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00109000812

General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

00 11 12 13 14 15 16 17 21 22 23 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

WORKSHOP MANUALFOREWORDThis Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL PYDE9802 WORKSHOP MANUAL ENGINE GROUP PWEEjjjj (Looseleaf edition) ELECTRICAL WIRING PHDE9802 BODY REPAIR MANUAL PBDE9802 PARTS CATALOGUE SPACE RUNNER B608V509Aj SPACE WAGON B608W509Aj

Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............

Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Automatic Transmission . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Wheel and Tyre . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . .

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Rear Suspension . . . . . . . . . . . . . . . Service Brakes . . . . . . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental Restraint System (SRS) . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . .

GDI is the trade mark which Mitsubishi Motors Corporation holds.E Mitsubishi Motors CorporationAug. 1998

Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . . . .

WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more (3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

21-1

CLUTCHCONTENTSGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2Clutch Pedal Inspection and Adjustment . . . . . . . 2 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321109000190

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7

21-2

CLUTCH -

General Information/Service Specifications/Lubricants/On-vehicle Service

GENERAL INFORMATIONThe clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control.

21100010093

SERVICE SPECIFICATIONSItems Clutch pedal height mm Clutch pedal clevis pin play mm Clutch pedal free play mm Distance between the clutch pedal and the toeboard when the clutch is disengaged mm Standard value 224 - 227 211 - 214 1- 3 6 - 13 125 or more

21100030150

LUBRICANTSItems Clutch fluid Push rod assembly Boot Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 Specified lubricants Brake fluid DOT3 or DOT4 Rubber grease Quantity As required

21100040078

Clutch pedal height

Clutch pedal clevis pin play

ON-VEHICLE SERVICECLUTCH PEDAL INSPECTION AND ADJUSTMENT

21100090158

A

B

1. Turn up the carpet, etc. under the clutch pedal. 2. Measure the clutch pedal height and the clutch pedal clevis pin play. Standard value (A): 224 - 227 211 - 214 Standard value (B): 1 - 3 mm

CLUTCH - On-vehicle ServiceSetting nut

21-3

3. If the clutch pedal height and the clutch pedal clevis pin play are outside the standard value, turn the setting nut to adjust them to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.Clutch pedal

12 Nm

Clutch pedal free play

4. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the toeboard when the clutch is disengaged are within the standard value ranges.C

Standard value (C): 6 - 13 mm Standard value (D): 125 mm or more 5. If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch. 6. Turn back the carpet, etc.

Distance between the clutch pedal and the toeboard when the clutch is disengaged

D

BLEEDINGSpecified fluid: Brake fluid DOT 3 or DOT 4

21100140143

Caution Use the specified brake fluid. Avoid using a mixture of the specified fluid and other fluid.

21-4 CLUTCH PEDAL

CLUTCH - Clutch Pedal21100160224

REMOVAL AND INSTALLATIONPost-installation Operation Clutch Pedal Adjustment (Refer to P.21-2)

5

712 Nm

4 612 Nm

2

1 10

3

8

9

Removal steps 1. Clutch switch 2. Clip 3. Snap pin 4. Bushing 5. Pin assembly

6. 7. 8. 9. 10.

Clutch master cylinder mounting nut Master cylinder member mounting bolt Clutch pedal Stopper Pedal pad

CLUTCH - Clutch Control

21-521100190216

CLUTCH CONTROLREMOVAL AND INSTALLATIONPre-removal Operation Clutch Fluid Draining Post-installation Operation D Clutch Fluid Supplying D Clutch Line Bleeding (Refer to P.21-3) D Clutch Pedal Adjustment (Refer to P.21-2)

3 1

4

5

7

912 Nm

6 8 812 Nm 19 Nm

2

29 Nm

Release cylinder push rod 15 Nm

Release fork

7, 8

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Clutch hose 9. Bracket 10. Clutch hose

21-6

CLUTCH - Clutch Control

3 1

4

5

7

2 9

12 Nm

7

6

812 Nm 19 Nm

Release cylinder push rod 15 Nm

Release fork

8

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Bracket 9. Clutch hose

CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLYCLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly.

21-721100210172

612 Nm

5

2

9 3 1 4

612 Nm

5

2

9 3 1 4

844 Nm

7

2

1

4

2 2

3Piston repair kit Disassembly steps 1. Piston stopper ring 2. Piston assembly "AA 3. Push rod assembly 4. Boot 5. Spring pin Clutch fluid: Brake fluid DOT3 or DOT4 Grease: Rubber grease

6. 7. 8. 9.

Nipple Gasket Damper assembly Master cylinder body

21-8

CLUTCH - Clutch Control INSTALLATION SERVICE POINT"AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjustment of clutch pedal easier. 103 mm 121 mm

22-1

MANUAL TRANSMISSIONCONTENTSLUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . 3 Transfer Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 322109000395

Transfer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Temperature Sensor Check . . . . . . . . . . . . . . . . 4

TRANSMISSION CONTROL* . . . . . . . . . . . . . . . . 5 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . 8 TRANSFER ASSEMBLY . . . . . . . . . . . . . . . . . . 15

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

22-2 LUBRICANTItem Transmission oil

MANUAL TRANSMISSION - Lubricant/Special Tools22100040310

Specified lubricant 2WD 4WD Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4

Quantity L 2.2 2.3 0.53

Transfer oil

SPECIAL TOOLSTool Number MB990635 or MB991113 Name Steering linkage puller Use Ball joint disconnection

221000600224

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger

MB991721

Sliding hammer

Driving out of the output shaft

MB991193

Plug

To prevent excessive transfer oil loss or system contamination

MANUAL TRANSMISSION - On-vehicle Service

22-322100090308

ON-VEHICLE SERVICETRANSMISSION OIL CHECKTransmission oil Filler plug hole

1. Remove the oil filler plug. 2. Oil level should be at the lower portion of the filler plug hole. 3. Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 Nm

TRANSMISSION OIL CHANGEFiller plug

22100100315

1. Remove the drain plug to drain oil. 2. Tighten the drain plug to the specified torque. 3. Remove the filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole. Transmission oil Specified oil: Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Quantity: 2.2 L 2.3 L 4. Tighten the filler plug to the specified torque.

32 Nm

Drain plug

TRANSFER OIL CHECKFiller plug

22100110134

Drain plug

1. Remove the oil filler plug. 2. Oil level should be at the lower portion of the filler plug hole. 3. Check that the transfer oil is not noticeably dirty, and it has a suitable viscosity. 4. Install the oil filler plug, and then tighten it to the specified torque. Tightening torque: 32 Nm

22-4

MANUAL TRANSMISSION - On-vehicle Service

TRANSFER OIL CHANGETransfer oil

22100120137

1. Remove the oil drain plug to drain oil. 2. Install the oil drain plug, and then tighten it to the specified torque. Tightening torque: 32 Nm 3. Remove the oil filler plug, and then fill with specified oil till the level comes to the lower portion of filler plug hole. Transfer oil Specified oil: Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Quantity: 0.53 L 4. Install the oil filler plug, and then tighten it to the specified torque. Specified torque: 32 Nm

OIL TEMPERATURE SENSOR CHECK

22100670038

1. Remove the oil drain plug, and then drain the transmission oil. 2. Remove the oil temperature sensor.

Oil temperature sensor

3. Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector. Standard value:Oil temperature _C 20 110Transmission oil

Resistance kW 2.31 - 2.59 0.145 - 0.149

4. If the resistance is not within the standard value, replace the oil temperature sensor. 5. Install the oil temperature sensor, and then tighten it to the specified torque. Tightening torque: 20 - 25 Nm 6. Install the drain plug and tighten it to the specified torque. Supply a transmission oil. (Refer to P.22-3.)

