SECTION 7C - AUTOMATIC TRANSMISSION (AW30-40LE)

General Description

Construction

Electronic Control Components

Transmission Control Module (TCM)

Control System Diagram

Control and Functions

Major Input/Output Components

Location of Clutch, Brake, One-way Clutch and Solenoid

Operation of Clutch, Brake and One-Way Clutch

Speed Change and Lock-up Pattern

Overdrive and Lock-up Operating Conditions

Diagnosis

Basic Troubleshooting

Self Diagnosis

Diagnosis with Tech 2

Using Tech 2 on the Vehicle

Connecting Tech 2 to the Vehicle

Transmission Data

TCC Data

Intermittent Conditions

Identification of Transmission Control Module (TCM)

Diagnostic Trouble Codes (DTC) Check

DTC P0120 (Flashing Code 21) Analog Throttle Signal Failure (VTH) (For UBS)

DTC P0502 (Flashing Code 24) Speed Meter Sensor Failure (SP1)

DTC P0705 (Flashing Code 17) Gear Selector Failure (PRND2L)

DTC P0710 (Flashing Code 16) Oil Temperature Sensor Failure (OT2)

DTC P0717 (Flashing Code 14) Input Revolution Sensor Failure (NC0)

DTC P0722 (Flashing Code 11) Output Revolution Sensor Failure (SP2)

DTC P0727 (Flashing Code 13) Engine Revolution Signal Failure (NE)

DTC P0743 (Flashing Code 33) Torque Converter Clutch Control Lock-up (ON/OFF)

Solenoid Failure (SL)

DTC P0748 (Flashing Code 35) Pressure Control Solenoid Failure (STH)

DTC P0753 (Flashing Code 31) Solenoid 1 Failure (S1)

DTC P0758 (Flashing Code 32) Solenoid 2 Failure (S2)

DTC P1120 (Flashing Code 22) PWM Throttle Signal Failure (TH) (For TFR/S)

DTC P1121 (Flashing Code 23) Analog Throttle Signal Failure (VREF, VGND)

(ForUBS)

Wiring Diagram

Connector List

Troubleshooting Chart

Manual Shifting Test

Stall Test

Time Lag Test

Hydraulic Test

Road Test

Shift Point Chart and Lock-Up Point Chart

TCM Voltage Check

On-Vehicle Service

Transmission Fluid Level and Condition

ATF Replacement

Neutral Start Switch Inspection

Brake Signal Inspection

Vehicle Speed Sensor Inspection

Input and Output Revolution Sensor Inspection

Pattern Select Switch Inspection

Overdrive Switch Inspection

Solenoid Inspection

ATF Temperature Sensor Inspection

Throttle Position Sensor Inspection (UBS and TFR/S)

Throttle Position Sensor Inspection (’01 TFR)

Selector Lever

Transmission Control Module (TCM)

Shift Solenoid and Lock-Up Solenoid

Valve Body Assembly and Pressure Control Solenoid

Rear Oil Seal (Adapter Housing, 44)

Rear Oil Seal (Extension Housing, 42)

Transmission Removal and Installation (UBS)

Transmission Removal and Installation (TFR/S)

Unit Repair

Major Components

Disassembly of Major Components (1)

Reassembly of Major Components (1)

Disassembly of Major Components (2)

Reassembly of Major Components (2)

Disassembly of Major Components (3)

Reassembly of Major Components (3)

Disassembly, Inspection and Reassembly of Minor Components

Oil Pump

OD Planetary Gear and OD Direct Clutch Assembly (C-0)

OD Support Assembly

Direct Clutch Assembly (C-2)

Forward Clutch Assembly (C-1)

Front Planetary Gear

Planetary Sun Gear and No.1 One-Way Clutch

Second Brake Assembly (B-2)

Rear Planetary Gear Assembly and Output Shaft

First and Reverse Brake Assembly (B-3)

Transmission Valve Body Assembly

Lower Valve Body

Upper Valve Body

Transmission Case

Torque Converter

Adapter Housing (44)

Extension Housing (42)

Main Data and Specifications

General Specifications

Torque Specifications

Special Tool

CAUTION:

When fasteners are removed, always reinstall them

at a the same location from which they were

removed. If a fastener needs to be replaced, use

the correct part number fastener for that

application. If the correct part number fastener is

not available, a fastener of equal size and strength

(or stronger) may be used.

Fasteners that are not reused, and those requiring

thread locking compound, will be called out. The

correct torque values must be used when installing

fasteners that require torque. If the above

conditions are not followed, parts or system

damage could result.

GENERAL DESCRIPTION

CONSTRUCTION

A07RY00001&A07L200001

ELECTRONIC CONTROL COMPONENTS - UBS JACKAROO

C07R200019

ELECTRONIC CONTROL COMPONENTS - TFR/S RODEO

C07L200001

TRANSMISSION CONTROL MODULE (TCM) - UBS JACKAROO

C07R200020

TRANSMISSION CONTROL MODULE (TCM) - TFR/S RODEO

C07L200002

CONTROL SYSTEM DIAGRAM - UBS JACKAROO

C07R200021

CONTROL SYSTEM DIAGRAM - TFR/S RODEO

C07L200003

CONTROL AND FUNCTIONS

Item Description

Shift and lock-up control • In D range, speed change point and Lock-up point can be

changed by setting pattern selection switch to "POWER",

"NORMAL" or "WINTER (UBS)" mode.

• Gear shift position in the conditions made up of transmission shift

positions (D.2.L) combined with pattern selection switch

(POWER, NORMAL, and WINTER) can be controlled in

accordance with vehicle speed and the opening of throttle valve.

Overdrive cut control • If O/D switch is set on in D range (O/D OFF lamp ON), gear shift

to O/ D is not effected.

• Overdrive is released at O/D switch on and high transmission oil

temperature (More than 130°C).

However, to prevent engine over revolution

• 4

→3 shifting at vehicle speed is less than 118 km/h (UBS) or

117 km/h (TF).

• 3

→4 shifting at vehicle speed is more than 131 km/h (UBS) or

125 km/h (TF).

Lock-up cut control • In D range, 2nd (TF), 3rd or O/D lock-up is conducted in

"POWER" or "NORMAL" mode.

• In 2, L range, lock-up is off in the whole area.

• Lock-up timing is controlled to reduce gear shift shock using kind

of gear shift (shift up, etc.) lock-up status at the time of gear shift

judgement, gear step and throttle opening after gear shift.

• Lock-up is released at brake on or high transmission oil

temperature

(More than 130°C  UBS) .

(More than 140°C  TF).

• Lock-up is prohibited when idling is defected by throttle position

sensor.

Driving mode select control • The TCM selects a suitable driving mode from the nine kinds for

the variety driving condition.

i) Economy mode ii)Power mode iii)Winter mode(UBS) iv)HOT1

mode v)HOT2 mode vi)L4 mode(4×4) vii)Slope mode(UBS)

(Up slope 1, Up slope 2 and Down slope mode)

• The priority of driving mode:

Economy < Power < Slope(UBS) < L4(4×4) < Winter(UBS) <

HOT1 < HOT2

Squat control • When the TCM detects D signal on, the TCM controls 1–3–1 shift

by setting a timer, in order to improve the shift feel at N→D.

Line pressure control • The TCM output current which corresponds to throttle oil pressure

to pressure control solenoid based on throttle opening.

Indicate oil temperature warning function • If the transmission oil temperature sensor senses that

transmission oil temperature is greater than 146°C, the TCM turn

on A/T OIL TEMP warning lamp. (The warning lamp is turned off,

if oil temperature is less than 126°C.)

Item Description

L4 mode control (4×4) • The TCM judges whether the transfer is engaged in high or low

based on the ratio rpm data from output speed sensor in the

transmission and the rpm data from speed meter sensor to select

the shift map.

Up and down hill control (UBS) • The TCM judges up and down hill, and change shift pattern based

on throttle opening and acceleration.

Correct oil temperature control • If the temperature exceeds a predetermined value, the TCM

selects the high oil temperature shift point for downshifting, thus

preventing the oil temperature from rising. (More than 130°C, D

range)

Winter mode control (UBS) • The TCM controls the vehicle start smoothly on low frictional road

(eg. snow or ice) by executing this control.

Activate condition:

1. Excluding "2", "L" range

2. Vehicle speed is less than 11 km/h

3. Transmission oil temperature is less than 115°C

4. Throttle opening is less than 8%

5. Excluding winter mode

Cancel condition:

1. When winter mode switch is pushed again

2. When either "2" or "L" is detected

3. Ignition switch "OFF"

4. Vehicle speed is more than 34 km/h for 1 second or mode

continuously

5. Transmission oil temperature is more than 130°C

Fail-safe function • When trouble occurs to vehicle sensor and each solenoid, TCM

automatically exerts fail-safe control not to spoil driveability.

• This control is exerted when sensor or actuator is in trouble, while

TCM works normally.

Diagnosis function • If there is an abnormality in vehicle sensors, each solenoid (S1-

S3, STH), or throttle position sensor, "CHECK TRANS" lamp is

actuated to warn the drive. But when the abnormality items have

been restored to normal, the light does not blink.

• Faulty parts are memorized in TCM. If self-diagnosis start signal

is inputted, "CHECK TRANS" lamp is blinked and results of

diagnosis are indicated. A history of faults remains recorded even

when IGN switch is off.

TECH 2 • Output of control data in the TCM

• Actuator (Solenoid) operation check

• Erasure of trouble code

MAJOR INPUT/OUTPUT COMPONENTS

Component Function

Vehicle speed sensor (Speedometer) Detects the vehicle speed (Back-up sensor of output revolution

sensor).

Output revolution sensor (Transmission) Detects the vehicle speed

Input revolution sensor (Transmission) Detects the input revolution (O/D direct clutch drum revolution).

Engine revolution sensor Detects the engine revolution.

Throttle position sensor Detects the throttle opening rate.

Neutral start switch Detects the select lever position.

Pattern select switch Detects whether the driver has selected "NORMAL",

"POWER", or "WINTER" (UBS) mode.

Overdrive switch Detects whether the driver has selected O/D.

Brake lamp switch Detects whether the driver has pressed the brake pedal or not.

Oil temperature sensor Detects the oil temperature.

Input

Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.

Input/

Output

Data link connector When connected with Tech2 or tester, can communicate the

data for function check, etc.

Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle

running condition on the basis of TCM output.

Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running

condition on the basis of TCM output.

Pressure control solenoid STH Adjusts throttle pressure by energizing current of linear

pressure control solenoid to prevent the shift shock and to

obtain shift smoothly.

"CHECK TRANS" lamp When trouble has occurred to throttle position sensor, vehicle

speed sensor, or solenoid, "CHECK TRANS" lamp is blinked to

warn the driver. If also displays the trouble code.

A/T OIL TEMP warning lamp Lights when ATF oil temperature rises. (Turned on at greater

than 146°C. Turned off at less than 126°C.

Power mode lamp Informs the driver whether the vehicle is in power mode or not.

Output

Winter mode lamp (UBS) Informs the driver whether the vehicle is in winter mode or not.

Computer

Transmission Control Module (TCM) Based on the signal from each switch and sensors, judges

necessary shift point and lock-up operation, and send signal to

each solenoid.

LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID

C07R200022

Legend

1. Overdrive direct clutch (C-0)

2. Overdrive brake (B-0)

3. Direct clutch (C-2)

4. Second coast brake (B-1)

5. Forward clutch (C-1)

6. Second brake (B-2)

7. First and reverse brake (B-3)

8. One-way clutch (No.2) (F-2)

9. Shift solenoid (S-1)

10. Shift solenoid (S-2)

11. One-way clutch (No.1) (F-1)

12. Pressure control solenoid (STH)

13. Lock-up solenoid (SL)

14. Overdrive one-way clutch (F-0)

OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH

: Operating : Free at coast down : Operating at lock-up

Shift lever

position Gear position C-0 C-1 C-2 B-0 B-1 B-2 B-3 F-0 F-1 F-2 S-1 S-2 S-3

P Parking

R Reverse

N Neutral

1st

2nd

3rd

O/D

1st

2nd

3rd

1st

(1*) 2nd

(2*) 3rd

(1*) Down-shift only in the L range and 2nd gear – no up-shift

(2*) Down-shift only in the L range and 3rd gear – no up-shift

SPEED CHANGE AND LOCK-UP PATTERN

If you select a speed range and a lock-up pattern as shown below by specifying respective positions of transmission

shift lever, transfer shift lever and pattern select switch, the transmission control computer controls speed change

and lock-up operations based on the specified pattern in accordance with the degree of throttle opening and vehicle

speed.

Transmission shift position

Pattern select sw.

position Overdrive switch

Overdrive switch

OFF

2 L

NORMAL, POWER 1st [2nd]* [3rd] [O/D] 1st [2nd]* [3rd] [O/D] 1st 2nd (3rd) 1st (2nd) (3rd)

WINTER (UBS) 3rd fixing  

[ ]: The lock-up operation is available.

( ): Transmission is shifted at high speed to prevent overrun.

*: TF model

OVERDRIVE AND LOCK-UP OPERATING CONDITIONS

The overdrive and lock-up clutch operate if the following conditions are satisfied.

Overdrive Lock-up clutch

Transmission shift position D range (1*)

O/D switch position ON (O/D OFF lamp OFF)

Brake lamp switch OFF

Throttle opening Except fully closed

Vehicle speed

(UBS)

About 49 km/h or more

(TFR/S)

About 34 km/h or more

(UBS)

3rd: About 50 km/h or more

O/D: About 65 km/h or more

(TFR/S)

2nd: About 35 km/h or more

3rd: About 49 km/h or more

O/D: About 59 km/h or more

(1*): If transmission oil temperature is more than 130°C (UBS and or 140°C (TFR/S), lock-up is

inhibit.

DIAGNOSIS

BASIC TROUBLESHOOTING

AW30-40LE transmission, called Electronic Controlled Transmission (ECT), differs from oil pressure control type

transmissions in that it is controlled by a microcomputer. Accordingly, its troubleshooting procedure differs also.

Before troubleshooting an ECT, first determine whether the problem is electrical or mechanical. To do this, just refer

to the basic troubleshooting flowchart provided below.

If the cause is already known, using the basic troubleshooting chart below along with the troubleshooting chart

should speed the procedure.

F07R200005

UBS

825R200084

TFR/S

825R200085

SELF DIAGNOSIS

Warning to the driver

When trouble has occurred to throttle position sensor,

vehicle speed sensor, or solenoid, “CHECK TRANS” lamp

is blinked (1.25 Hz) even during driving to warn the driver.

The trouble is recorded by trouble code is TCM.

When temporary trouble has been shooted, the “CHECK

TRANS” lamp stops blinking. This blinking can be stopped

by setting the ignition key off. But the trouble code remains

memorized in TCM.

F07LV002

UBS

TFR/S

Self-diagnosis code display

For quick search for faulty parts, 11 (TF) or 12 (UBS)

different items of trouble code are indicated by “CHECK

TRANS” lamp blinking.

The storaged trouble codes can be identified by shorting

the terminals No.11 and No.4 or 5 (ground) of diagnosis

connector with a lead wire.

F07LV001

Indication Method:

(1) Terminals No.11 and No.4 or 5 (ground) of diagnosis

connector are short circuited.

(2) Turn the ignition key to the ON position.

(3) In case there no trouble, normal code is indicated.

(4) In case a plurality of trouble codes have occurred at a

time, each code is indicated three times in numerical

order.

NOTE:

Power line runs through diagnosis connector.

Be careful shorting with a lead wire, etc.

(The vehicle side of control module may be damaged.)

For identification of trouble code, connect Tech 2 to

diagnosis connector.

Clear of trouble code memory

1. Clear the trouble code memory using F1: Clear DTC

Information for Tech 2.

