Automatic Transmission - F4A42 PDF

Black plate (1,1)
Transmission & Clutch Overhaul

TRANSMISSION OVERHAUL
3.3
(AUTOMATIC)
F4A42
23A AUTOMATIC TRANSMISSION
<F4A42>
Model YR 2007
English Edition RDWE-1GA082
Destination: all
September 2007 Printed in Malaysia
Copyright
Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)
Black plate (2,1)
Printed in Malaysia 27 September 2007 Eng

Black plate (3,1)
TRANSMISSION OVERHAUL (AUTOMATIC) TC03

Content /I
23A AUTOMATIC TRANSMISSION <F4A42>
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/1

3-DIMENSIONAL CROSS-SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/1
SECTION VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/3

HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/4
VALVE BODY SPRING IDENTIFICATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/5
SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE
PLATE FOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/10
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/11

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/11
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/16
DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/20
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/36
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/62

REASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/63
UNDERCOVER CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/64

UNDERDRIVE CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/65

DISASSEMBLY SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/65
REVERSE AND OVERDRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/68
Copyright
Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)

Black plate (4,1)
TC03 TRANSMISSION OVERHAUL (AUTOMATIC)

/II Content

DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/69
PLANETARY CARRIER ASSEMBLY <WITH ONE-WAY CLUTCH> . . . . . . . . . . . 23A/74

LOW-REVERSE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/76

REASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/77
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/77

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/79

TRANSFER DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/81

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/84
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/87

DISASSEMBLY SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/90
DRIVE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/91

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Black plate (5,1)

Content /III
NOTE

Black plate (6,1)

/1 GENERAL INFORMATION
GENERAL INFORMATION WTC23AGINFO005
1. The combination of highest-precision electronic and mechanical technology heralds a new era in
automatic transmission performance.
2. The gear shifting clutches use a hydraulic balancing mechanism to enable gear shifting at extra-
high engine speed.
3. The number of shafts has been decreased to two, increased use has been made of metal plates
and the one-way clutch has been abolished, which all contribute to reduce the weight.
4. Increased meshing ratios and improved rigidity of the gear supports and casing result in less
noise.
5. In addition, adoption of a new-developed automatic transmission fluid (ATF).
6. The number of oil cooler feed tubes is increased to two.
3-DIMENSIONAL CROSS-SECTION
DOIIT23AR9225

Black plate (7,1)
AUTOMATIC TRANSMISSION <F4A42> 23A

GENERAL INFORMATION /2
SECTION VIEW WTC23AGINFO006
DOIIT23AR9226

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/3 GENERAL INFORMATION
GENERAL INFORMATION WTC23AGINFO007
HYDRAULIC CIRCUIT
DOIIT23AR07155
Items
1. Reverse clutch 17. Underdrive pressure control valve
2. Low-reverse brake 18. Overdrive pressure control valve
3. Second brake 19. Damper clutch solenoid valve
4. Underdrive clutch 20. Low-reverse solenoid valve
5. Overdrive clutch 21. Second solenoid valve
6. Low-reverse accumulator 22. Underdrive solenoid valve
7. Second accumulator 23. Overdrive solenoid valve
8. Underdrive accumulator 24. Torque converter pressure control valve
9. Overdrive accumulator 25. Regulator valve
10. Damper clutch 26. Manual valve
11. Fail-save valve A 27. Oil filter
12. Fail-save valve B 28. Oil pan
13. Damper clutch control valve 29. Oil pump
14. Switch valve 30. Relief valve
15. Low-reverse pressure control valve 31. Oil strainer
16. Second pressure control valve

Black plate (9,1)

SPECIFICATIONS /4
SPECIFICATIONS WTC23ASPECS003
GENERAL SPECIFICATIONS
Items Specification
Transmission Model F4A42
Transmission type 4–speed forward, 1–speed reverse
Torque converter type 3–element, 1–stage, 2–phase type
Applicable engine F4PH
1st 2.842
2nd 1.529
3rd 1.000
Gear ratio
4th 0.712
Reverse 2.480
Final gear ratio 4.042
Number of underdrive clutch disc 4
Number of overdrive clutch disc 4
Number of reverse clutch disc 2
Number of low-reverse brake disc 5
Number of second brake disc 3
SERVICE SPECIFICATIONS
Items Standard value

Output shaft preload 0.01-0.09 mm (0-0.003 in)
Brake reaction plate end play 0-0.16 mm (0-0.006 in)
Low-reverse brake end play 1.35-1.81 mm (0.053-0.071 in)
Second brake end play 0.79-1.25 mm (0.031-0.049 in)
Underdrive sun gear end play 0.25-0.45 mm (0.009-0.017 in)
Input shaft end play 0.70-1.45 mm (0.027-0.057 in)
Differential case preload 0.045-0.105 mm (0.001-0.004 in)
Underdrive clutch end play 1.6-1.8 mm (0.062-0.07 in)
Reverse and overdrive clutch return spring end 0-0.09 mm (0-0.003 in)
play
Overdrive clutch end play 1.6-1.8 mm (0.062-0.07 in)
Reverse clutch end play 1.5-1.7 mm (0.059-0.066 in)
Backlash between differential side gear and 0.025-0.150 mm (0-0.005 in)
pinion

Black plate (10,1)

/5 SPECIFICATIONS
VALVE BODY SPRING IDENTIFICATION TABLE
Spring Wire diameter Outside diameter Free length Number of loop

Regulator valve spring 1.8 mm (0.07 in) 15.7 mm (0.618 86.7 mm (3.413 24 mm (0.944
in) in) in)
Underdrive pressure control 0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984
valve spring in) in)
Overdrive pressure control 0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984
valve in) in)
Low-reverse pressure con- 0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984
trol valve spring in) in)
Second pressure control 0.7 mm (0.027 in) 7.6 mm (0.299 in) 37.7 mm (1.484 25 mm (0.984
valve spring in) in)
Torque converter spring 1.6 mm (0.062 in) 11.2 mm (0.44 in) 34.4 mm (1.354 12.5 mm (0.492
in) in)
Damper clutch control valve 0.7 mm (0.027 in) 5.9 mm (0.232 in) 28.1 mm (1.106 19 mm (0.748
spring in) in)
Fail-save valve A spring 0.7 mm (0.027 in) 8.9 mm (0.35 in) 21.9 mm (0.862 9.5 mm (0.374
in) in)
Damping valve spring 1.0 mm (0.039 in) 7.7 mm (0.303 in) 35.8 mm (1.409 17 mm (0.669
in) in)
Line relief valve spring 1.0 mm (0.039 in) 7.0 mm (0.275 in) 17.3 mm (0.681 10 mm (0.393
in) in)
Orifice check ball spring 0.5 mm (0.019 in) 4.5 mm (0.177 in) 17.2 mm (0.677 15 mm (0.59 in)
in)
SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR
ADJUSTMENT
Part name Thickness Identification sym- Part no.

bol
Thrust washer 1.8 mm (0.07 in) 18 MD754509
(For adjustment of input shaft 2.0 mm (0.078 in) 20 MD754508
end play)
2.2 mm (0.086 in) 22 MD754507
2.4 mm (0.094 in) 24 MD753793
2.6 mm (0.102 in) 26 MD753794
2.8 mm (0.11 in) 28 MD753795

Black plate (11,1)

SPECIFICATIONS /6

bol
Snap ring 1.6 mm (0.062 in) None MD759666
(For adjustment of underdrive 1.7 mm (0.066 in) Blue MD759667
clutch and overdrive clutch end
play) 1.8 mm (0.07 in) Brown MD759668
1.9 mm (0.074 in) None MD752124
2.0 mm (0.078 in) Blue MD752125
2.1 mm (0.082 in) Brown MD752126
2.2 mm (0.086 in) None MD752127
2.3 mm (0.09 in) Blue MD752128
2.4 mm (0.094 in) Brown MD752129
2.5 mm (0.098 in) None MD752130
2.6 mm (0.102 in) Blue MD752131
2.7 mm (0.106 in) Brown MD752132
2.8 mm (0.11 in) None MD752133
2.9 mm (0.114 in) Blue MD752134
3.0 mm (0.118 in) Brown MD754680
Snap ring 2.2 mm (0.086 in) Blue MD754786
(For adjustment of low-reverse 2.3 mm (0.09 in) Brown MD754787
brake and second brake reaction
plates end plays) 2.4 mm (0.094 in) None MD758240
2.5 mm (0.098 in) Blue MD758241
Pressure plate 1.6 mm (0.062 in) L MD759567
(For adjustment of low-reverse 1.8 mm (0.07 in) 1 MD759414
brake and second brake end
plays) 2.0 mm (0.078 in) 0 MD759415
2.2 mm (0.086 in) 2 MD759416
2.4 mm (0.094 in) 4 MD759417
2.6 mm (0.102 in) 6 MD759418
2.8 mm (0.11 in) 8 MD759419
3.0 mm (0.118 in) D MD759420

