Solenoid Valves

CONTROL VALVE BODY








Disassembly

NOTICE:
a) Be especially careful when handling the control valve because it consists of the most precise and delicate parts of the transaxle. .
b) Neatly arrange removed parts to avoid confusing similar parts.
c) Clean removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes and passages with compressed air.

1. Remove oil pipe assembly.





2. Remove O-rings from oil pipe assembly.
3. Remove shift solenoid A.





4. Remove torque converter clutch solenoid valve and oil strainer.





5. Remove shift solenoids B and C.





6. Remove linear solenoid valve.





7. Remove nine bolts of upper control valve body.
8. Remove two screws from upper control valve body.





9. Remove gasket B, upper separator plate, oil filter, oil strainer and gasket A.





10. Remove seven main control valve body bolts, and remove main control valve.





11. Remove gasket D, main separator plate and gasket C.





12. Remove four rubber balls from main control valve body.





13. Remove oil strainer and two rubber balls from p remain control valve body.





14. Remove six bolts, then remove premain control valve body.





15. Remove gasket E, lower separator plate, oil filter and gasket F.





16. Remove oil strainer from lower control valve body.


Re-Assembly








NOTICE:
a) Before assembly, make sure all parts are perfectly clean.
b) Apply ATF to all parts.
c) Do not reuse gaskets or O-rings.




Rubber ball and oil strainer installation positions
Low control valve body




Premain control valve body
Lower control valve body side




Main control valve body side




Main control valve body
Premain control valve body side




Upper control valve body side




Upper control valve body




Bolt installation positions and external parts locations


1. Install oil strainer into lower control valve body, refer to Rubber ball and oil strainer installation positions diagram above.





2. Set oil filter into lower separator plate.





NOTICE: Gasket F and gasket E are not interchangeable. They are identified by their shape in area designated in illustration.





3. Set new gasket F, lower separator plate, and new gasket E onto lower valve body.




4. Set premain control valve body onto lower valve body and install seven bolts.




Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)





5. Install two rubber balls and oil strainers into their proper positions in premain control valve body. (Refer to Rubber ball and oil strainer installation positions diagram)




6. Install rubber balls into their proper positions in main control valve body. (Refer to Main control valve body)




NOTICE: Gasket C and gasket D are not interchangeable. They are identified by their shape in area designated in illustration.




7. Get the new gasket C, main separator plate and gasket D onto main control valve body.




8. Secure gasket C, main separator plate and gasket to main control valve body with two screws in locations shown.

Tightening torque: 11.3 - 16.5 inch lbs. (1.27 - 1.86 Nm, 13 - 19 kg.cm)

9. Set main control valve body onto premain control valve body.

NOTICE: Match bolt head letters as shown.




10. Loosely tighten bolts, refer to Bolt installation positions and external parts locations diagram.




11. Set the oil filter in upper separator plate.




NOTICE: Gasket A and gasket B are not interchangeable. They are identified by their shape in area designated in illustration.




12. Set new gasket A, upper separator plate and new gasket B onto upper control valve body.




13. Secure gasket A, upper separator plate and gasket B to upper control valve body with two screws in locations shown.




14. Set upper control valve body onto main control valve body and install nine bolts.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)

NOTICE: Match bolt head letters as shown.

15. Loosely tighten lower control valve body bolts. (Refer to Bolt installation positions and external parts locations diagram)




16. Install linear solenoid valve.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)




17. Install shift solenoids B and C, oil strainers and bracket.




18. Tighten mounting bolts.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)

19. Install torque converter clutch solenoid and oil strainer.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)




20. Install shift solenoid A and oil strainer onto upper valve body.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)

21. Apply AFT to new O-rings and install them onto oil pipe assembly.




22. Install oil pipe assembly.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)

23. Apply ATF to new O-ring and install it onto oil strainer assembly.




24. Install oil strainer onto control valve body and then tighten three bolts.

Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg.cm)

UPPER CONTROL VALVE BODY
Disassembly

NOTICE:
a) Each valve should slide in/out under its own weight.
b) When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hater.
c) If a valve surface or bore is scratched or damaged, replace control valve body.
d) Do not drop or lose valves or internal parts.
e) Before assembly, make sure all parts are thoroughly clean.
f) Apply ATF to all parts and bores.
g) Note proper direction of valves and internal parts.
h) Do not reuse any part that has been dropped.
i) Wrap a screwdriver or rod with tape before using it to insert a valve.





1. Disassemble in order shown in figure.

Inspection
1. Measure spring free lengths.





2. If not within specification, replace spring(s).

Re-Assembly
1. Insert solenoid reducing valve and solenoid reducing spring and secure them with spring retainer.





2. Insert RE accumulator valve and RE accumulator spring and secure them with spring retainer.

PREMAIN CONTROL VALVE BODY
Disassembly

NOTICE:
a) Each valve should slide in/out under its own weight.
b) When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hammer
c) If a valve surface or bore is scratched or damaged, replace control valve body.
d) Do not drop or lose valves or internal parts.
e) Before assembly, make sure all parts are thoroughly clean.
f) Apply ATF to all parts and bores.
g) Note proper direction of valves and internal parts.
h) Do not reuse any part that has been dropped.
i) Wrap a screwdriver or rod with tape before using it to insert valve.





1. Disassemble in order shown in figure.

Inspection
1. Measure spring free lengths.





2. If not within specification, replace spring(s).

Re-Assembly
1. Insert bypass spring, bypass valve and stop plug. Secure them with stop pin.





2. Insert 2-3 shift spring, 2-3 shift valve and plug. Secure them with stop pin.
3. Insert converter relief valve and converter relief spring. Secure them with spring retainer.





4. Insert lock-up control spring, lock-up control valve and stop plug. Secure them with stop pin.

MAIN CONTROL VALVE BODY
Disassembly

NOTICE:
a) Each valve should slide in/out under its own weight
b) When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hammer.
c) If a valve surface or bore is scratched or damaged, replace control valve body.
d) Do not drop or lose valves or internal parts.
e) Before assembly, make sure all parts are thoroughly clean.
f) Apply ATF to all parts and bores.
g) Note proper direction of valves and internal parts.
h) Do not reuse any part that has been dropped.
i) Wrap a screwdriver or rod with tape before using it to insert a valve.





1. Disassemble in order shown in figure.

Inspection
1. Measure spring free lengths.








2. If not within specification, replace spring(s).

Re-Assembly
1. Insert 3-4 shift spring, 3-4 shift valve and stop plug. Secure them with stop pin.
2. Insert low reducing spring, low reducing valve and stop plug. Secure them with stop pin.





3. Insert 1-2 shift spring, 1-2 shift valve and stop plug. Secure them with stop pin.





4. Insert pressure regulator valve, pressure regulator spring, pressure regulator spring seat, regulator plug sleeve, pressure regulator plug and stop plug. Secure them with roll pin.
5. Insert 2-3 timing valve and 2-3 timing spring.
Secure them with spring retainer.





6. Proceed to insert manual valve.