2. After more than 1 second has elapsed after the ignition

key has been turned ON, short between NO.11 and No.4

or 5 (ground) of data link connector. Then, after 1 second,

but within 6 seconds, discontinue shorting.

Flashing code

Trouble Code

(P-Code) Mode Diagnostic area and Failure

(P0722)

Output revolution sensor failure (SP2)

(P0727)

Engine revolution signal failure (NE)

(P0717)

Input revolution sensor failure (NC0)

(P0710)

Oil temperature sensor failure (OT2)

(P0705)

Gear selector failure (PRND2L)

(P0120)

Analog throttle signal failure (VTH)

(For UBS)

(P1120)

PWM throttle signal failure (TH)

(For TFR/S)

(P1121)

Analog throttle signal failure (VREF, VGND)

(For UBS)

(P0502)

Speed meter sensor failure (SP1)

(P0753)

Solenoid 1 failure (S1)

(P0758)

Solenoid 2 failure (S2)

(P0743)

Torque converter clutch control lock-up

(ON/OFF) solenoid failure (SL)

(P0748)

Pressure control solenoid failure (STH)

F07R200014

DIAGNOSIS WITH TECH 2

In this AW30-40LE transmission, troubleshooting can be

performed for electrical faults using the Tech 2 scan tool.

If the CHECK TRANS lamp blinks, or if an electrical fault in the

transmission may probably exist, check trouble codes using

the Tech 2 scan tool.

In the diagnostic procedures described in this manual, first

repair the faulty positions indicated by trouble code in the orde

of numbers and then perform troubleshooting for the fault

positions that are not indicated by trouble code. For correct

troubleshooting, it is necessary to first repair the trouble codes

of lower-order numbers, then to repair the trouble codes o

higher-order numbers in sequence.

How to Use This Manual:

Check trouble codes using the Tech 2 scan tool.

If no codes are set:

Refer to Data List and identify the electrical faults that are

not indicated by trouble code.

If codes are set:

Record all the codes displayed by the Tech 2 and check i

the codes are intermittent (intermittent faults).

Clear the codes.

Drive the vehicle for a test to reproduce the faulty status.

Check trouble codes again using the Tech 2.

If no code is displayed by test driving, the fault is

intermittent. In this case, refer to the cautions on

intermittent conditions.

If a code is present, refer to “DIAGNOSTIC TROUBLE

CODES (DTC) CHECK” for diagnosis.

Because a code of high-order number may be set for the

reason that a code of low-order number has been set afte

occurrence of a fault, perform repair work starting with a

lower-order number is ascending order.

USING TECH 2 ON THE VEHICLE

NOTE: Due to the constant evolution of TECH 2

software, the screens shown in this section may

differ slightly from those displayed for the vehicle

being tested.

Connecting TECH 2 To The Vehicle

1. Connect Tech 2 to the vehicle DLC, with the DLC

cable and the 16/19 pin adapter.

2. Switch the unit on by pressing the power button (2).

A green light (1) should come on indicating that the

tool is receiving power.

NOTE: At this time the technician should see the Power

On Self Test (POST) run. The POST is a built in

diagnostic self test for the TECH 2 that should find most

common system faults. The POST is run on every

power up to ensure the best operation of the tool. After

the completion of the POST, the TECH 2 unit will briefly

show the POST results. If POST passes, the tool will

continue onto the title screen. If POST fails, results of all

tests will be displayed, and this should show which test

failed. POST failures may be classified as fatal or non-

fatal. A fatal error will not allow the user to continue

using the tool. Failure of the keypad would be an

example of a fatal error. Non-fatal errors found during

the POST will allow continued use of the TECH 2, but

with some limitations. If either a fatal or non-fatal error

occurs, refer to the Troubleshooting section of the

TECH 2 User's Guide.

1. Power Status Indicator Light

2. PWR (Power) Key

3. SHIFT Key Status Indicator Light

4. SHIFT Key

3. At the Tech 2 title screen press the ENTER key to

continue.

UBS

TFR/S

4. A selection can be made from the Main Menu,

either by using a function key or by using the arrow

keys to highlight a menu choice and pressing

ENTER.

•NOTE: You will then need to supply some additional

information to the TECH 2. This requires navigation

through a series of lists (called picklists). On some

menus or picklists, the user can use a function key to

make a menu selection, but most of the picklists

require using the selection and action keys. If a

mistake is made in the selection process, or if a

different application or function is desired, press EXIT

to back up one level. Within an application, there may

be soft keys which are available for use. These soft

keys allow access to additional tool functions without

exiting a current tool function. Soft keys are made up

of sets which will appear together. To see the next set

of soft keys, select the More soft key.

The TECH 2 Main Menu contains the following:

F0: Diagnostics

Contains all functions to test, diagnose, monitor and

program the different vehicle systems.

F1: Service Programming System (SPS)

SPS is used in conjunction with Technical

Information System (TIS) 2000 to program vehicle

control units.

F2: View Capture Data

Contains all functions to work with one or two

previously recorded snapshots on one or two

vehicles. This function is to enable the viewing of

captured data without a vehicle.

F3: Tool Options

Contains the TECH 2 self test, set clock, set units,

set screen contrast and Getting Started.

F4: Download/Upload Help

Contains help information on the downloading and

uploading from the TECH 2 to the TIS 2000 CD-

ROM.

5. Select the correct Model Year with the arrow keys

and the press ENTER. The Vehicle identification

screen will then be displayed.

6. Select the correct Vehicle Type with the arrow keys

and the press ENTER. The System Select Menu

will then be displayed.

7. The desired system can be selected from the

System Select Menu with the function keys or with

arrow keys and then press ENTER.

F0:Powertrain contains all functions to test,

diagnose, and monitor the engine and transmission

systems that communicate with the Tech 2 via the

Powertrain Control Module (PCM).

F1: Chassis contains all functions to test,

diagnose, monitor the vehicles chassis systems;

TOD and ABS modules.

F2: Body contains all functions to test, diagnose,

monitor the instruments and Supplemental

Restraint System.

Once the test vehicle has been identified an

“Application (Powertrain) Menu" screen appears.

Please select the appropriate application.

The following table shows, which functions are used for

the available equipment versions.

F0: Diagnostic Trouble Codes

F0: Read DTC Info Ordered By Priority

F1: Clear DTC Information

F2: DTC Information

F0: History

F1: MIL SVS or Message Requested

F2: Last Test Failed

F3: Test Failed Since Code Cleared

F4: Not Ran Since Code Cleared

F5: Failed This Ignition

F1: Data Display

F0: Transmission Data

F1: TCC Data

F2: Snapshot

F3: Actuator Tests

F0: Lamps

F0: Check Light Test

F1: Power Lamp Test

F2: Winter Lamp Test

F3: AT Oil Temperature Lamp Test

F1: Solenoids

F0: Solenoid 2-3 Test

F1: Solenoid 1-2/3-4 Test

F2: TCC Solenoid Test

F3: Pressure Control Solenoid (PCS)

Diagnostic Trouble Codes

The purpose of the “Diagnostic Trouble Codes" mode

is to display stored TCM trouble codes.

When “Diagnostic Trouble Codes" is selected an

“Application Menu" screen appears.

Clear DTC Information

The purpose of the “Clear DTC Information" mode is to

command the clearing of stored TCM trouble codes.

When “Clear DTC Information" is selected, a “Clear

DTC Information", warning screen appears. This

screen informs you that by cleaning DTC's, “all stored

DTC information in controller will be erased".

Do you want to clear DTC's (Yes/No).

Press either the Yes or No key when answering.

After clearing codes, confirm system operation by test

driving the vehicle.

Allow the vehicle to shift through all four forward gears

in a manner which attempts to repeat the failure

condition.

NOTE: When the trouble has not been repaired and

the trouble code cannot be erased, check the vehicle

again.

DTC Information

When “DTC Information" is selected, an “Application

Menu" appears with a list of DTC information function

keys addressing DTC specifics and their origins.

Function key selections may vary for particular vehicle

and/or system.

Data Display

The purpose of the “Data Display" mode is to

continuously monitor data parameters.

The current actual values of all important sensors and

signals in the system are display through F1 mode.

When “Data Display" is selected an “Application Menu"

appears.

See “TRANSMISSION DATA" and “TCC DATA” on

next page.

Snapshot

When “Snapshot" is selected an “Application Menu"

appears.

When “Transmission Snapshot" application is selected

from the “Application Menu", a “Snapshot Menu"

appears, displaying several options. “Snapshot" options

may vary from one system to another.

“Snapshot" allows a recording of all vehicle

parameters. There parameters may then be replayed

at a future point in time.

This action allows you to focus on making the condition

occur, rather than trying to view all of the data in

anticipation of the fault. The snapshot will collect

parameter information around a trigger point that you

select.

When a snapshot is taken. It is recorded onto the

PCMCIA memory card. When the Tech2 is powered

down. Snapshots are not lost.

Actuator Tests

The purpose of “Actuator Tests" mode is to check for

correct operation of electronic system actuators.

Lamps

You can operate the lamps by pressing the ON and

OFF buttons.

Preconditions: P or N position

Solenoid

Solenoid S1(1-2/3-4), S2(2-3) and TCC Solenoid

(Torque Converter Clutch)

You can operate the solenoids by pressing the ON and

OFF buttons.

Preconditions: P or N position, no vehicle speed, no

engine speed

Pressure Control Solenoid (PCS)

You can operate the PC Solenoid by pressing the ON

and OFF buttons. ON will command a maximum

current of 1000 mA and OFF a minimum of 200 mA.

Preconditions: P or N position, no vehicle speed,

engine running

TRANSMISSION DATA

Item Unit Engine running at idle

Current Gear 1

Lock Up Inactive, Active Inactive

Selector Position Park

AT Output Speed (Automatic Transmission) RPM 0 RPM

Output Speed (Meter Signal Side) RPM 0 RPM

AT Input Speed (Automatic Transmission) RPM 0 RPM

Engine Speed RPM 695 ~ 745 RPM (UBS)

Vehicle Speed (Output Side) km/h 0 km/h

Throttle Position % 0%

Throttle Position Sensor V 0.25 ~ 0.45V

AT Oil Temperature (Automatic Transmission) °C, °F 70 ~ 80°C (158 ~ 176°F)

Shift Pattern

Desired PCS Pressure (Pressure Control

Solenoid) kPa

PCS Desired Current (Pressure Control Solenoid) mA

PCS Actual Current (Pressure Control Solenoid) mA

Overdrive Off Switch Off, On

Brake Switch Open 0V, Closed 12V Closed 12V

Winter Switch Open, Closed 0V Open

Power Switch Open, Closed 0V Open

Diagnostic Request Open, Closed Open

Winter Lamp Inactive 12V, Active 0V Inactive 12V

Power Lamp Inactive 12V, Active 0V Inactive 12V

Check Light Inactive 12V, Active 0V Inactive 12V

AT Oil Temperature Lamp (Automatic

Transmission) Inactive 12V, Active 0V Inactive 12V

Solenoid 2-3 Inactive 0V, Active 12V Inactive 0V

Solenoid 1-2/3-4 Inactive 0V, Active 12V Active 12V

TCC Solenoid (Torque Converter Clutch) Inactive 0V, Active 12V Inactive 0V

TCC DATA

Item Unit Engine running at idle

Current Gear 1

Lock Up Inactive, Active Inactive

AT Output Speed (Automatic Transmission) RPM 0 RPM

Output Speed (Meter Signal Side) RPM 0 RPM

AT Input Speed (Automatic Transmission) RPM 0 RPM

Engine Speed RPM 695 ~ 745 RPM (UBS)

Vehicle Speed (Output Side) km/h 0 km/h

Throttle Position % 0%

Gear Ratio :1 2.804

AT Oil Temperature (Automatic Transmission) °C, °F 70 ~ 80°C (158 ~ 176°F)

TCC Slip Speed RPM 695 ~ 745 RPM

TCC Solenoid Pressure Desired kPa 0 kPa

Desired TCC Solenoid Current mA 0 mA

Actual TCC Solenoid Current mA 0 mA

INTERMITTENT CONDITIONS

If the Tech2 displays a code as intermittent, or if after a test

drive a code does not reappear, the problem is most likely a

faulty electrical connection or loose wiring.

Terminals should always be the prime suspect.

Intermittent rarely occur in sophisticated electronic

components such as the Transmission Control Module (TCM).

When an intermittent problem is encountered, check suspect

circuits for:

Poor terminal to wire connection.

Terminals not fully seated in the connector body (backed

out).

Improperly formed or damaged terminals.

Loose, dirty, or corroded ground connections.

HINT: Any time you have an intermittent in more than one

circuit, check whether the circuits share a common

ground connection.

Pinched or damaged wires.

Electro-Magnetic Interference (EMI)

HINT: Check that all wires are properly routed away from

coil, and generator. Also check for improperl

installed electrical options, such as lights, 2-wa

radios, etc.

Use the F2: SNAPSHOT mode of the Tech2 to help isolate the

cause of an intermittent fault. The snapshot mode will record

information before and after the problem occurs. Set the

snapshot to "trigger" on the suspect code (or codes) or, if you

notice the reported symptom during test drive, trigger the

snapshot manually.

After the snapshot has been triggered, command the Tech2 to

play back the flow of data recorded from each of the various

sensors. Signs of an intermittent fault in a sensor circuit are a

sudden unexplainable jump in data values out of the normal

range.

IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)

826R200032

Legend

1. HOLDEN Part No:

‘02UBS 8-97230-821-0

‘02TFS 8-97303-885-0

‘02TFR 8-97303-884-0

2. Calibration Code

3. Production Date:

4. Software Version No.:

5. Model Year, Vehicle Model, Engine Type

DIAGNOSTIC TROUBLE CODES (DTC) CHECK

DTC

NUMBER

FLASHING

CODE DESCRIPTION

P0120 21 ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)

P0502 24 SPEED METER SENSOR FAILURE (SP1)

P0705 17 GEAR SELECTOR FAILURE (PRND2L)

P0710 16 OIL TEMPERATURE SENSOR FAILURE (OT2)

P0717 14 INPUT REVOLUTION SENSOR FAILURE (NC0)

P0722 11 OUTPUT REVOLUTION SENSOR FAILURE (SP2)

P0727 13 ENGINE REVOLUTION SIGNAL FAILURE (NE)

P0743 33 TORQUE CONVERTER CLUTCH CONTROL LOCK-UP (ON/OFF) SOLENOID

FAILURE (SL)

P0748 35 PRESSURE CONTROL SOLENOID FAILURE (STH)

P0753 31 SOLENOID 1 FAILURE (S1)

P0758 32 SOLENOID 2 FAILURE (S2)

P1120 22 PWM THROTTLE SIGNAL FAILURE(TH) (FOR TFR/S)

P1121 23 ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND) (FOR UBS)

DTC P0120 (FLASHING CODE 21)

ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)

D07R200063

Circuit Description:

When the signal of the engine throttle position sensor

located on the accelerator pedal is supplied to the

TCM, the TCM judges the opening condition of the

throttle.

The shift point of the transmission is determined by this

opening condition of the throttle.

Fail-safe control:

The TCM controls fail-safe by detecting analog throttle

signal (VTH) failure.

Failure detection:

• When the throttle input voltage is detected less

than 0.112V or more than 4.417V for 2.0 seconds.

Contents of control:

At failure detection

• Throttle opening for line pressure control ... Throttle

opening 100%

• Throttle opening for shift control ... Throttle opening

• Lock-up control inhibit

• Up hill and down hill control inhibit

• Squat control inhibit

At failure decision

Executes following items in addition to above

control items at failure detection.

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

Conditions of turning "CHECK TRANS" lamp

off:

Turns “CHECK TRANS” lamp off when judged 0km/h

by output revolution sensor after throttle signal input

voltage is detected more than 0.112V and less than

4.717V.