MANUAL TRANSMISSION - Transmission Control

22-522100380238

TRANSMISSION CONTROLREMOVAL AND INSTALLATION

Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly.Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation

10 14 11 9 12 10 6 712 Nm

1 2 3

4 5 8 135 Nm

"BA "BA "BA

AA" "AA "AA "AA

Shift cable and select cable assembly removal steps 1. Shift knob 2. Spring washer 3. Nut D Center console box (Refer to GROUP 52A.) 4. Insulator 5. Snap pin 6. Select cable connection (Shift lever side) 7. Clip 8. Shift cable connection (Shift lever side) 9. Clip 10. Snap pin 11. Select cable connection (Transmission side) 12. Shift cable connection (Transmission side)

13. Shift lever assembly "AA 14. Shift cable and select cable assembly Shift lever assembly removal steps "BA 1. Shift knob "BA 2. Spring washer "BA 3. Nut D Center console box (Refer to GROUP 52A.) 4. Insulator 5. Snap pin 6. Select cable connection (Shift lever side) 7. Clip 8. Shift cable connection (Shift lever side) 12. Shift lever assembly

22-6Tabs


REMOVAL SERVICE POINTSAA" CLIP REMOVAL Pry the tabs of the clip with a screwdriver or similar, and then remove the clip.

INSTALLATION SERVICE POINTSShift lever

"AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/ SHIFT CABLE CONNECTION/SELECT CABLE CONNECTION 1. Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position.

Neutral position

2. For the transmission side, the paint marks on the shift and select cable ends should face the snap pins. 3. Install new clips to the cable bracket at the transmission, and then install shift cable and select cable to the cable bracket. 4. Move the passenger compartment side shift lever to all positions and check that the operation is smooth.

"BA NUT/SPRING WASHER/SHIFT KNOB INSTALLATION 1. Screw in the nut all the way by hand, turn back half a turn, and then insert the spring washer. 2. Screw in the shift knob until it touches the spring washer, and make one more turn. Then turn more to adjust the shift pattern on the shift knob. 3. If the above steps are impossible, you can turn back the shift knob by one turn at most after screwing in all the way to adjust the shift pattern.


22-722100400101

SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY8 9 10

1 4 2 4 714 Nm

9 Nm 12 Nm

3 16 5

6 10 Nm

11

13

129 Nm

15 14

Disassembly steps 1. Lever assembly 2. Bolt 3. Select lever 4. Bushing 5. Return spring 6. Collar 7. Bolt 8. Cap

9. 10. 11. 12. 13. 14. 15. 16.

Shift lever Shift lever bushing Base bracket Lever mount bracket assembly Insulator Stay Lever mount bracket Base bracket

22-8

MANUAL TRANSMISSION - Transmission Assembly22100270290

TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION

Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body.Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Radiator and Coolant Reservoir Removal and Installation (Refer to GROUP 14.) D Starter Removal and Installation (Refer to GROUP 16.) D Under Cover Removal and Installation D D D D D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Check the Dust Cover for Crack or Damage by Pushing it with Finger Shift Lever Operation Check Instruments Operation Check Wheel Alignment Check (Refer to GROUP 33A - On-vehicle Service.)

19 Nm

619 Nm 48 Nm

2

1 3 4 5

10

912 Nm 12 Nm

869 Nm

912 Nm

9 9 724 - 33 Nm

Removal steps 1. Clip (Refer to P.22-5.) 2. Select cable connection (Refer to P.22-5.) 3. Shift cable connection (Refer to P.22-5.) 4. Back-up lamp switch connector 5. Vehicle speed sensor connector

AA" AB"

6. Clutch release cylinder connection 7. Tie rod end connection 8. Steering gear and linkage mounting bolts 9. Oil line mounting bolts 10. Transmission assembly upper coupling bolt

MANUAL TRANSMISSION - Transmission Assembly

22-9

57 Nm* 81 Nm*

24 24 23 26

2548 Nm

25

1439 Nm

14 15

1898 - 118 Nm 9 Nm 49 - 64 Nm*

17

40 Nm

13196 - 255 Nm

19

2044 Nm 49 - 64 Nm* 22 Nm

11

21 12177 Nm 78 Nm

22

78 Nm 177 Nm

11. Stabilizer link connection "CA 12. Lower arm connection 13. Wheel speed sensor connection (Refer to GROUP 35B.) AC" "BA 14. Drive shaft AC" "BA 15. Drive shaft and inner shaft 17. Transmission stay 18. Bell housing cover 19. Front roll stopper connection

20. 21. 22. AE" 23. "AA 24. AF" D AG" AG"

Rear roll stopper connection Stay Front member assembly Transmission mount bracket Transmission mount stopper Engine and transmission assembly supporting 25. Transmission assembly lower part coupling bolts 26. Transmission assembly

22-10


REMOVAL AND INSTALLATIONCaution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body.Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Transfer Oil Draining and Refilling (Refer to P.22-3.) D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Radiator and Coolant Reservoir Removal and Installation (Refer to GROUP 14.) D Starter Removal and Installation (Refer to GROUP 16.) D Propeller Shaft Removal and Installation (Refer to GROUP 25.) D D D D D D Under Cover Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Check the Dust Cover for Crack or Damage by Pushing it with Finger Shift Lever Operation Check Instruments Operation Check Wheel Alignment Check (Refer to GROUP 33A - On-vehicle Service.)

19 Nm 19 Nm

6

2

48 Nm

1 10 4 5 3

912 Nm 12 Nm

869 Nm

9 912 Nm

9 724 - 33 Nm

Removal steps 1. Clip (Refer to P.22-5.) 2. Select cable connection (Refer to P.22-5.) 3. Shift cable connection (Refer to P.22-5.) 4. Back-up lamp switch connector 5. Vehicle speed sensor connector

AA" AB"

6. Clutch release cylinder connection 7. Tie rod end connection 8. Steering gear and linkage mounting bolts 9. Oil line mounting bolts 10. Transmission assembly upper coupling bolt

MANUAL TRANSMISSION - Transmission Assembly57 Nm* 81 Nm*

22-11

24 2548 Nm

24 23

25 2639 Nm

14 17 1698 - 118 Nm 9 Nm 49 - 64 Nm*

1444 Nm

18

13

19

2049 - 64 Nm* 22 Nm

196 - 255 Nm

11

12177 Nm

21 2278 Nm 177 Nm

78 Nm

11. Stabilizer link connection "CA 12. Lower arm connection 13. Wheel speed sensor connection (Refer to GROUP 35B.) AC" "BA 14. Drive shaft AD" "BA 16. Output shaft D Transfer assembly removal (Refer to P.22-15.) 17. Transmission stay 18. Bell housing cover 19. Front roll stopper connection

20. 21. 22. AE" 23. "AA 24. AF" D AG" AG"

Rear roll stopper connection Stay Front member assembly Transmission mount bracket Transmission mount stopper Engine and transmission assembly supporting 25. Transmission assembly lower part coupling bolts 26. Transmission assembly

22-12Cord Ball joint


REMOVAL SERVICE POINTSAA" TIE ROD END DISCONNECTION Caution 1. Use the special tool to loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. not to let it come off.

