burnt.

CAUTION: If the lining of the disc is peeling offor discolored, or even if a part of thegroove is defaced, replace all discs.Before assembling new discs, soakthem in ATF for at least 15 minutes.

SS-09-16A

SS-09-15A

Mark Thickness Mark ThicknessA Th= 1.80 mm N Th= 2.26 mmB Th= 1.85 mm P Th= 2.29 mmC Th= 1.90 mm Q Th= 2.32 mmD Th= 1.95 mm R Th= 2.35 mmE Th= 2.00 mm S Th= 2.40 mmF Th= 2.05 mm T Th= 2.45 mmG Th= 2.08 mm U Th= 2.50 mmH Th= 2.11 mm V Th= 2.55 mmJ Th= 2.14 mm W Th= 2.60 mmK Th= 2.17 mm X Th= 2.65 mmL Th= 2.20 mm Y Th= 2.70 mmM Th= 2.23 mm

STD21.71 mm


(11) If the preload of counter driven gear doesnot satisfy the specification, select theadjuster shim from the table below and re-measure the value. Until the valve is withinthe specification, repeat the procedure.



SS-01-66A

SS-09-17A

SS-09-18A

SS-09-19A

F

P

D

SS-01-83A

SST

13. INSTALL 1ST & REVERSE BRAKE(1) Coat 2 new “O” rings with ATF, install them

to the 1st & reverse piston.

(2) Install the 1st reverse brake piston to thetransaxle case.

CAUTION: Be careful not to damage the “O”rings of the 1st & reverse brakepiston.

(3) Install the return spring to the transaxlecase.

(4) Install the 4 plates, 4 discs and flange.

(5) Using SST and a press, install the snap ring.CAUTION: Make sure that the snap ring is

installed in the groove of thetransaxle case correctly.



SS-09-23A

SS-09-68A

(4) Install a new spacer to the manual valvelever.

(5) Install the manual valve lever shaft andmanual valve lever.

SS-09-20A

SS-01-60A

SS-09-22AA

14. CHECK PISTON STROKE OF 1ST &REVERSE BRAKE

(1) Using a dial indicator and measuringterminal (SST), measure the 1st & reversebrake piston stroke while applying andreleasing compressed air (4.0 kgf/cm2).

15. INSTALL MANUAL VALVE LEVER SHAFT(a) Coat a new oil seal with ATF.(b) Install the oil seal to the transaxle case.

(3) Install the parking lock rod to the manualvalve lever.





SS-01-58A

SS-09-24A

SS-01-56A

(6) Using a pin punch and hammer, drive in anew pin.

(7) Turn the spacer and lever shaft to align thesmall hole for locating the staking position inthe spacer with the staking position mark onthe lever shaft.

(8) Using a pin punch, stake the spacer throughthe small hole.

(9) Check that the spacer does not turn.

(10) Install the manual detent spring with 1 bolt.

TT = 7.8-11.8 N.m (80-120 kgf.cm)

16. INSTALL PARKING LOCK PAWL(1) Install the parking lock pawl shaft, torsion

spring and parking lock pawl.

CAUTION: Check that the edge of torsionspring fits into the groove securely.

SS-01-55A

SS-09-25A



SS-01-54A

SS-09-26A

SST

SST

(2) Install the parking lock pawl bracket with the2 bolts.

TT = 5.9-8.8 N.m (60-90 kgf.cm)

18. INSTALL PLANETARY RING GEARHINT: Before installing the planetary ring gear, be

sure to replace the planetary ring gearflange of the planetary ring gear with a newone.

(1) Using SST and a press, install the planetaryring gear.

SS-09-21A

SST

SST

17. INSTALL COUNTER DRIVE GEAR(1) Using SST and a press, install the counter

drive gear.CAUTION: Be careful not to apply excessive

force to thee transaxle case.



SS-01-53A

SS-09-29A

(3) Install a new nut.

(4) Using a small torque wrench, while turning tocounter drive gear 100 turn par minute andmeasure the preload.

HINT: When the preload is smaller than thespecification, tighten the nut more andadjust the preload.

SST

SS-01-86C

(5) Using SST, lift the transaxle case.

SS-09-71A

(5) Using a chisel and a hammer, stake thecounter drive gear nut

New Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm)Reused Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm)



SS-09-31A

SS-09-32A

SS-09-33A

LockFreely

(2) Coat the planetary carrier thrust washer withpetroleum jelly and install it onto theplanetary gear.

20. INSTALL NO.2 ONE-WAY CLUTCH(1) Install the No.2 one-way clutch to the

transaxle.