(however, uses 0 km/h judgment by back-up vehicle

speed at output revolution failure)

Reversion conditions from fail-safe:

At failure detection

Immediately recovers when the throttle input

voltage is detected more than 0.112V and less than

4.717V.

At failure decision

Recovers at the same time as the conditions of

turning “CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. Check that the throttle input voltage is 0.25 to

0.45V.

2. At this test, check that as the throttle opens, the

voltage goes up and that the voltage reaches 3.74

to 4.56V at the full open status.

6. Check the power supply voltage (4.75 – 5.25V) of

the throttle position sensor.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0120 (FLASHING CODE 21)

ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)

Step Action Value(s) Yes No

1. With the engine “OFF”, turn the ignition “ON”.

2. Connect a voltmeter between the TCM 28

pin connector terminal (6) and ground

terminal (28).

Is the voltage within the specified valve?

0.25 0.45 V Go to Step 2 Go to Step 3

Open the throttle fully.

Is the voltage within the specified value?

3.74 4.56 V The problem is

intermittent.

Refer to

“Diagnostic

aids”.

Go to Step 3

Connect a voltmeter between the ECM 32 pin

connector terminal (E1-6) and (E2-22).

Is the voltage within the specified value?

0.25 0.45 V Go to Step 4 Go to Step 6

4 Open the throttle fully.

Is the voltage within the specified value?

3.74 4.56 V Go to Step 5 Go to Step 6

1. Check the wiring harness between the TCM

28 pin connector terminal (6) and ECM 32

pin connector terminal (E1-6).

2. Or TCM is faulty.

Was a problem found and corrected?

Go to Step 9

1. Disconnect the TPS 3 pin connecter.

2. Connect a voltmeter between the TPS 3 pin

connector terminal (3) and (1).

Is the voltage within the specified value?

4.75 5.25 V Go to Step 7 Go to Step 8

Check the TPS connector. If OK, replace the

TPS.

Is the replacement complete?

Go to Step 9

Check the wiring harness between the TPS and

ECM. If OK, replace the ECM.

Is the replacement complete?

Go to Step 9

1. After the repair is complete, use the scan tool

to select “DTC”, then “clear Info” function.

2. Make a road running test for the vehicle.

3. Review the scan tool “DTC Info”.

Has the last test failed or is the current DTC

displayed?

Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0502 (FLASHING CODE 24)

SPEED METER SENSOR FAILURE (SP1)

UBS

D07R200056

TFR/S

D07L200001

Circuit description:

Speed information is provided by the speed meter

sensor to the meter.

In the meter, the pulses of the speed meter sensor are

converted to speed signals (pulses), and these signals

are output to the TCM and ECM(TF). The TCM

converts these pulse voltages to km/h signals.

Fail-safe control:

The TCM controls fail-safe by detecting speed meter

signal failure.

Failure detection:

• When not even 1 pulse is input in the speed meter

signal during the time 100 pulses are input in the

output revolution sensor signal.

• When not even 1 pulse is input in the speed meter

signal during the time 27 pulses are input in the

output revolution sensor signal.

Contents of control:

At failure detection

• Keeps the condition of transfer (High/Low

judgment) just before detection until vehicle speed

is 0km/h, and changes shift map to L4 map (3→4

UP None) at vehicle speed is 0km/h. (For UBS)

• Uses high oil temperature map according to shift

map priority at correct oil temperature control.

• Up hill and down hill control inhibit. (For UBS)

• Stores the failure information in failure -memory.

• The failure detection of oil temperature sensor

inhibit

At failure decision

Executes following items in adition to above control

items at failure detection.

• Blinks "CHECK TRANS" lamp

Conditions of turning "CHECK TRANS" lamp

off:

Turns "CHECK TRANS" lamp off when judged 0km/h

by speed meter sensor after more than 1 pulse are

input in the speed meter signal during the time 27

pulses are input in the output revolution sensor.

Reversion conditions from fail-safe:

At failure detection and decision

Recovers at the same time as the conditions of turning

“CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

2. The cause of DTC P0502 setting is due to the

operation fault of the speed meter.

3. Speed signals are output from the meter. The

sensor power supply is given from the TCM.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0502 (FLASHING CODE 24)

SPEED METER SENSOR FAILURE (SP1)

Step Action Value(s) Yes No

1. Lift the driving wheels.

2. With the engine idling in gear D range.

Is the Tech 2 displayed speed the specified

value?

0 km/h Go to Step 2 DTC P0502 is

intermittent.

If other DTCs

are not stored

in memory.

Refer to

“Diagnostic

aids”.

2 Does the speed meter operate? Go to Step 3 Go to Step 4

1. Open the throttle and increase the revolution

speed of the driving wheels

2. Measure the voltage between the TCM 28

pin connector terminal (7) and TCM 20 pin

connector ground terminal (15 or 19) with a

voltmeter.

Does the voltage vary intermittently in the

specified value?

1.4 about 5V

(AC) (Vehicle

speed 10-20 km/h)

Go to Step 5 Go to Step 6

The speed meter or speed meter sensor is

faulty.

Was a problem found and corrected?

Go to Step 7

5 The TCM connect is faulty or the TCM is faulty.

Was a problem found and corrected?

Go to Step 7

The wiring harness between the speed meter

and TCM is open or the speed meter sensor is

faulty.

Was a problem found and corrected?

Go to Step 7

1. After the repair is complete, use the scan tool

to select “DTC”, then “Clear Info” function.

2. Make the road running test for the vehicle.

3. Review the scan tool “DTC Info”.

Has the last test failed or is the current DTC

displayed?

Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0705 (FLASHING CODE 17)

GEAR SELECTOR FAILURE (PRND2L)

UBS

D07R200057

TFR/S

D07L200002

Circuit description:

The neutral start switch gives the signals related to the

selector lever position (PRND2L) to the Transmission

Control Module (TCM). The neutral start switch turns

on when the select lever is shifted to the P, R, N, D, 2

or L range. The neutral start switch, which is connected

to the starter switch circuit, is available only when the

select lever is in the P or N range

The neutral start switch is connected to the

transmission manual shaft and installed in the

transmission case.

Fail-safe condition:

The TCM controls fail-safe by detecting selector

position switch failure.

Failure detection:

(1) OPEN:

• When all switches are OFF

• When the failure criteria continues for 30 seconds if

the vehicle speed which is calculated by output

revolution sensor is more than 30 km/h and the

engine revolution is more than 1500 rpm.

(2) SHORT:

• When more than two switches are ON at the same

time.

• When the failure criteria condition for 10 seconds.

Contents of control:

At failure detection

(1) OPEN: D range judgment

(2) SHORT: Judged by priority D>2>L>R>N>P

• Up hill and down hill control inhibit (For UBS)

• Winter mode inhibit (For UBS)

At failure decision

Excutes following items in addition to above control

items at failure detection.

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

• Reverse lockout control inhibit

Conditions of turning “CHECK TRANS” off:

Turns “CHECK TRANS” lamp off when only one of all

switches is ON.

Reversion conditions from fail-safe:

Turns “CHECK TRANS” lamp off when only one of all

switches is ON.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. It is judged whether the input signal received from

the neutral start switch by the TCM is proper or not.

5. The power status of the neutral start switch is

checked.

6. The continuity between neutral start switch

terminals and the continuity of the wire connected

to the neutral start switch are checked.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0705 (FLASHING CODE 17)

GEAR SELECTOR FAILURE (PRND2L)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter to the each terminals of

the TCM 28 pin connector and TCM 20 pin

connector ground terminal (15 or 19).

3. Measure the voltage shifting the selector

lever to very position.

(Comparison with table 1)

Is the displayed voltage at every position

normal?

See table 1 Go to Step 2 Go to Step 3

1. Clear the TCM memory.

2. Make a running test. (Greater than 30

seconds).

Is DTC P0705 displayed by self-diagnosis?

Go to Step 4 The continuity

of wiring is

temporarily

faulty.

Refer to

“Diagnostic

aids”.

3 Is the displayed voltage at every position

abnormal?

Go to Step 5 Go to Step 6

The TCM is faulty or the continuity of wiring is

temporarily faulty.

Refer to "Diagnostic aids".

Was a problem found and corrected?

Go to Step 9

1. Check if there is any breaking in the fuse and

wire connected to the 10 pin connector

terminal (3) of the neutral start switch.

2. Check the adjusted condition of the neutral

start switch.

3. If no fault is found, replace the neutral start

switch.

Was a problem found and corrected?

Go to Step 9

1. Disconnect the 10 pin connector of the

neutral start switch.

2. Make a continuity check between each

terminals of the neutral start switch with an

ohmmeter.

Is the continuity at every position normal?

See table 2 Go to Step 7 Go to Step 8

The wiring harness between the TCM and

neutral start switch is open or shorted.

Was a problem found and corrected?

Go to Step 9

8 Replace the neutral start switch.

Is the replacement complete?

Go to Step 9

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

Begin the

diagnosis

again.

Go to Step 1

System OK

(Table 1)

TCM 20 pin

terminal (-)

TCM 28 pin

terminal (+) Voltage (V)

8-16: P range

2 1 or less: Other than P range

8-16: R range

1 1 or less: Other than R range

8-16: N range

9 1 or less: Other than N range

8-16: D range

8 1 or less: Other than D range

8-16: 2 range

21 1 or less: Other than 2 range

8-16: L range

15 or 19

20 1 or less: Other than L range

(Table 2)

Terminal Neutral start switch 10 pin connector

Range 1 4 3 5 2 6 8 7 9

Continuity

DTC P0710 (FLASHING CODE 16)

OIL TEMPERATURE SENSOR FAILURE (OT2)

UBS

D07R200058

TFR/S

D07L200003

Circuit Description:

The oil temperature sensor is a thermistor sensor that

is installed in the transmission case and converts

temperature changes into continuous electric signals,

then outputs them to the Transmission Control Module

(TCM). When the ATF temperature is low, the

resistance of the sensor (thermistor) goes up, so that

the voltage of the TCM signal becomes high.

As the ATF is gradually warmed, the resistance of the

sensor goes down and the voltage becomes low. At the

normal operating ATF temperature (80°C/176°F) of the

transmission, the voltage of the TCM is about 3.7V.

Fail-safe condition:

The TCM controls fail-safe by detecting oil temperature

sensor failure.

Failure detection:

Short detection

• When the A/D value is detected less than 10

(220°C) for 5 minutes continuously while normal

judgment is not satisfied from ignition on.

Open detection

• After 15 minites passed when the engine revolution

is more than 400 rpm and the selector position

switch is selected on R, D, 2, L range.

• When the change of the A/D value from engine

start is less than 15 and the minnum A/D value is

more than 1000 (-10°C) from engine start.

Contents of control:

At failure detection

• Changes shift map to HOT2 map

• Controls as A/T oil temperature 200°C

• Lock-up control inhibit

• Up hill and down hill control inhibit (For UBS)

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

At failure decision

• Same as failure detection.

Conditions of turning "CHECK TRANS" off:

Turns "CHECK TRANS" lamp off when judged 0km/h

by output revolution sensor after the normal area of oil

temperature 40°C – 150°C is detected for 10 sec

continuously.

Reversion conditions from fail-safe:

Recovers at the same time as the conditions of turning

“CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. Check that the voltage of the oil temperature

sensor varies with ATF temperatures.

3. Check that the resistance of the oil temperature

sensor varies with ATF temperatures.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0710 (FLASHING CODE 16)

OIL TEMPERATURE SENSOR FAILURE (OT2)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter between the TCM 28

pin connector terminal (18) and (27).

Is the voltage as shown in the table?

See table Go to Step 2 Go to Step 3

1. Replace the TCM with a new one.

2. Make a running test.

Is DTC P0710 displayed by self-diagnosis?

Go to Step 4 The TCM is

faulty.

(TCM before

replacement)

Go to Step 9

1. Disconnect the TCM 28 pin connector.

2. Measure the resistance between the TCM 28

pin connecter terminal (18) and (27).

Is the resistance as shown in the table?

See table Go to Step 5 Go to Step 6

Check the wiring harness or connector

connection between the TCM and oil

temperature sensor.

Was a problem found and corrected?

Go to Step 9

The TCM is faulty or the continuity of wiring is

temporarily faulty.

Refer to "Diagnostic aids".

Was a problem found and corrected?

Go to Step 9

1. Disconnect the A/T 2 pin connector.

2. Measure the resistance between the A/T 2

pin connector terminal (1) and (2).

Is the resistance as shown in the table?

See table Go to Step 7 Go to Step 8

The wiring harness between the TCM and oil

temperature sensor connector is ground-shorted.

Was a problem found and corrected?

Go to Step 9

8 Replace the oil temperature sensor.

Is the replacement complete?

Go to Step 9

1. After the repair is complete, use the scan tool

the select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

Begin the

diagnosis

again.

Go to Step 1

System OK

(Table)

ATF temperature (°C/°F) Voltage (V) Resistance (kΩ)

20/68 Approx. 4.7

80/176 Approx. 3.7

0.5 − 30

DTC P0717 (FLASHING CODE 14)

INPUT REVOLUTION SENSOR FAILURE (NC0)

UBS

D07R200059

TFR/S

D07L200004

Circuit description:

Input revolution information is provided to TCM by the

input revolution sensor. This sensor is located in the

transmission case.

The input revolution sensor is an electromagnetic pulse

pickup type that generates a speed signal according to

the revolution of the transmission OD direct clutch

drum.

As a result, the sensor sends a sine wave signal (AC)

to the TCM, which converts this sine wave signal (pulse

voltage) to a RPM signal.

Fail-safe control:

The TCM controls fail-safe by detecting input revolution

sensor failure.

Failure detection:

• When not even 1 pulse is input in the input

revolution sensor during the time 4 pulses are input

in the output revolution sensor.

• When the failure criteria is continuously 1000 times

from the time ignition is turned ON until it is turned

OFF.

Prohibits failure detection when at least one among the

following conditions is satisfied.

• When D, 2 and L range signal is not fixed.

• When output revolution is less than 775 rpm.

• When the failure detection timer T1 (*1) is less than

25 seconds.

• Solenoid S1, S2, and selector position switch is on

failure detection or decision.

• At 4th gear.

• When passed less than 10 seconds after shift

command output.

*1: Failure detection inhibit timer T1

Timer starts when D, 2 or L range are detected (fixation

signal).

Contents of control:

At failure detection

• Lock-up control inhibit

• Up hill and down hill control inhibit (For UBS)

At failure decision

Executes following items in addition to above

control items at failure detection.

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

Conditions of turning "CHECK TRANS" off:

At D, 2 or L range and not shifting, turns "CHECK

TRANS" lamp off when judged 0km/h by output

revolution sensor after more than 1 pulse input in the

input revolution sensor and finished vehicle speed

calculation during the time 4 pulse are input in the

output revolution sensor.

Reversion conditions from fail-safe:

Recovers at the same time as the conditions of turning

“CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. When the engine is running, a revolution signal is

input from the input revolution sensor to the TCM.

2. At this test, the continuity of circuit wiring and the

input revolution sensor is checked.

4. At this test, the continuity of the input revolution

sensor is checked.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0717 (FLASHING CODE 14)

INPUT REVOLUTION SENSOR FAILURE (NC0)

Step Action Value(s) Yes No

1. Turn the ignition "ON" and the engine "ON".

2. With the engine edling, connect a voltmeter

between the TCM 28 pin connector terminal

(5) and ground terminal (17).

Does the voltage rary in the specified value?

(The voltage increases in proportion to the

speed.)

0-3 V (AC)

or more

DTC P0707 is

intermittent.

If other codes

are not stored,

refer to

“Diagnostic

aids”.