MB990635 or MB991113

Nut

AB" STEERING GEAR AND LINKAGE MOUNTING BOLT REMOVAL Remove the steering gear and linkage mounting bolts, and then support the steering gear box to the vehicle body with a wire.

Fig. 1

Transmission

AC" DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY REMOVAL Remove the drive shaft or the drive shaft and inner shaft assembly from the transmission by the following procedure:2WD (except SPACE WAGON - M/T - R.H.), 4WD (L.H.) 2WD (SPACE WAGON - M/T - R.H.) Fig. 1 Fig. 2 Fig. 3

Drive shaft

4WD (R.H.)

Fig. 2

Prybar Transmission Drive shaft

Center bearing bracket Hammer Transfer

Insert a pry bar between the drive shaft and the transmission case, and then pry off the drive shaft. Tap the center bearing bracket with a hammer to remove the drive shaft. Place a hammer on the projection at the transfer and insert a pry bar between the drive shaft and the transfer, and then pry off the drive shaft. Caution 1. Above-mentioned procedure must be observed. Pulling the B.J. assembly to remove the drive shaft or drive shaft and inner shaft assembly will damage the T.J. assembly. 2. Take care that the transmission oil seal will not be damaged by the drive shaft spline.

Fig. 3

Drive shaft

Hammer

Projection Prybar

MANUAL TRANSMISSION - Transmission AssemblyMB991721

22-13

AD" OUTPUT SHAFT REMOVAL 1. Use the special tool to withdraw the output shaft. Caution Be careful not to transmission by the 2. Use a shop towel to to let foreign material damage the oil seal of the spline of the output shaft. cover the transmission case not get into it.

Output shaft

AE" TRANSMISSION MOUNT BRACKET REMOVAL Carefully lower the transmission assembly with a garage jack, and remove the transmission mount bracket.

MZ203827

AF" ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING Set the special tool to the vehicle to support the engine and transmission assembly.

MB991453

AG" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly with a transmission jack. 2. Remove the transmission assembly lower part coupling bolts, and lower the transmission assembly to remove.

Engine side

INSTALLATION SERVICE POINTS"AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow points as shown in the illustration.

Transmission mount stopper

Transmission mount bracket

NOTE Disregard F and R stamped as a shared part.

22-14

MANUAL TRANSMISSION - Transmission Assembly"BA OUTPUT SHAFT/DRIVE SHAFT INSTALLATION Caution Be careful not to damage the oil seal of the transmission or transfer by the spline of the drive shaft or the output shaft.

Knuckle A

"CA LOWER ARM INSTALLATION 1. Install the lower arm assembly to the knuckle. Caution The lower arm should not protrude 4 mm or more from the knuckle end (A shown), otherwise grease may pour out from the dust cover. 2. If grease has poured out due to the excessive arm protrusion, the dust cover must be replaced (Refer to GROUP 33A - Lower Arm). 3. There should be not clearance between the knuckle and the dust cover.

Lower arm assembly

MANUAL TRANSMISSION - Transfer Assembly

22-15

TRANSFER ASSEMBLY REMOVAL AND INSTALLATIONCaution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body.Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Transfer Oil Draining and Refilling (Refer to P.22-4.) D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)

69 Nm

Gear oil: Hypoid gear oil SAE 75W - 85W or 75W - 90 conforming to API GL-4

2 1

Removal steps D Drive shaft connection (Refer to P.22-11.) D Output shaft (Refer to P.22-11.)

AA"

1. Front propeller shaft (Refer to GROUP 25.) 2. Transfer assembly

REMOVAL SERVICE POINTAA" TRANSFER ASSEMBLY REMOVAL Caution 1. Be careful not to damage the transfer oil seal lip. 2. Use the special tool to plug the transfer case opening to to prevent excessive oil loss or system contamination.

Oil seal lip

MB991113

NOTES

23-1

AUTOMATIC TRANSMISSIONCONTENTSSERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 44Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 A/T Control Component Location . . . . . . . . . . . . . 50 A/T Control Component Check . . . . . . . . . . . . . . . 5123109000576

Torque Converter Stall Test . . . . . . . . . . . . . . . . . . 53 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . 55 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Line Pressure Adjustment . . . . . . . . . . . . . . . . . . . . 61 Selector Lever Operation Check . . . . . . . . . . . . . . 61

TRANSMISSION CONTROL* . . . . . . . . . . . . . . 63 SHIFT LOCK AND KEY INTERLOCK MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . 68

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

23-2

AUTOMATIC TRANSMISSION -

Service Specifications/Lubricant/Special Tools

SERVICE SPECIFICATIONSItems Oil temperature sensor kW at 0_C at 100_C Resistance of damper clutch control solenoid valve coil (at 20_C) W Resistance of Low-Reverse solenoid valve coil (at 20_C) W Resistance of second solenoid valve coil (at 20_C) W Resistance of underdrive solenoid valve coil (at 20_C) W Resistance of overdrive solenoid valve coil (at 20_C) W Stall speed r/min 4G93 4G64 16.5 - 20.5 0.57 - 0.69 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2,200 - 2,700 2,300 - 2,800

23100030284

Standard value

LUBRICANTItems Transmission fluid Specified lubricant DIA QUEEN ATF SPII, ATF SPII M or equivalent Quantity L 7.8

23100040270

SPECIAL TOOLSTool Number MB991502 Name MUT-II sub assembly Use Checking of the diagnosis code

23100060351

MD998330 (including MD998331)

Oil pressure gauge (2,942 kPa)

Measurement of oil pressure

MD998332

Adapter

MD998900

Adapter

AUTOMATIC TRANSMISSION - Special ToolsTool Number MB990635 or MB991113 Name Steering linkage puller Use Ball joint disconnection

23-3

MB991610

Oil filter wrench

Removal and installation of automatic transmission oil filter

GENERAL SERVICE TOOL MZ203827

Engine lifter


MB991453

Engine hanger assembly


23-4

AUTOMATIC TRANSMISSION - Troubleshooting23100760657

TROUBLESHOOTINGSTANDARD FLOW OF DIAGNOSIS TROUBLESHOOTINGGathering information from customer.

Check ATF. OK

NG

Replace ATF.

Check trouble symptoms. Communication with MUT-II not possible

Read the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) Diagnosis code displayed Erase the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

Inspection Chart For Trouble Symptoms (Refer to P.23-24.)

No diagnosis code displayed Replace the A/T-ECU.

