parts catalogue manual

1. SERVICE MANUAL &
TECHNICAL BULLETIN
SERVICE MANUAL &
TECHNICAL BULLETIN
MODEL J01-J02 SERIES
SERVICEMANUAL
TECHNICALBULLETIN
MODEL
DX
SERIES

2. AUTOMATIC TRANSMISSION
(AT)
MODEL JOl & J02 SERIES
CONTENTS
SERVICE DATA AND SPECIFICATIONS , AT- 2
GENERAL SPECiFiCATIONS AT- 2
INSPECTION AND ADJUSTMENT AT- 2
TIGHTENING TORQUE AT- 4
TROUBLE DIAGNOSES AND CORRECTIONS AT- 5
OIL CIRCUIT AT- 8
OIL PRESSURE CIRCUIT DIAGRAM AT-10
AUTOMATIC TRANSMiSSiON AT-14
CONSTRUCTION AT-14
REMOVAL AND INSTAllATION AT-15
DISASSEMBLY . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT -16
ASSEMBLY AT-20
TEST AT-21
ADJUSTMENT , AT-23
SPECIAL SERVICE TOOLS , AT-25

3. Type
Clutch
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Torque converter
Type
1-speed AIT
Symmetrical, 3-element, 1-stage, 2-phase torque converter
Model J01 J02
Engine H15 T027 H2O-II H25 T027 8030
--
NF27L NF27H NF27L NF27H NF27H NF27H
Stall torque ratio
3.2: 1 2.8: 1 3.2: 1 2.8: 1 2.8: 1 2.8: 1
Transmission
____ ._. __ I 1_-s_
p
_e_e_d_f_o_rw_a_r_d_a_n_d_1-_sp_e_e_d_r_e_v__e_rs_e_,_co_n_s_t_an_t_-m_e_sh _
r Multi-disc clutch
---N-u-m-b-e-r -of--d-ri-ve-p.l.a-te----.-----t,l.--------_-- r=-- --------------Forward 1st 5 6
!
NU::::
r
:: dri~~1~tlate ---f- 5___ L ------:---
::~:r~;~_~::II . ~ __ ._____ _ 6 _
Gear ratio
Forward 1st I', 3.105
Reverse 1st 3.105
Oil pump .~. r=-=__ T_y_p_e .. In_t_e_rn_a_I_ly_i_n_te_r_m_e_s_h_in_g_i_n_vo_I_U_te_ge_a_r_p_u_m_p _
Automatic transmission fluid OEXRON™ or M2C-33E or F
Lubrication system
Cooling system
INSPECTION AND ADJUSTMENT
TORQUE CONVERTER
Unit: mm (in)
Forced lubrication by oil pump
Water-cooled by oil cooler
Lateral ru nout of drive plate
Standard
Service limit
0.0. of oil seal
contacting portion of sleeve
0.2 (0.008)
0.5 (0.020)
41.915 - 41.965
(1.6502 - 1.6522)
AT-2

4. TRANSMISSION
SERVICE DATA AND SPECIFICATIONS
LINE PRESSURE
Width of groove of
mainshaft servo ring
Standard
Service limit
Width of servo ri ng
Standard
Service Iim it
Thickness of drive plate
Unit: mm (in)
2.26 - 2.29
(0.0890 - 0.0902)
2.40 (0.0945)
2.11 - 2.16
(0.0831 - 0.0850)
2.07 (0.0815)
Main line pressure
Forwa rd and reverse
clutch oil pressure
Converter inlet pressure
Unit: kPa (bar, kg/em', psi)
883 - 1,079
(8.8 - 10.8,9 - 11, 128 - 156)
at 1,000 rpm or over
883 - 1,079
(8.8 - 10.8,9 - 11, 128 - 156)
at 1,000 rpm or over
196 - 392
(2.0 - 3.9, 2 - 4, 28 - 57)
at 1,000 rpm or over
Standard
Service limit
Thickness of driven plate
2.5 - 2.65
(0.0984 - 0.1043)
2.2 (0.087)
ENGINE STALL REVOLUTION
Unit: rpm
Standard
Service limit
Clearance between retaining
plate and snap ri ng
Standard
Limit
Backlash of each gear
OIL PUMP
1.5 - 1.7
(0.059 - 0.067)
1.4 (0.055)
1.8 - 2.4
(0.071 - 0.094)
6.5 (0.256)
0.10 - 0.15
(0.0039 - 0.0059)
Unit: mm (in)
Stall revolution
H15
H20-II
H25
TD27
BD30
OIL CAPACITY
Oil capacity in
transmission case
2,050 -2,250
2,350 - 2,550
1,900 - 2,100
1,850 - 2,050
2,000 - 2,200
Unit: liters (US qt, Imp qt)
5.5 (5-7/8,4-7/8)
Standard Service limit
Side clearance of 0.02 - 0.04
0.08 (0.0031)
oil pump gear (0.0008 - 0.0016)
Clearance between outer 0.14 - 0.21
0.25 (0.0098)
gear and crescent (0.0055 - 0.0083)
Clearance between outer 0.05 - 0.20
0.25 (0.0098)
gear and housing (0.0020 .0.0079)
Oil capacity in
torque converter
AT-3
2.5 (2-5/8,2-1/4)