Go to Step 2

1. Turn the ignition "OFF".

2. Disconnect the TCM 28 pin connector.

3. Connect an ohmmeter between the TCM 28

pin connector terminal (5) and (17).

Is the resistance within the specified value?

560-680 Ω

(at 20°C, 4×4)

387-473 Ω

(at 20°C, 4×2)

Go to Step 3 Go to Step 4

1. Replace the TCM with a new one.

2. Make a road running test for the vehicle.

Is DTC P0717 displayed?

 Go to Step 5 Go to Step 7

1. Disconnect the 2 pin connector of the input

revolution sensor.

2. Measure the resistance between each

terminals of the input revolution sensor 2 pin

connector with an ohmmeter.

Is the resistance within the specified value?

560-680 Ω

(at 20°C, 4×4)

387-473 Ω

(at 20°C, 4×2)

Go to Step 6 Go to Step 5

5 Replace the input revolution sensor.

Is the replacement complete?

 Go to Step 7 

Check the wiring harness between the TCM and

input revolution sensor for an open or shorted.

Was a problem found and corrected?

 Go to Step 7 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Reviews the scan tool "DTC Info".

Has the last test failed or is the current

DTC displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0722 (FLASHING CODE 11)

OUTPUT REVOLUTION SENSOR FAILURE (SP2)

UBS

D07R200060

TFR/S

D07L200005

Circuit description:

Vehicle speed information is provided to the TCM by

the output revolution sensor. This sensor is located in

the transmission adapter housing (4 4) or extension

housing (4 2). The output revolution sensor is an

electromagnetic pulse pickup type that generates a

speed signal according to the revolution of the

transmission output shaft. As a result, the sensor

sends a sine wave signal (AC) to the TCM, which

converts this sine wave signal (pulse voltage) to a km/h

signal.

Fail-safe control:

The TCM controls fail-safe by detecting output

revolution sensor failure.

Failure detection:

• When not even 1 pulse is input in the output

revolution sensor during the time 4 pulses are input

in the speed meter sensor.

• When the failure criteria is continuously 500 times

from the time ignition is turned ON until it is turned

OFF.

• Detection inhibit condition:

When speed meter sensor revolution is less than

80 rpm.

Contents of control:

At failure detection

• Uses the vehicle speed calculated by speed meter

sensor for shift control

• Keeps the condition of transfer (High/Low

judgment) just before detection until vehicle speed

is 0km/h, and changes shift map to L4 map

(3→4UP None) at vehicle speed 0km/h. (For UBS)

• Use high oil temperature map according to shift

map priority at correct oil temperature control.

• Squat control inhibit

• Up hill and down hill control inhibit (For UBS)

• Reverse lockout control inhibit

• Stores the failure information in failure-memory

At failure decision

Executes following items in addition to above

control items at failure detection.

• Blinks "CHECK TRANS" lamp

Conditions of turning "CHECK TRANS" off:

Turns "CHECK TRANS" lamp off when judged 0km/h

by speed meter sensor after more than 1 pulse input in

the output revolution sensor and finished vehicle speed

calculation during the time 4 pulse are input in the

speed meter sensor.

Reversion conditions from fail-safe:

Recovers at the same time as the conditions of turning

“CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. When the vehicle is running, a speed signal is input

from the output revolution sensor to the TCM.

2. At this test, the continuity of circuit wiring and the

output revolution sensor is checked.

4. At this test, the continuity of the output revolution

sensor is checked.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0722 (FLASHING CODE 11)

OUTPUT REVOLUTION SENSOR FAILURE (SP2)

Step Action Value(s) Yes No

1. Lift the driving wheels.

2. With the engine idling in gear, connect a

voltmeter between the TCM 28 pin connector

terminal (4) and ground terminal (16).

Does the voltage vary in the specified value?

(The voltage increase in proportion to the

speed.)

0-3 V or more DTC P0722 is

intermittent. If

other codes

are not stored,

refer to

"Diagnostic

aids".

Go to Step 2

1. Turn the ignition "OFF".

2. Disconnect the TCM 28 pin connector.

3. Connect an ohmmeter between the TCM 28

pin connector terminal (4) and (16).

Is the resistance within the specified value?

560-680

(at 20 )

Go to Step 3 Go to Step 4

1. Replace the TCM with a new one.

2. Make a road running test for the vehicle.

Is DTC P0722 displayed?

 Go to Step 5 The TCM is

faulty.

(TCM before

replacement)

Go to Step 7

1. Disconnect the 2 pin connector of the output

revolution sensor.

2. Measure the resistance between each

terminals of the 2 pin connector with an

ohmmeter.

Is the resistance within the specified value?

560-680

(at 20 )

Go to Step 6 Go to Step 5

5 Replace the output revolution sensor.

Is the replacement complete?

 Go to Step 7 

Check the wiring harness between the TCM and

output revolution sensor for an open or shorted.

Was a problem found and corrected?

 Go to Step 7 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0727 (FLASHING CODE 13)

ENGINE REVOLUTION SIGNAL FAILURE (NE)

UBS

D07R200061

TFR/S

D07L200006

Circuit description:

Engine revolution (rpm) signals are sent from Engine

Control Module (ECM) to the Transmission Control

Module (TCM).

The engine speed sensor is an electromagnetic pulse

pickup type that generates signals when the flywheel

gear revolves (2 pulses at a single revolution of the

flywheel gear).

The TCM converts these sine wave signals into engine

revolution (RPM) signals.

Fail-safe control:

The TCM controls fail-safe by detecting engine

revolution sensor failure.

Failure detection:

• When input revolution is more than 2000 rpm

• When not even 1 pulse is input in the engine

revolution signal during 5 seconds

• Detection inhibit condition: At 4th gear

Contents of control:

At failure detection

• Up hill and down hill control inhibit (For UBS)

• Oil temperature sensor failure detection inhibit

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure memory.

At failure decision

Same as failure detection

Conditions of turning "CHECK TRANS" lamp

off:

Turns "CHECK TRANS" lamp off when judged 0km/h

by speed meter sensor after the engine revolution

signal pulses are input 250 pulses normally.

(however, uses 0 km/h judgment by back-up vehicle

speed at output revolution failure)

Reversion conditions from fail-safe:

Recovers at the same time as the conditions of turning

“CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

2. Engine revolution signals are input from the ECM

into the TCM.

3. When the engine idling, voltage fluctuates with (AC

intermittent) range of less than 1.4V ⇔ 9 ∼ 16V.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0727 (FLASHING CODE 13)

ENGINE REVOLUTION SIGNAL FAILURE (NE)

Step Action Value(s) Yes No

1. Clear the TCM memory.

2. Turn the ignition "ON" and start the engine.

3. With the engine "OFF", turn the ignition

"ON".

Is DTC P0727 displayed by self-diagnosis?

 Go to Step 2 DTC P0727

was

temporarily

stored into

TCM memory.

Refer to

"Diagnostic

aids".

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter to the TCM 28 pin

connector terminal (15) and TCM 20 pin

connector ground terminal (15 or 19).

Is the voltage within the specified value?

9-16V Go to Step 3 Go to Step 4

1. With the ignition "ON" and the engine "ON".

2. Connect a voltmeter between the TCM 28

pin connector terminal (15) and TCM 20 pin

connector ground terminal (15 or 19).

Does the voltage vary in the specified value at

the engine idling?

Less than

1.4-9 16 V

(AC intermittently)

Go to Step 5 Go to Step 6

Check the wiring harness between the TCM and

ECM for breaking or voltage shorted.

Was a problem found and corrected?

 Go to Step 7 

Check the TCM connection. If OK, replace the

TCM.

Is the replacement complete?

 Go to Step 7 

Check the wiring harness between the TCM and

ECM for ground shorted. If OK, the ECM or the

engine revolution sensor is faulty.

Was a problem found and corrected?

 Go to Step 7 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running, test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0743 (FLASHING CODE 33) TORQUE CONVERTER CLUTCH

CONTROL LOCK-UP (ON/OFF) SOLENOID FAILURE (SL)

UBS

D07R200062

TFR/S

D07L200007

Circuit description:

The lock-up solenoid SL of the torque converter clutch

(TCC) controls the lock-up clutch by a signal according

to the lock-up range judgement of the TCM when the

vehicle runs.

This function can improve the fuel consumption to

almost the same extent as the manual transmission.

The lock-up solenoid SL is put into B+ by the TCM, so

that the solenoid is actuated with the result of lock-up.

Fail-safe control:

The TCM controls fail-safe by detecting SL solenoid

failure.

Failure detection:

GND SHORT detection

• When SHORT detection continues for 0.3 sec.

• When SHORT failure detection continues 8 times.

Open detection

• When OPEN detection continues for 0.5 sec.

• When OPEN failure detection continues 8 times.

Contents of control:

At failure detection

• Lock-up control inhibit

• If + B short failure is detected, keeps 1st gear when

the vehicle speed calculated by output revolution

sensor is less than 10km/h to prevent stall.

(Canceled at more than 15km/h)

At failure decision

• Executes following items in addition to above

control items at failure detection.

• Stores the failure information in failure-memory.

Conditions of turning “CHECK TRANS” lamp

off:

None

Reversion conditions from fail-safe:

When a normal condition is judged by rechecking on

the state of lock-up ON/OFF

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. When the key is ON, the voltage between the TCM

20 pin connector terminals (12) and (15 or 19) is

1.0 V or less.

2. When the gear is of the 2nd speed in the D range

and the throttle opening is about 50% at a higher

speed than about 40km/h, the TCM supplies 8 to

16 V, so that the solenoid is actuated with the result

of lock-up.

3.5.7.8. The resistance range of the solenoid is 11 to

15Ω (at 20°C).

Diagnostic aids:

In case of faulty connection, open or shorted circuit. to

the TCM 20 pin connector terminal (12), DTC P0743 is

displayed. A intermittent failure may be caused by a

poor connection, rubbed through wire insulation or a

wire broke inside the insulation.

DTC P0743 (FLASHING CODE 33) TORQUE CONVERTER CLUTCH

CONTROL LOCK-UP (ON/OFF) SOLENOID FAILURE (SL)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition "ON"

after warming up.

2. Connect a voltmeter between the TCM 20

pin connector terminal (12) and ground

terminal (15 or 19).

Is the voltage less than the specified value?

1 V Go to Step 2 Go to Step 3

1. Lift the driving sheels and support them.

2. At the D range and 2nd speed gear.

3. Make a test at a speed of about 40 km/h or

more with 50% or more opening of the

throttle.

Is the voltage between the TCM 20 pin connector

terminal (12) and ground terminal (15 or 19)

within the specified value?

8-16V Go to Step 4 Go to Step 5

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the resistance between the terminal

(12) and ground.

Is the resistance within the specified value?

11-15Ω

(at 20 )

Go to Step 6 Go to Step 7

1. Clear the TCM memory.

2. Make a running test.

Is DTC P0743 displayed by self-diagnosis?

 Go to Step 6 The continuity

of wiring is

intermittent.

Refer to

"Diagnostic

aids".

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the TCM 20 pin connector terminal

(12) and ground.

Is the resistance within the specified value?

11-15Ω

(at 20 )

Go to Step 6 Go to Step 8

The TCM is faulty or the continuity of wiring

harness is intermittent.

Was a problem found and corrected?

 Go to Step 12 

Disconnect the A/T 8 pin connector.

Is the resistance between the lock-up solenoid

connector terminal (7) and ground within the

specified value?

11-15Ω

(at 20 )

Go to Step 9 Go to Step 10

Disconnect the A/T 8 pin connector.

Is the resistance between the lock-up solenoid

connector terminal (7) and ground within the

specified value?

11-15Ω

(at 20 )

Go to Step 11 Go to Step 10

Check the wiring harness between the TCM 20

pin connector terminal (12) and A/T 8 pin

connector terminal (7) for open.

Was a problem found and corrected?

 Go to Step 12 

Step Action Value(s) Yes No

10 Replace the lock-up solenoid (SL).

Is the replacement complete?

 Go to Step 12 

Check the wiring harness between the TCM 20

pin connector terminal (12) and A/T 8 pin

connector terminal (7) for ground shorted.

Was a problem found and corrected?

 Go to Step 12 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0748 (FLASHING CODE 35)

PRESSURE CONTROL SOLENOID FAILURE (STH)

UBS

D07R200062

TFR/S

D07L200007

Circuit description:

The pressure control solenoid is a PWM duty control

solenoid located in the valve body.

The pressure control solenoid is a TCM-controled

device used to regulate transmission throttle pressure

by energizing current from the TCM.

Fail-safe control:

The TCM controls fail-safe by detecting pressure

control solenoid failure.

Failure detection:

IG short failure

• When the feedback A/D value is more than 1020

for 500 milli-second continuously.

• Detection inhibit condition: Prohibition during 1

second after reversion from open failure, because

the possibility of the mis-detection is high.

Open failure (Including GND Short)

• When the feedback A/D value is less than 15 for

more than 70 milli-second continuously, judges as

faliure, and turns the current of target output off,

after 1.5 second passed turns the current of target

value to normal. The A/D value is checked, and this

operation is repeated during 70 milli-second again.

• When it continues for 12.5 second in total.

Contents of control:

At failure detection

• Lock-up control inhibit

• Up hill and down hill control inhibit (For UBS)

• Squat control inhibit

At failure decision

• Executes following items in addition to above

control items at failure detection.

• Turns Solenoid power supply OFF

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure memory

*Prohibits failure detection of S1, S2, SL, STH, selector

position switch, and oil temperature sensor.

Conditions of turning "CHECK TRANS" off:

Turns "CHECK TRANS" lamp off after ignition is turned

ON→ OFF→ ON.

Reversion conditions from fail-safe:

At failure detection

When IG short failure···The feedback A/D value is

less than 1020 for 1 second continuously.

When open failure···Detection criteria is not

satisfied or the feedback A/D value is more than 15

for 1 second continuously.

At failure decision

Recovers at the same time as the conditions of

turning “CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. The solenoid resistance is within the range of 5 to

5.6Ω. (at 20°C)

2. This test checks for shorted circuit at the TCM.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P0748 (FLASHING CODE 35)

PRESSURE CONTROL SOLENOID FAILURE (STH)

Step Action Value(s) Yes No

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Connect an ohmmeter between the TCM 20

pin connector terminal (11) and (8).

Is the resistance within the specified value?

5-5.6Ω (at 20°C) Go to Step 2 Go to Step 3

1. Connect an ohmmeter between the TCM 20

pin connector terminal (11) and ground

terminal (15 or 19).

2. Then, connect between the TCM 20 pin

connector terminal (11) and ignition terminal

(20).

3. Then, connect TCM 20 pin connector

terminal (8) and ground terminal (15 or 19),

then between TCM 20 pin connector

terminal (8) and ignition terminal (20).

Does display a short circuit?

 Go to Step 4 The problem is

intermittent.

Refer to

"Diagnostic

aids".

1. Disconnect the A/T 8 pin connector.

2. Connect an ohmmeter between the A/T 8 pin

connector terminal (2) and (6).

Is the resistance within the specified value?

5-5.6Ω (at 20°C) Go to Step 5 Go to Step 6

4 Repair the short circuit.

Is the repair complete?

 Go to Step 7 

Repair the wiring harness for open between TCM

20 pin connector and A/T 8 pin connector.

Is the repair complete?

 Go to Step 7 

1. Check the wiring harness for open between

A/T 8 pin connector and pressure control

solenoid.

2. If OK, replace pressure control solenoid

(valve body assembly).

 Go to Step 7 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0753 (FLASHING CODE 31) SOLENOID 1 FAILURE (S1)

UBS

D07R200062

TFR/S

D07L200007

Circuit description:

The shift solenoid S1 changes the hydraulic route with

the signals from the TCM according to the vehicle

speed and the throttle opening to control shifting. When

the solenoid S1 or S2 fails, the hydraulic circuit is

mechanically operated as a backup.

