Automatic Transmission and A/T Differential
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | Service Limit | |
|---|---|---|---|---|---|
| Automatic transmission fluid | Capacity Use Honda ATF-Z1 | 4WD | Fluid change | 2.5 L (2.6 US qt) | |
| Overhaul | 7.2 L (7.6 US qt) | ||||
| 2WD | Fluid change | 2.6 L (2.7 US qt) | |||
| Overhaul | 7.0 L (7.4 US qt) | ||||
| ATF pressure | Line pressure | At 2,000 rpm in N or P position | 900-960 kPa (9.2-9.8 kgf/cm2 , 130-140 psi) | 850 kPa (8.7 kgf/cm2 , 120 psi) | |
| 1st clutch pressure | At 2,000 rpm in 1 position | 890-970 kPa (9.1-9.9 kgf/cm2 , 130-140 psi) | 840 kPa (8.6 kgf/cm2 , 120 psi) | ||
| 2nd clutch pressure | At 2,000 rpm in 2 position | 890-970 kPa (9.1-9.9 kgf/cm2 , 130-140 psi) | 840 kPa (8.6 kgf/cm2 , 120 psi) | ||
| 3rd clutch pressure | At 2,000 rpm in 3rd gear in D3 position | 890-970 kPa (9.1-9.9 kgf/cm2 , 130-140 psi) | 840 kPa (8.6 kgf/cm2 , 120 psi) | ||
| 4th clutch pressure | At 2,000 rpm in 4th gear in D position | 890-970 kPa (9.1-9.9 kgf/cm2 , 130-140 psi) | 840 kPa (8.6 kgf/cm2 , 120 psi) | ||
| 5th clutch pressure | At 2,000 rpm in 5th gear in D position | 890-970 kPa (9.1-9.9 kgf/cm2 , 130-140 psi) | 840 kPa (8.6 kgf/cm2 , 120 psi) | ||
| Torque converter | Stall speed Check with vehicle on level ground | - | 2,400 rpm | 2,250-2,550 rpm | |
| Clutch | Clutch end-plate-to-top disc clearance | 1st | - | 1.38-1.58 mm (0.054-0.062 in.) | |
| 2nd | - | 1.14-1.34 mm (0.045-0.053 in.) | |||
| 3rd | - | 1.23-1.43 mm (0.048-0.056 in.) | |||
| 4th, 5th | - | 0.93-1.13 mm (0.037-0.044 in.) | |||
| Clutch return spring free length | 1st, 2nd, 3rd | 45.1 mm (1.78 in.) | 48.8 mm (1.92 in.) | ||
| 4th, 5th | 33.5 mm (1.32 in.) | 31.5 mm (1.24 in.) | |||
| Clutch disc thickness | - | 1.94 mm (0.076 in.) | - | ||
| Clutch plate thickness | 1st, 3rd | 1.6 mm (0.063 in.) | When discolored | ||
| 2nd | 2.0 mm (0.079 in.) | When discolored | |||
| 4th, 5th | 2.0 mm (0.079 in.) | When discolored | |||
| Clutch wave-plate phase difference | - | 0.07-0.20 mm (0.003-0.008 in.) | 0.05 mm (0.002 in.) | ||
| 1st clutch end-plate thickness | Mark 1 | 2.6 mm (0.102 in.) | When discolored | ||
| Mark 2 | 2.7 mm (0.106 in.) | When discolored | |||
| Mark 3 | 2.8 mm (0.110 in.) | When discolored | |||
| Mark 4 | 2.9 mm (0.114 in.) | When discolored | |||
| Mark 5 | 3.0 mm (0.118 in.) | When discolored | |||
| Mark 6 | 3.1 mm (0.122 in.) | When discolored | |||
| Mark 7 | 3.2 mm (0.126 in.) | When discolored | |||
| Mark 8 | 3.3 mm (0.130 in.) | When discolored | |||
| Mark 9 | 3.4 mm (0.134 in.) | When discolored | |||
| 2nd clutch end-plate thickness | Mark 1 | 2.4 mm (0.095 in.) | When discolored | ||
| Mark 2 | 2.5 mm (0.098 in.) | When discolored | |||
| Mark 3 | 2.6 mm (0.102 in.) | When discolored | |||
| Mark 4 | 2.7 mm (0.106 in.) | When discolored | |||
| Mark 5 | 2.8 mm (0.110 in.) | When discolored | |||
| Mark 6 | 2.9 mm (0.114 in.) | When discolored | |||
| Mark 7 | 3.0 mm (0.118 in.) | When discolored | |||
| Mark 8 | 3.1 mm (0.122 in.) | When discolored | |||
| Mark 9 | 3.2 mm (0.126 in.) | When discolored | |||
| 3rd, 4th, 5th clutch end-plate thickness | Mark 1 | 2.1 mm (0.083 in.) | When discolored | ||