Check trouble symptoms. NG

Carry out the essential service (Refer to P.23-44.) Abnormality exists (no diagnosis code) No abnormality Recheck diagnosis codes which were read before the road test. Diagnosis code displayed To INSPECTION CHART DIAGNOSIS CODES (Refer to P.23-12.) FOR To INSPECTION CHART TROUBLE SYMPTOMS (Refer to P.23-24.) No diagnosis code displayed FOR

Road test (Refer to P.23-6.) Abnormality exists (diagnosis code present)

Search for cause. Found Repair NG Not found INTERMITTENT MALFUNCTION (GROUP 00 - Points to Note for Intermittent Malfunctions.) OK Completed

NG Confirmation test (road test)

OK

AUTOMATIC TRANSMISSION - Troubleshooting DIAGNOSIS FUNCTION1. N range lamp The N range lamp flashes at a frequency 1 Hz if there is an abnormality in any of table below which are related to the A/T the diagnosis code output if the N range at a frequency of approximately 1 Hz. N range lamp flashing itemsCrank angle sensor Input shaft speed sensor Output shaft speed sensor Each solenoid valve Out of phase at each shift point

23-523100770292

of approximately the items in the system. Check lamp is flashing

Caution If the N range lamp is flashing at a frequency of approximately 2 Hz (faster than at 1 Hz), it means that the automatic transmission fluid temperature is too high. Stop the vehicle in a safe place and wait until the N range lamp switches off. 2. Method of reading the diagnosis code Use the MUT-II or the N range lamp to take a reading of the diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

23-6ROAD TEST


Check by the following procedure.No. State prior to test and operation Ignition switch: OFF Ignition switch: ON Engine: Stopped Selector lever position: P Test and operation Judgement value Check item Diagnosis code No. 54 Inspection procedure page if there is an abnormality A/T Control relay system (23-23) Inhibitor switch system (23-35)

1

Ignition switch (1) ON Selector lever position (1) P, (2) R, (3) N, (4) D, (5) 3, (6) 2, (7) L

Data list No. 54 Battery voltage [V] Data list No. 61 (1) P, (2) R, (3)N, (4) D, (5) 3, (6) 2, (7) L

Control relay

2

Inhibitor switch

-

Data list No. 11 Accelerator pedal (1) 300 - 1,000 mV (1) Released (2) Half depressed (2) Gradually rises from (1) (3) Depressed (3) 4,500 - 5,500 mV Data list No. 25 (1) OFF (2) ON Brake pedal (1) Depressed (2) Released 3 Ignition switch: ST Engine: Stopped Warming up Starting test with lever P or N range Drive for 15 minutes or more so that the automatic fluid temperature becomes 70 90_C. Data list No. 26 (1) ON (2) OFF Starting should be possible Data list No. 15 Gradually rises to 70 - 90_C

Throttle position sensor Accelerator pedal position sensor Wide open throttle switch Stop lamp switch Starting possible or impossible Oil temperature sensor

11 12 14

Throttle position sensor system (23-13) Accelerator pedal position sensor system (23-13) Wide open throttle switch system (23-15) Stop lamp switch system (23-16) Starting impossible (23-27) Oil temperature sensor system (23-13)

25

26

-

4

15

AUTOMATIC TRANSMISSION - TroubleshootingNo. State prior to test and operation Test and operation Judgement value Check item Diagnosis code No. 26

23-7Inspection procedure page if there is an abnormality Stop lamp switch system (23-16)

5

Engine: Idling Selector lever position: N

Brake pedal (Retest) (1) Depressed (2) Released A/C switch (1) ON (2) OFF

Data list No. 26 (1) ON (2) OFF Data list No. 65 (1) ON (2) OFF

Stop lamp switch

Dual pressure switch

-

Dual pressure switch system (23-35) Crank angle sensor system (23-14) Serial communication system (23-23)

Data list No. 21 Crank angle Accelerator pedal (1) 550 - 850 r/min sensor (1) Released (2) Half depressed Gradually rises from (1) Data list No. 57 (2) Data changes Communication with engineECU

21

51

Selector lever position (1) N D (2) N R

Should be no abnormal shifting shocks Time lag should be within 2 seconds

Malfunction when starting

-

Engine stalling during shifting (23-29) Shocks when changing from N to D and large time lag (23-29) Shocks when changing from N to R and large time lag (23-30) Shocks when changing from N to D,N to R and large time lag (23-31) Does not move forward (23-27) Does not reverse (23-28) Does not move (forward or reverse) (23-28)

-

-

-

Driving impossible

-

23-8No.

AUTOMATIC TRANSMISSION - TroubleshootingState prior to test and operation Test and operation Judgement value Check item Diagnosis code No. Inspection procedure page if there is an abnormality -

6

Selector lever position: N (Carry out on a flat and straight road.)

Selector lever position and vehicle speed (1) Idling in L range (Vehicle stopped) (2) Driving at constant speed of 10 km/h in L position (3) Driving at constant speed of 30 km/h in 2 position (4) Driving at 50 km/h in 3 position with accelerator fully closed (5) Driving at constant speed of 50 km/h in D position (Each condition should be maintained for 10 seconds or more.) Selector lever position and vehicle speed (1) Release the accelerator pedal fully while driving at 50 km/h in 3rd gear. (2) Driving at constant speed of 50 km/h in 3rd gear.

Data list No. 63 (2) 1st, (4) 3rd, (3) 2nd, (5) 4th Data list No. 31 (2) 0 %, (4) 100 %, (3) 100 %, (5) 100 % Data list No. 32 (2) 0 %, (4) 0 %, (3) 0 %, (5) 100 % Data list No. 33 (2)100 %, (4) 100 %, (3) 0 %, (5) 0 % Data list No. 34 (2) 100 %, (4) 0 %, (3) 100 %, (5) 0 % Data list No. 29 (1) 0 km/h (4) 50 km/h

Shift condition

Low and reverse 31 solenoid valve

Low and reverse solenoid valve system (23-16) Underdrive solenoid valve system (23-16) Second solenoid valve system (23-16) Overdrive solenoid valve system (23-16) Vehicle speed sensor system (23-36) Input shaft speed sensor system (23-14) Output shaft speed sensor system (23-15) Damper clutch control solenoid valve system (23-17)

Underdrive solenoid valve Second solenoid valve Overdrive solenoid valve

32

33

34

Vehicle speed sensor

-

Data list No. 22 Input shaft (4) 1,800 - 2,100 speed sensor r/min Data list No. 23 Output shaft (4) 1,800 - 2,100 speed sensor r/min Data list No. 36 Damper clutch control solenoid (1) 0 % (2) Approx. 70 - 90 valve % Data list No. 52 (1) Approx. 100 - 300 r/min (2) Approx. 0 - 10 r/min

22

23

7

Selector lever position: 3 (Carry out on a flat and straight road.)

36 52

AUTOMATIC TRANSMISSION - TroubleshootingNo. State prior to test and operation Test and operation Judgement value Check item Diagnosis code No. -

23-9Inspection procedure page if there is an abnormality Shocks and running up (23-31) All points (23-32) Some points (23-33) No diagnosis code (23-33) Input shaft speed sensor system (23-14) Output shaft speed sensor system (23-15) Low and reverse solenoid valve system (23-16) Second solenoid valve system (23-16) 1st gear ratio is not specified (23-18) 2nd gear ratio is not specified (23-19) Second solenoid valve system (23-16) Overdrive solenoid valve system (23-16) 2nd gear ratio is not specified (23-19) 3rd gear ratio is not specified (23-20) Underdrive solenoid valve system (23-16) Second solenoid valve system (23-16) 3rd gear ratio is not specified (23-20) 4th gear ratio is not specified (23-21)

8

Use the MUT-II to stop the INVECSII function. Selector lever position: D (Carry out on a flat and straight road.)