Fail-safe control:

The TCM controls fail-safe by detecting S1, S2 shift

solenoid failure.

Failure detection:

GND SHORT detection

• When SHORT detection continues for 0.3 sec.

• When SHORT failure detection continues 8 times.

Open detection

• When OPEN detection continues for 0.5 sec.

• When OPEN failure detection continues 8 times.

Contents of control:

At failure detection

• Lock-up control inhibit

• Up hill and down hill control inhibit (For UBS)

• Squat control inhibit

• Changes solenoid output pattern as following figure

The shift theory at shift solenoid failure

Normal S1 failure S2 filure S1 and S2 failure

Shift

lever

Position Gear S1 S2 Gear S1 S2 Gear S1 S2 Gear S1 S2

1 ×

××

× 1

3 ×

××

O/D ×

××

× ×

××

× O/D

××

O/D

××

O/D

1 ×

××

× 1

3 ×

××

O/D ×

××

1 ×

××

× 1

O/D

At failure decision

Executes following items in addition to above control

items at failure detection.

• Turns Solenoid power supply OFF

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

*Prohibits failure detection of S1, S2, SL, STH,

Selector position switch, and Oil temp. sensor.

Conditions of turning "CHECK TRANS" off:

Turns "CHECK TRANS" lamp off after ignition is turned

ON→ OFF→ ON.

Reversion conditions from fail-safe:

At failure detection

When a normal judgment is obtained by rechecking

during shifting.

At failure decision

Recovers at the same time as the conditions of

turning “CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. With the key "ON", the voltage between the TCM

20 pin connector terminals (4) and (15 or 19) is 8 to

16V.

4. When the driving wheels revolve with the 3rd speed

gear, the voltage is 1 V or less.

3.6.8.11. The solenoid resistance is within the range of

11 to 15Ω (at 20°C).

Diagnostic aids:

In case of faulty connection, open or shorted circuit to

the TCM 20 pin connector terminal (4), DTC P0753 is

displayed. A intermittent failure may be caused by a

poor connection, rubbed through wire insulation or a

wire broke inside the insulation.

DTC P0753 (FLASHING CODE 31) SOLENOID 1 FAILURE (S1)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter between the TCM 20

pin connector terminal (4) and ground

terminal (15 or 19).

Is the voltage within the specified value?

8-16 V Go to Step 2 Go to Step 3

1. Lift the driving wheels and support them.

2. Turn the ignition "ON", and the engine "ON".

Can the speed be changed normally by

acceleration is the "NORMAL" mode and the D

range?

 Go to Step 4 Go to Step 8

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the resistance between the TCM 20

pin connector terminal (4) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 5 Go to Step 6

At the 3rd speed gear.

Is the voltage between the TCM 20 pin connector

terminal (4) and ground terminal (15 or 19) less

than the specified value?

1 V Go to Step 7 Go to Step 8

The TCM is faulty or the continuity of wiring

harness is intermittent.

Was a problem found and corrected?

 Go to Step 13 

Disconnect the A/T 8 pin connector.

Is the resistance between the solenoid S1

connector terminal (4) and ground within the

specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 9 Go to Step 10

1. Clear the TCM memory.

2. Make a running test.

Is DTC P0753 displayed by self-diagnosis?

 Go to Step 5 The continuity

of wiring is

intermittent.

Refer to

"Diagnostic

aids".

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the resistance between the TCM 20

pin connector terminal (4) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 5 Go to Step 11

Check the wiring harness between the TCM 20

pin connector terminal (4) and A/T 8 pin

connector terminal (4) for ground shorted.

Was a problem found and corrected?

 Go to Step 13 

10 Replace the solenoid S1.

Is the replacement complete?

 Go to Step 13 

1. Disconnect the A/T 8 pin connector.

2. Measure the resistance between the A/T 8

pin connector terminal (4) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 12 Go to Step 10

Step Action Value(s) Yes No

Check the wiring harness between the TCM 20

pin connector terminal (4) and A/T 8 pin

connector terminal (4) for open.

Was a problem found and corrected?

 Go to Step 13 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P0758 (FLASHING CODE 32) SOLENOID 2 FAILURE (S2)

UBS

D07R200062

TFR/S

D07L200007

Circuit description:

The solenoid S2 changes the hydraulic route with the

signals from the TCM according to the vehicle speed

and the throttle opening to control shifting. When the

solenoid S1 or S2 fails, the hydraulic circuit is

mechanically operated as a backup.

Fail-safe control:

The TCM controls fail-safe by detecting S1, S2 shift

solenoid failure.

Failure detection:

GND SHORT detection

• When SHORT detection continues for 0.3 sec.

• When SHORT failure detection continues 8 times.

Open detection

• When OPEN detection continues for 0.5 sec.

• When OPEN failure detection continues 8 times.

Contents of control:

At failure detection

• Lock-up control inhibit

• Up hill and down hill control inhibit (For UBS)

• Squat control inhibit

• Changes solenoid output pattern as "The shift

theory at shift solenoid failure". (See DTC P0753)

At failure decision

• Executes following items in addition to above

control items at failure detection.

• Turns Solenoid power supply OFF

• Blinks "CHECK TRANS" lamp

• Stores the failure information in failure-memory

*Prohibits failure detection of S1, S2, SL, STH,

Selector position switch, and Oil temperature

sensor.

Conditions of turning "CHECK TRANS" off:

Turns "CHECK TRANS" lamp off after ignition is turned

ON→ OFF→ ON.

Reversion conditions from fail-safe:

At failure detection

When a normal judgment is obtained by rechecking

during shifting.

At failure decision

Recovers at the same time as the conditions of

turning “CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. With the key "ON", the voltage between the TCM

20 pin connector terminals (3) or (15 or 19) is 1V or

less.

4. When the driving wheels revolve with the 2nd

speed gear, the voltage is 8 to 16V.

3.6.8.11. The resistance of the solenoid is in the range

of 11 to 15Ω (at 20).

Diagnostic aids:

In case of faulty connection, open or shorted circuit to

the TCM 20 pin connector terminal (3), DTC P0758 is

displayed. A intermittent failure may be caused by a

poor connection, rubbed through wire insulation or a

wire broken inside the insulation.

DTC P0758 (FLASHING CODE 32) SOLENOID 2 FAILURE (S2)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter between the TCM 20

pin connector terminal (3) and ground

terminal (15 or 19).

Is the voltage less than the specified value?

1 V Go to Step 2 Go to Step 3

1. Lift the driving wheels and support them.

2. Turn the ignition "ON", and the engine "ON".

Can the speed be changed normally by

acceleration is the "NORMAL" mode and the D

range?

 Go to Step 4 Go to Step 8

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the resistance between the TCM 20

pin connector terminal (3) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 5 Go to Step 6

At the 2nd speed gear.

Is the voltage between the TCM 20 pin connector

terminal (3) and ground terminal (15 or 19) within

the specified value?

8-16 V Go to Step 7 Go to Step 8

The TCM is faulty or the continuity of wiring

harness is intermittent.

Was a problem found and corrected?

 Go to Step 13 

Disconnect the A/T 8 pin connector.

Is the resistance between the solenoid S2

connector terminal (3) and ground within the

specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 9 Go to Step 10

1. Clear the TCM memory.

2. Make a running test.

Is DTC P0758 displayed by self-diagnosis?

 Go to Step 5 The continuity

of wiring is

intermittent.

Refer to

"Diagnostic

aids".

1. Turn the ignition "OFF".

2. Disconnect the TCM 20 pin connector.

3. Measure the resistance between the TCM 20

pin connector terminal (3) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 5 Go to Step 11

Check the wiring harness between the TCM 20

pin connector terminal (3) and A/T 8 pin

connector terminal (8) for ground shorted.

Was a problem found and corrected?

 Go to Step 13 

10 Replace the solenoid S2.

Is the replacement complete?

 Go to Step 13 

1. Disconnect the A/T 8 pin connector.

2. Measure the resistance between the A/T 8

pin connector terminal (8) and ground.

Is the resistance within the specified value?

11-15Ω (at 20°C)

12-16Ω (at 40°C)

Go to Step 12 Go to Step 10

Step Action Value(s) Yes No

Check the wiring harness between the TCM 20

pin connector terminal (3) and A/T 8 pin

connector terminal (8) for open.

Was a problem found and corrected?

 Go to Step 13 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

DTC P1120 (FLASHING CODE 22)

PWM THROTTLE SIGNAL FAILURE (TH) (For TFR/S)

TFR/S

Circuit description:

When the PWM signal of the engine throttle position

sensor located on the engine manifold (‘01TFR, For

Thailand) or accelerator pedal assembly (TFR/S) is

supplied to the TCM via the ECM, the TCM judges the

opening condition of the throttle

The shift point of th transmission is determined by this

PWM throttle signal.

Fail-safe control:

The TCM controls fail-safe by detecting PWM throttle

signal (TH) failue.

Failure detection:

 When the throttle input duty ratio is detected less

than 1%or more than 99% for 2.0 seconds.

Contents of control:

At failure detection

 Throttle opening for line pressure control = 100%

 Throttle opening for shift control = 0%

 Lock-up control inhibit

 Squat control inhibit

Flash the 'CHECK TRANS' lamp

Conditions of turning “CHECK TRANS” lamp

off:

Turns “CHECK TRANS” lamp off when judged 0km/h

by output revolution sensor after throttle signal input

duty ratio is detected at more than 1% and less than

99%.

(however, uses 0km/h judgment by back-up vehicle

speed at output revolution sensor failure)

Conditions to exit from fail-safe:

At failure detection

• Immediately recovers when the throttle input duty

ratio is detected more than 1% and less than 99%.

At failure detection

• Recovers at the same time as the conditions of

turning “CHECK TRANS” lamp off are satisfied.

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. Check that the throttle input voltage is 4.4 to 4.6V.

2. At this test, check that as the throttle opens, the

voltage goes up and that the voltage reached 0.4 to

0.6V at the full open status.

6. Check the power supply voltage (4.99-5.01V) of the

each throttle position sensors.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P1120 (FLASHING CODE 22)

PWM THROTTLE SIGNAL FAILURE (TH) (For TFR/S)

Step Action Value(s) Yes No

1. Connect a analog voltmeter between the

TCM 28 pin connector terminal (6) and TCM

20 pin connector terminal (15 or 19).

2. Turn the ignition "ON".

Is the voltage within the specified value?

4.4-4.6 V

Go to Step 2 Go to Step 3

Open the throttle fully.

Is the voltage within the specified value?

0.4-0.6 V

The problem is

intermittent.

Refer to

"Diagnostic

aids".

Go to Step 3

1. Turn the ignition "ON".

2. Measure the voltage between the ECM 81

pin connector terminal (26) and ground

terminal (47) (TFR/S), or ECM 32 pin

connector terminal (14) and ground terminal

(33 or 49) (

Is the voltage within the specified value?

4.4-4.6 V

Go to Step 4 Go to Step 6

4 Open the throttle fully.

Is the voltage within the specified value?

0.4-0.6 V

Go to Step 5 Go to Step 6

Check the wiring harness between the TCM 28

pin connector terminal (6) and ECM 81 pin

connector terminal (26) (TFR/S), or ECM 32 pin

connector terminal (14) ('01 TFR, for Thailand).

Or TCM is faulty.

Was a problem found and corrected?

 Go to Step 9 

1. Disconnect the TPS connector.

2. Connect a voltmeter between the TPS

connector terminal (C93-3) and (C93-1)

(TFR/S), or TPS connector terminal (B17-2)

and (B17-1), or (B18-3) and (B18-2) ('01

TFR, for Thailand).

Is the voltage within the specified value?

4.99-5.01 V Go to Step 7 Go to Step 8

Check the TPS connectors. If OK, replace the

TPS.

Is the replacement complete?

 Go to Step 9 

Check the wiring harness between the TPS and

ECM.

If OK, replace the ECM.

Is the replacement complete?

 Go to Step 9 

Step Action Value(s) Yes No

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin the

diagnosis

again.

Go to Step 1

System OK

*Reference (Oscilloscope waveform)

(TFR/S)

DTC P1121 (FLASHING CODE 23)

ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND)(For UBS)

D07R200063

Circuit description:

When the signal of the engine throttle position sensor

located on the accelerator pedal is supplied to the

transmission TCM, the TCM judges the opening

condition of the throttle.

The shift point of the transmission is determined by this

opening condition of the throttle.

Fail-safe control:

The TCM controls fail-safe by detecting analog throttle

signal (VREF, VGND) failure.

Failure detection:

• When the Vref input voltage is detected more than

5.55V or less than 4.45V.

• When the Vgnd input voltage is detected more than

0.40V or less than -0.40V.

• When the failure criteria is continuously for 1.0 sec.

Contents of control:

At failure detection

• Judges throttle opening of linear sensor (Vth) as

Vref:5V, Vgnd:0V

• Throttle learning control inhibit

• Up hill and down hill control inhibit

At failure decision

Executes following items in addition to above

control items at failure detection.

• Stores the failure information in failure-memory

Conditions of turning “CHECK TRANS” lamp

off:

None

Reversion conditions from fail-safe:

At failure detection

When the Vref input voltage is detected less than 5.55

V and more than 4.45 V.

When the Vgnd input voltage is detected less than 0.40

V and more than -0.40 V.

At failure decision

• Recovers when judged 0km/h by output revolution

sensor after the Vref input voltage is detected less

than 5.55V and more than 4.45V.

(however, uses 0 km/h judgment by back-up

vehicle speed at output revolution failure)

• Recovers when judged 0km/h by output revolution

sensor after the Vgnd input voltage is detected less

than 0.40V and more than -0.40V.

(however, uses 0 km/h judgment by back-up

vehicle speed at output revolution failure)

Test description:

The following numbers correspond to the step numbers

on the diagnostic chart.

1. Check the power supply voltage (4.75-5.25V) of

throttle position sensor.

Diagnostic aids:

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken inside

the insulation. Inspect related harness connector for

backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, poor terminal

to wire connection and damaged harness.

DTC P1121 (FLASHING CODE 23)

ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND)(For UBS)

Step Action Value(s) Yes No

1. With the engine "OFF", turn the ignition

"ON".

2. Connect a voltmeter between the TCM 28

pin connector terminal (19) and (28).

Is the voltage within the specified value?

4.75-5.25 V The problem is

intermittent.

Refer to

"Diagnostic

aids".

Go to Step 2

Connect a voltmeter between the ECM 32 pin

connector terminal (E1-4) and (E2-22).

Is the voltage within the specified value?

4.75-5.25 V Go to Step 3 Go to Step 4

Check the wiring harness between the TCM and

ECM.

Was a problem found and corrected?

 Go to Step 5 

Check the ECM 32 pin connectors. If OK,

replace the ECM.

Is the replacement complete?

 Go to Step 5 

1. After the repair is complete, use the scan tool

to select "DTC", then "Clear Info" function.

2. Make a road running test for the vehicle.

3. Review the scan tool "DTC Info".

Has the last test failed or is the current DTC

displayed?