(2) Check that the planetary gear turns freelycounterclockwise and locks clockwise.

SS-01-52A

(6) Fix the counter drive gear with parking lockpawl.

SS-09-30A

19. INSTALL PLANETARY GEAR(1) Install the planetary gear to the transaxle

housing.



SS-09-36A

SS-09-37A

F

D

P

SS-01-48A

22. INSPECT DISC, PLATE AND FLANGE OF2ND BRAKE

(1) Check to see if the sliding surface of the disc,plate and flange are worn or burnt.

CAUTION: If the lining of the disc is peeling off ordiscolored, or even if a part of thegroove is defaced, replace all discs.Before assembling new discs, soakthem in ATF for at least 15 minutes.

23. INSTALL 2ND BRAKE(1) Install the flange, 2 discs and 2 plates.(2) Install the 2nd brake return spring.CAUTION: Make sure that the snap ring is


(3) Coat 2 new “O” rings with ATF, install themto the 2nd brake piston.

SS-09-34A

SS-09-35A

(3) Install the anti-rattle clip in the place shownin the illustration (the space between theNo.2 one-way clutch outer race andtransaxle case), push the anti-rattle clip inuntil you hear the "click".

21. CHECK 2ND BRAKE PISTON RETURNSPRING

(1) Using vernier calipers, measure the freelength of thee spring together with springseat.



SS-09-40A

SS-01-46A

SS-01-83A

SST

(6) Place SST on the 2nd brake and compressthe piston return spring with a press.

(7) Using a screwdriver, install thee snap ring.CAUTION: Make sure that the snap ring is


24. INSTALL FRONT PLANETARY SUN GEAR(1) Coat the thrust bearing race with petroleum

jelly and install it onto the front planetary sungear.

(2) Install the front planetary sun gear to thetransaxle case.

SS-09-38A

SS-09-39A

(4) Install the 2nd brake piston into the 2ndbrake clutch cylinder.

CAUTION: Be careful not to damage to “O”rings.

(5) Install the 2nd brake.



SS-01-42A

SS-09-42A

SS-09-43A

(3) Install the rear planetary sun gear and one-way clutch assembly to the transaxle case.

26. INSTALL FORWARD CLUTCH HUB(1) Coat the thrust bearing race with petroleum

jelly and install it onto the transaxle case.CAUTION: Check the direction of race.

(2) Coat the thrust needle roller bearing withpetroleum jelly and install it onto the forwardclutch hub.

CAUTION: Check the direction of bearing.

SS-01-45A

SS-09-41A

(2) Coat the thrust bearing race with petroleumjelly and install it onto the rear planetary sungear and one-way clutch assembly.

CAUTION: Check the direction on the bearing.

25. INSTALL REAR PLANETARY SUN GEARAND ONE-WAY CLUTCH ASSEMBLY

(1) Install the thrust washer and one-way clutchassembly to the rear planetary sun gear.



SS-01-39A

SS-09-45A

27. INSTALL FORWARD & REVERSE CLUTCHASSEMBLY

(1) Install the thrust bearing race and thrustneedle roller bearing to the forward &reverse clutch assembly.

(2) Install the forward & reverse clutch assemblyto the transaxle case.

SS-01-40A

SS-09-44A

(3) Install the forward clutch hub to the transaxlecase.

(4) Coat the thrust bearing race with petroleumjelly and install it onto the forward clutchhub.



SS-09-47A

A

SS-09-70A

P

D

F

(2) Install the flange, 2 discs and 2 plates to thetransaxle case.

(3) Clean the connected part the transaxle caseand transaxle rear cover.

(4) As shown in the illustration, place a straightedge on the transaxle case and measure thedistance between the 2nd coast & o/d brakeflange and straight edge using verniercalipers. (Dimension A)

SS-09-16A

SS-09-46A

29. INSTALL O/D & 2ND COAST BRAKEFLANGE, DISC AND PLATE

(1) Using a screwdriver, install the snap ring tothe transaxle case.

CAUTION: Make sure that the snap ring isinstalled in the groove of thetransaxle case correctly.

28. INSPECT DISC, PLATE AND FLANGE OFO/D & 2ND COAST BRAKE

(1) Check to see if the sliding surface of thedisc, plate and flange are worn or burnt.

CAUTION: If the lining of the disc is peeling offor discolored, or even if a part of theprinted mark is defaced, replace alldiscs. Before assembly new discs,soak them in ATF for at least 15minutes.



SS-09-49A

SS-09-50A

(2) Coat the thrust needle roller bearing withpetroleum jelly and install it onto the forward& reverse clutch assembly.

