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Automatic Transmission and A/T Differential

AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION TABLE

Item Measurement Qualification Standard or New Service Limit
Automatic transmission fluid Capacity Use Honda ATF-Z1 Fluid change 2.5 L (2.6 US qt) -
Overhaul 5.85 L (6.18 US qt) -
ATF pressure Line pressure At 2, 000 rpm in P or N 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 1st gear in S or 1 890-970 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 2nd gear in S or 2 890-970 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 S or D3 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 S or D 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 S or D 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, 200 rpm  
Service limit 2, 050-2, 350 rpm  
Clutch Clearance between clutch end-plate and top disc 1st 1.62-1.82 mm (0.064-0.072 in.) -
2nd 0.5-0.7 mm (0.020-0.028 in.) -
3rd 0.73-0.93 mm (0.029-0.037 in.) -
4th 0.7-0.9 mm (0.028-0.035 in.) -
5th 0.73-0.93 mm (0.029-0.037 in.) -
Clutch return spring free length 1st 36.0 mm (1.42 in.) 34.5 mm (1.36 in.)
2nd 39.4 mm (1.56 in.) 37.4 mm (1.47 in.)
3rd 45.15 mm (1.778 in.) 43.0 mm (1.69 in.)
4th 39.4 mm (1.55 in.) 37.4 mm (1.47 in.)
5th 45.15 mm (1.778 in.) 43.0 mm (1.69 in.)
Clutch disc thickness 1st 1.94 mm (0.076 in.) -
2nd 1.96 mm (0.077 in.) -
3rd 1.94 mm (0.076 in.) -
4th 1.96 mm (0.077 in.) -
5th 1.94 mm (0.076 in.) -
Clutch plate thickness 1st 1.6 mm (0.063 in.) When discolored
2nd 2.3 mm (0.091 in.) When discolored
3rd 2.0 mm (0.079 in.) When discolored
4th 1.6 mm (0.063 in.) When discolored
5th 2.0 mm (0.079 in.) When discolored
Clutch wave-plate height 1st, 3rd, and 5th clutches 0.07-0.20 mm (0.003-0.008 in.) 0.05 mm (0.002 in.)
1st, 3rd, and 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 (0.094 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
2nd and 4th clutch end-plate thickness Mark AC or AM 2.1 mm (0.083 in.) When discolored
Mark AD or AN 2.2 mm (0.087 in.) When discolored
Mark AE or AP 2.3 mm (0.091 in.) When discolored
Mark AF or AQ 2.4 mm (0.094 in.) When discolored
Mark AG or AR 2.5 mm (0.098 in.) When discolored
Mark AH or AS 2.6 mm (0.102 in.) When discolored
Mark AJ or AT 2.7 mm (0.106 in.) When discolored
Mark AK or AU 2.8 mm (0.110 in.) When discolored
Mark AL or AV 2.9 mm (0.114 in.) When discolored
ATF pump ATF pump thrust clearance - 0.03-0.06 mm (0.001-0.002 in.) 0.07 mm (0.003 in.)
Clearance between ATF pump gear and main valve body Drive gear 0.210-0.265 mm (0.0083-0.0104 in.) -
Driven gear 0.070-0.125 mm (0.0028-0.0049 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 I.D. at needle bearing contact 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.) -
I.D. at sealing ring contact area - 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.) When worn or damaged
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 Mainshaft sealing ring contact I.D. - 29.000-29.021 mm (1.1417-1.1426 in.) 29.05 mm (1.144 in.)
Mainshaft Diameter of needle bearing contact area Stator shaft 22.984-23.000 mm (0.9049-0.9055 in.) When worn or damaged
5th gear collar 31.975-31.991 mm (1.2589-1.2595 in.) When worn or damaged
3rd gear 46.986-46.999 mm (1.8498-1.8503 in.) When worn or damaged
I.D. of gears 5th gear 37.000-37.016 mm (1.4567-1.4573 in.) When worn or damaged
3rd gear 52.000-52.013 mm (2.0472-2.0478 in.) When worn or damaged
Axial clearance of gears 5th gear 015-0.27 mm (0.006-0.106 in.) -
3rd gear 0.04-0.10 mm (0.002-0.004 in.) -
40 x 63 mm thrust washer thickness No. 1 3.750 mm (0.1476 in.) When worn or damaged
No. 2 3.775 mm (0.1486 in.) When worn or damaged
No. 3 3.800 mm (0.1496 in.) When worn or damaged
No. 4 3.825 mm (0.1506 in.) When worn or damaged
No. 5 3.850 mm (0.1516 in.) When worn or damaged
No. 6 3.875 mm (0.1526 in.) When worn or damaged
No. 7 3.900 mm (0.1535 in.) When worn or damaged
No. 8 3.925 mm (0.1545 in.) When worn or damaged
No. 9 3.950 mm (0.1555 in.) When worn or damaged
No. 10 3.975 mm (0.1565 in.) When worn or damaged
No. 11 4.000 mm (0.1575 in.) When worn or damaged
5th gear collar length - 60.4-60.5 mm (2.380-2.381 in.) -
5th gear collar flange thickness - 3.70-3.85 mm (0.146-0.152 in.) When worn or damaged
Sealing ring thickness - 1.91-1.97 mm (0.0752-0.0776 in.) 1.86 mm (0.0732 in.)