 Begin in the

diagnosis

again. Go to

Step 1

System OK

WIRING DIAGRAM

UBS

D07R200064

UBS

D07R200065

TFR/S

D07L200009

TFR/S

D07L200010

CONNECTOR LIST

UBS (For General Export)

No. Connector face No. Connector face

B-11

(WHITE)

E-29

B-14

(BLACK)

E-30

B-17

E-31

B-30

(WHITE)

E-32

B-35

(WHITE)

E-49

C-63

H-4

(BLACK)

C-78

H-5

(GREEN)

C-79

H-7

(RHD)

E-1

H-7

(LHD)

E-2

H-8

(RHD)

UBS

No. Connector face No. Connector face

H-8

(LHD)

H-42

(BLACK)

H-9

(RHD)

I-9

H-9

(LHD)

I-10

H-12

(RHD)

H-24

(RHD)

H-24

(LHD)

H-25

(LHD)

H-26

(RHD)

H-30

(NATURAL)

H-32

(BLACK)

TFR/S

No. Connector face No. Connector face

B-23

C-92

B-24

C-93

B-39

C-96

C-41

E-51

C-44

E-52

C-56

E-53

C-57

E-54

C-58

E-55

C-78

H-4

(BLACK)

C-79

H-5

(BLACK)

TFR/S

No. Connector face No. Connector face

H-6

(WHITE)

H-8

H-22

(GRAY)

TROUBLESHOOTING CHART

Number are arranged in order of probability.

Parform inspections starting with number one and working up.

MANUAL SHIFTING TEST

NOTE:

With this test, it can be determined whether the trouble

lies within the electrical circuit or is a mechanical

problem in the transmission.

1. Disconnect TCM connector

With the engine OFF, disconnect the TCM connector.

F07RY00024

2. Inspect manual driving operation

Check that the shift and gear positions correspond with

the table.

If the “L”, “2” and “D” range gear positions are difficult to

distinguish, do perform the following road test.

While driving, shift through the “L”, “2” and “D” renges.

Check that the gear change corresponds to the gea

position.

If any abnormality is found in the above test, do perform

the stall, time lag or gear change tests.

3. Connect TCM connector

With the engine off, connect the TCM connector.

F07RY00002

STALL TEST

The object of this test is to check the overall performance

of the transmission and engine by measuring the maximum

engine speeds at the “D” and “R” ranges.

NOTE:

(1) Perform the test at normal operation fluid

temperature (50 – 80º

ºº

ºC or 122-176 º

ºº

ºF).

(2) Do not continuously run this test longer than 5

seconds.

MEASURE STALL SPEED

1. Chock all four wheels.

2. Connect an engine tachometer.

3. Fully apply the parking brake.

4. Step down strongly on the brake pedal with your left

foot.

5. Start the engine.

6. Shift into the “D” range. Step all the way down on the

accelerator pedal with your right foot. Quickly read the

highest engine rpm.

Stall speed: 2450 150 rpm (UBS)

: 2300 150 rpm (TFR/S)

7. Perform the same test in the “R” range.

EVALUATION

1. If the engine speed is the same for both ranges but

lower than the specified value:

Engine output is insufficient.

Stator one-way clutch is not operating properly.

NOTE:

If more than 600 rpm below the specified value, the

torque converter could be faulty.

2. If the stall speed is “D” range is higher than specified:

Line pressure too low

Forward clutch slipping

No.2 one-way clutch not operating properly

3. If the stall speed in “R” range is higher than specified:

Line pressure too low

Direct clutch slipping

No.3 brake slipping

4. If the stall speed in the “R” and “D” ranges are highe

than specified:

Line pressure too low

Improper fluid level

F07RY00003

TIME LAG TEST

If the shift lever is shifted while the engine is idling, there

will be a certain time elapse or lag before the shock can be

felt. This is used for checking the condition of the forward

clutch, direct clutch, No.3 brake, and No.2 one-way clutch.

NOTE:

(1) Perform the test at normal operation fluid

temperature (50 – 80º

ºº

ºC or 122 – 176º

ºº

ºF)

(2) Be sure to allow one minute interval between

tests.

(3) Make three measurements and take the average

value.

MEASURE TIME LAG

1. Fully apply the parking brake.

2. Start the engine.

Check idling speed (A/C OFF).

3. Shift the shift lever from “N” to “D” range. Using a stop

watch, measure the time it takes from sihfting the leve

until the shock is felt.

Time lag: Less than 0.7 seconds

4. In same manner, measure the time lag for “N” “R”.

Time lag: Less than 1.2 seconds

EVALUATION

1. If “N” “D” time lag is longer than specified:

Line pressure too low

Forward clutch malfunction

No.2 one-way clutch not operating properly

2. If “N” “R” time lag is longer than specified:

Line pressure too low

Direct clutch malfunction

No.3 brake malfunction

3. If both time lag is longer than specified:

Line pressure too low

HYDRAULIC TEST

PREPARATION

1. Warm up the transmission fluid.

2. Remove the transmission case test plug and mount the

hydraulic pressure gauge.

Oil pressure gauge: 5-8840-0093-0

NOTE:

Perform the test at normal operation fluid temperature

(50 – 80º

ºº

ºC or 122 – 176º

ºº

ºF).

MEASURE LINE PRESSURE

1. Fully apply the parking brake and chock the fou

wheels.

2. Start the engine and check idling rpm.

3. Shift into “D” range, step down strongly on the brake

pedal with your left foot and, while manipulating the

accelerator pedal with the right foot, measure the line

pressures at the engine speeds specified in the table.

4. In the same manner, perform the test in “R” range.

Line pressure kPa (kg/cm2/psi)

Engine

speed “D” range “R” range

Idling

358 – 417

(3.6 – 4.3/

51 – 61)

588 – 686

(6.0 – 7.0/

85 – 100)

Stall

1,176 – 1,323

(12.0 – 13.5/

171 – 192)

1,607 – 1,940

(16.4 – 19.8/

233 – 282)

F07RY00004

EVALUATION

1. If the measured values at all ranges are higher than

specified:

Pressure control solenoid defective

Primary regulator valve defective

2. If the measured values at all ranges are lower than

specified:

Primary regulator valve defective

Oil pump defective

Pressure control solenoid defective

3. If pressure is low in “D” range only:

“D” range circuit fluid leakage

4. If pressure is low in “R” range only:

“R” range circuit fluid leakage

255RT004

F07R200015

F07RY00006

ROAD TEST

NOTE:

Perform the test at normal operation fluid temperature

(50 – 80ººººC or 122 – 176ººººF).

“D” RANGE TEST IN “NORMAL”, AND “POWER”

PATTERN RANGES

Shift into the “D” range and hold the accelerator pedal

constant at the 50% and 100% throttle valve opening

positions.

Push in one of the pattern selector buttons and check the

following:

1. 1-2, 2-3, 3-OD and lock-up, up-shifts should take place,

and shift points should conform to those shown in the

automatic shift diagram.

NOTE:

Drive the vehicle on level ground.

EVALUATION

(1) If there is no 12 up-shift:

Solenoid S2 is stuck

1-2 shift valve is stuck

(2) If there is no 23 up-shift:

Solenoid S1 is stuck

2-3 shift valve is stuck

(3) If there is no 3OD up-shift (throttle valve opening

1/2):

Solenoid S2 is stuck

3-OD shift valve is stuck

(4) If the shift point is defective:

Refer to “TROUBLESHOOTING CHART” in this

section.

(5) If the lock-up is defective:

Refer to “TROUBLESHOOTING CHART” in this

section.

2. In the same manner, check the shock and slip at the 1

2, 2 3 and 3 OD up-shifts.

EVALUATION

If the shock is excessive:

Refer to “TROUBLESHOOTING CHART” in this

section.

F07RY00007

3. Run at “D” range lock-up or OD gear and check fo

abnormal noise and vibration.

NOTE:

The check for the cause of abnormal noise and

vibration must be made with extreme care as it could

also be due to loss of balance in the propeller shaft,

differential, the torque converter, etc. or insufficient

bending, rigidity, etc. in the power train.

F07R200016

4. While running in “D” range, 2nd, 3rd gears and OD,

check to see that the possible kick-down vehicle speed

limits for 2 1, 3 1, 3 2, OD 3 and OD 2 kick-

downs conform to those indicated on the automatic shift

diagram.

5. Check for abnormal shock and slip at kick-down.

6. While running in “D” range, OD gear or “lock-up”, shift

to “2” and “L” ranges and check the engine braking

effect at each of these ranges.

7. Also check to see that downshift is made from 3 2 o

from OD to 3 and then to 2 immediately and that 2 1

downshift point is within the limits shown in the diagram

when tested by releasing the accelerator pedal and

shifting into position of “L” while driving in the third gea

or in overdrive.

F07RY00009

EVALUATION

(1) If there is no engine braking effect in the “2” range:

Second coast (No.1) brake is defective.

(2) If there is no engine braking effect in the “L” range:

First and reverse (No.3) brake is defective.

F07RY00010

(3) Also check to see that downshift is made from 3 2 o

from OD to 3 and then to 2 immediately and that 2 1

downshift point is within the limits shown in the

diagram when tested by releasing the accelerato

pedal and shifting into “L” position while driving in the

third gear or in overdrive.

F07R200017

F07RY00012

“2” RANGE TEST

Shift into “2” range and, while driving with the accelerato

pedal held constantly at the specified point (throttle valve

opening 50% and 100%), push in one of the pattern

selectors (only for 4 4) and check on the following points.

1. At each of the above throttle openings, check to see

that the 1 2 up-shift takes place and that the shift

points conform to those shown on the automatic shift

diagram.

NOTE:

There is no OD and no lock-up in the “2” range.

2. While running in the “2” range and 2nd gear, release

the accelerator pedal and check the engine’s braking

effect.

3. Check for 2 1 down-shift and abnormal noise at

acceleration and deceleration, and for shock at upshift

and down-shift.

F07R200018

“L” RANGE TEST

1. While running above 80 km/h (50 mph) in the “D” range,

release your foot from the accelerator pedal and shift

into the “L” range.

Then check to see that the 2 1 down-shift occurs at

the specified point shown on the automatic shift

diagram.

F07RY00014

2. While running in the “L” range, check to see that there

is no up-shift to 2nd gear.

3. While running in the “L” range, release the accelerato

pedal and check the engine braking effect.

4. Check for abnormal noise during acceleration and

deceleration.

F07RY00015

“R” RANGE TEST

Shift into the “R” range and, while starting at full throttle,

check for slipping.

“P” RANGE TEST

Stop the vehicle on a grade (more than 9%) and afte

shifting into the “P” range, release the parking brake.

Then check to see that the parking lock pawl holds the

vehicle in place.

SHIFT POINT CHART AND LOCK-UP POINT CHART

SHIFT POINT CHART (UBS)

(H2, H4)

(REAR AXLE RATIO: 4.300)

(RADIUS OF TIRE: 0.363m)

“NORMAL” mode

Up shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 39 – 45 78 – 84 128 – 134

D Half throttle 22 – 28 48 – 54 89 – 95

Fully opened 39 – 45 89 – 95

2 Half throttle 22 – 28 89 – 95

Down shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 30 – 36 65 – 71 115 – 121

Half throttle 9 – 15 27 – 33 64 – 70

Fully closed 9 – 15 22 – 28 37 – 43

Fully opened 30 – 36 85 – 91

Half throttle 9 – 15 85 – 91

Fully closed 9 – 15 85 – 91

Fully opened 43 – 49 85 – 91

Half throttle 43 – 49 85 – 91

Fully closed 43 – 49 85 – 91

“POWER” mode

Up shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 39 – 45 78 – 84 128 – 134

D Half throttle 29 – 35 58 – 64 89 – 95

Fully opened 39 – 45 89 – 95

2 Half throttle 22 – 28 89 – 95

Down shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 30 – 36 65 – 71 115 – 121

Half throttle 11 – 17 45 – 51 74 – 80

Fully closed 9 – 15 22 – 28 37 – 43

Fully opened 30 – 36 85 – 91

Half throttle 9 – 15 85 – 91

Fully closed 9 – 15 85 – 91

Fully opened 43 – 49 85 – 91

Half throttle 43 – 49 85 – 91

Fully closed 43 – 49 85 – 91

LOCK-UP POINT CHART (UBS)

(H2, H4)

(REAR AXLE RATIO: 4.300)

(RADIUS OF TIRE: 0.363m)

km/h

Throttle Opening: 20 %

Lock-up ON Lock-up OFF

Range A/T Mode

3rd 4th 3rd 4th

NORMAL 47 – 53 62 – 68 45 – 51 55 – 61

D POWER 47 – 53 66 – 72 45 – 51 62 – 68

SHIFT POINT CHART (TFR/S)

(H2, H4)

(REAR AXLE RATIO: 4.555)

(RADIUS OF TIRE: 0.348m)

“NORMAL” mode

Up shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 34 – 40 71 – 77 112 – 118

D Half throttle 24 – 30 44 – 50 75 – 81

Fully opened 34 – 40 76 – 82

2 Half throttle 28 – 34 76 – 82

Down shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 26 – 32 57 – 63 97 – 103

Half throttle 9 – 15 27 – 33 49 – 55

Fully closed 5 – 11 13 – 19 26 – 32

Fully opened 26 – 32 74 – 80

Half throttle 17 – 23 74 – 80

Fully closed 5 – 11 74 – 80

Fully opened 38 – 44 74 – 80

Half throttle 38 – 44 74 – 80

Fully closed 38 – 44 74 – 80

“POWER” mode

Up shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 34 – 40 71 – 77 112 – 118

D Half throttle 28 – 34 52 – 58 79 – 85

Fully opened 34 – 40 76 – 82

2 Half throttle 28 – 34 76 – 82

Down shift km/h

Range Throttle Opening 12 2 3 3 4

Fully opened 26 – 32 57 – 63 97 – 103

Half throttle 17 – 23 42 – 48 66 – 72

Fully closed 5 – 11 13 – 19 26 – 32

Fully opened 26 – 32 74 – 80

Half throttle 17 – 23 74 – 80

Fully closed 5 – 11 74 – 80

Fully opened 38 – 44 74 – 80

Half throttle 38 – 44 74 – 80

Fully closed 38 – 44 74 – 80

LOCK-UP POINT CHART (TFR/S)

(H2, H4)

(REAR AXLE RATIO: 4.555)

(RADIUS OF TIRE: 0.348m)

km/h

Throttle Opening: 20 %

Lock-up ON Lock-up OFF

Range A/T Mode

2nd 3rd 4th 2nd 3rd 4th

NORMAL 32 – 38 46 – 52 56 – 62 26 – 32 42 – 48 54 – 60

D POWER 32 – 38 46 – 52 56 – 62 26 – 32 42 – 48 54 – 60

TCM VOLTAGE CHECK

TCM voltage check is done to check for transmission and

transmission control module (TCM) problems which cannot

be detected by self-diagnosis.

Additionally, it serves as a back-up check for self-

diagnosis.

Measure the voltage drop and make a continuity test fo

each of the sensors, solenoids, and switches.

If the voltage is within the specified range and continuit

exists, that particular area of the TCM and automatic

transmission assembly is normal.

If voltage deviation or lack of continuity is discovered,

disconnect the applicable parts and check each of them

individually.

This will allow you to determine the trouble location (TCM,

automatic transmission unit, or another area of the

vehicle).

826RY00017

Inspection Tool

Use a circuit tester to measure voltage and circuit

continuity.

Insert the test probes from the connector wiring side. TCM

terminals are extremely small.

Wrap a piece of thin wire around the probe of tester.

This will make measurement easier.

NOTE:

TCM is located in the behind instrument panel of the

driver’s compartment.

TCM Voltage Check Procedure

1. Remove the TCM.

2. Turn the ignition switch on. Do not start the engine.

3. Measure the voltage at the terminal.

Refer the following table for the specified voltage

ranges.