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/7 SPECIFICATIONS

bol
Snap ring 1.6 mm (0.062 in) None MD761085
(For adjustment of reverse clutch 1.7 mm (0.066 in) Blue MD761086
end plays)
1.8 mm (0.07 in) Brown MD761087
1.9 mm (0.074 in) None MD352137
2.0 mm (0.078 in) Blue MD352138
2.1 mm (0.082 in) Brown MD352139
2.2 mm (0.086 in) None MD352140
2.3 mm (0.09 in) Blue MD352141
2.4 mm (0.094 in) Brown MD352142
2.5 mm (0.098 in) None MD352143
2.6 mm (0.102 in) Blue MD352144
2.7 mm (0.106 in) Brown MD352145
2.8 mm (0.11 in) None MD352146
Snap ring 1.48 mm (0.058 in) Brown MD755600
(For adjustment of reverse clutch 1.53 mm (0.06 in) None MD755601
and overdrive clutch spring
retainer end plays) 1.58 mm (0.062 in) Blue MD755602
1.63 mm (0.064 in) Brown MD755603
Thrust race 1.6 mm (0.062 in) — MD707267
(For adjustment of underdrive 1.7 mm (0.066 in) — MD759681
sun gear end plays)
1.8 mm (0.07 in) — MD723064
1.9 mm (0.074 in) — MD754794
2.0 mm (0.078 in) — MD707268
2.1 mm (0.082 in) — MD754795
2.2 mm (0.086 in) — MD723065
2.3 mm (0.09 in) — MD754796
2.4 mm (0.094 in) — MD724358
2.5 mm (0.098 in) — MD754797
2.6 mm (0.102 in) — MD754798

Black plate (13,1)

SPECIFICATIONS /8

bol
Spacer 1.88 mm (0.074 in) 88 MD756579
(For adjustment of output shaft 1.92 mm (0.075 in) 92 MD756580
preload)
1.96 mm (0.077 in) 96 MD756581
2.00 mm (0.078 in) 00 MD756582
2.04 mm (0.08 in) 04 MD756583
2.08 mm (0.081 in) 08 MD756584
2.12 mm (0.083 in) 12 MD756585
2.16 mm (0.085 in) 16 MD756586
2.20 mm (0.086 in) 20 MD756587
2.24 mm (0.088 in) 24 MD756588
2.28 mm (0.089 in) 28 MD756589
2.32 mm (0.091 in) 32 MD756590
2.36 mm (0.092 in) 36 MD756591
2.40 mm (0.094 in) 40 MD756592
2.44 mm (0.096 in) 44 MD756593
2.48 mm (0.097 in) 48 MD756594
2.52 mm (0.099 in) 52 MD756595
2.56 mm (0.1 in) 56 MD756596
2.60 mm (0.102 in) 60 MD756597
2.64 mm (0.103 in) 64 MD756598
2.68 mm (0.105 in) 68 MD756599
2.72 mm (0.107 in) 72 MD760685
2.76 mm (0.108 in) 76 MD760686

Black plate (14,1)

/9 SPECIFICATIONS

bol
Spacer: 0.71 mm (0.027 in) 71 MD754475
(For adjustment of differential 0.74 mm (0.029 in) 74 MD727660
case preload)
0.77 mm (0.03 in) 77 MD754476
0.80 mm (0.031 in) 80 MD727661
0.83 mm (0.032 in) 83 MD720937
0.86 mm (0.033 in) 86 MD720938
0.89 mm (0.035 in) 89 MD720939
0.92 mm (0.036 in) 92 MD720940
0.95 mm (0.037 in) 95 MD720941
0.98 mm (0.038 in) 98 MD720942
1.01 mm (0.039 in) 01 MD720943
1.04 mm (0.04 in) 04 MD720944
1.07 mm (0.042 in) 07 MD720945
1.10 mm (0.043 in) J MD710454
1.13 mm (0.044 in) D MD700270
1.16 mm (0.045 in) K MD710455
1.19 mm (0.046 in) L MD710456
1.22 mm (0.048 in) G MD700271
1.25 mm (0.049 in) M MD710457
1.28 mm (0.05 in) N MD710458
1.31 mm (0.051 in) E MD706574
1.34 mm (0.052 in) O MD710459
1.37 mm (0.053 in) P MD710460
Spacer: 0.75-0.82 mm (0.029- — MD722986
(For adjustment of backlash 0.032 in)
between differential side gear 0.83-0.92 mm (0.032- — MD722985
and pinion) 0.036 in)
0.93-1.00 mm (0.036- — MD722984
0.039 in)
1.01-1.08 mm (0.039- — MD722982
0.042 in)
1.09-1.16 mm (0.042- — MD722983
0.045 in)

Black plate (15,1)

SPECIFICATIONS /10
TORQUE SPECIFICATIONS
Items Value
Transmission Roll stopper bracket 7.0 kgm (70 Nm; 4.697 ft.lbs)
Wiring harness bracket 2.3 kgm (23 Nm; 1.543 ft.lbs)
Control cable bracket 2.3 kgm (23 Nm; 1.543 ft.lbs)
Eye bolt 3.1 kgm (31 Nm; 2.08 ft.lbs)
Oil cooler feed tube (to trans- 1.0 kgm (10 Nm; 0.671 ft.lbs)
mission case)
Oil cooler feed tube (to roll 1.1 kgm (11 Nm; 0.738 ft.lbs)
stopper bracket)
Pulse generator A 1.1 kgm (11 Nm; 0.738 ft.lbs)
Pulse generator B 1.1 kgm (11 Nm; 0.738 ft.lbs)
Manual control lever 2.2 kgm (22 Nm; 1.476 ft.lbs)
Inhibitor switch 1.1 kgm (11 Nm; 0.738 ft.lbs)
Valve body cover 1.1 kgm (11 Nm; 0.738 ft.lbs)
Valve body mounting bolt 1.1 kgm (11 Nm; 0.738 ft.lbs)
Fluid temperature sensor 1.1 kgm (11 Nm; 0.738 ft.lbs)
Manual control shaft detent 0.6 kgm (6 Nm; 0.402 ft.lbs)
Rear cover 2.3 kgm (23 Nm; 1.543 ft.lbs)
Torque converter housing 4.8 kgm (48 Nm; 3.221 ft.lbs)
Oil pump 2.9 kgm (29 Nm; 1.946 ft.lbs)
Transfer drive gear 3.4 kgm (34 Nm; 2.281 ft.lbs)
Output shaft lock nut 17.0 kgm (170 Nm; 11.408
ft.lbs)
Output shaft bearing retainer 2.9 kgm (29 Nm; 1.946 ft.lbs)
Oil filler plug 3.3 kgm (33 Nm; 2.214 ft.lbs)
Oil drain plug 3.3 kgm (33 Nm; 2.214 ft.lbs)
Components Transfer drive gear lock nut 19.5 kgm (195 Nm; 13.086
ft.lbs)
Differential drive gear 13.5 kgm (135 Nm; 9.059 ft.lbs)
Valve body 1.1 kgm (11 Nm; 0.738 ft.lbs)
Solenoid valve support 0.6 kgm (6 Nm; 0.402 ft.lbs)
Plate 0.6 kgm (6 Nm; 0.402 ft.lbs)
SEALANTS
Items Specified sealant

Rear cover
Torque converter housing Part no. MD974421 or equivalent
Valve body cover

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/11 SPECIAL TOOLS
SPECIAL TOOLS WTC23ASTOOL002
TOOLS
Tool Number Name Use

MB990607 Torque wrench socket Removal and installa-
tion of output shaft
lock nut
DOIIT23AR9005
MB990928 Installer adapter Removal of transfer

drive gear bearing
DOIIT23AR9006
MB990930 Installer adapter Installation of output

shaft taper roller bear-
ing outer race
DOIIT23AR9007
MB990931 Installer adapter Installation of cap
DOIIT23AR9008
MB990935 Installer adapter Installation of differen-

tial taper roller bearing
outer race
DOIIT23AR9009
MB990936 Installer adapter Installation of output

ing outer race
DOIIT23AR9010

Black plate (17,1)

SPECIAL TOOLS /12

MB990938 Handle Installation of input
shaft rear bearing
Use with installer
adapter
DOIIT23AR9011
MB991625 Special socket (41) Removal and installa-

tion of output shaft
lock nut
DOIIT23AR9012
MB991626 Socket (60) Removal and installa-

tion of transfer drive
gear lock nut
DOIIT23AR9013
MB991628 Spring compressor Removal and

installation low-
reverse brake snap ring
Measurement of
underdrive clutch and
overdrive clutch end
plays
DOIIT23AR9014
MB991631 Clearance dummy plate Measurement of low-

reverse brake and sec-
ond brake end plays
DOIIT23AR9015
MB991790 Spring compressor Measurement of

reverse clutch end play
DOIIT23AR07153

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/13 SPECIAL TOOLS

MD998333 Oil pump remover Removal of oil pump
DOIIT23AR9016
MD998334 Oil seal installer Installation of oil pump

oil seal
DOIIT23AR9017
MD998348 Bearing and gear puller Removal of transfer

drive gear bearing
DOIIT23AR9018
MD998350 Bearing installer Installation of output

shaft
DOIIT23AR9019
MD998412 Guide Installation of oil pump

and transfer drive gear
DOIIT23AR9020
MD998800 Oil seal installer Installation of drive

shaft oil seal
DOIIT23AR9021

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SPECIAL TOOLS /14

MD998801 Bearing remover Removal of each bear-
ing
DOIIT23AR9022
MD998812 Installer cap Use with installer and

installer adapter
DOIIT23AR9023
MD998813 Installer-100 Use with installer cap

and installer adapter
DOIIT23AR9024
MD998814 Installer-200 Use with installer cap

and installer adapter
DOIIT23AR9025
MD998820 Installer adapter (42) Installation of differen-

tial taper roller bearing
DOIIT23AR9027
MD998823 Installer adapter (48) Installation of output

ing
DOIIT23AR9028

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/15 SPECIAL TOOLS

MD998829 Installer adapter (60) Installation of transfer
drive gear bearing
DOIIT23AR9029
MD998903 Spring compressor Removal and installa-

tion of one-way clutch
inner race snap ring
DOIIT23AR07154

tion of underdrive
clutch snap ring
DOIIT23AR9030
MD998913 Dial gauge extension Measurement of low-

reverse brake and sec-
ond brake end plays
DOIIT23AR9031
MD998917 Bearing removal Removal of output

ing
DOIIT23AR9032

retainer tion of low-reverse
brake snap ring
Measurement of
underdrive clutch and
overdrive clutch plays
DOIIT23AR9033