| Mark 2 | 2.2 mm (0.087 in.) | When discolored | |||
| Mark 3 | 2.3 mm (0.091 in.) | When discolored | |||
| Mark 4 | 2.4 mm (0.095 in.) | When discolored | |||
| Mark 5 | 2.5 mm (0.098 in.) | When discolored | |||
| Mark 6 | 2.6 mm (0.102 in.) | When discolored | |||
| Mark 7 | 2.7 mm (0.106 in.) | When discolored | |||
| Mark 8 | 2.8 mm (0.110 in.) | When discolored | |||
| Mark 9 | 2.9 mm (0.114 in.) | When discolored | |||
| Mainshaft | Diameter of needle bearing contact area | At stator shaft | 22.984-23.000 mm (0.905-0.906 in.) | When worn or damaged | |
| At 5th gear | 51.975-51.991 mm (2.046-2.047 in.) | When worn or damaged | |||
| At 4th gear collar | 33.975-33.991 mm (1.3376-1.3382 in.) | When worn or damaged | |||
| I.D. of gears | 5th gear | 57.000-57.019 mm (2.2441-2.2448 in.) | When worn or damaged | ||
| 4th gear | 40.000-40.016 mm (1.5748-1.5754 in.) | When worn or damaged | |||
| End play of gears | 5th gear | 0.04-0.10 mm (0.002-0.004 in.) | - | ||
| 4th gear | 0.1-0.22 mm (0.004-0.009 in.) | - | |||
| 41 x 68 mm thrust washer thickness | No. 1 | 4.450 mm (0.1752 in.) | When worn or damaged | ||
| No. 2 | 4.475 mm (0.1762 in.) | When worn or damaged | |||
| No. 3 | 4.500 mm (0.1772 in.) | When worn or damaged | |||
| No. 4 | 4.525 mm (0.1781 in.) | When worn or damaged | |||
| No. 5 | 4.550 mm (0.1791 in.) | When worn or damaged | |||
| No. 6 | 4.575 mm (0.1801 in.) | When worn or damaged | |||
| No. 7 | 4.600 mm (0.1811 in.) | When worn or damaged | |||
| No. 8 | 4.625 mm (0.1821 in.) | When worn or damaged | |||
| No. 9 | 4.650 mm (0.1831 in.) | When worn or damaged | |||
| No. 10 | 4.675 mm (0.1841 in.) | When worn or damaged | |||
| No. 11 | 4.700 mm (0.1850 in.) | When worn or damaged | |||
| No. 12 | 4.725 mm (0.1860 in.) | When worn or damaged | |||
| No. 13 | 4.750 mm (0.1870 in.) | When worn or damaged | |||
| No. 14 | 4.775 mm (0.1880 in.) | When worn or damaged | |||
| No. 15 | 4.800 mm (0.1890 in.) | When worn or damaged | |||
| 4th gear collar length | - | 66.3-66.4 mm (2.610-2.614 in.) | - | ||
| Length of 4th gear collar flange from end | - | 19.15-19.30 mm (0.754-0.760 in.) | When worn or damaged | ||
| Sealing ring thickness | - | 1.91 -1.97 mm (0.0752-0.0776 in.) | 1.86 mm (0.0732 in.) | ||
| Width of sealing ring groove | - | 2.025-2.060 mm (0.0797-0.0811 in.) | 2.080 mm (0.0819 in.) | ||
| Clutch feed pipe O.D. | - | 7.97-7.98 mm (0.3138-0.3142 in.) | 7.95 mm (0.313 in.) | ||
| Clutch feed pipe bushing I.D. | - | 8.000-8.015 mm (0.3150-0.3156 in.) | 8.030 mm (0.3161 in.) | ||
| Countershaft | Diameter of needle bearing contact area | At torque converter housing | 36.005-36.015 mm (1.4175-1.4179 in.) | When worn or damaged | |
| At 4th gear | 34.982-34.998 mm (1.3772-1.3779 in.) | When worn or damaged | |||
| At reverse gear | 39.979-40.000 mm (1.5740-1.5748 in.) | When worn or damaged | |||
| I.D. of gears | 4th gear | 41.000-41.016 mm (1.6142-1.6148 in.) | When worn or damaged | ||
| Reverse gear | 46.000-46.016 mm (1.8110-1.8116 in.) | When worn or damaged | |||
| End play of gears | 5th gear | 0.00-0.48 mm (0.000-0.019 in.) | - | ||
| 4th gear | 0.04-0.27 mm (0.002-0.011 in.) | - | |||
| Reverse gear | 0.10-0.25 mm (0.004-0.010 in.) | - | |||