TCM STANDARD VOLTAGE

Terminal

Check circuit

+ –

Measuring condition Voltage (V)

Throttle fully closed (Idling) 0.25 ∼ 0.45

C79-6 C79-28

Throttle fully opened (WOT) 3.47 ∼ 4.56

Throttle position sensor

(UBS)

C79-19 C79-28 Key switch ON 4.75 ∼ 5.25

Throttle fully closed (Idling) (*1) 4.4 ∼ 4.6

Throttle position sensor

(TFR/S) C79-6 C78-15

or –19 Throttle fully opened (WOT) (*1) 0.4 ∼ 0.6

Output revolution sensor C79-4 C79-16 Engine idling in gear 0 ∼ 3

Input revolution sensor C79-5 C79-17 Engine idling 0 ∼ 3

Speed meter sensor C79-7 C78-15

or –19

Vehicle speed 10 ∼ 20 km/h Less than 1.4

⇔ about 5

Depress brake 7 ∼ 16

Brake switch C78-18 C78-15

or –19 Release brake Less than 1

O/D switch position ON

(O/D OFF lamp OFF) Less than 1

O/D switch C79-3 C78-15

or –19 O/D switch position OFF

(O/D OFF lamp ON) 7 ∼ 16

Selector “P” range 7 ∼ 16

Neutral start switch

(P) C79-2 C78-15

or –19 Selector all ranges except “P” Less than 1

Selector “R” range 7 ∼ 16

Neutral start switch

® C79-1 C78-15

or –19 Selector all ranges except “R” Less than 1

Selector “N” range 7 ∼ 16

Neutral start switch

(N) C79-9 C78-15

or –19 Selector all ranges except “N” Less than 1

Selector “D” range 7 ∼ 16

Neutral start switch

(D) C79-8 C78-15

or –19 Selector all ranges except “D” Less than 1

Selector “2” range 7 ∼ 16

Neutral start switch

(2) C79-21 C78-15

or –19 Selector all ranges except “2” Less than 1

Selector “L” range 7 ∼ 16

Neutral start switch

(L) C79-20 C78-15

or -19 Selector all ranges except “L” Less than 1

Engine revolution signal C79-15 C78-15

or -19

Engine idling Less than 1.4 ⇔ 9 ∼ 16

Diagnosis terminal C79-24 C78-15

or -19

Self-diagnosis ON 0 ∼ 1.5

Power pattern switch OFF (NORMAL) 8 ∼ 16

Power pattern switch C79-23 C78-15

or -19 Power pattern switch ON (POWER) Less than 1.4

Switch OFF 8 ∼ 16

Winter select switch C79-13 C78-15

or -19 Switch ON Less than 1.4

Electrical source (Battery) C78-13 C78-15

or -19

9 ∼ 16

Terminal

Check circuit

+ –

Measuring condition Voltage (V)

Electrical source (Ignition) C78-20 C78-15

or -19

Key switch ON 9 ∼ 16

Oil temperature warning lamp ON Less than 1

Oil temperature warning

lamp C79-11 C78-15

or -19 Oil temperature warning lamp OFF 8 ∼ 16

“CHECK TRANS” lamp ON Less than 1

“CHECK TRANS lamp” C79-10 C78-15

or -19 “CHECK TRANS” lamp OFF 8 ∼ 16

Power lamp ON Less than 1

Power lamp (UBS) C79-22 C78-15

or -19 Power lamp OFF 8 ∼ 16

Winter lamp ON Less than 1

Winter lamp (UBS) C79-12 C78-15

or -19 Winter lamp OFF 8 ∼ 16

OFF (3rd or O/D) Less than 1

Solenoid S1 C78-4 C78-15

or -19 ON (1st or 2nd) 8 ∼ 16

OFF (1st or O/D) Less than 1

Solenoid S2 C78-3 C78-15

or -19 ON (2nd or 3rd) 8 ∼ 16

OFF (Lock up OFF) Less than 1

Lock up solenoid SL C78-12 C78-15

or -19 ON (Lock up ON) 8 ∼ 16

Pressure control solenoid C78-11 C78-8 At throttle pressure changing Less than

1 ⇔ 8-16

ATF temperature 20° 4.70

Oil temperature sensor C79-18 C79-27

ATF temperature 80°C 3.65

Tech 2 diagnosis terminal

(J1850) C78-6 C78-15

or -19

On diagnosis communication 0-1.5 ⇔

6.25-8.0

Throttle position sensor

(ground) (UBS) C79-19 C78-15

or -19

Key switch ON -0.1 ∼ 0.1

*1: Reference (Oscilloscope waveform)

(TFR/S)

ON-VEHICLE SERVICE

UBS

242R200004

TRANSIMISSION FLUID LEVEL AND

CONDITION

Park vehicle on level ground and set parking brake.

With the engine idling, move the shift lever through all

positions from "P" to "L", then return to position "P".

Check to see If the level of fluid comes to "HOT" range o

about 80°C (176°F) on the dipstick gauge.

If the level of fluid is too low, replenish to bring it to

maximum level in "HOT" range.

Inspection of fluid condition

If the ATF is black or smells burnt, replace it.

ATF REPLACEMENT

NOTE:

Do not overfill.

1. Remove the drain plug from oil pan and drain the fluid.

2. Reinstall the drain plug securely.

Torque: 19 N m (1.9 kg m/14 Ib ft)

3. With the engine OFF, add new fluid through the fille

tube.

5.2 litres

Drain and refill

8.7 litres

Dry fill

Fluid DEXRON ATF

242R200005

4. Start the engine and shift the selector into all position

from "P" through "L", and then shift into "P".

5. With the engine idling, check the fluid level. Add fluid up

to the "COLD" level on the dipstick.

6. The ATF level must be checked again for correct level

with the "HOT" level.

NOTE:

To prevent fluid leaks, the drain plug gasket must be

replaced each time this plug is removed.

NEUTRAL START SWITCH INSPECTION

Inspection

With a circuit tester, make a continuity test on the neutral

start switch with the moving piece set in each position.

Terminal

Position 1 4 3 5 2 6 8 7 9

249RY00010

Continuity

Removal

Preparation:

Disconnect negative (-) battery cable.

1. Remove rear sound cover (UBS).

2. Remove the rear side ATF cooler pipe from the

transmission elbow.

3. Disconnect neutral start switch connector.

4. Unstake the lock washer, and then remove the shaft

nut.

5. Remove the neutral start switch.

Installation

To install, follow the removal steps in the reverse order,

noting the following points;

Torque:

Nut – 7 N m (0.7 kg m/61 Ib in)

Bolt – 13 N m (1.3 kg m/113 Ib in)

249RY00008

Adjustment

1. Loosen the neutral start switch bolt and set the shift

selector to the “N” range.

2. Align the groove and neutral basic line.

3. Hold in position and tighten the bolt.

Torque: 13 N m (1.3 kg m/113 Ib in)

310RW020

BRAKE SIGNAL INSPECTION

Check that the brake light comes on when the brake pedal

is depressed.

F07RY00017

VEHICLE SPEED SENSOR INSPECTION

1. Connect the vehicle speed sensor connector terminal

(1) to the battery ( +) terminal and terminal (2) to the

battery (-) terminal.

2. Connect a resistance of 1.3k ohm to 5k ohm (1.4W o

more) between terminals (1) and (3).

NOTE:

Be extremely careful not to connect the battery (+)

terminal to the terminal (3).

This may damage the vehicle speed sensor.

3. Rotate the shaft of the vehicle speed sensor slowly and

measure the voltage at both ends with a digital tester.

The voltage, with one rotation of shaft, fluctuates fou

times in the following range: 10 to 14V 2V or less.

Replace the sensor when the result of inspection is

found abnormal.

F07RY00018

INPUT AND OUTPUT REVOLUTION

SENSOR INSPECTION

1. Disconnect the input and output revolution senso

connector.

2. Use an ohmmeter to measure the resistance between

terminals 1 and 2.

Standard resistance

Input revolution sensor: 387 – 473 (at 20 , 4 2)

560 – 680 (at 20 , 4 4)

Output revolution sensor: 560 – 680 (at 20 )

UBS

F07RY00019

F07L100005

PATTERN SELECT SWITCH INSPECTION

Inspect that there is continuity between each terminals.

UBS

225R200003

225L200001

OVERDRIVE SWITCH INSPECTION

Inspect that there is continuity between each terminals.

220L100001

SOLENOID INSPECTION

1. Resistance check

Using an ohmmeter, check the resistance between

each terminals (S1/S2/SL) and body.

Solenoid S1, S2 and lock-up solenoid resistance:

11 – 15 (at 20 )

12 – 16 (at 40 )

Using an ohmmeter, check the resistance between

each terminals (STH) and (STHG).

Pressure control solenoid resistance:

5 – 5.6 (at 20 )

5.4 – 6.1 (at 40 )

NOTE:

If the pressure control solenoid resistance is not

within specification, replace the valve body

assembly.

2. Operation check

Check the solenoid operation by blowing into an oil hole

as shown in the figure.

Solenoid S1 and S2 (Normal close type)

When battery terminal is

disconnected No air leaks

When battery terminal is

connected Air passes through

244RX00001

Lock-up solenoid S3 (Normal open type)

When battery terminal is

disconnected Air passes through

When battery terminal is

connected No air leaks

244RY00005

249L100001

ATF TEMPERATURE SENSOR

INSPECTION

1. Disconnect the front side ATF cooler pipe from the

elbow and remove the elbow.

2. Remove the ATF temperature sensor from the

transmission case.

3. Place the ATF temperature sensor in a container o

ATF.

242RW013

4. Measure the resistance between each terminals.

Resistance: 0.5 – 30 k (at 0 - 120)

5. If either of the measured values exceeds the specified,

replace the ATF temperature sensor.

Torque: 15 Nm (1.5 kgm/11 Ibft)

THROTTLE POSITION SENSOR

INSPECTION (UBS and TFR/S)

1. Turn the starter switch to the “ON” position.

2. Measure the voltage between throttle position senso

connector terminals 2 (output) and 1 (ground).

NOTE:

Do not remove the sensor connector.

Make sure that power source (4.75 – 5.25V) is

measured between terminals 1 and 3 before

measurement at step 2.

Standard voltage:

Idling 0.25 – 0.45V

WOT 3.74 – 4.56V

256RY00001

SELECTOR LEVER

Inspection

1. Make sure that when the selector lever is shifted from

"P" to "L", a "clicking" can be felt at each shift position.

Make sure that the gear corresponds to that of the

position plate indicator.

2. Check to see if the selector lever can be shifted as

shown.

REMOVAL

Preparation:

Disconnect negative (-) battery cable.

1. Transfer Control Lever Knob (4 4)

2. Front Console

Disconnect wiring harness connectors.

UBS

256RW012

3. Selector Lever Assembly

1. Disconnect shift lock cable from the selector leve

assembly side (UBS).

2. Disconnect wiring harness connectors.

256RW013

3. Disconnect shift control rod from the selector leve

assembly side.

’01 TFR

220L200001

256RW014

’01 TFR

256L200001

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

Adjustment of select lever and control rod

1. Place the vehicle on a level surface.

NOTE:

If the vehicle is not on a level surface, the shift

select cable set position will vary with the

movement of the engine. To prevent possible

misadjustment of the cable, the vehicle must be

placed on a level surface.

2. Install the shift control rod (1) to the transfmission

select lever (2), and then place the lever in the "N"

position.

3. Set select lever in the "N" position.

4. Push selector lever forward and secure it (using a

rubber band (3), etc.) so that pin comes into contact

with the wall of detent plate.

5. Install the shift control rod (1) to the selector lever arm

(4).

Nut torque: 27 N m (2.8 kg m/20 Ib ft)

NOTE:

Do not apply oil to threaded portions.

6. (’01 TFR)

a. Turn nut (5) until it butts against boss (6).

b. Tighten nut (7) to lock boss while keeping nut (5)

stationary with a tool.

Nut torque: 27 N m (2.8 kg m/20 Ib ft)

c. Attach clip (8) and fix it with nut (9).

Nut torque: 7 N m (70 kg cm/61 Ib in)

7. After adjustment, operate select lever on a trial basis to

makes sure of its smooth operation and no abnormal

indication in each position.

256RW015

Adjustment of shift lock cable (UBS)

1. Set ignition key in "LOCK" position and selector lever in

"P" position.

2. Adjust cable screw cap on selector lever side to provide

a gap (slack for cable) of 1-2mm between rod on

steering lock side and stopper

Adjust cap as follows:

a. Pull screw cap (1) in arrow direction to put off slack o

inner cable.

b. With cable kept as (a), adjust gap between nut (2)

and bracket to 5mm (0.2in).

c. Lock inner cable by turning nut (3) while holding nut

(2) in place.

Lock nut torque: 3.7 N m (38 kg cm/33 Ib in)

NOTE:

Clean the rod threads and do not apply oil to the

threaded portions.

3. Make sure of proper operation of shift lock through

checks as follows:

a. Selector lever shall not be moved out of "P" position

with ingition key in "Lock" position.

b. Selector lever can be moved out of "P" position with

ignition key in "ON" position only when brake pedal is

depressed.

c. Ignition key can be turned to "LOCK" position onl

when selector lever is in "P" position (key can be

pulled out).

If (a) and (c) fail, readjust cable. If (b) fails, readjust

connector wiring and brake pedal switch.

UBS (RHD)

826R200033

826L100002

TRANSMISSION CONTROL MODULE

(TCM)

REMOVAL

Preparation:

Disconnect negative (-) battery cable.

1. Disconnect the TCM harness connectors.

2. Remove fixing nuts (3 pieces) and TCM from the

bracket.

NOTE:

The TCM is fitted under instrument panel of the

driver’s compartment by means of two stud bolts.

INSTALLATION

To install, follow the removal steps in reverse order.

249RY00011

249RY00012

SHIFT SOLENOID AND LOCK-UP

SOLENOID

REMOVAL

Preparation:

Disconnect negative (-) battery cable.

Remove the rear sound cover. (UBS)

Drain the fluid.

Refer to "ATF REPLACEMENT" in this section.

1. Remove the nineteen bolts and oil pan.

2. Remove the oil strainer assembly.

3. Disconnect the solenoid wiring connectors from the

shift solenoid S1(1), S2(2) and lock-up solenoid (3).

4. Remove each retaining bolts and solenoids.

INSTALLATION

To install, follow the removal steps in reverse order noting

the following point;

Torque:

Solenoid S1, S2 bolt 7 N m (0.7 kg m/61 Ib in)

Lock-up solenoid bolt 10 N m (1.0 kg m/87 Ib in)

VALVE BODY ASSEMBLY AND PRESSURE CONTROL SOLENOID

244RY00009

REMOVAL

Preparation:

Disconnect negative (-) battery cable.

Remove the rear sound cover. (UBS)

Drain the fluid.

Refer to "ATF REPLACEMENT" in this section.

1. Remove the nineteen bolts and oil pan.

244RY00003

2. Remove the oil strainer assembly.

3. Disconnect the solenoid wiring connectors from the

solenoids.

4. Remove the twenty bolts from the valve body.

5. Remove the valve body assembly and pressure control

solenoid.

When removing valve body assembly from the

transmission case, loosen the solenoid clamp bolt

and remove the pressure control solenoid from the

upper valve body assembly.

Also disconnect the harness connector from the

pressure control solenoid.

244RY00018

NOTE:

1. Two or more persons are required for removal

and installation of the valve body assembly and

pressure control solenoid.

2. The check valve assembly (1) and the C0

accumulator piston springs (2) will fall from the

transmission case during removal of valve body

assembly.

Protect these parts from damage.

The B0 (3), C2 (4), and B2 (5) accumulator piston

and springs may also fall free and must be

protected.

244RY00006

INSTALLATION

To install, follow the removal steps in reverse order noting

the following point;

1. Reinstall the parts removed with the valve bod

assembly to their assigned positions in the

transmission case (check valve assembly, C0

accumulator pistons, etc). Install the valve bod

assembly to the transmission case.

Refer to “REASSEMBLY OF MAJOR COMPONENT

(2).”

244RY00017

2. Solenoid clamp bolt

Torque : 7 N m (0.7 kg m/61 Ib in)

3. Valve body fixing bolts

Each bolt location and length (mm) is indicated in the

figure.