Sealing ring groove width - 2.025-2.060 mm (0.0797-0.0811 in.) 2.080 mm (0.0819 in.)
Clutch feed pipe O.D. 3rd clutch 7.97-7.98 mm (0.3138-0.3142 in.) 7.95 mm (0.313 in.)
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 Torque converter housing bearing 33.504-33.517 mm (1.3191-1.3196 in.) When worn or damaged
5th gear 32.986-32.999 mm (1.2987-1.2991 in.) When worn or damaged
Reverse selector hub 35.983-35.999 mm (1.4167-1.4173 in.) When worn or damaged
I.D. of gears 5th gear 39.000-39.016 mm (1.5354-1.5361 in.) When worn or damaged
Reverse gear 42.000-42.016 mm (1.6535-1.6542 in.) When worn or damaged
Axial clearance of gears 5th gear 0.04-0.27 mm (0.002-0.011 in.) -
Reverse gear 0.10-0.25 mm (0.004-0.010 in.) -
Reverse selector hub width - 29.25-29.45 mm (1.152-1.160 in.) -
Collar, 33.2 x 40 x 26 mm length - 25.95-26.00 mm (1.022-1.024 in.) -
Reverse selector hub O.D. - 51.87-51.90 mm (2.042-2.043 in.) When worn or damaged
Secondary shaft Diameter of needle bearing contact area 1st gear 30.986-30.999 mm (1.2199-1.2204 in.) When worn or damaged
2nd gear 42.986-42.999 mm (1.6924-1.6929 in.) When worn or damaged
4th gear collar 34.975-34.991 mm (1.3770-1.3776 in.) When worn or damaged
I.D. of gears 1st gear 38.000-38.016 mm (1.4961-1.4967 in.) When worn or damaged
2nd gear 49.000-49.016 mm (1.9291-1.9298 in.) When worn or damaged
4th gear 41.000-41.016 mm (1.6142-1.6148 in.) When worn or damaged
Axial clearance 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.) -
4th gear 0.10-0.22 mm (0.004-0.009 in.) -
31 x 50 mm thrust washer thickness No. 1 3.925 mm (0.1545 in.) When worn or damaged
No. 2 3.950 mm (0.1555 in.) When worn or damaged
No. 3 3.975 mm (0.1565 in.) When worn or damaged
No. 4 4.000 mm (0.1575 in.) When worn or damaged
No. 5 4.025 mm (0.1585 in.) When worn or damaged
No. 6 4.050 mm (0.1594 in.) When worn or damaged
No. 7 4.075 mm (0.1604 in.) When worn or damaged
No. 8 4.100 mm (0.1614 in.) When worn or damaged
No. 9 4.125 mm (0.1624 in.) When worn or damaged
No. 10 4.150 mm (0.1634 in.) When worn or damaged
No. 11 4.175 mm (0.1644 in.) When worn or damaged
No. 12 4.200 mm (0.1654 in.) When worn or damaged
No. 13 4.225 mm (0.1663 in.) When worn or damaged
No. 14 4.250 mm (0.1673 in.) When worn or damaged
No. 15 4.275 mm (0.1683 in.) When worn or damaged
No. 16 4.300 mm (0.1693 in.) When worn or damaged
No. 17 4.325 mm (0.1703 in.) When worn or damaged
43 x 54.5 mm thrust washer thickness No. 1 2.900 mm (0.114 in.) When worn or damaged
No. 2 2.925 mm (0.115 in.) When worn or damaged
No. 3 2.950 mm (0.116 in.) When worn or damaged
No. 4 2.975 mm (0.117 in.) When worn or damaged
No. 5 3.000 mm (0.118 in.) When worn or damaged
No. 6 3.025 mm (0.119 in.) When worn or damaged
No. 7 3.050 mm (0.120 in.) When worn or damaged
No. 8 3.075 mm (0.121 in.) When worn or damaged
No. 9 3.100 mm (0.122 in.) When worn or damaged
No. 10 3.125 mm (0.123 in.) When worn or damaged
No. 11 3.150 mm (0.124 in.) When worn or damaged
No. 12 3.175 mm (0.125 in.) When worn or damaged
No. 13 3.200 mm (0.126 in.) When worn or damaged
4th gear collar length - 32.9-33.0 mm (1.295-1.299 in.) -
4th gear collar flange thickness - 3.75-3.90 mm (0.148-0.154 in.) When worn or damaged
Sealing ring thickness - 1.87-1.97 mm (0.074-0.078 in.) 1.82 mm (0.072 in.)
Sealing ring groove width - 2.025-2.060 mm (0.0797-0.0811 in.) 2.080 mm (0.0819 in.)
