Attachment III - Technical Information
AX4S Low/Intermediate Servo Cover ReplacementINSPECTION
1. Check and record serial number and part number on transaxle build l.D. tag. See Figure 1. This ID tag is located on the top of the transaxle converter housing.
2. Using application table below, cross-reference vehicle line with corresponding transaxle part and serial numbers. See Figure 2.
^ If the serial number is not within the serial numbers in the table, no service action is required. Return vehicle to customer.
^ If the serial number is within the serial numbers in the table, proceed to "Service Procedure."
SERVICE PROCEDURE
1. Raise vehicle on hoist and position a drain pan under the transmission.
2. Remove heat shield from one transaxle case nib above servo cover. Position shield aside. See Figure 3.
3. On some models, there may be a catalytic converter reinforcement bracket that gets in the way when trying to remove the servo cover. Remove bolt from the bracket, then use the bolt as a spacer to hold the bracket away from the transaxle. See Figure 4.
4. NOTE:
The low/intermediate servo cover is under spring tension.
Remove three (3) servo retaining screws, then remove servo cover from piston as follows. Refer to Figure 5.
^ Obtain a 1/4 inch extension which is at least 14 inches long.
^ To compress the servo piston, move servo cover so that at the right hand side of the servo cover you can see a gap between the servo cover and the piston. Insert the end of the 1/4 inch extension at about the 4 o'clock position between the servo cover and piston.
^ Using the side of the catalytic converter as a fulcrum point, pull on the bottom end of the extension to move the piston inward. Be sure the force applied is near the center of the piston.
^ While holding the piston against spring tension, manipulate and rotate the servo cover to remove it from the piston.
^ The servo cover must be rotated so that the open side of the servo cover is facing up. In this position, the servo cover can be removed by sliding it across the top side of the bracket.
5. Remove and discard servo cover, O-ring seal and gasket.
6. Remove O-ring seal from servo piston. See Figure 6. Obtain new servo piston O-ring seal. Lubricate new O-ring seal with petroleum jelly and install it on the servo piston.
7. Obtain new servo cover, O-ring seal and gasket. Lubricate the inside of the servo cover and the O-ring. Install the O-ring onto the servo cover. Use petroleum jelly at each corner of the gasket to hold it in place, and install it onto the servo cover. See Figure 7.
8. Compress the servo piston and spring, and position the servo cover over the servo piston. Align the tab on the servo cover with the port on the transaxle case.
9. While holding the servo cover in place, hand start the servo cover retaining bolts. Evenly tighten the retaining bolts two or three turns at a time to prevent cocking the servo cover. Tighten bolts to 9-12 Nm (80 106 lb/in).
10. Install heat shield on transaxle case nib above servo cover.
11. Reinstall the bolt on the catalytic converter reinforcement bracket and lower the vehicle.
12. NOTE:
Vehicle road test is not necessary for this repair.
Start engine and move gear selector lever through all ranges allowing transaxle to engage in each position. With engine still running, check transaxle fluid level and adjust as necessary with Mercon Automatic Transmission Fluid.