5. SERVICE DATA AND SPECIFICATIONS
TIGHTENING TORQUE
@
Tightening torque N.m (kg-m, ft-lb)
@: 16-21 (1.6.2.1,12-15)
@: 9.1 - 11.8 (0.93 - 1.2,6.7 - 8.7)
@: 6.3 . 8.3 (0.64 - 0.85, 4.6 . 6.1)
@: 25 - 34 (2.5 - 3.5,18 - 25)
@: 30-40(3.1-4.1,22-30)
AT-4
eEl: 275 - 343 (28 - 35, 203 - 253)
@: 76.98(7.8-10,56-72)
C8J: 245 - 294 (25 - 30, 181 - 217)
CD: 89 - 118 (9.1 - 12,66 - 87) J02
CD: 78 - 98 (8 - 10,58 - 72) JOl
FAT303

6. TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
Low output Torque converter
• Low oil pressure
(1) Insufficient oil quantity Add oil.
(2) Air sucked from suction side Retighten or change packing.
(3) Clogged oil filter Clean or replace.
(4) Worn oil pump (low discharge) Replace.
(5) Fatigue of regulator valve coil spring Replace.
(6) Malfunction of regulator valve spool Repair or replace.
(7) Worn piston ring or O.ring Replace.
• Break in stator free wheel cam Replace torque converter assembly .
• Seized stator free wheel Replace torque converter assembly.
• Broken blades or interference of blade Replace torque converter assembly .
Transmission
• Use of improper oil or air bubbles
(1) Air sucked from suction side Replace.
Retighten or change packing.
(2) Air bubbles due to too low torque Adjust.
converter pressure
(3) Water in oil Change oil.
• Improper position of brake shift spool Adjust.
and link lever
• Slippery clutch
(1) Low main pressure Replace oil pump, control valve.
(2) Wear on piston ring'or O.ring Replace.
(3) Break in clutch piston Replace.
(4) Seizure or drag of clutch plate Replace.
Unusual rise of oil Torque converter
temperature
• Improper oil quantity Add or reduce oil.
• Clogged oil filter (insufficient circulating Clean or replace .
quantity)
• Interference of wheel vane Replace torque converter assembly .
• Faulty stator free wheel Replace torque converter assembly.
• Air sucked into system. Retighten or change gasket .
• Water oil tank or transmission case Change oil.
• To large resistance in piping (insufficient Repair or replace .
circulating quantity)
• Worn or seized bearing Repair or replace .
• Faulty instrument Replace .
AT-5

7. TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
Unusual rise of oil Transmission
temperature
• Dragging of clutch Replace clutch plate.
• Faulty instrument Replace.
• Worn or seized bearing Replace.
Noisy operation Torque converter
• Break in drive plate Replace drive plate.
• Worn or faulty bearing Replace torque converter assembly.
• Interference of vane wheel Replace torque converter assembly.
• Loose bolt Retighten or replace.
• Worn spline Replace torque converter assembly.
• Noise in gear pump Repair or replace.
Transmission
• Dragging of clutch due to seizure Replace clutch plate.
• Worn or seized bearing Replace.
• Break in gear Replace.
• Loose bolt Retighten or replace.
• Worn spline Replace.
• Cavitation caused by clogged strainer Clean or replace.
Unusual main pressure/ Too high pressure
torque converter oil
• Clogged oil filter (outlet side) Clean .
pressure
Malfunction of regulator valve Repair or replace valve .•
Clean or repair.
• Too large resistance in piping Repair.
• Cold weather (when high viscosity oil is Repair.
used)
• Faulty instrument Replace.
• Use of improper oil Change oil .
Too low pressure
• Faulty gear pump (wear) Replace.
• Excessive oil leak
(1) Faulty regulator valve coil spring Replace.
(2) Faulty regulator valve spool Repair or replace valve.
I
(3) Faulty modulator valve coil spring Replace.
I
• Air is sucked into system . Retighten or change packing.
, • Insufficient oil Add .
i
rO
Clogg,d oil fiI'" Clean or replace.
Transmission
• Excessive oil leak Replace .
• Faulty instrument Replace.
AT-6

