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Automatic Transmission and A/T Differential

Item
Measurement
Qualification
Standard or New
Service Limit
Automatic transmission fluid
Capacity
Use genuine Honda ATF-Z1
Fluid change
2.5 L (2.6 US qt, 2.2 Imp qt)
Overhaul
5.85 L (6.18 US qt, 5.15 Imp qt)
Pressure (Seven-position transmission)
Line pressure
At 2,000 rpm (min −1 ) in P or N
900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 psi)
850 kPa (8.7 kgf/cm 2 , 120 psi)
1st clutch pressure
At 2,000 rpm (min −1 ) in 1
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
2nd clutch pressure
At 2,000 rpm (min −1 ) in 2
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
3rd clutch pressure
At 2,000 rpm (min −1 ) in 3rd gear in D3
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
4th clutch pressure
At 2,000 rpm (min −1 ) in 4th gear in D
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
5th clutch pressure
At 2,000 rpm (min −1 ) in 5th gear in D
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
Pressure (Five-position transmission)
Line pressure
At 2,000 rpm (min −1 ) in P or N
900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 psi)
850 kPa (8.7 kgf/cm 2 , 120 psi)
1st clutch pressure
At 2,000 rpm (min −1 ) in 1st gear in S
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
2nd clutch pressure
At 2,000 rpm (min −1 ) in 2nd gear in S
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
3rd clutch pressure
At 2,000 rpm (min −1 ) in 3rd gear in S
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
4th clutch pressure
At 2,000 rpm (min −1 ) in 4th gear in S
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
5th clutch pressure
At 2,000 rpm (min −1 ) in 5th gear in S
890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 psi)
840 kPa (8.6 kgf/cm 2 , 120 psi)
Torque converter
Stall speed
Check with vehicle on level ground
2,200 rpm (min −1 )
2,050−2,350 rpm (min −1 )


Automatic Transmission and A/T Differential (cont'd)

Item
Measurement
Qualification
Standard or New
Service Limit
Clutch
Clutch 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
35.2 mm (1.39 in.)
34.5 mm (1.36 in.)
2nd
39.5 mm (1.56 in.)
37.4 mm (1.47 in.)
3rd
45.15 mm (1.778 in.)
43.0 mm (1.69 in.)
4th
39.5 mm (1.56 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 waved-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



Item
Measurement
Qualification
Standard or New
Service Limit
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 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
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 (0.5512−0.5526 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
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
At stator shaft
22.984−23.000 mm (0.9049−0.9055 in.)
When worn or damaged
At 5th gear collar
32.975−32.991 mm (1.2982−1.2989 in.)
When worn or damaged
At 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
End play
5th gear
0.15−0.27 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.)
Width of sealing ring groove
2.025−2.060 mm (0.0797−0.0811 in.)
2.080 mm (0.0819 in.)
3rd clutch feed pipe O.D.
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.)


Automatic Transmission and A/T Differential (cont'd)

Item
Measurement
Qualification
Standard or New
Service Limit
Countershaft
Diameter of needle bearing contact area
At torque converter housing
33.504−33.517 mm (1.3191−1.3196 in.)
When worn or damaged
At 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
End play
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 - 1/2
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
End play
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



Item
Measurement
Qualification
Standard or New
Service Limit
Secondary shaft - 2/2
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.)
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.
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 clutch
7.018−7.030 mm (0.2763−0.2768 in.)
7.045 mm (0.2774 in.)
4th clutch
11.500−11.518 mm (0.4528−0.4553 in.)
11.530 mm (0.4539 in.)
ATF guide collar I.D. at sealing ring contact area
21.200−21.221 mm (0.8346−0.8355 in.)
21.25 mm (0.8366 in.)
Idler gear shaft
End cover bearing contact area
30.003−30.013 mm (1.1812−1.1816 in.)
When worn or damaged
Cotters thickness
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 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



Item
Measurement
Qualification
Standard or New
Wire Diameter
O.D.
Free Length
No. of Coils
Main valve body spring
Cut valve B spring
0.8 mm (0.031 in.)
9.9 mm (0.290 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 (0.290 in.)
27.3 mm (1.075 in.)
8.0
Regulator valve body spring
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
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


Automatic Transmission and A/T Differential (cont'd)

Item
Measurement
Qualification
Standard or New
Wire Diameter
O.D.
Free Length
No. of Coils
Servo body spring
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



Item
Measurement
Qualification
Standard or New
Service Limit
A/T differential carrier
Pinion shaft contact area I.D.
18.010−18.028 mm (0.709−0.710 in.)
———
Clearance between carrier and pinion shaft
0.023−0.057 mm (0.001−0.002 in.)
0.1 mm (0.004 in.)
Driveshaft contact area I.D.
26.025−26.045 mm (1.024−1.025 in.)
———
Clearance between carrier and driveshaft
0.045−0.086 mm (0.002−0.003 in.)
0.12 mm (0.005 in.)
Intermediate shaft contact area I.D.
26.025−26.045 mm (1.024−1.025 in.)
———
Clearance between carrier and Intermediate shaft
0.045−0.086 mm (0.002−0.003 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
Reference
0.085−0.144 mm (0.003−0.006 in.)
0.2 mm (0.008 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 (0.002−0.004 in.)
0.12 mm (0.005 in.)