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TRANSMISSION /16

MD995566 Claw Removal of each outer
race
DOIIT23AR9034

tion of overdrive clutch
snap ring
DOIIT23AR9035
TRANSMISSION WTC23ASHAUL022
DISASSEMBLY AND REASSEMBLY
DOIIT23AR07149

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/17 TRANSMISSION
— Lubricate all internal parts with automatic transmission fluid during reassembly
— Apply sealant
— Non- reusable part

Disassembly steps
1. Torque converter 7. Pulse generator A
2. Roll stopper bracket 8. Pulse generator B
3. Control cable support bracket 9. Manual control lever
4. Oil level gauge 10. Inhibitor switch
5. Eye bolt 11. Valve body cover
6. Oil cooler feed tube 12. Manual control shaft detent
T1 : 1.1 kgm (11 Nm; 0.738 ft.lbs) T4 : 1.0 kgm (10 Nm; 0.671 ft.lbs)
DOIIT23AR07150

Black plate (23,1)

TRANSMISSION /18

Disassembly steps
13. Fluid temperature sensor 20. Second brake retainer oil seal
14. Valve body 21. Accumulator piston
15. Steel ball 22. Accumulator spring
16. Gasket 23. Accumulator spring
17. Snap ring 24. Manual control lever shaft roller
18. Solenoid valve harness 25. Manual control lever shaft
19. Strainer 26. Parking pawl rod
T1 : 1.1 kgm (11 Nm; 0.738 ft.lbs)
DOIIT23AR07151
— Apply sealant

Disassembly steps

Black plate (24,1)

/19 TRANSMISSION
27. Torque converter housing 33. Underdrive clutch and input shaft
28. Differential 34. Thrust bearing #2
29. Oil filter 35. Underdrive clutch hub
30. Oil pump 36. Outer race
31. Gasket 37. Spacer
32. Thrust washer #1
T7 : 2.9 kgm (29 Nm; 1.946 ft.lbs)
T8 : 4.8 kgm (48 Nm; 3.221 ft.lbs)
DOIIT23AR07152
— Lubricate all internal part with automatic transmission fluid during reassembly
— Apply sealant

Black plate (25,1)

TRANSMISSION /20
Disassembly steps 62. Parking pawl shaft

38. Rear cover 63. Spacer
39. Thrust race #8 64. Parking pawl spring
40. Seal ring 65. Parking roller support shaft
41. Input shaft rear bearing 66. Parking pawl
42. Thrust bearing #7 67. Parking roller support
43. Reverse and overdrive clutch 68. Snap ring
44. Thrust bearing #6 69. One-way clutch inner race
45. Overdrive clutch hub 70. O-ring
46. Thrust bearing #5 71. Spring retainer
47. Planetary reverse sun gear 72. Return spring
48. Snap ring 73. Low-reverse brake piston
49. Second brake piston 74. Transfer drive gear
50. Return spring 75. Cap
51. Pressure plate 76. Lock nut
52. Second brake disc 77. Output shaft
53. Second brake plate 78. Taper roller bearing
54. Planetary carrier assembly 79. Collar
55. Snap ring 80. Outer race
56. Reaction plate 81. Spacer
57. Snap ring 82. Snap ring
58. Low-reverse brake disc 83. Outer race
59. Low-reverse brake plate 84. Transmission case
60. Pressure plate
61. Wave spring
DISASSEMBLY WTC23ASHAUL023
CAUTION
(1) Because the automatic transmission is
manufactured from high-precision parts,
sufficient care must be taken not to scratch
or damage these parts during disassembly
and reassembly.
(2) The working area should be covered with a
rubber mat to keep it clean at all times.
(3) Do not wear any cloth gloves and do not
use any rags during disassembly. Use nylon
cloth or paper towels if you need to use
something.
(4) Parts which have been disassembled
should all be cleaned. Metal parts can be
cleaned with normal detergent, but they
should be dried completely using com-
pressed air.
(5) Clutch discs, plastic thrust plates and
rubber parts should be cleaned with auto-
matic transmission fluid (ATF) so that they
do not become dirty.
(6) If the transmission body has been
damaged, disassemble and clean the cooler
system also.

Black plate (26,1)

/21 TRANSMISSION
1. Remove the torque converter.

2. Use the dial gauge to measure the input
shaft end play.
3. Remove each bracket.
4. Remove the oil level gauge.
5. Remove the eye bolt, gasket and the oil
cooler feed tube.
DOIIT23AR07001
6. Remove the Pulse generator A and Pulse

generator B.
Symbol Description
7 Pulse generator A
8 Pulse generator B
DOIIT23AR07002
7. Remove the manual control lever, and then

remove the inhibitor switch.
Symbol Description
9 Control lever
10 Inhibitor switch
CAUTION
Make sure that the valve body is installed
before removing the manual control lever
DOIIT23AR07003 installation nut.
8. Use the special tool to remove the valve

body cover.
Symbol Description
11 Valve body cover
DOIIT23AR07004

Black plate (27,1)

TRANSMISSION /22
9. Remove the manual control shaft detent.
Symbol Description
12 Manual control shaft
detent
DOIIT23AR07005
10. Disconnect the harness connectors of the

valve body.
Symbol Description
18 Harness connectors of the
valve body
DOIIT23AR07006
11. Remove the valve body mounting bolt (28

pieces).
12. Remove the fluid temperature sensor.
Symbol Description
13 Fluid temperature sensor
CAUTION
Make sure that the manual control lever
and the inhibitor switch are removed.
DOIIT23AR07007
13. Remove the valve body, gasket and the

steel balls two pieces.
Symbol Description
14 Valve body
15 Steel balls
16 Gasket
CAUTION
DOIIT23AR07008 Do not lose the steel balls (2 pieces).

Black plate (28,1)

/23 TRANSMISSION
14. Remove the snap ring, and then remove the

solenoid valve harness.
Symbol Description
17 Snap ring
18 Solenoid valve harness
DOIIT23AR07009
15. Remove the strainer .
Symbol Description
19 Strainer
DOIIT23AR07010
16. Remove the second brake retainer oil seal.
Symbol Description
20 Second brake retainer oil
seal
DOIIT23AR07168
17. Remove each accumulator piston and

spring.
Symbol Description
A For low-reverse brake
B For underdrive clutch
C For second brake
D For overdrive clutch
DOIIT23AR07011

Black plate (29,1)

TRANSMISSION /24
18. Use the magnet to remove the manual

control lever shaft roller.
Symbol Description
24 Manual control lever shaft
roller
DOIIT23AR07169
19. Remove the manual control lever shaft and

parking pawl rod.
Symbol Description
25 Manual control lever shaft
26 Parking pawl rod
DOIIT23AR07012
20. Remove the torque converter housing

mounting bolts (18 pieces), and then
remove the torque converter housing.
Symbol Description
27 Torque converter housing
DOIIT23AR07164

Black plate (30,1)

/25 TRANSMISSION
21. Remove the O-rings two pieces.
Symbol Description
E O-rings
DOIIT23AR07014
22. Remove the differential.
Symbol Description
28 Differential
DOIIT23AR07015
23. Remove the oil filter.
Symbol Description
29 Oil filter
DOIIT23AR07016
24. Remove the oil pump mounting bolts (6

pieces).
DOIIT23AR07017

Black plate (31,1)

TRANSMISSION /26
25. Install the special tool (MD998333) as

shown in illustration.
DOIIT23AR07018
26. Screw the special tool to remove the oil

pump.
Symbol Description
30 Oil pump
27. Remove the oil pump gasket.
Symbol Description
31 Oil pump gasket
DOIIT23AR07165
28. Remove the thrust washer #1.
Symbol Description
32 Thrust washer #1
DOIIT23AR07019
29. Hold the input shaft, and then remove the

underdrive clutch.
Symbol Description
33 Underdrive clutch
DOIIT23AR07020

Black plate (32,1)

/27 TRANSMISSION
30. Remove the thrust bearing #2.
Symbol Description
34 Thrust bearing #2
DOIIT23AR07021
31. Remove the underdrive clutch hub.
Symbol Description
35 Underdrive clutch hub
DOIIT23AR07022
32. Remove the rear cover.