8. Condition
TROUBLE DIAGNOSES AND CORRECTIONS
Probable cause Corrective action
Oil leak from torque
conv.erter/transmission
No transmission of
power
• Oil leak from oil seal
• Oil leak from jointing surfaces of case
• Oil leak from joint or pipe
• Oil leak from drain plug
• Cracks or blowholes
• Flowing out of oil from transmission case
and tank
• Excessive oil
Torque converter
• Break in drive plate
• Insufficient oil
• Faulty oil pump driving system
• Broken shaft
• No oil pressure
Transmission
• Insufficient oil
• Improper location of inching spool and
link lever
• Improper location of forward/reverse
spool and link lever
• Clutch acting in both directions
(1) Faulty piston ring of servo case
(2) Clutch seizure/deformation
(3) Broken conical plate
• Seized clutch
• Broken shaft
• Break in clutch drum (snap ring groove)
• Broken snap ring for clutch drum
• Foreign matter caught in oil passage to
clutch
• Worn shaft spline
AT-7
Replace oil seal. Replace pump boss,
coupling, etc.
Retighten bolts or change packing.
Repair or replace pipe gasket.
Retighten or replace gasket.
Repair or replace.
Change oil.
Retighten or replace packing.
Repair.
Reduce oil.
Replace.
Add oil.
Replace.
Replace.
Replace.
Add oil.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace .
Replace .
Replace.
Clean or replace.
Replace.

9. Oil PASSAGES FROM Oil
STRAINER TO CONTROL VALVE
BODY
Oil circuit in transmission case
OIL CIRCUIT
OIL CIRCUIT
FAT014
Oil circuit in oil pump cover
Transmission case
FAT015
AT-8

10. OIL CIRCUIT
Oil circuit in transmission cover
"'I -= From pressure regulator valve
To mchmg va ve 'i ()0 n
To pressure regUl~to~ ~ a
valve ri'= <f) Q 0
I
I I
I I
I I ()
d nloo
To oil cooler
OIL PASSAGES FROM
CONTROL VALVE BODY TO
MAIN SHAFT
Oil circuit in servo case
........... ------ -.Transmission cover~
1, ~
~ -~
Oil channels in case face
7:
AT-9
FAT016
FAT017
FAT018

11. OIL PRESSURE CIRCUIT DIAGRAM
OIL PRESSURE CIRCUIT DIAGRAM
NEUTRAL RANGE
~ Line pressure
Torque converter pressure
~ Inching pressure
~ Lubrication pressure
Select
lever
Check valve
...
Inching valve
Inching hrake pedal
Relief valve
t t
...
~"~=
~
Torque converter
relief valve
Oil
cooler
Drain and suction circuit
f1E=T~~-"".
'
~ •... ~Jlg
: .'<' ~::.: ~~. =:r c
1
...•••.•••••.•.•.•••:••.•:••••
) Bt= Iii '~-.-......•..•.:•...:..:.r~./
/ ....
Oil pump .. i.. .
ltrill
Oil strainer
Transmission case
FAT286
AT-10