Monitor data list No. 11, 23, and 63 with the MUT-II. (1) Accelerate to 4th gear at a throttle position sensor output of 1.5V (accelerator opening angle of 30 %). (2) Gently decelerate to a standstill. (3) Accelerate to 4th gear at a throttle position sensor output of 2.5 V (accelerator opening angle of 50%). (4) While driving at 60 km/h in 4th gear, shift down to 3 range. (5) While driving at 40 km/h in 3rd gear, shift down to 2 range. (6) While driving at 20 km/h in 2nd gear, shift down to L range.

For (1), (2) and (3), the reading should be the same as the specified output shaft speed and no abnormal shocks should occur. For (4), (5) and (6), downshifting should occur immediately after the shifting operation is made.

Malfunction when shifting Displaced shifting points Does not shift

22

23

Does not shift from 1 to 2 or 2 to 1

31

33

41

42


33

34

42

43


32

33

43

44

23-10No.

AUTOMATIC TRANSMISSION - TroubleshootingTest and operation Judgement value Check item Diagnosis code No. 22 Inspection procedure page if there is an abnormality Input shaft speed sensor system (23-14) Output shaft speed sensor system (23-15) Reverse gear ratio is not specified (23-22)

State prior to test and operation

9

Selector lever position: N (Carry out on a flat and straight road.)

Monitor data list No. 22 and No. 23 with the MUT-II. II (1) Move selector lever to R range, drive at constant speed of 10 km/h.

The ratio between data list No. 22 and No. 23 should be the same as the gear ratio when reversing.

Does not shift

23

46

SHIFT PATTERN UPSHIFT PATTERNThrottle opening % 100 Thick line: Standard shift pattern

1 50

2

2

3

3

4

23 movement range 34 movement range

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

Output shaft speed r/min

DOWNSHIFT PATTERNThrottle opening % 100 1 2 (L) Thick line: Standard shift pattern

1 50

2

2

3

3

4 2 3 (L,2) 3 4 (L,2,3)

23 movement range 0

34 movement range 2,000 3,000 4,000 5,000 6,000 7,000

1,000


AUTOMATIC TRANSMISSION - Troubleshooting UPSHIFT PATTERN

23-11

Throttle opening % 100

Thick line: Standard shift pattern

1 50

2 2 23 movement range

3

3

4

34 movement range 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000


DOWNSHIFT PATTERNThrottle opening % 100 1 1 50 23 movement range 0 1,000 34 movement range 2,000 3,000 4,000 5,000 6,000 7,000 2 2 3 2 (L) 3 4 2 3 (L,2) 3 4 (L,2,3)

Thick line: Standard shift pattern


23-12Code 11 12 14 15 21 22 23 25 26 31 32 33 34 36 41 42 43 44 46 51 52 54 56


INSPECTION CHART FOR DIAGNOSIS CODEDiagnosis item Throttle position sensor system Accelerator pedal position sensor system Oil temperature sensor system Crank angle sensor system Input shaft speed sensor system Output shaft speed sensor system Wide open throttle switch system Stop lamp switch system Low and reverse solenoid valve system Underdrive solenoid valve system Second solenoid valve system Overdrive solenoid valve system Damper control clutch solenoid valve system 1st gear ratio does not meet the specification 2st gear ratio does not meet the specification 3rd gear ratio does not meet the specification 4th gear ratio does not meet the specification Reverse gear ratio does not meet the specification Abnormal communication with engine-ECU Damper control clutch solenoid valve system A/T Control relay system N range lamp system Defective system Short circuit to earth/ open circuit Short circuit to earth Short circuit Open circuit Sensor maladjustment Open circuit Open circuit Short circuit/open circuit Short circuit/open circuit Short circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit 23-13 23-13 23-13 23-13 23-14 23-14 23-15 23-15 23-16 23-16 23-16 23-16 23-16 23-17 23-18 23-19 23-20 23-21 23-22 23-23 23-17 23-23 23-24

Reference page

AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODESCode No. 11, 12, 14 Throttle position sensor system , accelerator pedal position sensor system If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the output is judged to be too high and diagnosis code No. 11 is output. If the TPS or APS output voltage is 0.2 V or lower at times other than when the engine is idling, the output is judged to be too low and diagnosis code No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if it is 1.2 V or higher when the engine is idling, the TPS or APS adjustment is judged to be incorrect and diagnosis code No. 14 is output. NG

23-13

Probable cause

D D D D

Malfunction Malfunction Malfunction Malfunction

of the throttle position sensor of the accelerator pedal position sensor of connector of the A/T-ECU

Throttle position sensor check (Refer to GROUP 13B - On-vehicle Servicelink=13100320030.) Accelerator pedal position sensor check (Refer to GROUP 13A - On-vehicle Servicelink=13600430011.) OK Check the following connectors: D A-73, B-11 D A-63, A-27, B-11 OK Harness check D Between throttle position sensor and A/T-ECU D Between accelerator pedal position sensor and A/T-ECU OK Check the trouble symptoms.

Replace

NG

Repair

NG

Repair

NG

Replace the A/T-ECU.

Code No. 15 Oil temperature sensor systemIf the oil temperature sensor output voltage is 2.6 V or more even after driving for 10 minutes or more (if the oil temperature does not increase), it is judged that there is an open circuit in the oil temperature sensor and diagnosis code No. 15 is output. NG

Probable causeD D D Malfunction of the oil temperature sensor Malfunction of connector Malfunction of the A/T-ECU

Oil temperature sensor check (Refer to P.23-51.) OK Check the following connectors: A-88, B-11 OK Harness check D Between oil temperature sensor and A/T-ECU OK Check the trouble symptoms.

Replace

NG

Repair

NG

Repair

NG


23-14

AUTOMATIC TRANSMISSION - TroubleshootingProbable causeD D D Malfunction of the crank angle sensor Malfunction of connector Malfunction of the A/T-ECU

Code No. 21 Crank angle sensor systemIf no output pulse is detected from the crank angle sensor for 5 seconds or more while driving at 25 km/h or more, it is judged that there is an open circuit in the crank angle sensor and diagnosis code No. 21 is output. NG

Check the following connectors: A-71, B-51, B-11 OK Harness check D Between crank angle sensor and A/T-ECU OK Crank angle sensor system check (Refer to GROUP 13 - Troubleshooting.) OK Check the trouble symptoms.