33. Remove the thrust race #8.
34. Remove the seal rings.
35. Remove the input shaft rear bearing.
Symbol Description
38 Rear cover
39 Thrust race #8
40 Seal rings
41 Input shaft rear bearing
DOIIT23AR07023
36. Remove the O-rings (F) (3 pieces).
Symbol Description
F O-rings
DOIIT23AR07024

Black plate (33,1)

TRANSMISSION /28
37. Remove the reverse and overdrive clutch

and the thrust bearing #7.
Symbol Description
43 Reverse and overdrive
clutch
DOIIT23AR07025
38. Remove the overdrive clutch hub and the

thrust bearing #6.
Symbol Description
45 Overdrive clutch hub
DOIIT23AR07026
39. Remove the thrust bearing #5.
Symbol Description
DOIIT23AR07027
40. Remove the planetary reverse sun gear.
Symbol Description
47 Planetary reverse sun gear
DOIIT23AR07028

Black plate (34,1)

/29 TRANSMISSION
41. Remove the snap ring.
Symbol Description
48 Snap ring
DOIIT23AR07029
42. Remove the second brake piston and the

return spring.
Symbol Description
49 Second brake piston
50 Rreturn spring
DOIIT23AR07030
43. Remove the pressure plate, second brake

discs and second brake plate(s).
Symbol Description
51 Pressure plate
52 Second brake discs
53 Second brake plate
No. of brake discs and plates
Brake disc Brake plate Pressure plate

DOIIT23AR07031
3 2 1

Black plate (35,1)

TRANSMISSION /30
44. Remove the planetary carrier assembly.
Symbol Description
54 Planetary carrier assembly
DOIIT23AR07032
Symbol Description
55 Snap ring
DOIIT23AR07035
46. Remove the reaction plate and the brake

disc.
Symbol Description
56 Reaction plate
DOIIT23AR07036
Symbol Description
57 Snap ring
DOIIT23AR07037

Black plate (36,1)

/31 TRANSMISSION
48. Remove the low-reverse brake plates, low-

reverse brake discs and pressure plate.
Symbol Description
58 Low-reverse brake discs
59 Low-reverse brake plates
60 Pressure plate
No. of Low-reverse brake discs and plates
Brake disc Brake plate Pressure

DOIIT23AR07038 plate
5 4 1
49. Remove the wave spring.
Symbol Description
61 Wave spring.
DOIIT23AR07039

Black plate (37,1)

TRANSMISSION /32
50. Remove the parking pawl shaft, and then

remove the spacer and spring.
Symbol Description
62 Parking pawl shaft
63 Spacer
64 Spring
DOIIT23AR07166
51. Remove the two parking roller support

shafts, and then remove the parking paws
case and parking roller support.
Symbol Description
65 Parking roller support
shafts
66 Parking paws case
DOIIT23AR07167

Black plate (38,1)

/33 TRANSMISSION
52. Use the special tool to remove the snap

ring.
Symbol Description
68 Snap ring
DOIIT23AR07042
53. Remove the one-way clutch inner race, O-

ring, spring retainer, return spring and the
low-reverse brake piston.
Symbol Description
69 One-way clutch inner race
70 O-ring
71 Spring retainer
72 Return spring
73 Low-reverse brake piston
DOIIT23AR07171
54. Remove the transfer drive gear mounting

bolts as follows:
First remove 4 or 3 bolts, then turn the gear
1/8 turn (458) and remove the remaining 3
or 4 bolts (7 bolt in total).
DOIIT23AR07043

Black plate (39,1)

TRANSMISSION /34
55. Remove the transfer drive gear.
Symbol Description
74 Transfer drive gear
DOIIT23AR07044
56. Remove the cap.
Symbol Description
75 Cap
DOIIT23AR07045
57. Straighten the locking tab of the output

shaft lock nut.
Symbol Description
76 Output shaft lock nut
DOIIT23AR07046
58. Use the special tool to remove the output

shaft lock nut.
CAUTION
The lock nut is a left-handed screw (anti-
clock wise).
DOIIT23AR07047

Black plate (40,1)

/35 TRANSMISSION
59. Remove the output shaft mounting bolt (4

pieces).
DOIIT23AR07048
60. Tap on the rear of the output shaft to

remove the output shaft, taper roller bear-
ing and the collar.
Symbol Description
77 Output shaft
78 Taper roller bearing
79 Collar
DOIIT23AR07170
61. Remove the spacer and the outer race.
Symbol Description
80 Outer race
81 Spacer
DOIIT23AR07172

Black plate (41,1)

TRANSMISSION /36
Symbol Description
82 Snap ring
DOIIT23AR07050
63. Remove the differential bearing outer race

and spacer from the torque converter
housing.
Symbol Description
27 Torque converter housing
36 Outer race
37 Spacer
DOIIT23AR07173
64. Remove the differential bearing outer race

from the transmission case.
Symbol Description
83 Transmission case
REASSEMBLY WTC23ASHAUL024
CAUTION
(1) Never reuse the gasket, O-ring, oil seal, etc.
Always replace with a new one when
DOIIT23AR07174
reassembling.
(2) Never use grease other than blue petrola-
tum jelly and white Vaseline.
(3) Apply ATF to friction components, rotating
parts, and sliding parts before installation.
Immerse a new clutch disc or brake disc in
ATF for at least two hours before assem-
bling them.
(4) Never apply sealant or adhesive to gaskets.
(5) When replacing a bushing, replace the
assembly which it belongs to.
(6) Never use any cloth gloves or any rags
during reassembly. Use nylon cloth or
paper towels if you need to use something.
(7) Change the oil in the cooler system.

Black plate (42,1)

/37 TRANSMISSION
1. Use the special tools to tap the differential

bearing outer race in the transmission case.
DOIIT23AR07051
2. Use the special tools to tap the output shaft

bearing outer race in the transmission case.
3. Install the used spacer and snap ring.
DOIIT23AR07052
4. Use the special tool (MB998412) to install

the tranfer drive gear.
4.1 First tighten 4 mounting bolts, then
turn the transfer drive gear bearing
to tighten 3 mounting bolt (7 bolt in
total).
Specified torque:
3.4 kgm (34 Nm; 2.281 ft.lbs)
DOIIT23AR07176

Black plate (43,1)

TRANSMISSION /38
5. Install the low-reverse brake piston, return

spring and spring retainer.
5.1 Check the placement of the identifi-
cation notches in the one-way clutch
inner race. Install the one-way clutch
inner race with O-ring to transfer
drive gear bearing so that the
notches fall along the A—A line.
Symbol Description
A Line
B Notches
69 One-way clutch inner
race
84 Transmission case
DOIIT23AR07175
6. Use the special tools install the snap ring.
Symbol Description
68 Snap ring
DOIIT23AR07042
7. Install the wave spring.
Symbol Description
61 Wave spring
DOIIT23AR07039

Black plate (44,1)

/39 TRANSMISSION
8. Install the low-reverse brake disc, low-

reverse brake plate, special tool
(MB991631) and snap ring as shown in the
figure.
Symbol Description
MB991631 Special tool
57 Snap ring
58 Low-reverse brake disc
59 Low-reverse brake plate
DOIIT23AR07177
Number of Low-reverse brake disc and

plates
Brake disc Brake plate Special tool
5 4 1
NOTE:
Do not install the pressure plate at this
time.
9. Install the reaction plate and the used snap

ring.
Symbol Description
55 Snap ring
56 Reaction plate
DOIIT23AR07178
10. Move the special tool to measure the end

play, and then replace the snap ring
installed in step 9 to adjust the end play
to standard value.
Standard value:0 ~ 0.16 mm (0.006 in)
DOIIT23AR07054

Black plate (45,1)

TRANSMISSION /40
11. Install the second brake disc, second brake

plate and replace the pressure plate of the
second brake with the special tool
(MB991631) as shown in the figure.
Symbol Description
52 Second brake disc
Number of Second brake disc and plates

DOIIT23AR07180 Brake disc Brake plate Special tool
3 2 1
12. Install the return spring, second brake

piston, and snap ring.
Symbol Description
50 Return spring
48 Snap ring
DOIIT23AR07179
13. Move the special tool (MB991631) to mea-

sure the end play.
Standard value (Reference):
0.79 mm (0.031 in) ~ 1.25 mm (0.049 in)
DOIIT23AR07056

Black plate (46,1)

/41 TRANSMISSION
Select a pressure plate which thickness is

within the following table, and replace the
special tool mounted in the step 10 with it.
[A (movement amount) + thickness of the
special tool (2.0 mm (0.078 in)) -
1.25 mm (0.049 in)] to [A (movement
amount) + thickness of the special tool (
2.0 mm (0.078 in)) - 0.79 mm (0.031 in)].
DOIIT23AR07181
Pressure plate:
Movement amount Thickness ID symbol Part No.
0.6~0.8 mm 1.6 mm L MD759567
0.8~1.0 mm 1.8 mm 1 MD759414
1.0~1.2 mm 2.0 mm 0 MD759415
1.2~1.4 mm 2.2 mm 2 MD759416
1.4~1.6 mm 2.4 mm 4 MD759417
1.6~1.8 mm 2.6 mm 6 MD759418
14. Reverse the transmission .