Clutch feed pipe O.D. 2nd clutch 6.97-6.98 mm (0.2744-0.2748 in.) 6.95 mm (0.2736 in.)
4th clutch 11.47-11.48 mm (0.4516-0.4520 in.) 11.45 mm (0.4508 in.)
Clutch feed pipe bushing O.D. 2nd 7.018-7.030 mm (0.2763-0.2768 in.) 7.045 mm (0.2774 in.)
4th 11.500-11.518 mm (0.4528-0.4535 in.) 11.530 mm (0.4539 in.)
ATF guide collar of sealing ring contact I.D. - 21.200-21.221 mm (0.8346-0.8355 in.) 21.25 mm (0.8366 in.)
Idler gear shaft Diameter of needle bearing contact area End cover side 30.003-30.013 mm (1.1812-1.1816 in.) When worn or damaged
Thickness of cotters - 1.39-1.42 mm (0.055-0.056 in.) -
Reverse idler gear Reverse idler gear shaft O.D. at needle bearing contact area - 14.99-15.00 mm (0.590-0.591 in.) When worn or damaged
I.D. - 20.001-20.014 mm (0.7874-0.7880 in.) When worn or damaged
I.D. of transmission housing of gear contact area - 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
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 ) Cut valve B spring - 0.8 mm (0.031 in.) 9.9 mm (0.390 in.) 27.3 mm (1.075 in.) 8.0
Shift valve A spring - 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7
Shift valve C spring - 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7
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 - 0.6 mm (0.024 in.) 7.1 mm (0.280 in.) 29.6 mm (1.165 in.) 11.2
Cooler check valve spring - 0.85 mm (0.033 in.) 6.6 mm (0.260 in.) 27.0 mm (1.063 in.) 11.3
Shift valve D spring - 0.8 mm (0.031 in.) 5.6 mm (0.220 in.) 28.1 mm (1.106 in.) 15.9
Servo control valve spring - 0.8 mm (0.031 in.) 9.9 mm (0.390 in.) 27.3 mm (1.075 in.) 8.0
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.) 44.00 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
1st accumulator spring B - 2.4 mm (0.094 in.) 12.2 mm (0.480 in.) 35.0 mm (1.378 in.) 7.7
1st accumulator spring A - 2.4 mm (0.094 in.) 18.6 mm (0.732 in.) 50.1 mm (1.972 in.) 6.7
4th accumulator spring - 2.5 mm (0.098 in.) 14.6 mm (0.575 in.) 29.9 mm (1.177 in.) 4.9
Servo body spring (see ) Cut valve A spring - 0.9 mm (0.035 in.) 9.9 mm (0.390 in.) 22.3 mm (0.878 in.) 6.9
Shift valve B spring - 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7
5th accumulator spring A - 2.5 mm (0.098 in.) 16.6 mm (0.654 in.) 46.9 mm (1.846 in.) 7.8
5th accumulator spring B - 1.9 mm (0.075 in.) 10.0 mm (0.394 in.) 38.5 mm (1.516 in.) 10.6
2nd accumulator spring A - 1.8 mm (0.071 in.) 14.6 mm (0.575 in.) 43.8 mm (1.724 in.) 7.9
2nd accumulator spring B - 1.85 mm (0.073 in.) 9.4 mm (0.370 in.) 32.5 mm (1.280 in.) 8.7
3rd accumulator spring A - 1.8 mm (0.071 in.) 14.6 mm (0.575 in.) 43.8 mm (1.724 in.) 7.9
3rd accumulator spring B - 1.85 mm (0.073 in.) 9.4 mm (0.370 in.) 32.5 mm (1.280 in.) 8.7
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. - 18.010-18.028 mm (0.7091-0.7098 in.) -
Clearance between carrier and pinion shaft - 0.023-0.057 mm (0.0009-0.0022 in.) 0.1 mm (0.004 in.)
Driveshaft contact area I.D. - 26.025-26.045 mm (1.0246-1.0254 in.) -
Clearance between carrier and driveshaft - 0.045-0.086 mm (0.0018-0.0034 in.) 0.12 mm (0.005 in.)
Intermediate shaft contact area I.D. - 26.025-26.045 mm (1.0246-1.0254 in.) -
Clearance between carrier and intermediate shaft - 0.075-0.111 mm (0.0030-0.0044 in.) 0.12 mm (0.005 in.)
Tapered roller bearing starting torque (preload) For new bearing 2.7-3.9 N.m (28-40 kgf.cm, 24-35 lbf.in.) Adjust
For reused bearing 2.5-3.6 N.m (25-37 kgf.cm, 22-32 lbf.in.) Adjust
Final driven gear backlash References 0.085-0.144 mm (0.0033-0.0057 in.) 0.2 mm (0.01 in.)
A/T differential pinion gear Backlash - 0.05-0.15 mm (0.002-0.006 in.) -
I.D. - 18.042-18.066 mm (0.7103-0.7113 in.) -
Clearance between pinion gear and pinion shaft - 0.055-0.095 mm (0.0022-0.0037 in.) 0.12 mm (0.005 in.)
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