Repair

NG

Repair

NG


Code No. 22 Input shaft speed sensor systemIf no output pulse is detected from the input shaft speed sensor for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis code No. 22 is output. If diagnosis code No. 22 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

Probable causeD D D D Malfunction Malfunction Malfunction Malfunction of of of of the input shaft speed sensor the underdrive clutch retainer connector A/T-ECU

L: Refer to the Transmission Workshop Manual.Measure at the input shaft speed sensor connector A-90. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK approx. 5 V (3) Continuity between 1 and earth OK: Continuity OK Measure output waveform of the input shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-43 (Inspection procedure using an oscilloscope). There is no noise in the output waveform. OK Check the trouble symptoms. NG NG Check the following connectors: A-90, B-14, B-93, B-89, B-11 OK Check the following harness: D Between the input shaft speed sensor and the ignition switch D Between the input shaft speed sensor and A/T-ECU OK Check the trouble symptoms. Replace the input shaft speed sensor. NG A/T overhaul K D Replace the retainer. NG Repair

NG

Repair

NG


Check the trouble symptoms.

underdrive

clutch

Check the trouble symptoms. NG NG Replace the A/T-ECU. Eliminate the cause of the noise.

AUTOMATIC TRANSMISSION - TroubleshootingCode No. 23 Output shaft speed sensor systemIf the output from the output shaft speed sensor is continuously 50% lower than the vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnosis code No. 23 is output. If diagnosis code No. 23 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

23-15

Probable causeD D D D Malfunction Malfunction Malfunction Malfunction of of of of the output shaft speed sensor the transfer drive gear or driven gear connector the A/T-ECU

L: Refer to the Transmission Workshop Manual.Measure at the output shaft speed sensor connector A-82. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK: approx. 5 V (3) Continuity between 1 and earth OK: Continuity OK Measure output waveform of the output shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-43 (Inspection procedure using an oscilloscope). There is no noise in the output waveform. OK Check the trouble symptoms. NG NG Check the following connectors: A-82, B-14, B-93, B- 89, B-11 OK Check the following harness: D Between the output shaft speed sensor and the ignition switch D Between the output shaft speed sensor and A/T-ECU OK Check the trouble symptoms. Replace the output shaft speed sensor. Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise. NG Replace the A/T-ECU. NG Repair

NG

Repair

NG


Code No. 25 Wide open throttle switch systemIf the wide open throttle switch is on for 1 second or more with the throttle valve opening angle at 70% or less, it is judged that there is a short circuit in the wide open throttle switch and diagnosis code No. 25 is output.

Probable causeD D D Malfunction of the wide open throttle switch Malfunction of connector Malfunction of A/T-ECU

Wide open throttle switch check (Refer to P.23-64.) OK Check the following connectors: B-61, B-10 OK Harness check D Between the wide open throttle switch and the A/T-ECU. OK Check the trouble symptoms.

NG

Replace

NG NG

Repair

Repair

NG


23-16

AUTOMATIC TRANSMISSION - TroubleshootingProbable causeD D D Malfunction of the stop lamp switch Malfunction of connector Malfunction of the A/T-ECU

Code No. 26 Stop lamp switch systemIf the stop lamp switch is on for 5 minutes or more while driving, it is judged that there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output.

Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.) OK Check the following connectors: B-28, B-65, B-14, B-10 OK Harness check D Between stop lamp switch and A/T-ECU OK Check the trouble symptoms.

NG

Replace

NG

Repair

NG

Repair

NG


Code No. 31 Low and reverse solenoid valve system Code No. 32 Underdrive solenoid valve system Code No. 33 Second solenoid valve system Code No. 34 Overdrive solenoid valve systemIf the resistance value for a solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG

Probable cause

D D D

Malfunction of solenoid valve Malfunction of connector Malfunction of the A/T-ECU

Solenoid valve check (Refer to P.23-52.) OK Check the following connectors: A-88, A- 12X, B-12, B-10 OK Harness check D Between solenoid valve and A/T-ECU OK Replace the solenoid valve.

Replace

NG

Repair

NG

Repair

Check the trouble symptoms.

NG


AUTOMATIC TRANSMISSION - TroubleshootingCode No. 36, 52 Damper clutch control solenoid valve systemIf the resistance value for the damper clutch control solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the damper clutch control solenoid valve and diagnosis code No. 36 is output. If the drive duty rate for the damper clutch control solenoid valve is 100 % for a continuous period of 4 seconds or more, it is judged that there is an abnormality in the damper clutch control system and diagnosis code No. 52 is output. When diagnosis code No. 36 is output, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG

23-17

Probable causeD D D Malfunction of the damper clutch control solenoid valve Malfunction of connector Malfunction of the A/T-ECU

Damper clutch control solenoid valve check (Refer to P.23-52.) OK Check the following connectors: A-88, A-12X, B-12 OK Harness check D Between damper clutch control solenoid valve and A/T-ECU OK Replace the damper clutch control solenoid valve. Check the trouble symptoms.

Replace

NG

Repair

NG

Repair

NG


23-18

AUTOMATIC TRANSMISSION - TroubleshootingProbable causeD D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system underdrive clutch system

Code No. 41 1st gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 1st gear ratio is not the same as the output from the input shaft speed sensor after shifting to 1st gear has been completed, diagnosis code No. 41 is output. If diagnosis code No. 41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

L: Refer to the Transmission Workshop Manual.MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK Yes Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Yes

NG

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms. NG Eliminate the cause of the noise.

Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 42, No. 43, or no diagnosis code is output). D Low and reverse brake system check (No. 46 or no diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

AUTOMATIC TRANSMISSION - TroubleshootingCode No. 42 2nd gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis code No. 42 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

23-19

Probable causeD D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system underdrive clutch system


Yes

NG


Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 43, or no diagnosis code is output). D Second brake system check (No. 44 or no diagnosis code is output).

NG



23-20

AUTOMATIC TRANSMISSION - TroubleshootingProbable causeD D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear underdrive clutch system overdrive clutch system

Code No. 43 3rd gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code No. 43 is output. If diagnosis code No. 43 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.


Yes

NG


Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 42, or no diagnosis code is output). D Overdrive clutch system check (No. 44 or no diagnosis code is output).

NG



AUTOMATIC TRANSMISSION - TroubleshootingCode No. 44 4th gear ratio does not meet the specificationIf the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from the input shaft speed sensor after shifting to 4th gear has been completed, diagnosis code No. 44 is output. If diagnosis code No. 44 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

23-21

Probable causeD D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system overdrive clutch system


Yes

NG


Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Second brake system check (No. 42 or no diagnosis code is output). D Overdrive clutch system check (No. 43 or no diagnosis code is output).

NG



23-22

AUTOMATIC TRANSMISSION - Troubleshootingdoes not meet the Probable causeD D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system reverse clutch system

Code No. 46 Reverse gear ratio specification

If the output from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output from the input shaft speed sensor after shifting to reverse gear has been completed, diagnosis code No. 46 is output. If diagnosis code No. 46 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.


Yes

NG


Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Low and reverse brake system check (No. 41 or no diagnosis code is output). D Reverse clutch system check (No diagnosis code is output).