15. Install the special tool (MD998913) in a dial
gauge, and then move the special tool
(MB991631) to measure its movement.
Standard value of end play (Referance):
1.35 mm (0.053 in) ~ 1.81 mm (0.071 in)
DOIIT23AR07058
Reference
Select a pressure plate which thickness is
within the following table, and replace the
special tool mounted at the step 6 with it.
[A (movement amount) + thickness of the
special tool (2.0 mm (0.078 in)) -
1.81 mm (0.071 in)] to [A (movement
amount) + thickness of the special tool (
2.0 mm (0.078 in)) - 1.35 mm (0.053 in)]
DOIIT23AR07182

Black plate (47,1)

TRANSMISSION /42
Pressure plate:
Movement amount Thickness ID symbol Part No.
1.0~1.2 mm 1.6 mm L MD759567
1.2~1.4 mm 1.8 mm 1 MD759414
1.4~1.6 mm 2.0 mm 0 MD759415
1.6~1.8 mm 2.2 mm 2 MD759416
1.8~2.0 mm 2.4 mm 4 MD759417
2.0~2.2 mm 2.6 mm 6 MD759418
2.2~2.4 mm 2.8 mm 8 MD759419
2.4~2.6 mm 3.0 mm D MD759420
16. Remove the parts installed from steps 7 to
15.
17. Tighten the mounting bolts of the output

shaft bearing retainer to the specified
torque.
Specified torque:
2.9 kgm (29 Nm; 1.946 ft.lbs)
DOIIT23AR07048
18. Install the output shaft in the transmission

case, and then use the special tool to install
the collar and taper roller bearing in the
output shaft.
DOIIT23AR07060

Black plate (48,1)

/43 TRANSMISSION
19. Apply ATF to a new lock nut, and use the

special tool to tighten the lock nut to the
specified torque. Then turn back one turn,
and tighten to the specified again.
Specified torque:
17.0 kgm (170 Nm; 11.408 ft.lbs)
CAUTION
The lock nut is a left-hand screw (anti clock-
wise).
DOIIT23AR07061
20. Move the output shaft to measure operat-

ing amount, and then replace the spacer
installed in step 3 with a new one which
thickness is within the following value.
[A (operating amount) + B (thickness of the
old spacer) + 0.01 mm (0 in)) to [A
(operating amount) + B (thickness of the
old spacer) + 0.09 mm (0.003 in)]
DOIIT23AR07062
21. Stake the lock nut with a punch (two

pleces).
DOIIT23AR07063
22. Install the new cap as shown in the figure.
Symbol Description
75 Cap
DOIIT23AR07064

Black plate (49,1)

TRANSMISSION /44
23. Install the parking pawl, spacer, and spring.

Then install the parking pawl shaft.
Symbol Description
62 Parking pawl shaft
63 Spacer
64 Spring
66 Parking pawl
DOIIT23AR07183
24. Install the parking roller support, and then

the two parking roller support shafts.
Symbol Description
shaft
DOIIT23AR07184

Black plate (50,1)

/45 TRANSMISSION
DOIIT23AR07069
IDENTIFICATION OF THRUST BEARINGS, THRUST RACES,
AND THRUST WASHERS
O.D I.D Thickn- Part number Symbol O.D I.D Thickn- Part number Symbol
ess ess
59 47 1.8 mm MD754509 #1 48.9 37 1.6 mm MD707267 #8
mm mm (0.07 in) mm mm (0.062
(2.322 (1.85 (1.925 (1.45- in)
in) in) in) 6 in)
59 47 2.0 mm MD754508 #1 48.9 37 1.7 mm MD759681 #8
mm mm (0.078 mm mm (0.066
(2.322 (1.85 in) (1.925 (1.45- in)
in) in) in) 6 in)
59 47 2.2 mm MD754507 #1 48.9 37 1.8 mm MD723064 #8
mm mm (0.086 mm mm (0.07
(2.322 (1.85 in) (1.925 (1.45- in)
in) in) in) 6 in)
59 47 2.4 mm MD753793 #1 48.9 37 1.9 mm MD754794 #8
mm mm (0.094 mm mm (0.074
(2.322 (1.85 in) (1.925 (1.45- in)
in) in) in) 6 in)

Black plate (51,1)

TRANSMISSION /46
O.D I.D Thickn- Part number Symbol O.D I.D Thickn- Part number Symbol
ess ess
59 47 2.6 mm MD753794 #1 48.9 37 2.0 ml MD707268 #8
mm mm (0.102 mm mm (2.105
(2.322 (1.85 in) (1.925 (1.45- U.S.qts;
in) in) in) 6 in) 1.736
Imp.qt-
s)
59 47 2.8 mm MD753795 #1 48.9 37 2.1 mm MD754795 #8
mm mm (0.11 in) mm mm (0.082
(2.322 (1.85 (1.925 (1.45- in)
in) in) in) 6 in)
49 36 3.6 mm MD756846 #2 48.9 37 2.2 mm MD723065 #8
mm mm (0.141 mm mm (0.086
(1.929 (1.41- in) (1.925 (1.45- in)
in) 7 in) in) 6 in)
49 36 3.6 mm MD756846 #3 48.9 37 2.3 mm MD754796 #8
mm mm (0.141 mm mm (0.09
(1.929 (1.41- in) (1.925 (1.45- in)
in) 7 in) in) 6 in)
45.3 31 3.3 mm MD757647 #4 48.9 37 2.4 mm MD724358 #8
mm mm (0.129 mm mm (0.094
(1.783 (1.22 in) (1.925 (1.45- in)
in) in) in) 6 in)
49 36 3.6 mm MD756846 #5 48.9 37 2.5 mm MD754797 #8
mm mm (0.141 mm mm (0.098
(1.929 (1.41- in) (1.925 (1.45- in)
in) 7 in) in) 6 in)
49 36 3.6 mm MD756846 #6 48.9 37 2.6 mm MD754798 #8
mm mm (0.141 mm mm (0.102
(1.929 (1.41- in) (1.925 (1.45- in)
in) 7 in) in) 6 in)
59 37 2.8 mm MD754595 #7 — — — — —
mm mm (0.11 in)
(2.322 (1.45-
in) 6 in)
25. Install the overdrive planetary carrier

assembly.
Symbol Description
54 Overdrive planetary car-
rier assembly
DOIIT23AR07032

Black plate (52,1)

/47 TRANSMISSION
26. Install the planetary reverse sun gear.
Symbol Description
47 Planetary reverse sun
gear
DOIIT23AR07028
27. Install the wave spring.
Symbol Description
61 Wave spring
DOIIT23AR07039
28. Install the pressure plate, low-reverse brake

disc, and low-reverse brake plate.
Symbol Description
58 Low-reverse brake disc
59 Low-reverse brake plate
60 Pressure plate
Number of low-reverse brake discs and

plates
DOIIT23AR07071
5 4 1

Black plate (53,1)

TRANSMISSION /48
29. Install the snap ring.
Symbol Description
57 Snap ring
DOIIT23AR07072
30. Install the reaction plate.
Symbol Description
56 Reaction plate
DOIIT23AR07073
Symbol Description
55 Snap ring
DOIIT23AR07074
32. Install the second brake disc, second brake

plate , and pressure plate.
Symbol Description
51 Pressure plate
52 Second brake disc
DOIIT23AR07075

Black plate (54,1)

/49 TRANSMISSION
Number of second brake discs and plates

3 2 1
33. Install the return spring and second brake

piston.
Symbol Description
50 Return spring
DOIIT23AR07076
Symbol Description
48 Snap ring
DOIIT23AR07077
35. Install the thrust bearing #5.
Symbol Description
CAUTION
Be careful about the installation direction
of the thrust bearing
DOIIT23AR07078

Black plate (55,1)

TRANSMISSION /50
36. Install the overdrive clutch hub and thrust

bearing #6 to the reverse and overdrive
clutch.
Symbol Description
clutch
45 Overdrive clutch hub
CAUTION
DOIIT23AR07079 Be careful about the installation direction
of the thrust bearing
37. Install the reverse and overdrive clutch, and

thrust bearing #7.
Symbol Description
clutch
CAUTION
Be careful about the installation direction
DOIIT23AR07080 of the thrust bearing
38. Install the three O-rings.
Symbol Description
F O-rings
DOIIT23AR07024

Black plate (56,1)

/51 TRANSMISSION
39. Use the special tool and tap the input shaft
bearing in the rear cover.
40. Install the two seal rings in the grooves of
the rear cover.
41. Install the thinnest thrust race #8 on the
thrust bearing #7.
DOIIT23AR07081
42. Measure end play of the underdrive sun

gear and record the measurement value.
Symbol Description
NOTE
Installing the underdrive clutch hub makes
it easy to measure the end play of the
underdrive sun gear.
Standard value: 0.25 mm (0.009 in)~
0.45 mm (0.017 in)
DOIIT23AR07082
Select a thrust race #8 whose thickness
corresponds to the measured value from
the table below, and replace the thrust race
installed in step 41 with the selected one.
Thrust race #8
Mesurement Thickness Part No.
value
0.3~0.4 mm 1.6 mm MD707267
0.4~0.5 mm 1.7 mm MD759681
0.5~0.6 mm 1.8 mm MD723064
0.6~0.7 mm 1.9 mm MD754794
0.7~0.8 mm 2.0 mm MD707268
0.8~0.9 mm 2.1 mm MD754795
0.9~1.0 mm 2.2 mm MD723065
1.0~1.1 mm 2.3 mm MD754796
1.1~1.2 mm 2.4 mm MD724358
1.2~1.3 mm 2.5 mm MD754797
1.3~1.4 mm 2.6 mm MD754798

Black plate (57,1)

TRANSMISSION /52
43. Squeeze out the liquid gasket of

1.6 mm (0.062 in) in diameter and apply it
to the shown points of the rear cover.
Liquid gasket: Sealant Part No. MD974421
or equivalent
DOIIT23AR07083
44. Install the rear cover, and tighten its

mounting bolts to the specified torque.
Specified torque:
2.3 kgm (23 Nm; 1.543 ft.lbs)
DOIIT23AR07095
45. Install the underdrive clutch hub.
Symbol Description
DOIIT23AR07022
46. Install the thrust bearing #2.
Symbol Description
CAUTION
Install the thrust bearing in correct direc-
tion.
DOIIT23AR07084

