ABBREVIATIONS USED IN THIS MANUAL

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COMPONENT PARTS General Notes The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-locking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group can not be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly for other component groups. GENERAL CLEAN<strong>IN</strong>G NOTES: 1. All disassembled parts should be washed clean with any fluid passages and holes blown through with compressed air. 2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene in your face. 3. The recommended automatic transmission fluid kerosene should be used for cleaning. PARTS ARRANGEMENT: AUTOMATIC TRANSAXLE - Component Parts (General Notes) 1. After cleaning, the parts should be arranged in proper order to allow efficient inspection, repairs, and reassembly. 2. When disassembling a valve body, be sure to keep each value together with the corresponding spring. 3. New brakes and clutches that are to be used for replacement must be soaked in transmission fluid for at least fifteen minutes before assembly. GENERAL ASSEMBLY: 1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly. 2. All gaskets and rubber O-rings should be replaced. 3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced. 5. Check thrust bearings and races for wear or damage. Replace if necessary. 6. Use petroleum jelly to keep parts in place. AX-47
AX-48 Pin Second Coast Brake Band ♦ Non-reusable part AT7702 AT7703 AUTOMATIC TRANSAXLE - Component Parts (Second Coast Brake) Second Coast Brake Inner Spring E-Ring Cover Outer Spring Snap Ring Piston Rod Plate Washer Oil Seal Ring Piston ♦ O-Ring DISASSEMBLY OF SECOND COAST BRAKE PISTON 1. REMOVE OIL SEAL R<strong>IN</strong>G Remove the oil seal ring from the piston. AT5657 2. REMOVE PISTON ROD (a) Remove the E-ring while pushing the piston with needle-nose pliers.
Page 1 and 2:
IN-6 INTRODUCTION - Abbreviations U
Page 3 and 4:
AT5715 AT5716 AUTOMATIC TRANSAXLE -
Page 5 and 6:
General Specifications Type of Tran
Page 7 and 8:
FUNCTION OF COMPONENTS Component Fu
Page 9 and 10:
Hydraulic Control System The hydrau
Page 11 and 12:
AX-102 AT7927 A241E A240L, A243L AT
Page 13 and 14:
AX-104 A241E AT8032 A243L A240L AT3
Page 15 and 16:
AX-106 N-m (kgf-cm, ft-lbf) ♦ Non
Page 17 and 18:
AX-108 SST AT8061 AT8078 AT8059 Pin
Page 19 and 20:
AX-1 10 AT8497 AT2980 AT8058 AT2981
Page 21 and 22:
AX-1 12 AT8484 AT8485 AT5831 AT7886
Page 23 and 24:
AX-1 14 AT8005 AT8004 AUTOMATIC TRA
Page 25 and 26:
AX-1 16 8. Be sure to install the t
Page 27 and 28:
AX-1 18 AT2956 AT2911 AT0593 AT2910
Page 29 and 30:
AX-120 AT0544 AT0700 AT0701 AT7931
Page 31 and 32:
AX-122 AT2961 AT2901 AT2900 AT2899
Page 33 and 34:
AX-124 AT8482 AT7999 AT1293 AT1294
Page 35 and 36:
AX-126 AT0604 AT0523 AT2892 AT8034
Page 37 and 38:
AX-128 AT0607 AT5829 AT3139 AT0610
Page 39 and 40:
AX-130 AT5704 AT2965 AT2966 AT0798
Page 41 and 42:
AX-132 AT2592 AT7891 AT0626 AT0627
Page 43 and 44:
AX-134 AT2968 AT2023 AT2969 AT0635
Page 45 and 46:
AX-136 AT0525 AT8484 AT5711 AT2766
Page 47 and 48:
AX-138 AT2869 AT2867 AT2865 AT8302
Page 49 and 50:
AX-140 AT5707 AT0643 AT5692 AT7991
Page 51 and 52:
AX-142 AT5685 AT2975 AT2855 AT2854
Page 53 and 54:
AX-144 AT5684 AT7926 AT7887 AT5683
Page 55 and 56:
AX-146 AT5639 AT5730 AT7762 AT5638
Page 57 and 58:
AX-148 22 (225, 16) Snap Ring Disc
Page 59 and 60:
AX-150 AT8074 AT8069 AT8496 AT8079
Page 61 and 62:
AX-152 AT2850 AT8071 AT8051 AT8057
Page 63 and 64:
AX-154 AT0653 AT3135 AT3433 AT0108
Page 65 and 66:
AX-156 AT3111 AT2863 AT3141 AT2865
Page 67 and 68:
AX-158 A AT0352 AT3035 AT8049 AT065
Page 69 and 70:
AX-160 AT2877 AT2878 AT0518 AT7891
Page 71 and 72:
AX-162 AT2883 AT2884 AT0139 AT2885
Page 73 and 74:
AX-164 AT2892 AT0523 AT0376 AT2888
Page 75 and 76:
AX-166 AT0627 AT2893 AT7996 AT2895
Page 77 and 78:
AX-168 AT8072 AT7999 AT2897 AT7889
Page 79 and 80:
AX-170 AT0541 AT8058 AT0543 AT0544
Page 81 and 82:
AX-172 AT2907 AT2908 Torx Wrench AT
Page 83 and 84:
AX-174 AT7994 AT7995 SST AUTOMATIC
Page 85 and 86:
Thrust Washer Direct Clutch Race Oi
Page 87 and 88:
COMPONENT PARTS (See page AX-48 to
Page 89 and 90:
AT8355 AT8356 AT8357 AT8358 AT8359
Page 91 and 92:
Primary Regulator Valve Sleeve AT33
Page 93 and 94:
AT3381 AT3380 Key 3 - 4 Shift Valve
Page 95 and 96:
AT3383 AT3385 AT3389 AT3387 AUTOMAT
Page 97 and 98:
AT8361 AT8362 AT3408 AT8368 AT8369
Page 99 and 100:
AT8366 AT8367 AT8371 AUTOMATIC TRAN
Page 101 and 102:
AT8270 AT8261 AT8262 AT8263 AT8264
Page 103 and 104:
AT8279 AT8280 AT8271 SST AT7754 AT8
Page 105 and 106:
AT7750 AT7751 AT7752 AT8287 AT8286
Page 107 and 108:
AT8471 AT7753 SST AT7754 AT3498 AT8
Page 109 and 110:
AT8375 AT8284 AT8277 AT8285 AT8296
Page 111 and 112:
AT8299 AT8300 AT8291 AUTOMATIC TRAN
Page 113 and 114:
♦ O-Ring 5.4 (55, 48 in.-lbf) AUT
Page 115 and 116:
29 (300, 22) Governor Driven Gear U
Page 117 and 118:
AT5652 AT2848 AT2849 AT2850 AT2851
Page 119 and 120:
AT5684 AT7932 AT2852 AT0102 AT0103
Page 121 and 122: A240L A243L AT3135 A241E AT2584 AT3
Page 123 and 124: AT2861 AT3111 AT2863 AT3141 AT2865
Page 131 and 132: AT2892 AT0523 Ex. A240L AT0525 AT05
Page 139 and 140: AT2908 Q00981 AT2910 AT0555 AT2911
Page 141 and 142: AT4331 AUTOMATIC TRANSAXLE (A241H)
Page 143 and 144: Front Bearing Race Thrust Bering Re
Page 145 and 146: AT5696 Torx Wrench AT5643 AT0548 AT
Page 171: AT8074 AT3447 AUTOMATIC TRANSAXLE (
Page 175 and 176: AX-50 AT7707 Less than 5 mm (0.20 i
Page 177 and 178: AX-52 AT3611 AT2732 AT0153 AT0154 A
Page 183 and 184: AX-58 A241E AT3617 AT5832 AT7710 Fl
Page 187 and 188: ♦ Non-reusable part AT7716 AT2742
Page 189 and 190: AT2699 AT0191 AT0323 Hold Align Sna
Page 193 and 194: AT2919 AT0200 AT2920 Front Bearing
Page 195 and 196: N-m (kgf-cm, ft-lbf) Non-reusable p
Page 203 and 204: ♦ Non-reusable part AT2942 AT0572
Page 207 and 208: Flange Disc Plate AT3113 AT2952 AT2
Page 209 and 210: A241E ♦ Gasket Plate ♦ O-Ring N
Page 211 and 212: A241E AT8032 A240L, A243L AT3048 AT
Page 213 and 214: Check Ball Primary Regulator Plunge
Page 215 and 216: LOCATION OF KEYS, PINS, VIBRATING S
Page 217 and 218: SPECIFICATIONS OF VALVE BODY SPRING
Page 219 and 220: A240L, A243L AT3051 AT3052 Plug Key
Page 221 and 222: LOCATION OF KEYS AND STRAINER A240L
Page 223 and 224:
IN-4 Seal Lock Adhesive IN0036 INTR
Page 225 and 226:
IN-2 ♦ Oil Seal N-m (kgf-cm, ft-l
Page 227 and 228:
TR-40 SERVICE SPECIFICATIONS SERVIC
Page 229 and 230:
AX-232 SERVICE SPECIFICATIONS SERVI
Page 231 and 232:
AX-234 SERVICE DATA (Cont’d) Accu
Page 233 and 234:
AX-236 SERVICE DATA (Cont’d) Diff
Page 235 and 236:
AX-12 Illustration Part No. Part Na
Page 237 and 238:
AX-14 SST (SPECIAL SERVICE TOOLS) (
Page 239 and 240:
STANDARD BOLT TORQUE SPECIFICATIONS
Page 241 and 242:
TR-2 29 (300, 22) Transfer Right Ca
Page 243 and 244:
TR-4 AT3354 AT3360 AT3364 AT3362 AT
Page 245 and 246:
TR-6 AT7764 AT3357 AT3448 SST SST T
Page 247 and 248:
TR-8 AT7767 AT7768 AT7769 AT8089 AT
Page 249 and 250:
TR-10 AT7776 AT7777 SST TRANSFER (A
Page 251 and 252:
TR-12 AT8009 AT7778 AT3342 AT7779 A
Page 253 and 254:
TR-14 N-m (kgf-cm, ft-lbf) ♦ Non-
Page 255 and 256:
TR-16 AT8068 AT8063 TRANSFER (A241H
Page 257 and 258:
TR-18 AT7782 Matchmarks AT7783 AT77
Page 259 and 260:
TR-20 AT7790 AT8354 AT7791 AT7792 S
Page 261 and 262:
TR-22 AT7794 AT7788 AT7795 AT7787 -
Page 263 and 264:
TR-24 AT7798 AT7787 AT7786 Matchmar
Page 265 and 266:
TR-26 Transfer Shift Lever Shaft Di
Page 267 and 268:
TR-28 AT8054 AT8064 AT8243 AT8244 A
Page 269 and 270:
TR-30 AT8245 AT8244 AT3401 AT8260 A
Page 271 and 272:
TR-32 AT8115 AT8267 AT8268 Adjustin
Page 273 and 274:
TR-34 AT3361 AT3360 AT3308 AT3358 A
Page 275 and 276:
TR-36 AT3362 AT3357 AT3415 AT8115 A
Page 277 and 278:
TR-38 AT3361 AT3312 AT3356 AT3354 A
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ABBREVIATIONS USED IN THIS MANUAL

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