(3) Remove any packing material and be carefulnot to get oil on the contacting surfaces onthe transaxle rear cover on transaxle case.

(4) Apply FIPG to the transaxle rear cover.

(5) As shown in the illustration, place a straightedge on the o/d brake piston and measurethe distance between the transaxle rearcover and straight edge using verniercalipers, (Dimension B)

(6) Calculate the piston stroke value using thefollowing formula. Select flange whichsatisfies the piston stroke value and install it.

Piston stroke = Dimension A - Dimension B

30. INSTALL TRANSAXLE REAR COVER(1) Install new 4 apply gaskets to the transaxle

rear cover.


SS-09-48A

B

SS-01-36A



SS-09-51A

SS-09-52A

33. INSTALL DIRECT CLUTCH HUB(1) Install the direct clutch hub to the transaxle

case.

34. INSTALL DIRECT CLUTCH(1) Install thee thrust bearing race and thrust

needle roller bearing to the transaxle case.

SS-01-35A

SS-01-34A

SS-01-29A

32. INSTALL DIFFERENTIAL GEARASSEMBLY

(5) Install the transaxle rear cover to thetransaxle case with the 9 bolts.

TT = 19.6-29.4 N.m (200-300 kgf.cm)

31. INSTALL COUNTER DRIVEN GEARASSEMBLY



SS-01-28A

SS-01-27A

(3) Install the 6 bolts.

TT = 19.6-29.4 N.m (200-300 kgf.cm)

37. MEASURE INPUT SHAFT END PLAY(1) Measure the end play in axial direction.

End Play 0.3-0.9 mm

(2) Install the direct clutch assembly to thetransaxle case.

35. INSTALL NEW APPLY GASKET

36. INSTALL OIL PUMP(1) Install the thrust needle roller bearing to the

transaxle case.CAUTION: Check the direction of the bearing.(2) Place the oil pump through the input shaft,

and align the bolt holes of the oil pump withthe transaxle case.

SS-01-31A

SS-01-30A

SS-09-53A



SS-01-25A

SS-01-24A

40. INSTALL TRANSAXLE WIRE(1) Coat a new “O” ring with ATF install it to the

transaxle wire.

(2) Install the transaxle wire the to the transaxlecase with the 1 bolt.

TT = 3.9-6.9 N.m (40-70 kgf.cm)

SS-09-54A

SS-09-55A

SS-09-67A

38. CHECK INPUT SHAFT ROTATION(1) Make sure that the input shaft rotates

smoothly.

39. INSTALL TRANSAXLE HOUSING(1) Remove any packing material and be careful

not to get oil on the contacting surfaces ofthe transaxle housing or transaxle case.

(2) Apply FIPG to the transaxle housing.

(3) Install the transaxle housing to the transaxlecase with the 16 bolts.

TT = 23.5-35.5 N.m (240-360 kgf.cm)HINT: Apply seal packing or equivalent to the 3

bolts indicated by arrows.



SS-01-16A

SS-01-15A

43. INSTALL BRAKE DRUM GASKET(1) Coat a new brake drum gasket with ATF,

install it to the transaxle case.

44. INSTALL CHECK VALVE(1) Install the spring and check valve.

SS-01-17A

41. INSTALL ACCUMULATOR PISTON ANDSPRING

(1) Coat new 6 “O” rings with ATF and installthem to the pistons.

(2) Coat the 3 springs and 3 accumulatorpistons with ATF, install them to the holes.

42. INSTALL APPLY GASKET(1) Coat a new apply gasket with ATF, install it

to the transaxle case.

Free (mm) Outer (mm) ColorC2 Acum. 57.20 17.50 Light GreenC1 Acum. 54.70 17.20 BlueB1 Acum. 47.13 16.00 Pink

PART NAMESPRING

SS-09-56A

B1 Acum.

C1 Acum.

C2 Acum.



SS-01-13A

SS-01-12A

(3) Connect the 5 connectors.(4) Install the ATF temperature sensor with

clamp and 3 bolts.CAUTION: Make sure that the transaxle wire

does not come out from the oil paninstallation surface.

46. INSTALL OIL STRAINER(1) Install a new gasket to the oil strainer.

SS-09-57A

SS-09-69A

20 mm

20 mm

36 mm49 mm

28 mm

28 mm

40 mm(2) Install the transaxle wire connectors and

harness to the valve body assembly with the14 bolts.

