Automatic Transmission: Other Ford Focus II

DIRECT CLUTCH HUB SHIM SELECTION CHART

DIRECT CLUTCH HUB SHIM SELECTION CHART

TRANSFER SHAFT SHIM SELECTION CHART

TRANSFER SHAFT SHIM SELECTION CHART

DIFFERENTIAL SHAFT SHIM SELECTION CHART

DIFFERENTIAL SHAFT SHIM SELECTION CHART

INTERMEDIATE/OVERDRIVE BAND BOLT CHART

INTERMEDIATE/OVERDRIVE BAND BOLT CHART

LINE PRESSURE CHART

LINE PRESSURE CHART

STALL SPEED CHART

STALL SPEED CHART

PWM solenoid valves 1-3

PWM solenoid valves 1, 2 and 3 control the pressure to the bands and clutches.

Shift solenoid (on/off) valves 1 and 2

The shift solenoid (on/off) valves switch the different oil passages in the valve body to direct the pressure to the individual clutches and bands.

The use of the shift solenoid valves are needed for direct actuation of the individual clutches and bands.

Main regulating valve

The main regulating valve (variable force solenoid) controls the required main line pressure for the individual transmission ranges.

The main line pressure is controlled dependent on the current engine load.

Scheme 226

The shift lever is secured on a square on the manual shaft. Axial movement of the selector lever cable is changed into rotation of the manual shaft.

In the transmission, the manual shaft operates the parking pawl engaging lever and the actuating lever of the manual valve.

The manual valve, a valve operated entirely manually, is moved by means of the manual valve actuating lever in the valve body.

The manual valve guarantees the functions during hydraulic emergency operation.

Scheme 227

The transmission end of the manual selector lever cable is attached to a ball on the lever on the manual shaft.

The cable abutments are secured to the transmission housing, and then to the bracket of the manual selector lever.

The adjuster for the manual selector lever cable is located at the transmission side of the sheath.

At the manual selector lever end the cable is clipped onto a ball.

Scheme 228

The final drive input gear is splined to the planet carrier of the front planetary gear set and drives the transfer shaft input gear of the intermediate gear stage.

The transfer shaft output gear of the intermediate gear stage drives the final drive assembly.

The torque is transmitted to the halfshafts through the final drive assembly.

The differential offsets differences in speed of rotation of the halfshafts.

The intermediate gear stage is designed so that the final drive ratio can be adapted to requirements when the automatic transmission is used in conjunction with different engines.

Range Selection

The transaxle range selector has 6 positions: P, R, N, D, 2, 1.

Scheme 229

Park

In manual selector lever position P no gear is selected. The parking pawl is engaged manually by the manual selector lever cable and the shift shaft.

For safety reasons, always apply the parking brake whenever the vehicle is parked.

Reverse

In manual selector lever position R reverse gear is selected. REVERSE allows the vehicle to be operated in a rearward direction, at a reduced gear ratio.

Neutral

In manual selector lever position N no gear is selected. The driveline is not locked, so the wheels are free to rotate.

The vehicle may be started in NEUTRAL.

Drive

In manual selector lever position D and when the O/D switch is not pressed, the transmission control allows all the gears to be selected. When the O/D switch is pressed, shifting into 4th gear is prevented or the transmission shifts down to 3rd gear.

1 Position

In manual selector lever position 1 only 1st gear is selected. In addition to the 1st gear one-way clutch, the transmission control closes the reverse gear brake to produce engine braking effect in overrun.

If the manual selector lever is moved to position 1 at an excessive vehicle speed for 1st gear, the transmission control only allows the downshift to take place when the corresponding vehicle speed has been reached.

2 Position

In manual selector lever position 2 only 2nd gear is selected. The transmission control does not allow shifting into 1st gear.

If the manual selector lever is moved to position 2 at an excessive vehicle speed for 2nd gear, the transmission control only allows the downshift to take place when the corresponding vehicle speed has been reached.

Scheme 230

Scheme 231

Scheme 232

Planetary Gear Sets

The individual gears are shifted by means of 2 planetary gear sets, connected one behind the other.

Clutches and Bands

The individual ratios are selected by means of 4 multi-plate clutches, a brake band and a roller one-way clutch.

The components are controlled by the PCM through pulse width modulation (PWM) solenoid valves.

Scheme 233

The torque converter transmits engine torque hydraulically to the transmission input shaft.

The stator boosts the torque to the input shaft (approximately 85% difference in speed between the impeller and the turbine).

The stator is made of synthetic resin to reduce weight.

To increase the efficiency of the automatic transmission, the torque converter has an apply clutch. When the torque converter lock-up clutch is closed, the torque is transmitted directly from the crankshaft through the torque converter housing to the transmission input shaft.

The torque converter clutch is applied hydraulically by the PCM by means of the solenoid valves in the valve body in 3rd and 4th gears. Apply is dependent on the throttle position, vehicle speed and manual selector lever position.

Scheme 234

The fluid pump is a crescent gear pump and is driven directly from the crankshaft by means of drivers on the converter impeller hub. The fluid pump is bolted to the transmission housing.

The stator support is part of the fluid pump. Splines on the support locate and hold the converter stator.

Scheme 235

Scheme 236

The PCM is located under the trim panel on the right-hand A-pillar.

On vehicles with automatic transmissions, the EEC-V PCM controls the transmission in addition to the engine management system. In this case, a module with 104 pins is used.

The PCM evaluates the incoming signals from the individual sensors and actuates the solenoid valves in the valve body of the transmission directly according to the operating state.

Diagnostic checks can be carried out on the transmission through the data link connector (DLC) above the central junction box (CJB).

Emergency Operating Program

If correct gear shifting can no longer be guaranteed due to failure of certain signals, the PCM changes to an emergency operating program.

The driver is informed of the operation of the emergency operating program by the illumination of the powertrain warning indicator in the instrument cluster.

Continued motoring is guaranteed in the following limited conditions

1. Maximum main line pressure
2. Third gear in manual selector lever positions D, 2 and 1 without the torque converter lock-up clutch
3. Reverse gear in manual selector lever position R

Throttle Position (TP) Sensor

The throttle position (TP) sensor is located on the throttle body.

It supplies the PCM with information about the position of the throttle plate.

It also detects the speed of actuation of the throttle plate.

The PCM uses the signals for the following functions among other things

1. to determine the shift timing.
2. to control the main line pressure.
3. to control the torque converter lock-up clutch.
4. for kickdown.

In case of absence of the TP signal the engine control uses the signals of the mass air flow (MAF) and intake air temperature (IAT) sensors as a substitute signal. The main line pressure is increased and hard shifts may occur.

Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor

The MAF sensor is located between the air cleaner housing and the air intake hose leading to the throttle housing.

The IAT sensor is incorporated in the housing of the MAF sensor.

The MAF sensor in conjunction with the IAT sensor provides the PCM with the primary load signal.

The PCM uses the signals for the following functions among other things

1. to control the shift operations.
2. to control the main line pressure.

If the MAF sensor fails, the signal of the TP sensor is used as a substitute.

Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor is located on the engine/transmission flange.

The CKP sensor is an inductive sensor which provides the PCM with information about the engine speed and position of the crankshaft.

The signal is used for the following functions among other things

1. to control the torque converter lock-up clutch.
2. to check the torque converter slip.
3. to control the main line pressure.

No substitute signal is available for the CKP sensor. If the signal is not present, the engine stops.

Turbine Shaft Speed (TSS) Sensor

The turbine shaft speed (TSS) sensor is located in the transmission housing over the transmission input shaft.

The TSS sensor is an inductive sensor which senses the speed of rotation of the transmission input shaft.

The signal is used for the following functions

1. to control the shift operations.
2. to control the torque converter clutch.
3. to check the torque converter slip.

If the TSS sensor fails, the signal of the output shaft speed (OSS) sensor is used as a substitute signal.

Scheme 237

The OSS sensor is located in the transmission housing above the rotor in the differential.

The OSS sensor is an inductive sensor which detects the vehicle speed by means of a rotor on the differential.

The signal is used for the following functions among other things

1. to determine the shift timing.
2. to supply the vehicle speed input signal for the PCM.

If the OSS sensor fails, the signal of the TSS sensor is used as a substitute signal.

Scheme 238

The transmission range (TR) sensor is located on the manual shaft on the transmission housing.

When the manual shaft is moved by means of the manual selector lever cable, an engagement pin in the inner ring of the TR sensor moves through the different positions. The signals are transmitted to the PCM, the reversing lamps and the starter inhibitor relay.

Note. Correct operation of the TR sensor is only guaranteed when the manual selector lever cable is adjusted correctly.

The signals of the TR sensor are used for the following functions

1. to recognize the manual selector lever position.
2. to actuate the starter inhibitor relay.
3. to actuate the reversing lamps.

No substitute signal is available for the TR sensor.

If the connection is cut, the vehicle cannot be started.

Stoplamp Switch

The brake pedal position (BPP) switch is mounted on the brake pedal bracket.

It switches the stoplights on and tells the EEC-V PCM when the brakes are applied.

The signal of the stoplamp switch is used by the PCM for the following functions

1. to release the torque converter lock-up clutch when the brake pedal is depressed.
2. to switch off the manual selector lever shift lock when the brake pedal is depressed in PARK.

No substitute signal is available for the BPP switch.

If the connection to the BPP switch is cut, the manual selector lever cannot be moved out of PARK.

Air Conditioning

If the PCM registers a kickdown signal (WOT, throttle plate opened 95%), the air conditioning is switched off for a maximum of 15 seconds.

Starter Inhibitor Relay

The relay prevents the engine starting in manual selector lever positions R, D, 2 and 1.

The relay obtains the information about the position of the selector lever directly from the TR sensor.

Ignition Key Lock Solenoid

The solenoid is incorporated in the ignition lock. In manual selector lever position P the ground connection to the solenoid is cut. The locking pin does not engage in the ignition lock.

In all the other manual selector lever positions, the ground connection to the solenoid is closed and the locking pin engages in the ignition lock.

When the manual selector lever is not in position P, removal of the ignition key is prevented.

O/D Indicator

The O/D indicator is located in the instrument cluster and is colored green.

Scheme 239

It tells the driver that shifting into 4th gear is prevented by the transmission control.

The O/D light flashes to tell the driver that the transmission control has switched to the emergency operating program or that the transmission fluid temperature is too high.

Know and Understand the Concern

In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer contact may be necessary in order to begin to verify the concern. Understand the conditions as to when the concern occurs, for example

1. Hot or cold vehicle temperature
2. Hot or cold ambient temperature
3. Vehicle driving conditions
4. Vehicle loaded/unloaded

After understanding when and how the concern occurs, proceed to verify the concern.

Verification of Condition

This article provides information that must be used in both determining the actual cause of customer concerns and executing the appropriate procedures.

The following procedures must be used when verifying customer concerns for the engine.

Determine Customer Concern

Note. Some transaxle conditions can cause engine concerns. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the following items

1. Hot or cold vehicle operating temperature
2. Hot or cold ambient temperatures
3. Type of terrain
4. Vehicle loaded/unloaded
5. City/highway driving
6. Upshift
7. Downshift
8. Coasting
9. Engagement
10. Noise/vibration - check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent.

Shift Lever Linkage Check

Check shift lever linkage adjustment by matching the detents in the transaxle range selector lever with those in the transaxle. If they match, the error is in the indicator. Do not adjust the shift linkage.

Hydraulic leakage at the manual control valve can cause delay in engagements and slipping while operating if the linkage is not correctly adjusted. Refer to AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS for shift linkage adjustment.

Check TSBs

Refer to all TSBs which pertain to the transaxle concern and follow the procedure as outlined.

Output State Control (OSC) Mode

Output state control (OSC) allows the technician to take control of certain parameters to function the transaxle. For example, OSC allows the technician to shift the transaxle only when commanding a gear change. If the technician commands 1st gear in OSC, the transaxle will remain in 1st gear until the technician commands the next gear. For another example, the technician can command a shift solenoid to turn ON or OFF when carrying out an electrical circuit check. OSC has 2 modes of operation for transaxle, the BENCH Mode and the DRIVE Mode. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC.

Note. To operate OSC, the transmission range (TR) sensor and the vehicle speed sensor (VSS) must be operational. No diagnostic trouble codes (DTCs) related to the TR sensor or the VSS can be present.

Note. Technician should carry out a key off before initiating any OSC activities in order to clear any previously learned failure mode effects management (FMEM) actions from the vehicle memory.

1. The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to vehicle requirements for each individual test.
2. If the vehicle requirements are NOT MET when SENDING the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted.
3. If, AFTER SENDING an OSC value, the vehicle requirements are no longer met, the PCM will cancel the OSC value and NO ERROR message will appear. Once the vehicle requirements are met again, the PCM will automatically SEND the previous OSC value without any additional actions required by the technician.
4. The OSC value XXX may be sent anytime to cancel OSC.

Output State Control (OSC) Procedures

1. Carry out visual inspection and vehicle preparation as necessary.
2. Select "Vehicle and Engine Selection" menu.
3. Select appropriate vehicle and engine.
4. Select "Diagnostic Data Link."
5. Select "Powertrain Control Module."
6. Select "Diagnostic Test Mode."
7. Select "KOEO On-Demand Self Test and KOER On-Demand Self Tests."
8. Carry out test and record DTCs.
9. Repair all non-transaxle DTCs.
10. Repair all VSS and TR sensor DTCs.
11. Make sure that VSS/TR sensors are functional.
12. Select "Active Command Modes."
13. Select "Output State Control."
14. Select "Trans-Bench Mode or Trans-Drive Mode."

OSC - Transaxle Bench Modes

The following Transaxle BENCH Modes may be used as necessary during diagnostics.

SSA, SSB in Bench Mode

The BENCH Mode allows the technician to carry out electrical circuit checks on the following components

1. SSA - Activates SSA OFF or ON.
2. SSB - Activates SSB OFF or ON.

OSC "SSA/B" BENCH Mode operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Transaxle range selector lever in P.
4. Key ON.
5. Engine OFF.