Black plate (58,1)

/53 TRANSMISSION
47. Hold the input shaft, and install the

underdrive clutch.
Symbol Description
33 Underdrive clutch
DOIIT23AR07020
47.1 Place two beads of solder [each 10

mm in length, 3.5 mm in diameter]
on the underdrive clutch retainer as
shown in the illustration.
Symbol Description
A Input shaft
B Underdrive clutch
retainer
C Two beads of
solder
DOIIT23AR07188
47.2 Install special tool in the illustrated

place.
47.3 Install the oil pump to the transaxle
case.
NOTE
Do not instal the oil pump gasket at
this time.
47.4 Tighten the oil pump mounting bolts
(6 pieces) to the specified torque.
Specified torque:
2.9 kgm (29 Nm; 1.946 ft.lbs)
DOIIT23AR07085
47.5 Remove the oil pump mounting

bolts.
47.6 Using special tool, remove the oil
pump, and then take out the crushed
solders.
DOIIT23AR07018

Black plate (59,1)

TRANSMISSION /54
47.7 Use a micrometer to measure the

thickness of the crushed solder beads
and record the measured value.
Symbol Description
T Thickness
47.8 Select a thrust washer #1 whose
thickness corresponds to the mea-
sured value from table below.
DOIIT23AR07088
Thrust washer #1:

Measurement valuet Thickness ID symbol Part No.
2.25~2.45 mm 1.8 mm 18 MD754509
2.45~2.65 mm 2.0 mm 20 MD754508
2.65~2.85 mm 2.2 mm 22 MD754507
2.85~3.05 mm 2.4 mm 24 MD753793
3.05~3.25 mm 2.6 mm 26 MD753794
3.25~3.45 mm 2.8 mm 28 MD753795
48. Install the used thrust washer #1 that was

selected in step 47.8 on the underdrive
clutch retainer.
Symbol Description
32 Thrust washer #1
DOIIT23AR07019
49. Use the special tool to install a new oil

pump gasket and oil pump.
CAUTION
Never reuse the old gasket.
50. Tighten the oil pump mounting bolts to the
specified torque.
Specified torque:
2.9 kgm (29 Nm; 1.946 ft.lbs)
DOIIT23AR07085

Black plate (60,1)

/55 TRANSMISSION
51. Measure end play of the input shaft meets

the standard value.
Standard value: 0.70 mm (0.027 in)~
1.45 mm (0.057 in)
DOIIT23AR07086
52. Install the oil filter.
Symbol Description
29 Oil filter
DOIIT23AR07016
53. Install the differential.
Symbol Description
28 Differential
DOIIT23AR07015
54. Place a solder (approx. 10 mm (0.393 in) in

length, 3 mm (0.118 in) in diameter) on the
torque converter housing as shown in the
figure.
Symbol Description
G Solder
DOIIT23AR07087

Black plate (61,1)

TRANSMISSION /56
55. Install the torque converter housing to the

transmission case without applying sealant.
Tighten its mounting bolts to the specified
torque.
Specified torque:
4.8 kgm (48 Nm; 3.221 ft.lbs)
56. Loose the bolts, and remove the outer race
and solder.
DOIIT23AR07013
57. Use a micrometer measure the thickness of

the pressed solder. Select a spacer which
thickness is within the following value.
Symbol Description
T Thickness
Standard value: 0.045 mm (0.001 in) ~
0.105 mm (0.004 in)
DOIIT23AR07088
58. Assemble the spacer selected in step 57 and

install the outer race to the torque con-
verter housing. Use the special tool to press
in the outer race.
DOIIT23AR07089
59. Squeeze out the liquid gasket of

1.6 mm (0.062 in) in diameter and apply it
to the shown points of torque converter .
Liquid gasket: Part No. MD974421 or
equivalent
DOIIT23AR07090

Black plate (62,1)

/57 TRANSMISSION
60. Install the two O-rings.
Symbol Description
E O-rings
DOIIT23AR07014
61. Install the torque converter, and then

tighten its 18 mounting bolts to the
specified torque.
Specified torque:
4.8 kgm (48 Nm; 3.221 ft.lbs)
DOIIT23AR07013
62. Install the manual control lever shaft and

parking pawl rod.
Symbol Description
25 Manual control lever
shaft
26 Parking pawl rod
63. Install the manual control lever shaft roller.
DOIIT23AR07185

Black plate (63,1)

TRANSMISSION /58
64. Install the accumulator pistons, new seal

rings, and springs.
NOTE
The accumulator springs are identified as
shown in the figure.
Symbol Description
A For low-reverse brake
B For underdrive clutch
C For second brake
D For overdrive clutch
DOIIT23AR07091
65. Install the strainer.
Symbol Description
19 Strainer
DOIIT23AR07010
66. Install the second brake retainer oil seal.
Symbol Description
20 Second brake retainer oil
seal
DOIIT23AR07168

Black plate (64,1)

/59 TRANSMISSION
67. Install the solenoid valve harness, and then

secure the snap ring to the connector
groove.
Symbol Description
17 Snap ring
18 Solenoid valve harness
DOIIT23AR07009
68. Install the valve body, gasket, and two steel

balls.
Symbol Description
14 Valve body
15 Steel balls
16 Gasket
DOIIT23AR07008
69. Install the fluid temperature sensor.
Symbol Description
13 Fluid temperature sensor
70. Install the 28 mounting bolts of the valve
body.
DOIIT23AR07007
71. Connect the connectores of the valve body.
DOIIT23AR07092

Black plate (65,1)

TRANSMISSION /60
No. Part to be connected Cable color Connector housing color

1 Underdrive solenoid valve White, red, red Black
2 Overdrive solenoid valve Orange, red Black
3 Low-reverse solenoid valve Brown, yellow Milky white
4 Second solenoid valve Green, red, red Milky white
5 Damper clutch control sole- Blue, yellow, yellow Black
noid valve
6 Fluid temperature sensor Black, red Black
72. Install the manual control shaft detent.
Symbol Description
12 Manual control shaft
detent
DOIIT23AR07005
73. Apply the liquid gasket to the valve body

cover.
Liquid gasket: Part No. MD974421 or
equivalent
DOIIT23AR07093
74. Install the valve body cover, and then

tighten its mounting bolts to the specified
torque.
Symbol Description
11 Valve body cover
Specified torque:
1.1 kgm (11 Nm; 0.738 ft.lbs)
DOIIT23AR07187

Black plate (66,1)

/61 TRANSMISSION
75. Install the inhibitor switch and manual

control lever.
Symbol Description
9 Manual control lever
10 Inhibitor switch
DOIIT23AR07003
76. Install the Pulse generator A and output

Pulse generator B.
Symbol Description
7 Pulse generator A
8 Pulse generator B
77. Install the eye bolt, a new gasket, and the

oil cooler feed tube.
78. Install the oil dipstick.
DOIIT23AR07002 79. Install the brackets.
80. Install the torque converter, and secure it so

that the shown dimension meets the refer-
ence value.
Reference value:approx 12.2 mm (0.48 in)
CAUTION
Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful
not to damage the oil seal lip when
installing the torque converter.
DOIIT23AR07094

Black plate (67,1)

OIL PUMP /62
OIL PUMP WTC23ASHAUL025
DOIIT23AR07096
— Apply ATF, blue petrolatum jelly
— Non-reusable part
Disassembly steps
1. O-ring
2. Seal ring
3. Oil seal
4. Oil pump assembly

Black plate (68,1)

/63 OIL PUMP
REASSEMBLY SERVICE POINTS WTC23ASHAUL026

OIL SEAL INSTALLATION
Use the special tool to tap the oil seal in the oil
pump assembly.
DOIIT23AR07097
O-RING INSTALLATION
Install a new O-ring to the outer groove of the
oil pump, and apply ATF, blue petrolatum jelly
or white Vaseline to the outer inside diameter
of the O-ring.
Symbol Description
A O-ring
B Outer groove
DOIIT23AR07098

Black plate (69,1)

UNDERCOVER CLUTCH AND INPUT SHAFT /64
UNDERCOVER CLUTCH AND INPUT SHAFT WTC23ASHAUL027
DOIIT23AR07099
Number of clutch disc and plates

Clutch disc Clutch plate Clutch reaction plate
4 4 1
Lubricate all internal parts with automatic transmission fluid during reassembly.

Black plate (70,1)

/65 UNDERDRIVE CLUTCH AND INPUT SHAFT
Disassembly steps 9. Spring retainer

1. Snap ring 10. D-ring
2. Input shaft 11. Return spring
3. Seal ring 12. Underdrive clutch piston
5. Clutch reaction plats 14. D-ring
6. Clutch disc 15. Underdrive clutch retainer
7. Clutch plate
8. Snap ring
UNDERDRIVE CLUTCH AND INPUT

SHAFT WTC23ASHAUL028
DISASSEMBLY SERVICE POINTS

SNAP RING REMOVAL
Use the special tools to remove the snap ring.
Symbol Description
8 Snap ring
DOIIT23AR07100
UNDERDRIVE CLUTCH PISTON REMOVAL

Use air pressure to remove the underdrive
clutch piston.
DOIIT23AR07156

Black plate (71,1)

UNDERDRIVE CLUTCH AND INPUT SHAFT /66
REASSEMBLY SERVICE POINTS

D-RING INSTALLATION
Apply ATF, blue petrolatum jelly or white
Vaseline to new D-ring and install carefully.
Symbol Description
10, 13,14 D-ring
DOIIT23AR07101
SNAP RING INSTALLATION

Use the special tools to install the snap ring.
Symbol Description
8 Snap ring
DOIIT23AR07100
CLUTCH PLATE / CLUTCH DISC / CLUTCH

REACTION PLATE INSTALLATION
1. Align each teeth missing part of the clutch
plate, clutch disc and clutch reaction plate
to the outer circumference hole of the
underdrive clutch retainer.
Symbol Description
A Teeth missing part
B Outer circumference hole
DOIIT23AR07102 CAUTION
Immerse the clutch disc in ATF before
assembling it.