TT = 9.8-11.8 N.m (100-120 kgf.cm)CAUTION: When installing the valve body to

the transaxle case, do not let eachof accumulator pistons B1, C1 andC2 incline. When installing the valvebody to the transaxle case, do nothold the solenoids.

45. INSTALL VALVE BODY ASSEMBLY(1) Connect the manual valve control rod to the

manual valve lever as shown in theillustration.



SS-01-07A

SS-01-82A

48. INSTALL INPUT SPEED SENSOR ANDNO.1 BREATHER PLUG

(1) Install the No.1 breather plug.(2) Install the input speed sensor with the 1 bolt.

TT = 3.9-6.9 N.m (40-70 kgf.cm)

49. INSTALL VEHICLE SPEED SENSOR(1) Install the vehicle speed sensor to the

transaxle case with the 1 bolt.

TT = 5.9-8.8 N.m (60-90 kgf.cm)

SS-01-11A

SS-09-58A

SS-01-09A

47. INSTALL OIL PAN(1) Install the 2 magnets in the oil pan.

(2) Install a new gasket to the oil pan and installthem to the transaxle case with the 18 bolts.

TT = 6.0-7.9 N.m (60-80 kgf.cm)

(2) Install the oil strainer to the valve body withthe 3 bolts.

TT = 7.8-11.8 N.m (80-120 kgf.cm)



SS-09-59A

SS-09-60A

53. INSTALL NEUTRAL START SWITCH(1) Install the neutral start switch onto the

manual valve lever shaft and temporarilyinstall the 2 adjusting bolts.

(2) Install a new lock washer and nuts.

TT = 4.3-6.5 N.m (44-66 kgf.cm)

(3) Temporarily install the control lever.

SS-01-80A

SS-01-06A

SS-01-05A

51. INSTALL SCREW PLUG(1) Coat a new “O” ring with ATF, install it to the

screw plug.(2) Install the screw plug to the transaxle case.

TT = 5.9-8.8 N.m (60-90 kgf.cm)

52. INSTALL UNION(1) Coat new 2 “O” rings with ATF, install them

to the unions.(2) Install the 2 unions to the transaxle case.

TT = 19.6-29.4 N.m (200-300 kgf.cm)

50. INSTALL BRACKET(1) Install the bracket to the transaxle case with

the 1 bolt.

TT = 19.6-29.4 N.m (200-300 kgf.cm)



SS-09-64A

A

Torque Converter

Transaxle Housing

SS-09-72A

(9) Install the control lever, washer and nut.

TT = 9.8-14.7 N.m (100-150 kgf.cm)

54. INSTALL TORQUE CONVERTER(1) Install the torque converter.(2) Check the distance of A.

A = 11.1 mmCAUTION: If the distance is out of standards,

adjust within standartds again.

(8) Using a screwdriver, stake the nut with thelock washer.

SS-09-63A

(4) Remove control lever.(5) Set the SST and inspect that SST pointer

align neutral basic line.(6) Align the groove with neutral basic line.(7) Tighten the 2 bolts.

TT = 4.3-6.5 N.m (44-66 kgf.cm)

SS-09-73A

SST

SS-09-74A

Neutral basic line

SST pointer

SST

[ RM-87 ] SERVICE SPECIFICATIONS


SERVICE SPECIFICATIONS

GENERAL

CLUTCH & BRAKE

C1 ( FORWARD CLUTCH)

A/T TYPEBASE A/T

1st 2.8752nd 1.5683rd 1.0004th 0.697

Reverse 2.300Counter 1.019

Differential 3.750ATF TYPE

VOLUME ATF 5.6L (75 degree C)

GEAR RATIO

81-40LE30510-81C008

Esso JWS-3309: ISU DEXRON Ⅲ = 1:1

Clutch / Brake Flange(F)

Plate(P)

Disc(D)

C1 (Forward Clutch) 1 4 4C2 (Direct Clutch) 1 2 2C3 (Rear Clutch) 2 1 2B1 (O/D & 2nd Coast Brake) 1 2 2B2 (2nd Brake) 1 2 2B3 (1st & Reverse Brake) 1 4 4

PART NAME SPEC.Piston Stroke 1.30-1.50 mmPack Clearance 1.30-1.50 mmFlange Thickness Th= 3.0 mmType Th= 3.1 mm

Th= 3.2 mmTh= 3.3 mmTh= 3.4 mmTh= 3.5 mmTh= 3.6 mm

STD24.04 mm




C2 ( DIRECT CLUTCH) C3 ( REVERSE CLUTCH)

B1 ( O/D & 2ND COAST BRAKE) B2 ( 2ND BRAKE)