OSC Command Values

1. OFF - turns solenoid OFF.
2. ON - turns solenoid ON.
3. XXX - cancels OSC sent value.
4. SEND - sends the values to PCM.

BENCH Mode procedure for SSA, SSB

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - SSA, SSB (SS1, SS2)."
6. Select "ON" to turn solenoid ON.
7. Press "SEND" to send command.
8. Select "OFF" to turn solenoid OFF.
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

SSC, SSD and SSE in Bench Mode

The BENCH Mode is also used to test the functionality of pulse width modulated solenoids of the transaxle. During Bench Mode, the SSC/D/E solenoids can ramp in increments of 25% from 0% to 100% duty cycle and 100% to 0% duty cycle.

The OSC functions for the parameters SSC/D/E allow the technician to choose the following options

1. SSC - Activates SSC to selected values.
2. SSD - Activates SSD to selected values.
3. SSE - Activates SSE to selected values.
4. 00 - sets SSC/D/E duty cycle to 00%.
5. 25 - sets SSC/D/E duty cycle to 25%.
6. 50 - sets SSC/D/E duty cycle to 50%.
7. 75 - sets SSC/D/E duty cycle to 75%.
8. 100 - sets SSC/D/E duty cycle to 100%.

OSC "SSC/D/E" BENCH Mode operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Transaxle range selector level in P.
4. Key ON.
5. Engine ON.
6. Engine speed at least 1,500 RPM.
7. Pressure gauge installed (optional).

OSC Command Values

1. 00 - sets SSC/D/E duty cycle to 00%.
2. 25 - sets SSC/D/E duty cycle to 25%.
3. 50 - sets SSC/D/E duty cycle to 50%.
4. 75 - sets SSC/D/E duty cycle to 75%.
5. 100 - sets SSC/D/E duty cycle to 100%.
6. XXX - cancels OSC value sent.
7. SEND - sends the values to PCM.

BENCH Mode procedure for SSC, SSD and SSE

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDS" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - SSC, SSD, SSE."
6. Select Value "0-100 percent."
7. Press "SEND" to send command.
8. Select "XXX" to cancel at any time.
9. Press "SEND" to send command.

PCA in Bench Mode

Note. PCA, EPC and VFS all refer to the solenoids. PCA is preferred for this transmission because the scan tool display PCA.

The BENCH Mode procedure for SSC, SSD and SSE is also used to test the functionality of the transaxle electronic pressure control. During BENCH Mode, the PCA solenoid can ramp in increments of 20 psi from 50 psi to 150 psi and 150 psi to 50 psi.

Note. PCA pressure represents transaxle line pressure. The technician should measure PCA pressure using the line pressure tap.

The OSC function for the parameter PCA allows the technician to choose the following options

1. EPC - Activates PCA to selected values.
2. 50 - sets PCA pressure to 50 psi.
3. 70 - sets PCA pressure to 70 psi.
4. 90 - sets PCA pressure to 90 psi.
5. 110 - sets PCA pressure to 110 psi.
6. 130 - sets PCA pressure to 130 psi.
7. 150 - sets PCA pressure to 150 psi.

OCS "PCA" BENCH Mode should ONLY be operated to check PRESSURE FUNCTIONALITY using an installed pressure gauge when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor are operational.
3. Key ON.
4. Engine ON.
5. Engine speed at least 1,500 rpm.

OSC "PCA" BENCH Mode should ONLY be operated to compete PCA SOLENOID CIRCUIT PINPOINT TESTS when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Transmission range selector lever in P.
4. Key ON.
5. Engine ON.

OSC Command Values

1. 50 - sets PCA pressure to 50 psi.
2. 70 - sets PCA pressure to 70 psi.
3. 90 - sets PCA pressure to 90 psi.
4. 110 - sets PCA pressure to 110 psi.
5. 130 - sets PCA pressure to 130 psi.
6. 150 - sets PCA pressure to 150 psi.
7. XXX - cancels OSC sent value.
8. SEND - sends the values to PCM.

BENCH Mode Procedure for PCA

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - PCA."
6. Select Value "50 - 150 psi."
7. Press "SEND" to send command.
8. Select "XXX" to cancel at any time.
9. Press "SEND" to send the command.

OSC - Transmission Drive Modes

The DRIVE Mode allows control of 3 transaxle parameters. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC. The recommended procedure, when using the DRIVE Mode, is to control one parameter at a time.

The DRIVE Mode allows the technician to carry out the following functions on the transaxle

1. GEAR - allows upshifts or downshifts.
2. TCC - engages or disengages the torque converter clutch.
3. FIRM_SFT - commands a higher control pressure during upshift only.

Electronic Pressure Control solenoid A (EPC) for this transaxle cannot directly be controlled during DRIVE Mode testing. Pressures may be raised during an upshift via the firm shift control function (FIRM_SFT).

GEAR in Drive Mode

This OSC function is used to test the transaxle shift functions.

Note. When the technician commands 1st gear during OSC mode, engine braking is automatically activated for 1st gear. Be aware that normal transaxle operation does not use engine braking in 1st gear.

The OSC function for the GEAR parameter allows the technician to choose the following options

1. 1 - PCM selects 1st gear.
2. 2 - PCM selects 2nd gear.
3. 3 - PCM selects 3rd gear.
4. 4 - PCM selects 4th gear.

OSC "GEAR" Mode operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Engine "ON."
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. Gear selected is equal to or below maximum gear available (PID "GEARTOP").
7. Torque converter clutch must be commanded OFF (PID "TCC"-O percent or OFF).
8. Maximum vehicle speed for downshift into 1st gear is 40 km/h (25 mph).
9. Maximum vehicle speed for downshift into 2nd gear is 97 km/h (60 mph).
10. Maximum vehicle speed for downshift into 3rd gear is 204 km/h (127 mph).
11. Minimum vehicle speed for an upshift to 4th gear is 32 km/h (20 mph).

OSC Command Values

1. 1 - PCM selects 1st gear.
2. 2 - PCM selects 2nd gear.
3. 3 - PCM selects 3rd gear.
4. 4 - PCM selects 4th gear.
5. XXX - cancels OSC sent value.
6. SEND - sends the values to PCM.

Drive Mode Procedure for GEAR

Note. The OSC GEAR Mode is not allowed when the torque converter clutch is commanded ON. The normal transmission strategy may command the torque converter clutch to engage in 3rd gear when using OSC gear. If this occurs, the OSC gear will be cancelled and the PCM will command the normal shift schedule. Therefore, it is advisable to use the OSC "TCC" to command the torque converter clutch OFF before using OSC gear. Refer to TCC IN DRIVE MODE in this article.

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans-Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - GEAR."
6. Select Value "1-4."
7. Press "SEND" to send command.
8. Re-Select Value "1-4."
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND" to send command.

TCC in Drive Mode

This OSC function is used to test whether the torque converter clutch is engaging and disengaging correctly.