| Collar, 35 x 47 x 7.8 mm thickness | - | 7.8 mm (0.31 in.) | - | ||
| Collar, 37 x 41 x 54.3 mm length | - | 54.25-54.30 mm (2.136-2.138 in.) | - | ||
| Reverse selector hub width | - | 25.45-25.65 mm (1.002-1.010 in.) | - | ||
| Reverse selector hub O.D. | - | 55.87-55.90 mm (2.200-2.201 in.) | When worn or damaged | ||
| Secondary shaft | Diameter of needle bearing contact area | At 1st gear | 39.986-39.999 mm (1.5742-1.5748 in.) | When worn or damaged | |
| At 2nd gear | 39.986-39.999 mm (1.5742-1.5748 in.) | When worn or damaged | |||
| At 3rd gear collar | 36.975-36.991 mm (1.4557-1.4563 in.) | When worn or damaged | |||
| I.D. of gears | 1st gear | 47.000-47.016 mm (1.8504-1.8510 in.) | When worn or damaged | ||
| 2nd gear | 46.000-46.016 mm (1.8110-1.8116 in.) | When worn or damaged | |||
| 3rd gear | 43.000-43.016 mm (1.6929-1.6935 in.) | When worn or damaged | |||
| End play of gears | 1st gear | 0.04-0.12 mm (0.002-0.005 in.) | - | ||
| 2nd gear | 0.04-0.12 mm (0.002-0.005 in.) | - | |||
| 3rd gear | 0.10-0.22 mm (0.004-0.009 in.) | - | |||
| 37 x 58 mm thrust washer thickness | No. 1 | 3.900 mm (0.154 in.) | When worn or damaged | ||
| No. 2 | 3.925 mm (0.155 in.) | When worn or damaged | |||
| No. 3 | 3.950 mm (0.156 in.) | When worn or damaged | |||
| No. 4 | 3.975 mm (0.156 in.) | When worn or damaged | |||
| No. 5 | 4.000 mm (0.157 in.) | When worn or damaged | |||
| No. 6 | 4.025 mm (0.158 in.) | When worn or damaged | |||
| No. 7 | 4.050 mm (0.159 in.) | When worn or damaged | |||
| No. 8 | 4.075 mm (0.160 in.) | When worn or damaged | |||
| No. 9 | 4.100 mm (0.161 in.) | When worn or damaged | |||
| No. 10 | 4.125 mm (0.162 in.) | When worn or damaged | |||
| No. 11 | 4.150 mm (0.163 in.) | When worn or damaged | |||
| No. 12 | 4.175 mm (0.164 in.) | When worn or damaged | |||
| No. 13 | 4.200 mm (0.165 in.) | When worn or damaged | |||
| No. 14 | 4.225 mm (0.166 in.) | When worn or damaged | |||
| No. 15 | 4.250 mm (0.167 in.) | When worn or damaged | |||
| No. 16 | 4.275 mm (0.168 in.) | When worn or damaged | |||
| No. 17 | 4.300 mm (0.169 in.) | When worn or damaged | |||
| No. 18 | 4.325 mm (0.170 in.) | When worn or damaged | |||
| No. 19 | 4.350 mm (0.171 in.) | When worn or damaged | |||
| No. 20 | 4.375 mm (0.172 in.) | When worn or damaged | |||
| 40 x 51.5 mm thrust washer thickness | No. 1 | 4.80 mm (0.189 in.) | When worn or damaged | ||
| No. 2 | 4.85 mm (0.191 in.) | When worn or damaged | |||
| No. 3 | 4.90 mm (0.193 in.) | When worn or damaged | |||
| No. 4 | 4.95 mm (0.195 in.) | When worn or damaged | |||
| No. 5 | 5.00 mm (0.197 in.) | When worn or damaged | |||
| No. 6 | 5.05 mm (0.199 in.) | When worn or damaged | |||
| 3rd gear collar length | - | 43.9-44.0 mm (1.728-1.732 in.) | - | ||
| Length of 3rd gear collar flange from end | - | 5.25-5.40 mm (0.207-0.213 in.) | When worn or damaged | ||
| Sealing ring thickness | - | 1.91-1.97 mm (0.0752-0.0776 in.) | 1.86 mm (0.0732 in.) | ||
| Width of sealing ring groove | - | 2.025-2.060 mm (0.0797-0.0811 in.) | 2.080 mm (0.0819 in.) | ||
| Clutch feed pipe O.D. | 3rd clutch feed pipe | 11.47-11.48 mm (0.4516-0.4520 in.) | 11.45 mm (0.4508 in.) | ||
| 1st clutch feed pipe | 6.97-6.98 mm (0.2744-0.2748 in.) | 6.95 mm (0.2736 in.) | |||