B3 ( 1ST & REVERSE BRAKE)

OIL PUMP


Th= 3.4 mmSTD

36.04 mmPiston ReturnSpring Free Length


Th= 3.4 mmTh= 3.6 mm

PART NAME SPEC.Piston Stroke 0.65-1.05 mmPack Clearance 0.65-1.05 mm

STD18.99 mm



STD15.85 mm



STD21.71 mm


PART NAMEBody Bush STD. 38.113-38.138 mm

MAX 38.188 mmStator Shaft Bush STD. 18.424-18.450 mm

MAX 18.50 mmBody Clearance STD. 0.10-0.17 mm

MAX 0.22 mmTip Clearance Drive STD. 0.07-0.15 mm

MAX 0.20 mmTip Clearance Driven STD. 0.07-0.15 mm

MAX 0.20 mmSide Clearance of STD. 0.02-0.05 mmDrive and Driven Gear MAX 0.10 mm

SPEC.



OIL SEAL

PLANETARY GEAR BUSHING

SOLENOID

T/A HOUSING - T/C BOSS DISTANCE

ACCUMULATOR SPRING

SPEC.T/A Housing Oil seal in depth 2.6-3.6 mmT/A Case Oil seal in depth 3.8-4.8 mmManual Shaft Oil seal in depth 0.75-1.25 mm

PART NAME

PART NAME SPEC.S1 12-16 ohm (20 degree C)S2 11-15 ohm (20 degree C)ST 11-15 ohm (20 degree C)SL 11-15 ohm (20 degree C)

SPEC.T/A Housing-T/C Distance 11.1 mm

Free (mm) Outer (mm) ColorC2 Acum. 57.20 17.50 Light GreenC1 Acum. 54.70 17.20 BlueB1 Acum. 47.13 16.00 Pink

PART NAMESPRING

PART NAMEPla. Gear Bush Fr Mid Rr STD. 30.00-30.026 mm

Fr Mid Rr MAX 30.076 mmPla. FR Sun Fr Rr STD. 21.500-21.526 mmGear Bush Fr Rr MAX 21.576 mmPla. RR Sun Fr Rr STD. 21.500-21.526 mmGear Bush Fr Rr MAX 21.576 mm

SPEC.



TIGHTENING TORQUE

TT (Tightening Torque)Vehicle Speed Sensor M8-25 5.9-8.8 N.m (60-90 kgf.cm)Neutral Start Switch M6-20 4.3-6.5 N.m (44-66 kgf.cm)Neutral Start Switch Nut --- 9.8-14.7 N.m (100-150 kgf.cm)Input Speed Sensor M6-16 3.9-6.9 N.m (40-70 kgf.cm)Union 1/2-20UNF 19.6-29.4 N.m (200-300 kgf.cm)Screw Plug 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm)Oil Pan M6-14.5 6.0-7.9 N.m (60-80 kgf.cm)Oil Strainer M6-12 7.8-11.8 N.m (80-120 kgf.cm)Transaxle Wire M6-16 3.9-6.9 N.m (40-70 kgf.cm)T/A Housing - T/A Case M8-60 23.5-35.5 N.m (240-360 kgf.cm)Oil Pump - T/A Case M8-20 19.6-29.4 N.m (200-300 kgf.cm)T/A Case - T/A Rear Cover M8-25 19.6-29.4 N.m (200-300 kgf.cm)Parking Lock Pawl Bracket M6-16 5.9-8.8 N.m (60-90 kgf.cm)Manual Detent Spring M6-16 7.8-11.8 N.m (80-120 kgf.cm)No.1 Transaxle Case Plate M6-12 7.8-11.8 N.m (80-120 kgf.cm)Oil Reservoir Lock Plate M6-12 3.9-6.9 N.m (40-70 kgf.cm)Oil Apply Pipe Clamp M6-12 3.9-6.9 N.m (40-70 kgf.cm)Screw Plug - Rear Cover 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm)T/A Housing - Bracket M8-16 19.6-29.4 N.m (200-300 kgf.cm)Stator Shaft - Oil Pump Body M6-16.7 7.8-11.8 N.m (80-120 kgf.cm)

2 M6-203 M6-491 M6-491 M6-366 M6-205 M6-281 M6-40

PART NAME

Solenoid - Lower Valve Body

Valve Body

121121183116692113141

14

10.0-12.0 N.m (100-200 kgf.cm)

9.8-11.8 N.m (100-120 kgf.cm)

8

5

124361534 daewoo-8140le-repair

Automotive

Transcript of 124361534 daewoo-8140le-repair