The OSC function for the TCC parameter allows the technician to choose the following

1. TCC - activates TCC OFF and ON.
2. ON - turns TCC ON.
3. OFF - turns TCC OFF.

OSC "TCC OFF" DRIVE Mode operates ONLY when

1. VSS and TR sensors are operational.
2. No VSS and TR sensor DTCs present.
3. Engine ON.
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. No transaxle gear shifts are in progress.

OSC "TCC ON" DRIVE Mode operates ONLY when

1. VSS and TR sensors are operational.
2. No VSS and TR sensor DTCs present.
3. Engine "ON".
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. Transaxle in second or higher gear.
7. TFT is between 16°C and 133°C (60°F and 270°F).
8. Brake is "OFF" when vehicle speed is below 20 mph.
9. Engine speed at least 1,500 RPM.
10. Speed ratio across the converter (PID "TCCRAT") is between 0.70 and 1.05.
11. No transaxle gear shifts are in progress.

OSC Command Values

1. OFF - Turns TCC OFF.
2. ON - Turns TCC ON.
3. XXX - Cancels OSC value sent.
4. SEND - Sends the values to PCM.

DRIVE Mode Procedure for TCC

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - TCC."
6. Select "ON" to turn TCC ON.
7. Press "SEND" to send command.
8. Select "OFF" to turn TCC OFF.
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND" to send command.

FIRM_SFT in Drive Mode

This OSC function is used to raise pressure during an upshift to determine whether the pressure control system is functioning correctly. Firmer shifts indicate that the pressure control system works at higher pressure. The best test for isolating pressure control system problems is to carry out the EPC solenoid test in BENCH Mode using a hydraulic pressure gauge.

The OSC functions for the parameter FIRM_SFT allows the technician to choose the following options

1. FIRM_SFT - Activates the firm shift channel.
2. ON - sets control pressure high for all upshifts (determined by the PCM).
3. OFF - sets control pressure to normal for all upshifts (determined by the PCM).

OSC "FIRM_SFT" DRIVE Mode operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs present.
3. Transaxle range selector lever in O/D.
4. Engine "ON."
5. Key "ON."
6. Vehicle speed greater than 2 mph.
7. TCC cannot be forced ON using NGS OSC mode (PID "OSCTCC" not equal to ON)

OSC Command Values

1. ON - sets control pressure high for all upshifts (determined by the PCM)
2. OFF - sets control pressure to normal for all upshifts (determined by the PCM)
3. XXX - cancel OSC for FIRM_SFT
4. SEND - sends the values to the PCM DRIVE Mode procedure for FIRM_SFT

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - FIRM_SFT."
6. Select "ON" to turn Firm Shift Mode ON.
7. Select "SEND" to send command.
8. Select "OFF" to turn Firm Shift Mode OFF.
9. Select "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Select "SEND" to send command.

Using Output State Control (OSC) and Accessing PIDs

To confirm that the OSC value was sent by the NGS and the PCM has accepted the OSC substitution, a corresponding PID or PIDs for each OSC parameter should be monitored. Additional PIDs should be monitored to help the technician adequately diagnose the transaxle.

The following is a list of OSC parameters and their corresponding PIDs

DIAGNOSTIC PARAMETERS IDENTIFICATION (PID) CHART

To confirm that the OSC substitution occurred, SEND the OSC value and monitor the corresponding PID value. If no ERROR MESSAGE was received and the value of the corresponding PID is the same as the value sent from OSC, then the OSC substitution was successful.

The following general PID list may be of use to the technician when exercising OSC

DIAGNOSTIC PARAMETERS IDENTIFICATION (PID) CHART

Before Pinpoint Tests

Note. Before entering pinpoint tests, check the powertrain control module wiring harness for correct connections, bent or broken pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and actuators for damage. Refer to the INTRODUCTION - GASOLINE .

Note. If a concern still exists after electrical diagnosis, refer to DIAGNOSIS BY SYMPTOM in this article.

If DTCs appear while carrying out the on-board diagnostics, refer to DIAGNOSTIC TROUBLE CODE (DTC) CHARTS for the appropriate repair procedure. Prior to entering pinpoint tests, refer to any TSBs for transaxle concerns.

Pinpoint Tests - OSC Equipped Vehicle

SPECIAL TOOL(S) 73 III Automotive Meter 105-R0057 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool Pressure Gauge Assembly 307-004 (T57L-77820-A)

Scheme 240

Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary.

Engine Idle Speed Check

Refer to the INTRODUCTION - GASOLINE for diagnosis and testing of the engine idle speed.

Engagement Concern: No Forward In O/D Only

ENGAGEMENT CONCERN: NO FORWARD IN O/D ONLY

Engagement Concern: No Forward Only (All Positions)

ENGAGEMENT CONCERN: NO FORWARD ONLY (ALL POSITIONS)

Engagement Concern: No Reverse

ENGAGEMENT CONCERN: NO REVERSE

Engagement Concern: Harsh Reverse Only

ENGAGEMENT CONCERN: HARSH REVERSE ONLY

Engagement Concern: Harsh Forward Only

ENGAGEMENT CONCERN: HARSH FORWARD ONLY

ENGAGEMENT CONCERN: HARSH FORWARD ONLY

Engagement Concern: Delayed/Soft Reverse Only

ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE ONLY

Engagement Concern: Delayed/Soft Forward

ENGAGEMENT CONCERN: DELAYED/SOFT FORWARD

Engagement Concerns: No Forward And No Reverse

ENGAGEMENT CONCERNS: NO FORWARD AND NO REVERSE

Engagement Concerns: Harsh Forward And Reverse

ENGAGEMENT CONCERNS: HARSH FORWARD AND REVERSE

Engagement Concerns: Delayed/Soft Forward And Reverse

ENGAGEMENT CONCERNS: DELAYED/SOFT FORWARD AND REVERSE

Shift Concerns: Some/All Shifts Missing (Automatic Mode Only)

SHIFT CONCERNS: SOME/ALL SHIFTS MISSING (AUTOMATIC MODE ONLY)

Shift Concerns: Timing Concerns - Early/Late

SHIFT CONCERNS: TIMING CONCERNS - EARLY/LATE

Shift Concerns: Timing Concerns - Erratic/Hunting

SHIFT CONCERNS: TIMING CONCERNS - ERRATIC/HUNTING

Shift Concerns: Feel - Soft/Slipping

SHIFT CONCERNS: FEEL - SOFT/SLIPPING

Shift Concerns: Feel - Harsh (Some/All)

SHIFT CONCERNS: FEEL - HARSH (SOME/ALL)

