A/T - Poor 1st to 2nd Gear Upshift/Harsh Shifts
Group: TRANSAXLENumber: 96-40-016
Date: SEPTEMBER, 1996
Model: 90-94 EXCEL & SONATA
92-95 ELANTRA, 91-92 SCOUPE
Subject:
KICKDOWN SERVO SEAL REPLACEMENT AND SERVO ADJUSTMENT
THIS TSB SUPERSEDES TSB # 94A0-O1O "KICKDOWN SERVO SEAL REPLACEMENT AND SERVO ADJUSTMENT"
DESCRIPTION:
The kickdown servo should be checked if the following conditions occur:
Poor shift quality on the 1-2 upshift
Harsh shift complaints that have developed after 15,000 to 20,000 miles
The procedure below describes the inspection and repair of the kickdown servo.
SERVICE PROCEDURE:
1. Wear proper eye protection and completely remove all dirt and other materials around the kickdown servo switch cover.
2. Remove the snap ring.
3. Remove the kickdown servo switch cover.
4. Hold the kickdown servo rod from turning by holding the kickdown servo socket wrench (09454-331018) and loosen the locknut by turning the kickdown servo socket wrench (09454-33101A) counterclockwise.
5. Loosen the locknut approximately 3-4 threads to the edge of the flat groove on the servo rod.
6. Remove the inner snap ring.
7. If the servo piston cannot be moved out of the bore, remove the plug from the kickdown brake pressure port and apply air (no more than 25 psi) to the port to move the servo assembly outward for easy removal. CAUTION: Hold a rag over the bore to catch the servo piston.
8. Separate the kickdown servo sleeve from the servo piston. Remove the O-ring on the servo sleeve and replace it with a new one. Remove the D-rings from the servo piston and replace them with new ones. Always lubricate the rubber O-rings and D-rings with ATF before assembly.
NOTE:
Check the kickdown servo bore for scratches and nicks. Polish the bore with emery cloth, if necessary.
9. For vehicles with an air exhaust plug, check the air exhaust plug with a steel wire and ensure that the steel retainer is in position as shown in TSB number 92-40-007. If the steel retainer has come out of position and entered the kickdown servo bore, scoring of the bore may have occurred. Light scoring may be polished out. Deep scoring will require ATM case replacement.
10. Carefully reinstall the kickdown servo assembly into its bore and install the snap ring.
11. Using the kickdown servo wrench, 09454-33101B, turn the kickdown servo rod clockwise and torque to 10 Nm. (7.2 lb-ft).
CAUTION:
Confirm that the locknut is loose on the servo rod and does not interfere with the torque adjustment
12. Loosen the servo rod two turns.
13. As a final step, torque the servo rod to 5 Nm. (3.6 lb-ft), then loosen the servo rod 2 to 2-1/4 turns.
14. Hold the kickdown servo rod from turning using the kickdown servo wrench (09454-33101B) and tighten the locknut with the kickdown servo socket wrench (09454-33101A) to specification.
Locknut: 25-32 Nm. (250 - 320 kg.cm., 18 - 23 lb.ft.)
15. Install a new 0-ring in the groove surrounding the kickdown servo switch cover. Install the kickdown servo switch cover into the case, then install the snap ring.
WARRANTY INFORMATION:
Normal warranty operation codes and time apply.