Black plate (72,1)

/67 UNDERDRIVE CLUTCH AND INPUT SHAFT
2. Install the clutch reaction plate in the

shown direction.
Symbol Description
5 Clutch reaction plate
6 Clutch discs
7 Clutch plates
C Shear droop
Number of clutch discs and plates

DOIIT23AR07103
Clutch disc Clutch plate Clutch reaction
plate
4 4 1

Check that the clearance between the snap ring
and the clutch reaction plates is within the
standard value. When measuring the clearance,
use the special tool to press the clutch reaction
plate evenly. If not within the standard value,
select a snap ring to adjust.
Standard value: 1.6-1.8 mm (0.062-0.07 in)
DOIIT23AR07104

Black plate (73,1)

REVERSE AND OVERDRIVE CLUTCH /68
REVERSE AND OVERDRIVE CLUTCH WTC23ASHAUL029
DOIIT23AR07105
Number of clutch disc and plates

Clutch disc Clutch plate Clutch reaction plate
4 4 1

Black plate (74,1)

/69 REVERSE AND OVERDRIVE CLUTCH
Disassembly steps 10. Spring retainer

2. Clutch reaction plate 12. Return spring
3. Clutch disc 13. Overdrive clutch
piston
4. Clutch plate 14. D-ring
5. Snap ring 15. Reverse clutch
6. Clutch reaction plate piston
7. Clutch disc 16. D-ring
8. Clutch plate 17. Reverse clutch
retainer
9. Snap ring
18. D-ring
19. D-ring
DISASSEMBLY SERVICE POINT WTC23ASHAUL030

SNAP RING REMOVAL
Use the special tools to remove the snap ring.
Symbol Description
9 Snap ring
DOIIT23AR07106
OVERDRIVE CLUTCH PISTON REMOVAL

Use air pressure to remove the overdrive clutch
piston.
DOIIT23AR07157

Black plate (75,1)

REVERSE CLUTCH PISTON REMOVAL

Use air pressure to remove the reverse clutch
piston.
DOIIT23AR07158

D-RING INSTALLATION
Apply ATF, blue petrolatum jelly or white vase-
line to new D-ring and install carefully.
Symbol Description
11, 16, 14, 18, 19 D-ring
DOIIT23AR07113
REVERSE CLUTCH PISTON INSTALLATION

Align the outer circumference holes of the
reverse clutch piston and the reverse clutch
retainer to assembly them.
Symbol Description
A&B Outer circumference holes
DOIIT23AR07107

1. Set special tools as shown in the illustration.
2. Tighten the nut on the special tool to press
down on the spring retainer and reverse
clutch retainer, and then install the snap
ring.
Symbol Description
9 Snap ring
DOIIT23AR07106

Black plate (76,1)

3. Check that the clearance between the snap

ring and the return spring retainer is within
the standard value. If not within the
standard value, select a snap ring to adjust.
Standard value: 0 mm (0 in)
DOIIT23AR07108

Install the clutch reaction plate in the shown
direction.
Symbol Description
7 Clutch discs
8 Clutch plates
C Shear droop
DOIIT23AR07103
CAUTION
Immerse the clutch disc in ATF before assem-
bling the clutch disc.
Number of clutch discs plates
Clutch disc Clutch plate Clutch reac-

tion plate
4 4 1

Black plate (77,1)


Check that the clearance between the snap ring
and the clutch reaction plate is within the
standard value. When measuring the clearance,
use the special tool to press the clutch reaction
plate evenly. If not within the standard value,
select a snap ring to adjust.
Symbol Description
5 Snap ring
Standard value: 1.6 mm (0.062 in)
DOIIT23AR07159

1. Align each teeth missing part (part A) of the
clutch plate, clutch disc and clutch reaction
plate to the outer circumference hole (part
B) of the reverse clutch retainer.
Symbol Description
A Teeth missing of the
clutch plate, clutch disc
and clutch reaction
plate
DOIIT23AR07110
B Outer circumference
hole of the reverse
clutch retainer
CAUTION
Immerse the clutch disc in ATF.

Black plate (78,1)

2. Install the clutch reaction plate in the

shown direction.
Symbol Description
3 Clutch discs
4 Clutch plates
C Shear droop
DOIIT23AR07111

1. Install the snap ring into the groove of
reverse clutch retainer.
Symbol Description
1 Snap ring
2. Set special tools MB991790 and MD998924
as shown in the illustration, and compress
the clutch element.
3. Check that the clearance between the snap
ring and the clutch reaction plates is within
the standard value, if not within the
standard value, select a snap ring to adjust.
Standard value: 1.5 mm (0.059 in)
DOIIT23AR07160

Black plate (79,1)

PLANETARY CARRIER ASSEMBLY <WITH ONE-WAY CLUTCH> /74
PLANETARY CARRIER ASSEMBLY <WITH ONE-WAY CLUTCH> WTC23ASHAUL031
DOIIT23AR07161
Apply automatic transmission fluid to all moving parts before installation.
Disassembly steps 6. Underdrive sun gear

1. Stopper plate 7. Thrust bearing #4
2. One-way clutch 8. Snap ring
3. Snap ring 9. Overdrive planetary carrier
4. Output planetary carrier 10. Overdrive annulus gear
5. Thrust bearing #3

Black plate (80,1)

/75 PLANETARY CARRIER ASSEMBLY <WITH ONE-WAY CLUTCH>
REASSEMBLY SERVICE POINTS WTC23ASHAUL041

THRUST BEARING #3 / THRUST BEARING #4
INSTALLATION
Check the installation direction of thrust bear-
ings number #3 and #4, and install them as
shown.
Symbol Description
5 Thrust bearings #3
7 Thrust bearings #4
DOIIT23AR07162
ONE-WAY CLUTCH INSTALLATION

Insert the one-way clutch into the overdrive
annulus gear so that the arrow points to the
output planetary carrier side.
Symbol Description
2 One-way clutch
4 Output planetary carrier
10 Overdrive annulus gear
DOIIT23AR07163

Black plate (81,1)

LOW-REVERSE BRAKE /76
LOW-REVERSE BRAKE WTC23ASHAUL032
DOIIT23AR07115
Disassembly steps
1. D-ring
2. D-ring
3. Low-reverse brake piston

Black plate (82,1)

/77 SECOND BRAKE
REASSEMBLY SERVICE POINT

D-RING INSTALLATION
DOIIT23AR07117
SECOND BRAKE WTC23ASHAUL033
DOIIT23AR07116

Black plate (83,1)

SECOND BRAKE /78
Disassembly steps
1. Second brake retainer
2. D-ring
3. Second brake piston
4. D-ring

D-RING INSTALLATION
DOIIT23AR07118

Black plate (84,1)

/79 OUTPUT SHAFT
OUTPUT SHAFT WTC23ASHAUL034
DOIIT23AR07119
Disassembly steps
1. Transfer driven gear
2. Bearing retainer
3. Outer rece
4. Tapper roller bearing
5. Output shaft

Black plate (85,1)

OUTPUT SHAFT /80

NOTE:
Recomended to use hydraulic machine i.e press
machine to perform the diassembly service
point.
TRANSFER DRIVEN GEAR REMOVAL
Use the special tool, press the output shaft to
remove the transfer driven gear.
DOIIT23AR07120
TAPER ROLLER BEARING REMOVAL

Use the special tool, press the output shaft to
remove the taper roller bearing.
DOIIT23AR07121

NOTE:
machine to perform the reassembly service
point.
TAPER ROLLER BEARING INSTALLATION
Use the special tools to install the taper roller
bearing.
DOIIT23AR07122
OUTER RACE INSTALLATION

Use the special tools to install the outer race.
DOIIT23AR07123

Black plate (86,1)

/81 TRANSFER DRIVE GEAR
TRANSFER DRIVEN GEAR INSTALLATION

Use the special tools to install the transfer
driven gear.
DOIIT23AR07124
TRANSFER DRIVE GEAR WTC23ASHAUL035
DOIIT23AR07125

Black plate (87,1)

TRANSFER DRIVE GEAR /82
Disassembly steps
1. Lock nut
2. Transfer drive gear bearing
3. Transfer drive gear
T1 : 19.5 Kgf.m

LOCK NUT REMOVAL
1. Pull up the turning stopper of the lock nut.
DOIIT23AR07126
2. Use the special tool to remove the lock nut.
DOIIT23AR07127
TRANSFER DRIVE GEAR BEARING REMOVAL

Use the special tools to remove the transfer
drive gear bearing.
DOIIT23AR07128

Black plate (88,1)

/83 TRANSFER DRIVE GEAR

TRANSFER DRIVE GEAR BEARING
INSTALLATION
Use the special tools to install the transfer gear
bearing.
DOIIT23AR07129
LOCK NUT INSTALLATION