Shift Concerns: No 1st Gear In Drive, Engages In Higher Gear

SHIFT CONCERNS: NO 1ST GEAR IN DRIVE, ENGAGES IN HIGHER GEAR

Shift Concerns: No 1st Gear In Manual 1st

SHIFT CONCERNS: NO 1ST GEAR IN MANUAL 1ST

Shift Concerns: No Manual 2nd Gear

SHIFT CONCERNS: NO MANUAL 2ND GEAR

Shift Concern: No 1-2 Shift

SHIFT CONCERN: NO 1-2 SHIFT

Shift Concern: No 2-3 Shift

SHIFT CONCERN: NO 2-3 SHIFT

Shift Concern: No 3-4 Shift

SHIFT CONCERN: NO 3-4 SHIFT

Shift Concern: No 4-3 Shift

SHIFT CONCERN: NO 4-3 SHIFT

Shift Concern: No 3-2 Shift

SHIFT CONCERN: NO 3-2 SHIFT

Shift Concern: No 2-1 Shift

SHIFT CONCERN: NO 2-1 SHIFT

Shift Concern: Soft/Slipping 1-2

SHIFT CONCERN: SOFT/SLIPPING 1-2

Shift Concern: Soft/Slipping 2-3

SHIFT CONCERN: SOFT/SLIPPING 2-3

Shift Concern: Soft/Slipping 3-4

SHIFT CONCERN: SOFT/SLIPPING 3-4

Shift Concern: Soft/Slipping 4-3

SHIFT CONCERN: SOFT/SLIPPING 4-3

Shift Concern: Soft/Slipping 3-2

SHIFT CONCERN: SOFT/SLIPPING 3-2

Shift Concern: Soft/Slipping 2-1

SHIFT CONCERN: SOFT/SLIPPING 2-1

Shift Concern: Harsh 1-2 Shift

SHIFT CONCERN: HARSH 1-2 SHIFT

Shift Concern: Harsh 2-3 Shift

SHIFT CONCERN: HARSH 2-3 SHIFT

Shift Concern: Harsh 3-4 Shift

SHIFT CONCERN: HARSH 3-4 SHIFT

Shift Concern: Harsh 4-3 Shift

SHIFT CONCERN: HARSH 4-3 SHIFT

Shift Concern: Harsh 3-2 Shift

SHIFT CONCERN: HARSH 3-2 SHIFT

Shift Concern: Harsh 2-1 Shift

SHIFT CONCERN: HARSH 2-1 SHIFT

Other Concerns: Shift Lever Efforts High

OTHER CONCERNS: SHIFT LEVER EFFORTS HIGH

Other Concerns: External Leaks

OTHER CONCERNS: EXTERNAL LEAKS

Other Concerns: Poor Vehicle Performance

OTHER CONCERNS: POOR VEHICLE PERFORMANCE

Other Concerns: Engine Will Not Crank

OTHER CONCERNS: ENGINE WILL NOT CRANK

Other Concerns: No Park Range

OTHER CONCERNS: NO PARK RANGE

Other Concerns: Overheating

OTHER CONCERNS: OVERHEATING

Other Concerns: No Engine Braking In Manual 1

OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1

Other Concerns: Slips/Chatters In 1st Gear

OTHER CONCERNS: SLIPS/CHATTERS IN 1ST GEAR

Other Concerns: Slips/Chatters In 2nd Gear

OTHER CONCERNS: SLIPS/CHATTERS IN 2ND GEAR

Other Concerns: Slips/Chatters In 3rd Gear

OTHER CONCERNS: SLIPS/CHATTERS IN 3RD GEAR

Other Concerns: No Engine Braking In All Gears

OTHER CONCERNS: NO ENGINE BRAKING IN ALL GEARS

Materials

MATERIALS

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1. Remove the fluid pan. For additional information, refer to «TRANSMISSION FLUID PAN»(ref-255393-S09613262712007053100000) in this article.
2. Disconnect the transmission fluid temperature (TFT) sensor electrical connector.
3. Remove the fluid filter. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.
4. Remove the ground wire bolt. Disconnect the electrical connectors and remove the main control wiring harness. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid PCA; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black). NOTE: Note the locations of the 2 long bolts.
5. Remove the main control valve body and accumulators. NOTE: Each accumulator is equipped with 2 springs. All 4 springs are different sizes. NOTE: Note the size and location of the accumulator springs to aid assembly. NOTE: Note the shape of each piston and the piston bore from which the piston was removed. The shape and size will vary depending on application. The piston must be installed in its correct bore during assembly.
6. Remove the accumulator pistons and springs.

MATERIALS

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1. Remove the battery tray. For additional information, refer to «BATTERY MOUNTING AND CABLES»(ref-255404) .
2. Remove the air cleaner assembly. Disconnect the crankcase ventilation hose. Disconnect the air cleaner outlet hose. Remove the bolts and pull out the air cleaner resonator. NOTE: The resonator is plugged into the bracket.
3. Remove the air cleaner intake hose with the resonator.
4. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
5. Remove the TSS sensor bolt and sensor. Check the TSS sensor bore.
6. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.

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1. Apply a light coat of clean automatic transmission fluid to the O-ring seal before installation. CAUTION: Apply thread sealer to the bolt.
2. Install the TSS sensor and bolt. Tighten to 10 Nm (89 lb-in).
3. Connect the TSS sensor electrical connector. NOTE: The resonator is plugged into the bracket.
4. Instal the air cleaner intake hose with the resonator.
5. Install the air cleaner assembly. Connect the crankcase ventilation hose. Connect the air cleaner outlet hose. Position the air cleaner into the resonator and install the bolts.
6. Install the battery tray. For additional information, refer to «BATTERY MOUNTING AND CABLES»(ref-255404) .

Output Shaft Speed (OSS) Sensor

MATERIALS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-255374) .
2. Place a drain pan beneath the output shaft speed (OSS) sensor.
3. Remove the OSS sensor. Disconnect the electrical connector. Remove the bolt. Inspect the OSS bore.
4. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.

Halfshaft Seal - LH

SPECIAL TOOL(S) Slide Hammer 100-001 (T50T-100-A) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Remover, Halfshaft 205-241 (T86P-3541-A) Installer, Axle Oil Seal 205-259 (T87P-3254-A) Remover, Tie-Rod End 211-001 (TOOL-3290-D)

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1. Loosen the strut and spring assembly top mount nuts by 5 turns. CAUTION: Leave the tie-rod end retaining nut in place to protect the ball joint stud.
2. Loosen the tie-rod end retaining nut. CAUTION: Protect the ball joint seal using a soft cloth to prevent damage.
3. Using the special tool, detach the tie-rod from the wheel knuckle. Remove and discard the retaining nut.
4. Detach the lower arm from the wheel knuckle. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
5. Using the special tools, detach the halfshaft from the transaxle. Allow the oil to drain into a suitable container.
6. Remove the halfshaft seal.

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1. Using the special tools, install the halfshaft seal. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees. CAUTION: Do not damage the halfshaft seal. CAUTION: Make sure the snap ring is correctly seated.
2. Attach the halfshaft to the transaxle.
3. Attach the lower arm to the wheel knuckle. Tighten to 63 Nm (46 lb-ft). WARNING: Install a new tie-rod end retaining nut. Failure to follow this instruction may result in personal injury.
4. Attach the tie-rod end to the wheel knuckle. Tighten to 40 Nm (30 lb-ft).
5. Tighten the strut and spring assembly top mount nuts. Tighten to 35 Nm (26 lb-ft).
6. Check the transmission fluid level and top off with automatic transmission fluid, if necessary.