12. OIL PRESSURE CIRCUIT DIAGRAM
FORWARD RANGE
~ line pressure
~~~t~~~~~~tTorque converter pressure
_ Inching pressure
~ Lubrication pressure
Drain and suction circuit
Oil
cooler
Oil cooler
relief valve
~~................................................•
Torque converter
relief valve
Oil strainer
... 0)--"" Inching brake
~pedal
: Inching valve
AT-11
Select
lever
FAT287

13. OIL PRESSURE CIRCUIT DIAGRAM
REVERSE RANGE
~ Line pressure
::::::::::::::::Torque converter pressure
~ Inching pressure
~ Lubrication pressure
Drain and suction circuit
Oil cooler
~~ , .
Torque converter
relief valve
.............. :
~~ Inching brake pedal
: Inching valve
t •
Select
lever
••
Oil strainer Transmissi on case
AT-12
FAT288

14. INCHING
~ Line pressure
}}}} Torque converter pressure
_ Inching pressure
~ Lubrication pressure
Drain and suction circuit
Oil cooler
relief valve
Oil
cooler
Torque converter
relief valve
OIL PRESSURE CIRCUIT DIAGRAM
.. ~ '.,h'., h"k,ped"
: Inchmg valve
S,h,,' "Iw _ _
F..-L.R
• t
.-----19
AT-13
Select
lever
FAT289

15. CONSTRUCTION
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
ri5! 14) (1x (12) 11 @
IT
FAT285
1 Drive cover
2 Turbine runner
3 Stator
4 One-way clutch
5 Pump impeller
6 Oil pump sleeve
7 Oil pump housing
8 Oil pump cover
9 Main shaft
10 Reverse gear
11 Control valve
12 Clutch piston
13 Return spring
14 Clutch drum
15 Forward gear
16 Servo case
17 Needle bearing
18 Oil pump
AT-14
19 Orifice
20 Drive pinion shaft
21 Pinion shaft spacer
22 Reduction gear
23 Bearing cover
24 Idler gear
25 Idler shaft

16. REMOVAL AND
INSTALLATION
1. Remove differential carrier with
engine and transmission.
Refer to ER section for removal.
2. Separate engine from transmission
case.
3. Remove torque converter.
4. Remove oil pump.
S. Pull out drive pinion rear end
cover.
AUTOMATIC TRANSMISSION
PD015
6. Remove drive pinion fixing nut at
drive pinion rear end.
7. Remove differential carrier
mounting bolts, and remove dif-
ferential carrier from transmission
case.
AT-15
FPD017
8. To install, reverse order of re-
moval.

17. DISASSEMBLY
TRANSMISSION
Snap ring
'~ -F'~ oIWard gear
~
"'~
~
Servo case
Drive plate
AUTOMATIC TRANSMISSION
Snap ring
"'00 P;~oo retorn ~~~ ~spnng ;))~)).!1 ~~j)
~~) L1R~,,~ g'~
// !
/? /
.~
Snap ring
Retaining Ipate
Drive plate
Driven plate
245.294
(25.30 18. 1.2171
CfJ . N. .m (kg-m, ft-Ib)
FAT290
AT-16

18. I. Remove oil level gauge.
2. Remove transmission cover fixing
bolts, and remove cover from case.
FAT035
3. Remove oil pump assembly.
4. Remove bearing cover CD from
torque converter side. Screw bolt
into the threaded hole in the center
of bearing cover and pull up bolt to
remove cover CD. Straighten lock
plate CID and remove nut @.
FAT185
AUTOMATIC TRANSMISSION
5. Pull out idler shaft toward dif-
ferential carrier.
When pulling out idler shaft, support
idler gear by hand as it must be left
inside transmission case.
FAT037
6. Remove servo case.
AT-17
7. Pul1 out clutch drum toward
torque converter.
FAT039
8. Remove reduction gear and dis-
tance piece from transmission case.

19. AUTOMATIC TRANSMISSION
01 L PUMP AND TORQUE CONVERTER
Torque converter assembly
]
T 30-40
(3.1 - 4.1,
22.30)
~
Oil pump housing
1
I,
L Oil pump cover
CfJ : N'm (kg-m, ft-lb)
FAT291
CONTROL VALVE
I. Remove seven control valve body
tightening bolts, and remove the valve
body.
2. Remove side plate.
Use care not to lose springs and
valves.
3. Remove two valve stopper bolts.
FAT293
FAT292
FAT051
1 Transmission cover
2 Control valve body
AT-18

20. AUTOMATIC TRANSMISSION
4. Pull out select valve toward select
lever side. Remove balls and springs.
CAUTION:
If select valve is pulled out by force in
the opposite direction, it will be dam.
aged by steel ball in the valve body.
6. Remove snap ring from check
valve body, and take off check valve
and spring.
5. Remove the following parts:
Check valve body, modulator piston,
spring, relief valve, pressure regulation
valve, inching valve.
1 Ball
2 Select valve
3 Check valve body
4 Modulator piston
5 Relief valve
6 Pressure regulator valve
7 Inching valve
FAT054
CLUTCH
I. Remove snap rings from forward
gear and reverse gear. Use snap ring
pliers. Then, remove main shaft
spacers, forward and reverse gears and
thrust washers.
