assignment
DESCRIPTION
Gear BoxTRANSCRIPT
1
1. Reverse Clutch Snap Ring
Inspection
Check that the clearance between the snap ring and clutch reaction plates is within the standard value. When measuring the clearance, press the clutch reaction plate by force of 5 kg (50N) evenly. If not within the standard value, select a snap ring to adjust
Standard Value:
Result:
Remarks:
2. Overdrive Clutch Snap Ring Inspection
Check that the clearance between the snap ring and clutch reaction plates is within the standard value. If not within the standard value, select a snap ring to adjust.
Standard Value:
Result:
Remarks:
3. Underdrive Clutch Snap Ring
Inspection
Check that the clearance between the snap ring and clutch reaction plates is within the standard value. When measuring the clearance, press the clutch reaction plate by force of 5 kg (50N) evenly. If not within the standard value, select a snap ring to adjust
Standard Value:
Result:
Remarks:
4. Reaction Plate End Play Inspection
Replaced the pressure plate of the low reverse brake with special tools, and then install the brake disc and plate.
Move the special tool to measure the end play and than replace the snap ring to adjust the end play to standard value
Standard Value:
Result:
Remarks:
5. Low reverse Brake Pressure Plate end play Inspection
Replaced the pressure plate of the second brake with special tools, and then install the brake disc and plate as shown in the figure.
Install the return spring, second brake piston and snap ring
Move the special tool to measure the end play
Standard Value:
Result:
Remarks:
6. Second Brake Pressure Plate end play Inspection
Reverse the transmission
Move the special tool to measure the endplay.
Standard Value:
Result:
Remarks:
7. Output shaft Pre load Inspection
Move the output shaft to measure operating amount (A) and then replace the spacer installed in step (2) with a new one which thickness is within the following value
(A /Operating Amount) + (B / thickness of the old spacer) + 0.07 mm to (A /Operating Amount) + (B / thickness of the old spacer) + 0.09 mm
Standard Value:
Result:
Remarks:
8. Under Drive Sun Gear End Play Inspection
Install the used trust race No 8 at the rear cover
Measure endplay of the underdrive sun gear. Replace the thrust race to adjust the play to the standard value.
Note: Installing the underdrive clutch hub to makes is easy to measure
Standard Value:
Result:
Remarks:
9. Input Shaft End Play Inspection
Measure end play of input shaft. Replace the thrust washer installed to adjusted the play to the standard value.
Standard Value:
Result:
Remarks:
10. Differential End Play Inspection
Install the 1.25 mm thick spacer. Place a solder (B) approximately 10 mm in length, 3mm diameter on the differential
Measure used micrometer the thickness (T)
(T-0.45mm) to (T-o.165mm)
Standard Value:
Result:
Remarks:
11. Inhibitor Switch Inspection
Inhibitor Indicator
Continuity Check
Remarks
P
Terminal 3 & 8
Terminal 9 & 10
R
Terminal 7 & 8
N
Terminal 4 & 8
Terminal 9 & 10
D
Terminal 1 & 83
Terminal 5 & 82
Terminal 2 & 81
Terminal 6 & 8
12. Solenoid Valve Inspection
Measure the resistance between terminals 1 and 2 of each solenoid valve.
Name
Resistance
DAMPER clutch Solenoid Valve
Low Reverse Solenoid Valve
Second Brake Solenoid Valve
Underdrive Solenoid Valve
Overdrive Solenoid Valve
Hydraulic Pressure Test
(1) Warm up the engine until the automatic transmission fluid temperature is 80--100C.
(2) Jack up the vehicle so that the wheels are free to turn.
(3) Connect the special tools (2,942-kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900]) to each pressure discharge port.
(4) Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table, and check that the measured values are within the standard value ranges.
(5) If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.
