Content .. 6 7 8 9 ..

Honda Odyssey 2004. Manual - part 8

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4-speed Automatic Transmission and Differential - 1999-2001 Models

Item

Measurement

Qualification

Standard or New

Service Limit

2-6

Standards and Service Limits

ATF (Automatic

Transmission

Fluid)

Capacity

Use Honda ATF-Z1 (ATF)

Fluid change

2.9

(3.1 US qt)

Overhaul

7.2

(7.6 US qt)

ATF pressure

Line pressure

At 2,000 rpm in

N or P position

850

910 kPa

(8.7

9.3 kgf/cm , 120

130 psi)

800 kPa

(8.2 kgf/cm , 120 psi)

4th clutch pressure

At 2,000 rpm in

D4 position

840

920 kPa

(8.6

9.4 kgf/cm , 120

130 psi)

790 kPa

(8.1 kgf/cm , 120 psi)

3rd clutch pressure

At 2,000 rpm in

D4 position

840

920 kPa

(8.6

9.4 kgf/cm , 120

130 psi)

790 kPa

(8.1 kgf/cm , 120 psi)

2nd clutch pressure

At 2,000 rpm in

2 position

840

920 kPa

(8.6

9.4 kgf/cm , 120

130 psi)

790 kPa

(8.1 kgf/cm , 120 psi)

1st clutch pressure

At 2,000 rpm in

1 position

840

920 kPa

(8.6

9.4 kgf/cm , 120

130 psi)

790 kPa

(8.1 kgf/cm , 120 psi)

Torque converter

Stall speed

Check with vehicle on level ground

2,400 rpm

2,250

2,550 rpm

Clutch

Clutch end plate-to-top disc

clearance

1st

1.2

1.4 mm

(0.047

0.055 in.)

2nd

0.85

1.05 mm

(0.033

0.041 in.)

3rd

0.55

0.75 mm

(0.022

0.030 in.)

4th

0.55

0.75 mm

(0.022

0.030 in.)

Clutch return spring free length

1st

45.7 mm (1.80 in.)

43.7 mm (1.72 in.)

2nd

63.0 mm (2.48 in.)

61.0 mm (2.40 in.)

3rd, 4th

33.5 mm (1.32 in.)

31.5 mm (1.24 in.)

Clutch disc thickness

1.94 mm (0.076 in.)

Clutch plate thickness

1st

2.0 mm (0.079 in.)

When discolored

2nd

2.0 mm (0.079 in.)

When discolored

3rd

2.3 mm (0.091 in.)

When discolored

4th

2.0 mm (0.079 in.)

When discolored

1st and 2nd clutch end plate thickness

Mark 1

3.10 mm (0.122 in.)

When discolored

Mark 2

3.20 mm (0.126 in.)

When discolored

Mark 3

3.30 mm (0.130 in.)

When discolored

Mark 4

3.40 mm (0.134 in.)

When discolored

Mark 6

2.60 mm (0.102 in.)

When discolored

Mark 7

2.70 mm (0.106 in.)

When discolored

Mark 8

2.80 mm (0.110 in.)

When discolored

Mark 9

2.90 mm (0.114 in.)

When discolored

Mark 0

3.00 mm (0.118 in.)

When discolored

3rd and 4th clutch end plate thickness

Mark 1

2.10 mm (0.083 in.)

When discolored

Mark 2

2.20 mm (0.087 in.)

When discolored

Mark 3

2.30 mm (0.091 in.)

When discolored

Mark 4

2.40 mm (0.094 in.)

When discolored

Mark 5

2.50 mm (0.098 in.)

When discolored

Mark 6

2.60 mm (0.102 in.)

When discolored

Mark 7

2.70 mm (0.106 in.)

When discolored

Mark 8

2.80 mm (0.110 in.)

When discolored

Mark 9

2.90 mm (0.114 in.)

When discolored

03/07/29 09:04:32 61S0X050_020_0006

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Item

Measurement

Qualification

Standard or New

Service Limit

2-7

Valve body

Stator shaft needle bearing contact I.D.

Torque converter

side

27.000

27.021 mm (1.0630

1.0638 in.) When worn or

damaged

ATF pump side

29.000

29.021 mm (1.1417

1.1426 in.) When worn or

damaged

ATF pump gear thrust clearance

0.03

0.06 mm (0.001

0.002 in.)

0.07 mm (0.003 in.)

ATF pump gear-to-body clearance

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

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.)

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.

32.000

32.025 mm (1.2598

1.2608 in.) 32.050 mm (1.2618 in.)