Halfshaft Seal - RH

SPECIAL TOOL(S) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Installer, Output Shaft Seal 307-572

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1. Loosen the strut and spring assembly top mount nuts by 5 turns.
2. Detach the lower arm from the wheel knuckle.
3. Remove and discard the center bearing cap and locknuts.
4. Detach the halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container.
5. Remove the halfshaft seal.

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1. Using the special tools, install the halfshaft seal. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees. CAUTION: Do not damage the halfshaft seal.
2. Install the halfshaft into the transaxle. NOTE: Install a new halfshaft bearing cap and locknuts.
3. Install the center bearing cap and locknuts. Tighten to 25 Nm (18 lb-ft).
4. Attach the lower arm to the wheel knuckle (LH side shown). Tighten to 63 Nm (46 lb-ft).
5. Tighten the strut and spring assembly top mount nuts. Tighten to 35 Nm (26 lb-ft).
6. Check the transmission fluid level and top off with automatic transmission fluid, if necessary.

Transmission Range (TR) Sensor

SPECIAL TOOL(S) Alignment Tool, Transmission Range Sensor 307-415

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1. Disconnect the transmission range (TR) sensor electrical connector and the selector lever cable. NOTE: Failure to hold the shift lever while loosening or tightening the manual shaft lever will transmit rotational torque to the TR switch and shift mechanism.
2. Remove the TR sensor (automatic transaxle shown removed for clarity). Remove the manual control lever. Remove the bolts.

MATERIALS

MATERIALS

MATERIALS

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1. Remove the top portion of the pump.
2. Inspect the lower portion of the pump and gear pocket for nicks, scratches, gouges or wear.
3. Remove the pump seal.
4. Inspect the upper portion of the pump for nicks, scratches or gouges.
5. Inspect the pump gears for nicks, scratches or gouges.

Forward Clutch

SPECIAL TOOL(S) Compressor, Spring Washer 307-209 Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)

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MATERIALS

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1. Remove the forward clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, install the forward clutch assembly in a suitable press.
3. Using the special tool, remove the forward clutch balance piston snap ring. CAUTION: If damage is found to the forward clutch balance piston seals, install a new balance piston.
4. Remove and inspect the forward clutch balance piston.
5. Remove the forward piston return spring. CAUTION: If damage is found to the forward clutch piston seals, install a new forward clutch piston.
6. Remove the forward clutch piston assembly.

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1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Inspect the forward clutch piston bore surfaces for nicks or scratches. Install a new balance piston if necessary.
3. Lubricate and install the forward clutch piston assembly.
4. Install the forward piston return spring.
5. Lubricate and install the forward clutch balance piston.
6. Using the special tool, install the forward clutch assembly in a suitable press.
7. Using the special tool, install the forward clutch balance piston snap ring.
8. Install the forward clutch pressure, friction and steel plates. Install the plates. Install the retaining ring.
9. Measure the clutch pack clearance. Install the forward clutch on the pump assembly. Install the special tool. Mount the dial indicator holding fixture on the pump assembly and position the dial indicator plunger on the pressure plate. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the dial indicator in 3 different areas. Average the measurements.
10. Compare the forward clutch pack clearance to the specification (1.5-1.8 mm [0.0590-0.0708] in). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance. COMPONENTS THICKNESS REFERENCE Part Number Thickness - 1.15-1.25 mm (0.0452-0.0492 in) - 1.35-1.45 mm (0.0531-0.0570 in) - 1.55-1.65 mm (0.0610-0.0649 in) - 1.75-1.85 mm (0.0688-0.0728 in) - 1.95-2.05 mm (0.0767-0.0807 in) - 2.15-2.25 mm (0.0846-0.0885 in)

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1. Remove the reverse drum snap ring.
2. Remove the sun gear.
3. Remove the sun gear thrust bearing.
4. Remove the direct clutch hub.
5. Remove the direct clutch thrust bearing.
6. Remove the direct clutch assembly.

Direct Clutch

SPECIAL TOOL(S) Compressor, Spring Washer 307-209 Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)

MATERIALS

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1. Remove the direct clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the selective snap ring.
3. Remove the direct clutch balance piston.
4. Remove the direct clutch return spring. CAUTION: If damage is found on the direct clutch piston seals, install a new direct clutch piston.
5. Remove and inspect the direct clutch piston.

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1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Inspect the direct clutch piston bore surfaces for nicks or scratches. Install a new direct clutch piston if necessary.
3. Lubricate and install the direct clutch piston.
4. Install the direct clutch return spring.
5. Install the direct clutch balance piston.
6. Using the special tool, install the selective snap ring.
7. Install the direct clutch pressure, friction and steel plates. Install the plates. Install the retaining ring.
8. Measure the clutch pack clearance. Install the direct clutch on the transaxle end cover. Install the special tool. Mount the dial indicator holding fixture on the transaxle end cover and position the dial indicator plunger on the pressure plate. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the dial indicator in 3 different areas. Average the measurements.
9. Compare the direct clutch pack clearance to the specification (1.0-1.3 mm [0.0393-0.0511 in]). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance. COMPONENTS THICKNESS REFERENCE Part Number Thickness - 1.15-1.25 mm (0.0452-0.0492 in) - 1.35-1.45 mm (0.0531-0.0570 in) - 1.55-1.65 mm (0.0610-0.0649 in) - 1.75-1.85 mm (0.0688-0.0728 in) - 1.95-2.05 mm (0.0767-0.0807 in) - 2.15-2.25 mm (0.0846-0.0885 in)

Reverse Clutch

SPECIAL TOOL(S) Compressor, Clutch Spring 307-015 (T65L-77515-A)

MATERIALS

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1. Remove the reverse clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the reverse clutch piston return spring retainer ring and retainer.
3. Remove the reverse clutch piston return spring.
4. Remove the reverse clutch piston assembly. CAUTION: If damage is found to the reverse clutch piston seals, install a new reverse clutch piston.
5. Inspect the seal bore in drum, inner and outer seals.

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1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Lubricate and install the reverse clutch piston assembly.
3. Install the reverse clutch piston return spring.
4. Using the special tool, install the reverse clutch piston return spring retainer and retainer ring.
5. Install the reverse clutch pressure, friction and steel plates. Install the plates. Install the retaining ring. Check the clearance. For additional information, refer to «SPECIFICATIONS»(ref-255393-S24194255792007053100000) in this article.

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1. Inspect the planet internal bearing for damage.
2. Remove the snap ring.
3. Remove the rear planet assembly.
4. Remove the thrust bearing.
5. Remove the forward planet sun gear.
6. Remove the thrust bearing.
7. Remove the forward planet assembly.
8. Inspect the low and reverse ring gear.
9. Remove the top retainer of the one-way clutch.
10. Remove the top one-way clutch ring.
11. Remove the low one-way clutch assembly.
12. Remove the lower one-way ring.