Standard Hydraulic Pressure Test
Measurement ConditionStandard Hydraulic Pressure kPa
Selector Lever PositionShift PositionEngine Speed (RPM)UD Clutch PressureREV Clutch PressureOD Clutch PressureLRB Pressure2Nd Brake Pressure
P2,500
RReverse2,500
N2,5002,500
D1 gear2,500
2 gear2,500
3 gear2,500
4 gear2,500
Service Data Reference Table
Item NoCheck ItemCheck RequirementNormal ValueActual Value
11Throttle Position SensorEngine: Stopped Selector Lever Position PAccelerator Pedal Release
Accelerator Pedal Halfly depressed
Accelerator Pedal Depressed
15Oil Temperature sensorWarming UpAccelerator Pedal Release
Accelerator Pedal Halfly depressed
Accelerator Pedal Depressed
21Crank Angle SensorEngine: Idling Selector Lever Position PAccelerator Pedal Release
Accelerator Pedal Halfly depressed
Accelerator Pedal Depressed
22Input Shaft Speed sensorSelector Lever Position 3Driving at constant speed 50km/h at 3rd gear
Item NoCheck ItemCheck RequirementNormal ValueActual Value
23Output Shaft Speed sensorSelector Lever Position 3Driving at constant speed 50km/h at 3rd gear
26Stop lamp SwitchIgnition switch: ON
Engine: StoppedBrake pedal: Depressed
Brake Pedal Release
29Vehicle Speed SensorSelector Lever Position 3Idling with 1st gear (Vehicle Stooped)
Driving at constant speed of 50 km/h in 3rd gear
31Low and Reverse Solenoid Duty%Select lever position L, 2, 3, D10 km/h 1 gear
32Underdrive Solenoid Duty%30 km/h 2nd gear
33Second Brake Solenoid Duty%50 km/h 3rd gear
34Overdrive Solenoid Duty%70 km/h in 4th gear
36DCCSVSelector lever position 3Driving at 50km/h in 3rd gear with acc released
Item NoCheck ItemCheck RequirementNormal ValueActual Value
36DCCSVSelector lever position 3Driving at 70km/h in 3rd gear with acc released
54Control Relay Output VoltageIG SW:OFFIG SW: ON - OFF
61Inhibitor SwitchIG SW: ON
Engine StoppedLever: P
Lever: R
Lever: N
Lever: D
Lever: 3
Lever: 2
Lever: 1
63 Shift PositionSelect Lever Position: L., 2, 3, DDriving at constant speed 10km/h at 1st gear
Driving at constant speed 30km/h at 2nd gear
Driving at constant speed 50km/h at 3rd gear
Driving at constant speed 70km/h at 4th gear
Remarks:
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WAJA 1.8 DPO TRANSMISSION
1. Adjusting The Leaf Spring Lever
Hold the mulfunction switch lever in the extreme position (1st gear hold) using a plastic clip and a bolt in the mechanism housing.
Removed the Bolt (c)
Position the leaf spring lever by placing the roller (A) in the hollow of sector (B) corresponding to 1st gear hold.
By Used Fit tool B.Vi. 1462 instead and in place of bolt (C) screw the tool in fully whist holding the leaf spring lever.
Tighten bolt (D) to correct torque.
Remove the tool and refit bolt (C).
Remarks:
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2. Malfunction Switch Inspection
Placed the gear lever position in the Neutral position
Place Multimeter to the two electrical terminals on the position control tabs
Check the resistance of malfunction switch (MFS) by turn the MFS switch
Standard Value: Resistance at contact Terminal = 0(
Result:
Remarks:
3. Anti Start Relay Inspection
Check the continuity between terminal 1 and 2
By give power supply to terminal 1, check the continuity between terminal 3 and 4
Caution:
Wrong give power supply to terminal will damage the relay
Continuity between terminal 1& 2
Continuity between terminal 3& 4
Remarks:
3. Solenoid Valve Inspection
Check the resistance of the electro valve.
ElectrovalveStandard ValueActual Value
EVM & EVLUP Approx. 1ohm
EVCApprox. 40 ohm
Remarks:
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