Accumulator

body

Sealing ring contact I.D.

35.000

35.025 mm (1.3780

1.3789 in.) 35.05 mm (1.3799 in.)

Stator shaft

Sealing ring contact I.D.

29.000

29.013 mm (1.1417

1.1422 in.) 29.050 mm (1.1437 in.)

03/07/29 09:04:33 61S0X050_020_0007

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4-speed Automatic Transmission and A/T Differential - 1999-2001 Models (cont’d)

Item

Measurement

Qualification

Standard or New

Service Limit

2-8

Standards and Service Limits

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 3rd gear

52.975

52.991 mm (2.0856

2.0863 in.) When worn or

damaged

At 4th gear collar

33.975

33.991 mm (1.3376

1.3382 in.) When worn or

damaged

I.D. of 3rd gear

59.000

59.019 mm (2.3228

2.3236 in.) When worn or

damaged

I.D. of 4th gear

40.000

40.016 mm (1.5748

1.5754 in.) When worn or

damaged

End play of 3rd gear

0.03

0.11 mm (0.001

0.004 in.)

End play of 4th gear

0.10

0.22 mm (0.004

0.009 in.)

41 x 73 mm thrust shim thickness

No. 1

7.85 mm (0.309 in.)

When worn or

damaged

No. 2

7.90 mm (0.311 in.)

When worn or

damaged

No. 3

7.95 mm (0.313 in.)

When worn or

damaged

No. 4

8.00 mm (0.315 in.)

When worn or

damaged

No. 5

8.05 mm (0.317 in.)

When worn or

damaged

No. 6

8.10 mm (0.319 in.)

When worn or

damaged

Thrust washer thickness

27 x 47 x 5 mm

5.00 mm (0.197 in.)

When worn or

damaged

Length of 4th gear collar

58.5

58.6 mm (2.303

2.307 in.)

4th gear collar flange thickness

4.45

4.60 mm (0.175

0.181 in.)

When worn or

damaged

Sealing ring thickness

32 mm sealing

ring

1.85

1.95 mm (0.073

0.077 in.)

1.800 mm (0.071 in.)

29 mm sealing

ring

1.85

1.95 mm (0.073

0.077 in.)

1.800 mm (0.071 in.)

Width of sealing ring groove

2.025

2.060 mm (0.080

0.081 in.)

2.080 mm (0.082 in.)

Clutch feed pipe O.D.

3rd clutch

5.97

5.98 mm (0.2350

0.2354 in.)

5.95 mm (0.2343 in.)

4th clutch

11.47

11.48 mm (0.4516

0.4520 in.)

11.45 mm (0.4508 in.)

Clutch feed pipe bushing I.D.

3rd clutch

6.018

6.030 mm (0.2369

0.2374 in.)

6.045 mm (0.2380 in.)

4th clutch

11.500

11.518 mm (0.4528

0.4535 in.) 11.530 mm (0.4539 in.)

03/07/29 09:04:33 61S0X050_020_0008

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Item

Measurement

Qualification

Standard or New

Service Limit

2-9

Countershaft

Diameter of needle bearing contact

area

At 4th gear

34.975

34.991 mm (1.3770

1.3776 in.) When worn or

damaged

At 2nd gear

39.979

40.000 mm (1.574

1.575 in.)

When worn or

damaged

At park gear

41.964

41.980 mm (1.6521

1.6528 in.) When worn or

damaged

At right end

38.505

38.515 mm (1.5159

1.5163 in.) When worn or

damaged

I.D. of 4th gear

41.000

41.016 mm (1.6142

1.6148 in.) When worn or

damaged

I.D. of idler gear

50.000

50.016 mm (1.9685

1.9691 in.) When worn or

damaged

I.D. of reverse gear

46.000

46.016 mm (1.8110

1.8116 in.) When worn or

damaged

End play of 1st gear

0.00

0.33 mm (0.000

0.013 in.)

End play of 4th gear

0.04

0.27 mm (0.002

0.011 in.)

End play of idler gear

0.015

0.045 mm (0.0006

0.0018 in.)

End play of reverse gear

0.10

0.25 mm (0.004

0.010 in.)

Length of distance collar

53.92

53.96 mm (2.123

2.124 in.)

Cotter thickness

1.99

2.02 mm (0.078

0.080 in.)

Reverse selector hub O.D.

55.87

55.90 mm (2.1996

2.2008 in.)

When worn or

damaged

03/07/29 09:04:33 61S0X050_020_0009

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