1. Apply ATF to a new lock nut and tighten it
to the specified torque. Then turn back one
turn, and tighten to the specified torque
again.
DOIIT23AR07127
2. Use punch or other to prevent the nut from

turning (two points).
DOIIT23AR07130

Black plate (89,1)

DIFFERENTIAL /84
DIFFERENTIAL WTC23ASHAUL036
DOIIT23AR07131
Lubricate all internal parts with automatic transmission fluid during reassembly
Disassembly steps
1. Differential drive gear 6. Washers
2. Taper roller bearing 7. Side gears
3. Lock pin 8. Spacers
4. Pinion shaft 9. Differential case
5. Pinions
T1 : 13.5 kgm (135 Nm; 9.059 ft.lbs)

Black plate (90,1)

/85 DIFFERENTIAL

WTC23ASHAUL037
NOTE:
machine to perform the diassembly service
point.
TAPER ROLLER BEARING REMOVAL
Use the special tool, press the differential case
to remove the taper roller bearing.
DOIIT23AR07132

NOTE:
machine to perform the reassembly service
point.
SPACER, SIDE GEAR, WASHER, PINION,
PINION SHAFT INSTALLATION
1. Install the spacers to the back side of the
side gears, and then assemble the side gears
into the differential case.
NOTE :
DOIIT23AR07133 Select the medium size spacer 0.93~1.00
mm (0.036~0.039 in) when assembling a
new side gear.
2. Attach the washers to the back side of the
pinions, engage the pinions simultaneously
to the side gears, and settle the gears by
turning.
3. Insert the pinion shaft.
DOIIT23AR07134

Black plate (91,1)

DIFFERENTIAL /86
4. Measure the backlash between the side

gears and pinions.
Standard value:0.025-0.150 mm (0-0.005 in)
5. If not within the standard value, change a
spacer and measure the backlash again.
NOTE :
Adjust so that both backlashes are equal.
DOIIT23AR07135
LOCK PIN INSTALLATION

Install the lock pin in the shown direction.
Symbol Description
4 Lock pin
5 Pinion shaft
10 Differential case
DOIIT23AR07136
TAPER ROLLER BEARING INSTALLATION

Use the special tools to install the taper roller
bearing.
Symbol Description
3 Taper roller bearing
DOIIT23AR07137
DIFFERENTIAL DRIVE GEAR INSTALLATION

Apply ATF to the bolt, tighten the bolts to the
specified torque in the shown sequence.
Specified torque:
13.5 kgm (135 Nm; 9.059 ft.lbs)
DOIIT23AR07138

Black plate (92,1)

/87 VALVE BODY
VALVE BODY WTC23ASHAUL038
DOIIT23AR07139
Disassembly steps
1. Solenoid valve support 11. Steel ball (orifice check ball)
2. Underdrive solenoid valve 12. Spring
3. Second solenoid valve 13. Plate
4. Damper clutch control solenoid valve 14. Damping valve
5. Overdrive solenoid valve 15. Damping valve spring
6. Low-reverse solenoid valve 16. Steel ball (line relief)
7. Manual valve 17. Spring
8. Cover 18. Steel ball (orifice check ball)
9. Plate
19. Spring
10. Outside valve body assembly
20. Inside valve body assembly

Black plate (93,1)

VALVE BODY /88
T1 : 0.6 kgm (6 Nm; 0.402 ft.lbs)

T2 : 1.1 kgm (11 Nm; 0.738 ft.lbs)
DOIIT23AR07140
Disassembly steps
21. Roller 32. Fail-save valve A spring
22. Damper clutch control valve sleeve 33. Fail-save valve A1
23. Damper clutch control valve 34. Plate
24. Damper clutch control valve spring 35. Plug
25. Plate 36. Torque converter valve
26. Screw 37. Torque converter valve spring
27. Regulator valve spring 38. Plate
28. Regulator valve 39. Fail-save valve B sleeve
29. Plate 40. Fail-save valve B
30. Fail-save valve A sleeve 41. Inside valve body
31. Fail-save valve A2

Black plate (94,1)

/89 VALVE BODY
DOIIT23AR07141
Disassembly steps
42. Roller 52. Switching valve
43. Overdrive pressure control valve sleeve 53. Roller
44. Overdrive pressure control valve 54. Underdrive pressure control valve sleeve
45. Overdrive pressure control valve spring 55. Underdrive pressure control valve
46. Roller 56. Underdrive pressure control valve spring
47. Low-reverse pressure control valve sleeve 57. Roller
48. Low-reverse pressure control valve 58. Second pressure control valve sleeve
49. Low-reverse pressure control valve spring 59. Second pressure control valve
50. Plate 60. Second pressure control valve spring
51. Plug 61. Outside valve body

Black plate (95,1)

VALVE BODY /90
DISASSEMBLY SERVICE POINT WTC23ASHAUL039

SOLENOID VALVES REMOVAL
Mark solenoid valves by white paint to make
reassembly easier.
Symbol Description
2 Underdrive solenoid valve
3 Second solenoid valve
4 Damper clutch control solenoid
valve
DOIIT23AR07145
5 Overdrive solenoid valve
6 Low-reverse solenoid valve

SPRING / STEEL BALL / DAMPING VALVE /
DAMPING VALVE SPRING INSTALLATION
Insert the spring, steel ball, damping valve and
damping valve spring in the position as shown
in illustration.
Symbol Description
14 Damping valve
15 Damping valve spring
DOIIT23AR07142 16, 18 Steel ball
17, 19 Spring
SPRING / STEEL BALL INSTALLATION

Insert the spring and steel ball in the position as
shown in illustration.
Symbol Description
11 Steel ball
12 Spring
DOIIT23AR07143

Black plate (96,1)

/91 DRIVE SHAFT OIL SEAL
SOLENOID VALVES INSTALLATION

1. Apply ATF, blue petrolatum jelly or white
Vaseline to O-ring, and install carefully.
2. Install the solenoid valves by referring to
the marks during disassembly.
Symbol Description
2 Underdrive solenoid valve
3 Second solenoid valve
4 Damper clutch control solenoid
valve
DOIIT23AR07144
5 Overdrive solenoid valve
6 Low-reverse solenoid valve
DRIVE SHAFT OIL SEAL WTC23ASHAUL040
DOIIT23AR07146

Black plate (97,1)

DRIVE SHAFT OIL SEAL /92
Disassembly steps
1. Oil seal
2. Torque converter housing
3. Oil seal
4. Transmission case

Use the special tool to install the oil seal.
DOIIT23AR07147

Use the special tool to install the oil seal.
DOIIT23AR07148

Black plate (98,1)

/93 DRIVE SHAFT OIL SEAL
NOTE

Black plate (99,1)

INDEX /1

3
Content

Black plate (100,1)
F4A42 Model YR 2007 English Edition RDWE-1GA082 September 2007 Printed in Malaysia

Automatic Transmission - F4A42 PDF

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Automatic Transmission - F4A42 PDF

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Black plate (1,1)

Transmission & Clutch Overhaul

Printed in Malaysia 27 September 2007 Eng

TRANSMISSION OVERHAUL (AUTOMATIC) TC03

23A AUTOMATIC TRANSMISSION <F4A42>

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/11

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/62

UNDERCOVER CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/64

UNDERDRIVE CLUTCH AND INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/65

REVERSE AND OVERDRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/68

Printed in Malaysia 27 September 2007 Eng

TC03 TRANSMISSION OVERHAUL (AUTOMATIC)

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/68

PLANETARY CARRIER ASSEMBLY <WITH ONE-WAY CLUTCH> . . . . . . . . . . . 23A/74

LOW-REVERSE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/76

SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/77

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/79

TRANSFER DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/81

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/87

DRIVE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A/91

Printed in Malaysia 27 September 2007 Eng

TRANSMISSION OVERHAUL (AUTOMATIC) TC03

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

GENERAL INFORMATION WTC23AGINFO005

Printed in Malaysia 27 September 2007 Eng

AUTOMATIC TRANSMISSION <F4A42> 23A

SECTION VIEW WTC23AGINFO006

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

GENERAL INFORMATION WTC23AGINFO007

Printed in Malaysia 27 September 2007 Eng

AUTOMATIC TRANSMISSION <F4A42> 23A

Items Standard value

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

VALVE BODY SPRING IDENTIFICATION TABLE

Spring Wire diameter Outside diameter Free length Number of loop

Part name Thickness Identification sym- Part no.

Printed in Malaysia 27 September 2007 Eng

AUTOMATIC TRANSMISSION <F4A42> 23A

Part name Thickness Identification sym- Part no.

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

Part name Thickness Identification sym- Part no.

Printed in Malaysia 27 September 2007 Eng

AUTOMATIC TRANSMISSION <F4A42> 23A

Part name Thickness Identification sym- Part no.

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

Part name Thickness Identification sym- Part no.

Printed in Malaysia 27 September 2007 Eng

AUTOMATIC TRANSMISSION <F4A42> 23A

Items Specified sealant

Printed in Malaysia 27 September 2007 Eng

23A AUTOMATIC TRANSMISSION <F4A42>

SPECIAL TOOLS WTC23ASTOOL002

Tool Number Name Use

MB990928 Installer adapter Removal of transfer

MB990930 Installer adapter Installation of output

MB990931 Installer adapter Installation of cap

MB991628 Spring compressor Removal and

MD998924 Spring compressor Removal and installa-