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1. Install the lower one-way ring.
2. Inspect the rollers and the springs of the one-way clutch.
3. Make sure the low one-way clutch is installed with the tab pointing in the direction as shown.
4. Install the low one-way clutch.
5. Install the top one-way clutch ring.
6. Install the top retainer of the one-way clutch.
7. Install the forward planet assembly.
8. Install the thrust bearing.
9. Inspect the front sun gear retaining ring.
10. Install the forward planet sun gear.
11. Install the thrust bearing.
12. Install the rear planet assembly.
13. Install the snap ring.

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1. Remove the solenoid body bolts and the solenoid body.
2. Remove and discard the solenoid body gaskets.
3. Remove and discard the seals.
4. Disassemble the main control valve body.

Transaxle

SPECIAL TOOL(S) Alignment Tool, Transmission Range Sensor 307-415 Handle, Torque Converter 307-091 (T81P-7902-C) Installer, Differential Bearing Cup 205-118 (T77F-4222-A) Installer, Differential Fluid Seal 307-256 (T92P-77000-FH) Select Gauge, Transmission Band 307-416 Shim Gauge, Differential/Transfer Gear Bearing 307-417 Installer, Axle Oil Seal 205-259 (T87P-3254-A) Holding Tool, Final Drive Input Gear 307-413 Mounting Bracket, Transmission 307-410 Installer, Drive Pinion Bearing Cup 205-024 (T67P-4616-A) Installer, Transfer Gear Bearing Cup 307-418 Shim Selection Set 308-164 (T88C-77000-JF) Plate, Bearing/Oil Seal 205-090 (T75L-1165B) Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Installer, Output Shaft Seal 307-572 Socket, Final Drive Input Nut 307-414 Shim Selection Set 308-161 (T88C-77000-C) Wrench Guide Plate 307-420 Retainer, Torque Converter 307-346 (T97T-7902-A)

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MATERIALS

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1. Using the special tool, install the final drive input gear bearing. Install the final drive input gear bearing. Install the special tool.
2. Using an arbor press and the special tools, seat the final drive input gear bearing.
3. Install a new collapsible spacer.
4. Using the special tool, position the final drive input gear. CAUTION: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case.
5. Rotate the transaxle 180 degrees.
6. Using the special tools, install the final drive input gear bearing.
7. Rotate the transaxle 180 degrees.
8. Using the special tool, lock the final drive input gear.
9. Rotate the transaxle 180 degrees. NOTE: A high tightening torque specification of 400 Nm (295 lb-ft) is necessary to crush the collapsible spacer for correct bearing preload. NOTE: If the preload is too high, a new collapsible spacer must be installed.
10. Using the special tools, tighten the nut to achieve the preload specification.
11. Rotate the transaxle 180 degrees. NOTE: Make sure that the final drive rotates.
12. Unlock the special tool.
13. Rotate the transaxle 180 degrees. CAUTION: Make sure the bearing preload is between 0.4-0.7 Nm (3.5-6.2 lb-in). NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.
14. Using the special tools, measure the rotating torque. Rotational torque is 0.4-0.7 Nm (3.5-6.2 lb-in).
15. After achieving the correct torque, remove the special tools and stake the nut to prevent movement.
16. Rotate the transaxle 180 degrees.
17. Position the transfer shaft gears in the transaxle case.
18. Install the parking pawl return spring.
19. Connect the spring. Install the parking pawl abutment. Install the lever. Install the pin. Connect the spring.
20. Install the parking pawl assembly cover and bolts. Tighten to 13 Nm (10 lb-ft).
21. Install the differential case assembly.
22. Position the bearing cups.
23. Install the special tools. CAUTION: Do not use the bolts from special service kit 308-164 they will not work. Use only the bolts from the special service kit 308-161. NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.
24. Using the special tools, assemble the transaxle for end play measurement. Position the converter housing. Install the special tool bolts and seat the case cover flat. Tighten to 5 Nm (44 lb-in).
25. Remove the converter housing. Remove bolts. Remove the converter housing.
26. Remove the special tools.
27. Remove the bearing cups. NOTE: If the plunger is above the contact surface, the reading will be incorrect.
28. To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim. For additional information, refer to «SPECIFICATIONS»(ref-255393-S24194255792007053100000) in this article. NOTE: If the plunger is above the contact surface, the reading will be incorrect.
29. To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim. For additional information, refer to «SPECIFICATIONS»(ref-255393-S24194255792007053100000) in this article.
30. Using the special tool, install the correct transfer shaft shim and bearing cup into the converter housing.
31. Using the special tool, install the correct differential shaft shim and differential case bearing cup into the converter housing.
32. Apply a 1 mm (0.04 in) thick bead of sealer to the case half.
33. Position the converter housing on the transaxle case and install the bolts. Tighten to 22 Nm (16 lb-ft).
34. Install the intermediate/overdrive band servo piston return spring.
35. Install the intermediate/overdrive servo piston.
36. Install the O-ring seal. NOTE: The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.
37. Install the intermediate/overdrive band servo piston cover. Tighten to 13 Nm (10 lb-ft).
38. Install the shifter assembly and bolt. Tighten to 13 Nm (10 lb-ft). NOTE: Lubricate the O-ring with clean automatic transmission fluid prior to assembly.
39. Install the new O-rings on the manual lever shaft.
40. Install the manual lever shaft. NOTE: The roll pin does not need to sit flush with the shifter assembly.
41. Install a new manual lever shaft roll pin.
42. Loosely install the transmission range (TR) sensor. NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.
43. Install the thinner and longer neutral drive accumulator springs.
44. Install the neutral drive accumulator piston.
45. Install the 1-2 accumulator springs.
46. Install the 1-2 accumulator piston.
47. Inspect the seals. Lubricate the seals in clean automatic transmission fluid. Install the transaxle internal harness electrical connector. NOTE: Make sure that the manual valve is in the manual control valve shift lever. NOTE: Do not fully tighten the bolts at this stage.
48. Install the main control valve body.
49. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown. Tighten to 9 Nm (80 lb-in). NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.
50. Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid PCA; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black). Tighten to 10 Nm (89 lb-in).
51. Install the fluid filter.
52. Connect the transmission fluid temperature (TFT) sensor. NOTE: Do not use more than the specified amount of sealer on the pan or internal transaxle damage could occur.
53. Apply a bead 1.5 mm (0.06 in) diameter of sealer to the transmission fluid pan.
54. Install the transmission fluid pan. Tighten to 10 Nm (89 lb-in).
55. Rotate the transaxle 180 degrees.
56. Install the low/reverse clutch piston. NOTE: Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.
57. Install the low/reverse clutch return spring.
58. Install the wave spring.
59. Install the low one-way clutch inner race. NOTE: The opening of the retaining ring must be at the 10 o'clock position.
60. Install the low one-way clutch retaining ring.
61. Install the low/reverse plates and pressure plate.
62. Install the low reverse clutch plate selective retaining ring. Check the clutch clearance. NOTE: Make sure that the snap ring is installed before installing the planet assembly.
63. Install the planet assembly. CAUTION: The edge of the planet assembly must fit flush with the transaxle case.
64. Inspect the planet assembly installation. CAUTION: The planet assembly must only rotate counterclockwise.
65. Check to make sure that the one way clutch is correctly installed. Rotate the planet assembly clockwise and counterclockwise.
66. Install the intermediate/overdrive drum assembly.
67. Install the intermediate/overdrive band.
68. Install the direct clutch cylinder thrust bearing with the rollers facing up.
69. Install new end cover-to-case seals.
70. Install new end cover seals.
71. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater. CAUTION: Failure to support the transaxle end cover in the center can result in inaccurate measurements.
72. Measure the gap between the transaxle end cover and the transaxle assembly. Position the transaxle end cover on the transaxle assembly. Support the transaxle end cover in the center. Measure the gap between the transaxle end cover and the transaxle assembly.
73. Remove the transaxle end cover. NOTE: The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.001-0.020 in). NOTE: The correct shim thickness is between minimum and maximum.
74. Choose and install the correct direct clutch hub bearing shim: Line 1: total amount of shim thickness used during transaxle end cover mock up. Line 2: measure the gap between transaxle end cover and transaxle case. Line 3: subtract Line 2 from Line 1 to obtain the actual clearance. Line 4: subtract 0.25 mm (0.001 in) from Line 3 for maximum shim thickness. Subtract 0.50 mm (0.020 in) from Line 3 for the minimum thickness shim. CAUTION: Applying too much sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.
75. Apply a 1 mm (0.04 in) bead of sealer to the transaxle end cover.
76. Install the transaxle end cover. Tighten to 22 Nm (16 lb-ft).
77. Using the special tool, collapse the intermediate/overdrive band. Tighten to 5 Nm (44 lb-in), then back out three 1/2 turns.
78. Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.
79. Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown. NOTE: Apply thread sealer to the bolt.
80. Install the intermediate/overdrive band anchor bolt. Tighten to 45 Nm (33 lb-ft).
81. Rotate the transaxle 180 degrees.
82. Install the forward clutch hub.
83. Install the forward clutch assembly.
84. Install the forward clutch thrust washer.
85. Install new fluid pump seals and lubricate with clean automatic transmission fluid.
86. Install the fluid pump (do not force the pump down at this time).
87. Install the fluid pump bolts. Use the bolts to seat the fluid pump. Tighten the bolts in a crisscross pattern. Tighten to 30 Nm (22 lb-ft).
88. Install the output shaft speed (OSS) sensor. Tighten to 10 Nm (89 lb-in). NOTE: Apply thread sealer to the bolt.
89. Install the turbine shaft speed (TSS) sensor. Tighten to 10 Nm (89 lb-in).
90. Using the special tool, align the TR sensor and tighten the bolts. Tighten to 10 Nm (89 lb-in). CAUTION: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt.
91. Install the manual control lever. Tighten to 30 Nm (22 lb-ft).
92. Install the vent cap past the second detent notch.
93. Using the special tool, install the LH halfshaft seal.
94. Using the special tool, install the RH halfshaft seal.
95. Install the differential opening cover.
96. Install the torque converter.
97. Using the special tool, secure the torque converter.
98. Remove the special tool from the transaxle.