2. Using special tool KV31101400,
press down spring retainer, and re-
move snap ring that secures retainer.
Then, remove spring retainer and
clutch piston spring.
FAT055
3. Remove snap ring from outside of
clutch drum. Remove retaining plate,
plates and piston.
4. Disassemble the opposite side in
the same manner.
I Clutch drum
2 Piston ring
3 Piston c1utch
4 Driven plates
5 Drive plates
6 Retaining plate
7 Snap ring
AT-19
8 Clutch piston spring
9 Spring retainer
10 Snap ring
11 Thrust washer
12 Reverse gear
13 Conical plate
FAT294

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22. ASSEMBLY
TRANSMISSION
Assembly is in the reverse order of
disassembly, observe the following:
• Be sure to assemble thrust washer
on front of forward gear or re-
verse gear with its grooved side
facing the gear.
Gear side
FAT062
• Backlash of each gear.
Standard:
0.10 - 0.15 mm
(0.0039 - 0.0059 in)
II
FAT064
• Lateral runout of drive plate.
Standard:
Lessthan 0.2 mm (0.008 in)
Service limit:
0.5 mm (0.020 in)
FAT065
AUTOMATIC TRANSMISSION
TORQUE CONVERTER
Assembly is in the reverse order of
disassembly, observe the following:
• Measure diameter of oil pump
sleeve part contacting oil seal.
41.915 - 41.965 mm
(1.6502 -1.6522 in)
FAT295
FLUSHING TORQUE CONVERTER
Before reassembling torque converter,
flush its interior as follows:
1. Completely drain torque con-
verter oil.
CAUTION:
Repeatedly tilt torque converter to the
left and right' until oil is completely
drained.
Tilt torque converter to the left and
right repeatedly until remaining oil
is completely drained.
Gr~~D
'~J
• l
FAT274
2. Pour approximately 1.5 liter
(1-5/8 US qt, 1-3/8 Imp qt) of light
oil into torque converter. Rotate
torque converter elements with input
shaft, then drain oil. Repeat this pro-
cedure until oil is clean and free from
foreign matter.
AT-20
CAUTION:
After completely flushing torque con-
verter, completely drain light oil.
3. Pour approximately 1 liter (1-1/8
US qt, 7/8 Imp qt) of Automatic
Transmission- Fluid into torque con-
verter and flush in a manner similar to
step 2 above (two or three times).
OIL PUMP
Assembly is in the reverse order of
disassembly. Observe the following:
• Measure clearance between tooth
top of outer gear and crescent.
Standard:
0.14 - 0.21 mm
(0.0055 - 0.0083 in)
Service limit:
0.25 mm (0.0098 in)

23. AUTOMATIC TRANSMISSION
FAT059
FAT057
1 Drive plate
2 Driven plate
Driven plate thickness:
Standard:
1.5 -1.7 mm
(0.059 - 0.067 in)
Service limit:
1.4 mm (0.055 in)
FAT048
• Measure clearance between outer
gear and oil pump housing.
Standard:
0.05 . 0.20 mm
(0.0020 - 0.0079 in)
Service limit:
0.25 mm (0.0098 in)
• Measure clearance between inner
gear and pump cover and clearance
between outer gear and pump
cover.
Standard:
0.02 . 0.04 mm
(0.0008 - 0.0016 in)
Service limit:
0.25 mm (0.0098 in)
= ~
== =
• After assembling each clutch,
measure clearance between retain-
ing plate and snap ring.
Standard:
1.8 - 2.4 mm
(0.071 - 0.094 in)
Service limit:
6.5 mm (0.256 in)
• Measure width of servo ring grooves
on main shaft.
Standard:
2.26 . 2.29 mm
(0.0890 - 0.0902 in)
Service limit:
2.40 mm (0.0945 in)
TEST
LINE PRESSURE TEST
Tools and equipment
Oil pressure gauge assembly
(with adapters)
ST022lS000
Engine tachometer
Wrench
Sealing tape
Chock
FAT046
1 Oil pump housing
2 Outer gear
3 Inner gear
CLUTCH
Assembly IS m the reverse order of
disassembly. Observe the following:
• Check drive plate and driven plate
for wear. Replace if necessary.
Drive plate thickness:
Standard:
2.5 - 2.65 mm
(0.0984 - 0.1043 in)
Service limit:
2.2 mm (0.087 in)
FAT296
• Measure width of servo rings.
Standard:
2.11.2.16 mm
(0.0831 - 0.0850 in)
Service limit:
2.07 mm (0.0815 in)
Test procedures
1. Before testing, check coolant, en-
gine oil and torque converter oil; warm
up torque converter oil to operating
temperature.
2. Secure front and rear wheels with
chocks and apply hand brake.
3. Remove blind plug and connect
oil pressure gauge to its opening.
4. Mount engine tachometer.
5. Measure clutch oil pressure while
engine is running more than 1,000 rpm
with gears shifted into Forward or Re-
verse position.
6. Measure torque converter oil pres-
sure while engine is running more than
1,000 rpm.
AT-21