NG



AUTOMATIC TRANSMISSION - TroubleshootingCode No. 51 Abnormal communication with engine-ECUIf normal communication is not possible for a continuous period of 1 second or more when the ignition switch is at the ON position, the battery voltage is 10 V or more and the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosis code No. 51 is also output if the data being received is abnormal for a continuous period of 4 seconds under the same conditions. Check the following connectors: D B-54, B-52, B-10 D B-53, B-52, B-10 OK Harness check D Between engine-ECU and A/T-ECU OK Check the trouble symptoms. NG Replace the engine-ECU. Check the trouble symptoms. NG Replace the A/T-ECU. NG

23-23

Probable causeD D D Malfunction of connector Malfunction of the engine-ECU Malfunction of the A/T-ECU

Repair

NG

Repair

Code No. 54 A/T control relay systemIf the A/T control relay voltage is less than 7 V after the ignition switch has been turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control relay circuit and diagnosis code No. 54 is output. Then the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG

Probable causeD D D Malfunction of the A/T control relay Malfunction of connector Malfunction of the A/T-ECU

Check the A/T control relay. (Refer to P.23-52.) OK Check the following connectors: A-12X, A-29, B-12, B-10 OK Harness check D Between control relay and body earth D Between control relay and fusible link D Between control relay and A/T-ECU OK Check the trouble symptoms.

Replace

NG

Repair

NG

Repair

NG


23-24

AUTOMATIC TRANSMISSION - TroubleshootingProbable causeD D D Malfunction of the N range lamp bulb Malfunction of connector Malfunction of the A/T-ECU

Code No. 56 N range lamp systemIf the N range signal is off after an N range lamp illumination instruction (ON instruction) has been given, it is judged that there is a short-circuit in the N range lamp earth and diagnosis code No. 56 is output. NG

Check the N range lamp bulb (Refer to GROUP 52A - Instrument Panel.) OK Check the following connectors: B-01, B-14, A-89, B-10 OK Harness check D Between N range lamp bulb and A/T-ECU OK Check the trouble symptoms.

Replace

NG

Repair

NG

Repair

NG


INSPECTION CHART FOR TROUBLE SYMPTOMSTrouble symptom MUT-II can not communicate with any systems. MUT-II can not communicate with the A/T-ECU. Driving impossible Starting impossible Does not move forward Does not reverse Does not move (forward or reverse) Malfunction when starting Engine stalling when shifting Shocks when changing from N to D and large time lag Shocks when changing from N to R and large time lag Shocks when changing from N to D, N to R and large time lag Malfunction when shifting Shocks and running up Inspection procedure No. 1 2 3 4 5 6 7 8 9 10 11

23100800588

Reference page 23-25 23-26 23-27 23-27 23-28 23-28 23-29 23-29 23-30 23-31 23-31

AUTOMATIC TRANSMISSION - TroubleshootingTrouble symptom Displaced shifting points All points Some points Does not shift Malfunction while driving No diagnosis codes Poor acceleration Vibration Inhibitor switch system Dual pressure switch system Vehicle speed sensor system Inspection procedure No. 12 13 14 15 16 17 18 19

23-25Reference page 23-32 23-33 23-33 23-34 23-34 23-35 23-35 23-36

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1 MUT-II can not communicate with any systems.It is suspected that this malfunction is caused by a defective power supply and earth circuits of the diagnosis connector. Measure at diagnosis connector B-25. NG D Voltage between terminal No. 16 and body earth OK: Battery voltage OK Measure at diagnosis connector B-25. D Continuity between terminal Nos. 4, NG 5 and body earth OK: Continuity OK

Probable causeD D Malfunction of diagnosis connector Malfunction of harness or connector

Check the following connectors: NG B-25, B-91, B-92, B-66 OK Check the trouble symptoms. NG

Repair

Check the harness wire between the fusible link and the diagnosis connector, and repair if necessary. Repair

Check the following connector: B-25 OK Check trouble symptoms.

NG

NG

Check trouble symptoms. NG Replace the MUT-II.

Check the harness wire between the diagnosis connector and the earth, and repair if necessary.

23-26

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 2 MUT-II can not communicate with the A/T-ECU.It is suspected that this malfunction is caused by an open circuit in A/T-ECU power supply circuit or diagnosis output circuit. NG Check the following connectors: B-12, B-10, B-14, B-102, B-25 OK Check trouble symptoms. NG Check the harness wire between the A/T-ECU and the diagnosis connector, and repair if necessary.

Probable causeD D Malfunction of harness or connector Malfunction of A/T-ECU NG

Measure at diagnosis connector B-25 and A/T-ECU connectors B-12, B-10. D Disconnect the connectors, and measure at the harness side. D Continuity between the following terminals: No. 1 (of diagnosis connector) and 23 (of B-12) No. 7 (of diagnosis connector) and 63 (of B-10) OK: Continuity OK Measure at A/T-ECU connector B-12. D Disconnect the connector, and measure at the harness side. D Ignition switch: ON D Voltage between Nos. 11, 24 and body earth OK: Battery voltage OK

Repair

NG

Check the following connectors: B-12, B-14, B-93, B-89 OK Check trouble symptoms.

NG

Repair

NG

Check the harness wire between the ignition switch and the A/T-ECU, and repair if necessary.

Measure at A/T-ECU connectors B-12, NG B-10. D Disconnect the connector, and measure at the harness side. D Continuity between terminal Nos. 12, 13, 25, 26, 72 - body earth OK: Continuity OK OK

Check the following connectors: B-12, B-10 OK Check trouble symptoms.

NG

Repair

NG

Check the harness wire between the A/T-ECU and the earth, and repair if necessary. Replace the A/T-ECU.

Check the following connectors: B-12, B-10 NG Repair

Check trouble symptoms.

NG

AUTOMATIC TRANSMISSION - TroubleshootingINSPECTION PROCEDURE 3 Starting impossibleStarting is not possible when the selector lever is in P or N range. In such cases, the cause is probably a defective inhibitor switch system, transmission control cable assembly, engine system, torque converter or oil pump.

23-27

Probable causeD D D D D Malfunction of the inhibitor switch system Malfunction of the transmission control cable assembly Malfunction of the engine system Malfunction of the torque converter Malfunction of the oil pump

Check the inhibitor switch system (Refer to P.23-35, INSPECTION PROCEDURE 17). OK Check the transmission control cable assembly. OK Check the engine system. D Control system, ignition system, fuel system, main engine system OK

NG

L: Refer to the Transmission Workshop Manual.Repair, replace

NG

Repair, replace

NG

Repair, replace

NG Torque converter check D Check for incorrect installation (inserted at an angle, etc.) and for damaged splines. OK Replace the oil pump assembly. L (The oil pump cannot be disassembled.)

Repair if possible. If the splines are damaged and repairs are not possible, replace the torque converter assembly.

INSPECTION PROCEDURE 4 Does not move (forward)If the vehicle does not move forward when the selector lever is shifted from N to D, 3, 2 or L range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body.

Probable causeD D D D Abnormal line Malfunction of Malfunction of Malfunction of pressure the underdrive solenoid valve the underdrive clutch the valve body

L: Refer to the Transmission Workshop Manual.MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure test (Refer to P.23-55.) D Measure the hydraulic pressure for each element when in L range. Standard value: Refer to P.23-56. OK OK Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. NG D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case. NG Replace the solenoid valve. L

NG

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

23-28Does not reverse


INSPECTION PROCEDURE 5 Probable causeD D D D D D Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse brake or valve body.