| Clutch feed pipe bushing O.D. | 3rd clutch feed pipe | 11.500-11.518 mm (0.4528-0.4553 in.) | 11.530 mm (0.4539 in.) | ||
| 1st clutch feed pipe | 7.018-7.030 mm (0.2763-0.2768 in.) | 7.045 mm (0.2774 in.) | |||
| ATF guide collar of sealing ring contact I.D. | - | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | ||
| Idler gear shaft | Diameter of needle bearing contact area | End cover side | 32.003-32.013 mm (1.2600-1.2604 in.) | When worn or damaged | |
| Thickness of cotters | - | 1.39-1.42 mm (0.0547-0.0559 in.) | - | ||
| Reverse idler gear | Reverse idler gear shaft diameter at needle bearing contact area | - | 14.99-15.00 mm (0.5902-0.5906 in.) | When worn or damaged | |
| I.D. | - | 20.007-20.020 mm (0.7877-0.7882 in.) | When worn or damaged | ||
| I.D. of reverse idler gear shaft contact area on transmission housing | - | 14.800-14.818 mm (0.5827-0.5834 in.) | - | ||
| I.D. of reverse idler gear shaft holder | - | 14.800-14.824* mm (0.5827-0.5836 in.) | When worn or damaged | ||
| ATF pump | ATF pump thrust clearance | - | 0.03-0.06 mm (0.001-0.002 in.) | 0.07 mm (0.003 in.) | |
| ATF pump gear-to-body clearance | Drive gear | 0.210-0.265 mm (0.008-0.010 in.) | - | ||
| Driven gear | 0.070-0.125 mm (0.003-0.005 in.) | - | |||
| ATF pump driven gear I.D. | - | 14.016-14.034 mm (0.5518-0.5525 in.) | When worn or damaged | ||
| ATF pump driven gear shaft O.D. | - | 13.980-13.990 mm (0.5504-0.5508 in.) | When worn or damaged | ||
| Stator shaft | Needle bearing contact I.D. | Torque converter side | 27.000-27.021 mm (1.063-1.064 in.) | When worn or damaged | |
| ATF pump side | 29.000-29.021 mm (1.1417-1.1426 in.) | - | |||
| Sealing ring contact area I.D. | - | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | ||
| Reverse shift fork | Fork finger thickness | - | 5.90-6.00 mm (0.232-0.236 in.) | 5.40 mm (0.213 in.) | |
| Park gear and pawl | - | - | - | When worn or damaged | |
| Servo body | Shift fork shaft bore I.D. | - | 14.000-14.010 mm (0.5512-0.5516 in.) | - | |
| Shift fork shaft valve bore I.D. | - | 37.000-37.039 mm (1.4567-1.4582 in.) | 37.045 mm (1.4585 in.) | ||
| Regulator valve body | Sealing ring contact I.D. | - | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | |
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | |||
|---|---|---|---|---|---|---|
| Wire Diameter | O.D. | Free Length | No. of Coils | |||
| Main valve body spring (see ) | Shift valve A spring | - | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 |
| Shift valve B spring | - | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | |
| Shift valve C spring | - | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | |
| Relief valve spring | - | 1.0 mm (0.039 in.) | 9.6 mm (0.378 in.) | 34.1 mm (1.343 in.) | 10.2 | |
| Lock-up control valve spring | - | 0.65 mm (0.026 in.) | 7.1 mm (0.280 in.) | 23.1 mm (0.909 in.) | 12.7 | |
| Cooler check valve spring | - | 0.85 mm (0.033 in.) | 6.6 mm (0.260 in.) | 27.0 mm (1.063 in.) | 11.3 | |
| Servo control valve spring | - | 0.7 mm (0.028 in.) | 6.6 mm (0.260 in.) | 35.7 mm (1.406 in.) | 17.2 | |
| Shift valve E spring | - | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | |
| Regulator valve body spring (see ) | Stator reaction spring | - | 4.5 mm (0.177 in.) | 35.4 mm (1.394 in.) | 30.3 mm (1.193 in.) | 1.92 |
| Regulator valve spring A | - | 1.9 mm (0.075 in.) | 14.7 mm (0.579 in.) | 80.6 mm (3.173 in.) | 16.1 | |
| Regulator valve spring B | - | 1.6 mm (0.063 in.) | 9.2 mm (0.362 in.) | 44.0 mm (1.732 in.) | 12.5 | |
| Torque converter check valve spring | - | 1.2 mm (0.047 in.) | 8.6 mm (0.339 in.) | 33.8 mm (1.331 in.) | 12.2 | |
| Lock-up shift valve spring | - | 1.0 mm (0.039 in.) | 6.6 mm (0.260 in.) | 35.5 mm (1.398 in.) | 18.2 | |
| 3rd accumulator spring | - | 2.5 mm (0.098 in.) | 14.6 mm (0.575 in.) | 29.9 mm (1.177 in.) | 4.9 | |
| 1st accumulator spring A | - | 2.4 mm (0.094 in.) | 18.6 mm (0.732 in.) | 49.0 mm (1.929 in.) | 7.1 | |
| 1st accumulator spring B | - | 2.3 mm (0.091 in.) | 12.2 mm (0.480 in.) | 31.5 mm (1.240 in.) | 6.6 | |
| Servo body spring (see ) | Shift valve D spring | - | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 |
| 4th accumulator spring B | - | 2.3 mm (0.091 in.) | 12.2 mm (0.480 in.) | 31.5 mm (1.240 in.) | 6.6 | |
| 4th accumulator spring A | - | 2.4 mm (0.094 in.) | 18.6 mm (0.732 in.) | 49.0 mm (1.929 in.) | 7.1 | |
| 2nd accumulator spring B | - | 2.1 mm (0.083 in.) | 10.8 mm (0.425 in.) | 34.0 mm (1.339 in.) | 8.2 | |
| 2nd accumulator spring A | - | 2.1 mm (0.083 in.) | 16.6 mm (0.654 in.) | 48.7 mm (1.917 in.) | 8.4 | |
| 5th accumulator spring | - | 2.5 mm (0.098 in.) | 14.6 mm (0.575 in.) | 29.9 mm (1.177 in.) | 4.9 | |
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| A/T differential carrier | Pinion shaft contact area I.D. | - | 18.000-18.025 mm (0.709-0.719 in.) | - |
| Carrier-to-pinion shaft clearance | - | 0.017-0.109 mm (0.001-0.004 in.) | - | |
| Driveshaft contact area I.D. | - | 28.015-28.045 mm (1.103-1.104 in.) | - | |
| Carrier-to-driveshaft clearance | - | 0.035-0.086 mm (0.002-0.003 in.) | 0.12 mm (0.005 in.) | |
| Carrier bearing starting torque (preload) | For new bearing | 2.7-3.9 N.m (28-40 kgf.cm, 24-35 lbf.in.) | Adjust | |
| For used bearing | 2.5-3.6 N.m (25-37 kgf.cm, 22-32 lbf.in.) | Adjust | ||
| Final driven gear backlash | - | 0.085-0.144 mm (0.003-0.006 in.) | 0.2 mm (0.008 in.) | |
| A/T differential pinion gear | Backlash | - | 1.1-1.6 mm (0.04-0.06 in.) | - |
| I.D. | - | 18.042-18.066 mm (0.7103-0.7113 in.) | - | |
| Pinion gear-to-pinion shaft clearance | - | 0.059-0.095 mm (0.0023-0.0037 in.) | 0.12 mm (0.005 in.) | |
| Transfer assembly | Diameter of transfer shaft on bearing contact area | At roller bearing | 38.485-38.500 mm (1.5152-1.5157 in.) | 38.43 mm (1.513 in.) |
| At tapered roller bearing | 24.975-24.990 mm (0.9833-0.9839 in.) | 24.92 mm (0.9811 in.) | ||
| Transfer drive gear diameter | At tapered roller bearing | 40.002-40.018 mm (1.5749-1.5755 in.) | 38.95 mm (1.533 in.) | |
| Diameter of transfer driven gear on tapered roller bearing contact area | At driven gear side | 35.002-35.018 mm (1.3780-1.3787 in.) | 34.95 mm (1.376 in.) | |
| At shaft splines side | 26.975-26.988 mm (1.0620-1.0625 in.) | 26.92 mm (1.060 in.) | ||
| Transfer gear backlash | - | 0.06-0.16 mm (0.002-0.006 in.) | Adjust | |
| Total starting torque (preload) | - | 1.96-3.14 N.m (20.0-32.0 kgf.cm, 17.4-27.8 lbf.in.) | Adjust |