MATERIALS

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

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Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

1. Make sure that the torque converter is installed correctly. CAUTION: Lubricate the torque converter pilot hub with multi-purpose grease.
2. Check the installation depth of the torque converter. Lay a steel straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
3. Remove the special tool.
4. If the transaxle was replaced, install the transaxle opening cover.
5. Using a high-lift jack, secure the transaxle using a safety strap. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
6. Move the transaxle into position.
7. Note the location of the different length bolts and install the 5 converter housing bolts. Tighten to 47 Nm (35 lb-ft).
8. Install the 3 converter housing bolts. Tighten to 47 Nm (35 lb-ft). CAUTION: Only rotate the engine in a clockwise direction or engine damage will occur. NOTE: Only install new self-locking nuts.
9. Install 4 new torque converter-to-flexplate nuts. Tighten to 40 Nm (30 lb-ft).
10. Remove the safety strap from the transaxle. NOTE: Inspect the O-ring for damage before installing the fluid filler tube.
11. Install the fluid filler tube. Tighten to 8 Nm (71 lb-in).
12. Install the engine rear mount bracket. Tighten to 80 Nm (59 lb-ft). NOTE: Using the engine support bar, raise the engine and transaxle assembly slightly to install rear mount.
13. Install the engine rear mount and nuts. Tighten to 48 Nm (35 lb-ft). Tighten to 150 Nm (111 lb-ft).
14. Install the fluid cooler tubes.
15. Connect the output shaft speed (OSS) sensor electrical connector. NOTE: Install a new snap ring.
16. Install the LH drive halfshaft. NOTE: Install new nuts and a new center bearing cap.
17. Install the RH halfshaft together with the intermediate shaft.
18. Install the mounting bracket for the halfshaft intermediate bearing. Tighten to 25 Nm (18 lb-ft).
19. Install both of the lower control arms to the knuckles. Tighten to 63 Nm (46 lb-ft).
20. Install both of the tie-rod ends to the knuckles. Tighten to 40 Nm (30 lb-ft).
21. Connect the stabilizer bar at the strut. Tighten to 55 Nm (41 lb-ft).
22. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-255382) .
23. Install the engine RH support insulator. Install the insulator bolt and nut. Tighten to 48 Nm (35 lb-ft). Install the bolt. Tighten to 48 Nm (35 lb-ft).
24. Install the starter isolator.
25. Install the starter motor and insert the 3 bolts. Tighten to 35 Nm (26 lb-ft).
26. Connect the oil sending unit.
27. Connect the starter motor electrical connectors.
28. Connect the bracket to the starter stud.
29. Install the fluid filler tube and shift cable bracket bolts. Tighten to 20 Nm (15 lb-ft). Tighten to 8 Nm (71 lb-in).
30. Note the location of the different length bolts and install the upper center converter housing bolts. Tighten to 47 Nm (35 lb-ft).
31. Position the electrical connector bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
32. Install the electrical connector bracket nut. Tighten to 25 Nm (18 lb-ft).
33. Install the shift cable clip. Tighten to 47 Nm (35 lb-ft).
34. Connect the turbine shaft speed (TSS) sensor electrical connector.
35. Connect the shift cable to the manual control lever. NOTE: The TR connector seal is a high compression type and requires a "press to click" installation for a weatherproof seal.
36. Connect the electrical connectors. Transmission range (TR) sensor. Transaxle solenoid electrical connector.
37. Tighten the LH strut and spring assembly top mount nuts. Tighten to 30 Nm (22 lb-ft).
38. Install the air cleaner resonator. Install the resonator and nuts. Connect the air cleaner outlet hose. Connect the crankcase ventilation hose. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn the strategy.
39. Install the battery tray and battery. For additional information, refer to «BATTERY MOUNTING AND CABLES»(ref-255404) .
40. Fill the transaxle with clean automatic transmission fluid.