L: Refer to the Transmission Workshop Manual.MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure check (Refer to P.23-55.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-56. OK Hydraulic pressure check (Refer to P.23-55.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-56. OK Reverse clutch system and low and reverse brake system check OK L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained NG when air is blown through the reverse clutch oil hole and the low reverse brake oil hole in the transmission case. NG Replace the low and reverse solenoid valve. L

NG

NG


Reverse clutch and low and reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

INSPECTION PROCEDURE 6 Does not move (forward or reverse)If the vehicle does not move forward or reverse when the selector lever is shifted to any position while the engine is idling, the cause is probably abnormal line pressure, or a malfunction of the power train, oil pump or valve body.

Probable causeD D D D Abnormal line Malfunction of Malfunction of Malfunction of pressure power train the oil pump the valve body

L: Refer to the Transmission Workshop Manual.Hydraulic pressure check (Refer to P.23-55.) D Measure the hydraulic pressure for each element when moving forward and back. Standard value: Refer to P.23-56. NG Replace the oil pump assembly. L (The oil pump cannot be disassembled.) OK Power train check L D Disassemble the transmission, check the condition of the planetary carrier, output shaft and differential, etc.

NG


AUTOMATIC TRANSMISSION - TroubleshootingINSPECTION PROCEDURE 7 Engine stalling when shiftingIf the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine system, damper clutch solenoid valve, valve body or torque converter (damper clutch malfunction).

23-29

Probable causeD D D D Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the valve body Malfunction of the torque converter (Malfunction of the damper clutch)

L: Refer to the Transmission Workshop Manual.Engine system check D Check the control system, ignition system, fuel system and main system. OK Replace the damper clutch control solenoid valve. Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly. NG Replace the torque converter. NG Repair, replace

INSPECTION PROCEDURE 8 Shocks when changing from N to D and large time lagIf abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve body, TPS or APS .

Probable causeD D D D D D D Abnormal underdrive clutch pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Malfunction of the idle position switch Malfunction of the TPS Malfunction of the APS

L: Refer to the Transmission Workshop Manual.MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK When does the shock occur? When shifting Hydraulic pressure test (Refer to P.23-55.) D Measure the underdrive clutch pressure when shifting from N to D. Standard value: Refer to P.23-56. OK Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case. NG Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer. OK NG NG Replace the underdrive solenoid valve. L

When starting Shocks sometimes occur No Yes

MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle. OK NG Code Nos. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)


23-30


INSPECTION PROCEDURE 9 Shocks when changing from N to R and large time lagIf abnormal shocks or a time lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction of the reverse clutch, low and reverse brake, valve body, TPS or APS .

Probable causeD D D D D D D D D Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body Malfunction of the idle position switch Malfunction of the TPS Malfunction of the APS

L: Refer to the Transmission Workshop Manual.MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK When does the shock occur? When shifting Hydraulic pressure test (Refer to P.23-55.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-56. OK NG NG NG Replace the low and reverse solenoid valve. L

When starting Shocks sometimes occur No Yes

MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle. OK NG Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)

Hydraulic pressure test (Refer to P.23-55.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-56. OK Reverse clutch system and low reverse brake system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the reverse clutch oil hole and low and reverse brake oil hole in the transmission case. NG Reverse clutch and low reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

OK


AUTOMATIC TRANSMISSION - TroubleshootingINSPECTION PROCEDURE 10 Shocks when changing from N to D, N to R and large time lagIf abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range and from N to R range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the oil pump or valve body.

23-31

Probable causeD D D Abnormal line pressure Malfunction of the oil pump Malfunction of the valve body

L: Refer to the Transmission Workshop Manual.Hydraulic pressure test (Refer to P.23-55.) D Measure the hydraulic pressure for each element when in D range and R range. Standard value: Refer to P.23-56. OK When does the shock occur? When shifting Replace the oil pump assembly. L (The oil pump cannot be disassembled.) NG Adjust the line pressure. (Refer to P.23-61.) NG When starting


INSPECTION PROCEDURE 11 Shocks and running upIf shocks occur when driving due to upshifting or downshifting and the transmission speed becomes higher than the engine speed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch.

Probable causeD D D D D Abnormal line Malfunction of Malfunction of Malfunction of Malfunction of pressure each solenoid valve the oil pump the valve body each brake or each clutch

L: Refer to the Transmission Workshop Manual.MUT-II Actuator test D No. 1 Low and reverse solenoid valve D No. 2 Underdrive solenoid valve D No. 3 Second solenoid valve D No. 4 Overdrive solenoid valve OK: Sound of operation can be heard. OK Adjust the line pressure. (Refer to P.23-61.) OK Clutch and brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer. NG Replace the solenoid valve.

NG

Replace the oil pump assembly. L (The oil pump cannot be disassembled.) NG Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

23-32


INSPECTION PROCEDURE 12 All points (Displaced shifting points)If all shift points are displaced while driving, the cause is probably a malfunction of the output shaft speed sensor, TPS or of a solenoid valve.

Probable causeD D D D D D Malfunction of Malfunction of Malfunction of Abnormal line Malfunction of Malfunction of the output shaft speed sensor the throttle position sensor each solenoid valve pressure the valve body the A/T-ECU

L: Refer to the Transmission Workshop Manual.MUT-II Data list D No. 23 Output shaft speed sensor OK: Increases in proportion to vehicle speed. OK MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle OK MUT-II Data list D No. 31 Low and reverse solenoid valve duty % D No. 32 Underdrive solenoid valve duty % D No. 33 Second solenoid valve duty % D No. 34 Overdrive solenoid valve duty % OK: Refer to the table below. OK Adjust the line pressure. (Refer to P.23-61.) NG Code No. 23 - Output shaft speed sensor system (Refer to P.23-15.)

NG

Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)

NG

Replace the solenoid valve. L NG Replace the A/T-ECU.

NG


No. 31 Driving at constant speed in 1st gear Driving at constant speed in 2nd gear Driving at constant speed in 3rd gear Driving at constant speed in 4th gear 0% 100 % 100 % 100 %

No. 32 0% 0% 0% 100 %

No. 33 100 % 0% 100 % 0%

No. 34 100 % 100 % 0% 0%

AUTOMATIC TRANSMISSION - TroubleshootingINSPECTION PROCEDURE 13 Some points (Displaced shifting points)If some of the shift points are displaced while driving, the cause is probably a malfunction of the valve body, or it is related to control and is not an abnormality.

23-33

Probable causeD Malfunction of the valve body

L: Refer to the Transmission Workshop Manual.INVECS-II CANCEL COMMAND D Use the MUT-II to stop the INVECS-II function. Does standard shifting occur normally? Yes No Does the problem occur only when the automatictransmissionfluidtemperature is - 29_C or lower or 125_C or higher? Yes It is related to control and is not an abnormality. No Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

INSPECTION PROCEDURE 14 No diagnosis codes (Does not shift)If shifting does not occur while driving and no diagnosis codes are output, the cause is probably a malfunction of the inhibitor switch, or A/T-ECU. No

Probable causeD D Malfunction of the inhibitor switch Malfunction of the A/T-ECU NG

Does the transmission remain in 3rd gear with selector lever in position D ? Yes Is backup power being supplied to the A/T-ECU? No Yes Is power being supplied to the A/T-ECU? No Power supply circuit check D Pay particular attention to open circuits in the harnesses, poor connector connections and open

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