Torque : 10 N m (1.0 kg m/87 Ib in)

4. Oil strainer fixing bolts

Torque : 10 N m (1.0 kg m/87 Ib in)

5. Oil pan fixing bolts

Torque : 8 N m (0.8 kg m/69 Ib in)

REAR OIL SEAL (ADAPTER HOUSING, 4X4)

REMOVAL

1. Remove the front and rear propeller shaft assembl

form the transfer case.

2. Remove the transfer case assembly from the

transmission case.

Refer to Section 4 “DRIVELINE/AXLE”.

3. Using a screwdriver, remove the rear oil seal.

240RY00003

INSTALLATION

1. Apply ATF to a new rear oil seal lip.

2. Using oil seal installer, install the rear oil seal to the

adapter housing.

Oil seal installer : 5-8840-2282-0

3. Install the transfer case assembly.

4. Install the front and rear propeller shaft assembly.

Torque:

Flange bolt : 63 Nm (6.4 kgm/46 Ibft)

Center bearing retainer bolt

: 69 Nm (7.0 kgm/51 Ibft)

REAR OIL SEAL (EXTENSION HOUSING, 4X2)

REMOVAL

1. Remove the rear propeller shaft assembly.

2. Using a screwdriver, remove the rear oil seal.

249L100005

INSTALLATION

1. Apply ATF to a new rear oil seal lip.

2. Using oil seal installer, install the rear oil seal to the

extension housing.

Oil seal installer : 5-8840-2702-0

3. Install the rear propeller shaft.

Torque:

Flange bolt : 63 N m (6.4 kg m/46 Ib in)

Center bearing retainer bolt

: 69 N m (7.0 kg m/51 Ib ft)

TRANSMISSION REMOVAL AND INSTALLATION (UBS)

240R200031

Removal Steps

11. Under cover and flex plate-torque

converter bolt

12. Rear mounting nut

13. 3rd crossmember

14. Oil level gauge and tube

15. Starter

16. Breather hose

17. Engine-transmission bolt

18. Transmission assembly

Installation Steps

1. Transfer protector

2. Rear sound cover

3. Front sound cover

4. Rear propeller shaft

5. Front propeller shaft

6. Exhaust pipe

7. Harness connector

8. Front console, selector lever assembly,

and transfer control lever

9. Transfer case assembly

10. ATF cooler pipe and clamp To install, follow the removal steps in reverse

order.

REMOVAL

Preparation:

Remove engine hood.

Disconnect negative (-) battery cable.

1. Transfer protector

2. Rear sound cover

3. Front sound cover

4. Rear propeller shaft

5. Front propeller shaft

NOTE:

pply alignment marks on the flange at both front

and rear sides.

6. Exhaust pipe

Remove the 2nd front exhaust pipe from the 1st front

exhaust pipe and exhaust silencer.

7. Harness connector

Disconnect the engine harness connectors from the

transmission side.

8. Front console, selector lever assembly, and

transfer control lever

Disconnect the transfer control lever knob.

Remove the front console.

Disconnect the harness connector.

Remove the transfer control lever.

Remove the selector lever assembly.

Disconnect the shift control rod from the selecto

lever assembly.

9. Transfer case assembly

Disconnect the breather hose from the transfer case.

Remove the transfer case assembly from the

transmission.

10. ATF cooler pipe and clamp

Disconnect two ATF cooler pipes from A/T side.

253RY00001

Remove oil pipe clamp from torque converter housing

side.

Loosen oil pipe clamp bolt at engine mount side.

240RY00026

11. Under cover and flex plate-torque converter bolt

Remove the under cover.

Turn the crankshaft to gain access to each bolt.

Remove the six torque coverter fixing bolts.

NOTE:

New fixing bolts should be replaced fo

reassembly.

022RY00001

12. Rear mounting nut

Support transmission with a jack.

Remove two rear mounting nuts from the 3rd

crossmember.

13. 3rd crossmember

14. Oil level gauge and tube

15. Starter

Remove the mounting bolts, and pull the starte

toward the front of the vehicle.

Lay the starter alongside the engine.

16. Breather hose

17. Engine-transmission bolt

Remove engine-transmission fixing bolts.

Disconnect the breather hose from the breather hose

2 way.

18. Transmission assembly

NOTE:

Keep the oil pan positioned down.

Be careful not to let the torque converter slide out.

INSTALLATION

To install, follow the removal steps in reverse order, noting

the following point;

1. Torque

Rear mounting to 3rd

crossmember 50 N m (5.1 kg m/37 Ib ft)

Torque converter bolt 29 N m (3.0 kg m/22 Ib ft)

ATF cooler pipe to

transmission 44 N m (4.5 kg m/33 Ib ft)

Exhaust pipe flange to

flange 43 N m (4.4 kg m/32 Ib ft)

3rd crossmember to flame 76 N m (7.8 kg m/56 Ib ft)

Front propeller shaft bolt 63 N m (6.4 kg m/46 Ib ft)

Rear propeller shaft bolt 63 N m (6.4 kg m/46 Ib ft)

Under cover bolt 6 N m (0.6 kg m/52 Ib in)

Transfer protector 37 N m (3.8 kg m/27 Ib ft)

Engine-Transmission Bolt Torque

225R200006

Transmission-Transfer Case Bolt Torque

260RY00001

TRANSMISSION REMOVAL AND INSTALLATION (TFR/S)

240L200001

Removal Steps

9. Rear mounting nut

10. 3rd crossmember

11. Oil level gauge and tube

12. Starter

13. Breather hose

14. Engine – transmission bolt

15. Transmission assembly

1. Center console, rear console, select

lever assembly, and transfer control

lever (4 4)

2. Transfer protector (4 4)

3. Rear propeller shaft

4. Front propeller shaft (4 4)

5. Exhaust pipe

6. Harness connector

7. ATF cooler pipe and clamp

8. Under cover and flex plate-torque

converter bolt

Installation Steps

To install, follow the removal steps in reverse

order.

REMOVAL

Preparation:

Remove engine hood.

Disconnect negative (-) battery cable.

1. Center console, rear console, select leve

assembly, and transfer control lever (4 4)

Disconnect the control rod from the select leve

assembly.

2. Transfer protector (4 4)

3. Rear propeller shaft

Disconnect the center bearing bracket, and remove

rear propeller shaft.

4. Front propeller shaft (4 4)

5. Exhaust pipe

6. Harness connector

Disconnect the engine harness connectors from the

transmission side.

253LV001

7. ATF cooler pipe and clamp

Disconnect two ATF cooler pipes from A/T side.

Remove oil pipe clamp from the under cover and

torque converter housing side.

240RW037

8. Under cover and flex plate-torque converter bolt

Remove the under cover.

Turn the crankshaft to gain access to each bolt.

Remove the six torque converter fixing bolts.

NOTE:

New fixing bolts should be replaced fo

reassembly.

9. Rear mounting nut

Support transmission with a jack.

Remove two rear mounting nuts from the 3rd

crossmember.

If necessary, remove the rear mounting from the

transmission.

10. 3rd crossmember

11. Oil level dipstick and tube

12. Starter

Remove the mounting bolts, and pull the starte

toward the front of the vehicle.

Lay the starter alongside the engine.

13. Breather hose

14. Engine-transmission bolt

Remove engine-transmission fixing bolts.

15. Transmission assembly

If necessary, remove the transfer case from the

transmission assembly. (44)

Refer to Section 4 “DRIVE LINE/AXLE” for removal

and installation.

NOTE:

Keep the oil pan positioned down.

Be careful not to let the torque converter slide out.

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

1. Torque

Rear mounting to

crossmember 41 N m (4.2 kg m/30 Ib ft)

Rear mounting to

transmission 41 N m (4.2 kg m/30 Ib ft)

Torque converter bolt 29 N m (3.0 kg m/22 Ib ft)

ATF cooler pipe to

elbow 44 N m (4.5 kg m/33 Ib ft)

Exhaust pipe flange to

flange 43 N m (4.4 kg m/32 Ib ft)

Exhaust pipe to exhaust

manifold 67 N m (6.8 kg m/4.9 Ib ft)

Rear propeller shaft bolt 63 N m (6.4 kg m/46 Ib ft)

Center bearing retainer

bolt 69 N m (7.0 kg m/51 Ib ft)

Front propeller shaft bolt 63 N m (6.4 kg m/46 Ib ft)

3rd crossmember bolt 76 N m (7.8 kg m/56 Ib ft)

Under cover bolt 6 N m (0.6 kg m/52 Ib in)

Engine – Transmission Bolt Torque

E07L200003

Transmission-Transfer Case Bolt Torque (Reference)

260RY00001

UNIT REPAIR

MAJOR COMPONENTS

Disassembly, inspection and reassembly of each

component group is indicated in the following chapter.

Before reassembly, make sure, again, that all component

groups are assembled correctly.

If something wrong is found in a certain component group

during assembly, inspect and repair this group

immediately.

GENERAL ASSEMBLY NOTES:

1. The automatic transmission is composed of highl

precision-finished parts, necessitating careful inspection

before assembly because even a small nick could cause

fluid leakage or affect performance.

2. Before assembling new clutch discs and brake bands,

soak them in automatic transmission fluid for at least thirt

minutes.

3. Apply automatic transmission fluid on the sliding or rotating

surfaces of parts before assembly.

4. Use petroleum jelly to keep small parts in their palces.

5. Do not use adhesive cements on gaskets and simila

parts.

6. When assembling the transmission, be sure to use new

gaskets and O-rings.

7. Dry all parts with compressed air – never use shop rags.

8. Be sure to install the thrust bearings and races in the

correct direction and position.

240RY00022

DISASSEMBLY OF MAJOR

COMPONENTS (1)

240R200036

Disassembly steps

1. Torque converter

2. Transmission control rod and select

lever (UBS and TFR/S)

4. Neutral start switch

5. Elbow

6. Oil temperature sensor

7. Breather hose

8. Input revolution sensor

9. Output revolution sensor (4x4)

10. Output revolution sensor (4x2)

11. Speedometer sensor, speedometer

driven gear and plate (4 

x2)

12. Extension housing (4



x2)

13. Adapter housing (4  x4)

14. Transmission assembly

Disassembly steps

1. Torque converter

2. Transmission control rod and select lever (UBS and

TFR/S)

3. Not applicable for Australian vehicles

249RW003

4. Neutral start switch

Unstake the lock washer.

Remove the nut and bolts, and then remove the neutral

start switch.

Remove the lock washer and grommet.

240RY00001

5. Elbow

Remove two elbows from transmission case.

6. Oil temperature sensor

7. Breather hose

8. Input revolution sensor

9. Output revolution sensor (4 4)

10. Output revolution sensor (4 2)

11. Speedometer sensor, speedometer driven gear and

plate (4 ×

××

× 2)

12. Extension housing (4 ×

××

× 2)

13. Adapter housing (4 ×

××

× 4)

240R200021

14. Transmission assembly

Install special tool to the transmission unit.

Holding fixture: 5-8840-2152-0 (J-37227)

Fixture base: 5-8840-0003-0 (J-3289-20)

REASSEMBLY OF MAJOR

COMPONENTS (1)

240R200035

Reassembly steps

1. Transmission assembly

2. Extension housing (4 2)

3. Speedometer driven gear, plate, and

speedometer sensor (4 2)

4. Adapter housing (4 4)

5. Neutral start switch

6. Oil temperature sensor

7. Elbow

8. Transmission control rod and select

lever (UBS and TFR/S)

9. Transmission control rod and select

lever - Not applicable for Australian vehicles

10. Output revolution sensor (4 2)

11. Output revolution sensor (4 4)

12. Input revolution sensor

13. Breather hose

14. Torque converter

Reassembly steps

1. Transmission assembly

2. Extension housing (4 2)

Install a new gasket and the extension housing to the

transmission case.

Torque: 51 N m (5.2 kg m/38 Ib ft)

3. Speedometer driven gear, plate, and speedomete

sensor (4 2)

Torque:

Plate bolt – 15 N m (1.5 kg m/11 Ib ft)

Speedometer sensor – 25 N m (2.5 kg m/18 Ib ft)

241RY00020

4. Adapter housing (4 4)

Remove any gasket material on the contacting surfaces

of the adapter housing and transmission case.

Apply liquid gasket (TB1281-B or its equivalent) (1) and

install the apply gaskets (2) to the adapter housing as

shown in the figure.

Install the adapter housing to the transmission case.

Torque: 34 N m (3.5 kg m/25 Ib ft)

249L100003

5. Neutral start switch

Using the transmission select lever, fully turn the

manual valve lever shaft back and return two notches.

It is now in neutral.

Insert the neutral start switch onto the manual valve

lever shaft and temporarily tighten the adjusting bolt.

Install the lock washer and nut.

Torque: 7 N m (0.7 kg m/61 Ib in)

Align the neutral standard line and the switch groove

and tighten the adjusting bolt.

Torque: 13 N m (1.3 kg m/113 Ib in)

Bend the tabs of the lock washer.

NOTE:

Bend at least two of the lock washer tabs.

249L100001

6. Oil temperature sensor

Install the oil temperature sensor to the transmission

case.

Torque: 15 N m (1.5 kg m/11 Ib ft)

UBS

249RW003

249R200009

7. Elbow

Coat new O-rings with ATF, install them to the two

elbows.

Install the two elbows as shown in the figure.

Torque: 29 N m (3.0 kg m/22 Ib ft)

8. Transmission control rod and select lever (UBS and

TFR/S)

9. N/A Australian vehicles

Torque: 29 N m (3.0 kg m/22 Ib ft)

10. Output revolution sensor (4 2)

11. Output revolution sensor (4 4)

12. Input revolution sensor

13. Breather hose

240RY00005

14. Torque converter

Using calipers and a straight edge, measure from the

installed surface of the transmission housing.

Correct distance: 67 mm (2.64 in) or more

DISASSEMBLY OF MAJOR

COMPONENTS (2)

242R200006

Disassembly steps

1. Converter housing

2. Oil pan

3. Oil strainer assembly

4. Valve body

5. Check valve, spring

6. Spring

7. Accumulator piston (B-2)

8. Accumulator piston (C-2)

9. Accumulator piston (B-0)

10. Accumulator piston (C-0)

11. Second brake drum gasket

12. Solenoid wiring

13. Snap ring, rotor, key (4 4)

14. Snap ring, speedometer sensor drive

gear, ball (4 2)

15. Spacer, rotor, key, snap ring (4 2)

240R200022

Disassembly steps

1. Converter housing

Remove the six bolts.

Remove the converter housing.

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2. Oil pan

NOTE:

Do not turn over the transmission as this will

contaminate the valve body with foreign materials

in the bottom of the oil pan.

Remove the nineteen bolts.

Remove oil pan by lifting the transmission case.

Seal cutter: 5-8840-2153-0 (J-37228)

240RY00008

Examine particles in oil pan

Remove the magnet and use it to collect any steel

chips.

Look carefully at the chips and particles in the oil pan

and on the magnet to anticipate what type of wear you

will find in the transmission:

Steel (magnetic) …… bearing, gear and clutch plate

wear

Brass (non-magnetic)… bushing wear

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3. Oil strainer assembly

Remove four bolts holding the oil strainer (UBS and

TFR/S).

244L100001

Remove three bolts holding the oil strainer (’01 TFR).

NOTE:

When reassembling components, install a new oil

strainer assembly.

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4. Valve body

Disconnect the connectors from the solenoid S1 (1), S2

(2), lock-up solenoid (3) and pressure control solenoid

(4).

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Remove the twenty bolts from valve body.

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5. Check valve, spring

6. Spring

Remove the check valve and spring.

Remove two springs from C-0 accumulator piston.

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7. Accumulator piston (B-2)

8. Accumulator piston (C-2)

Remove accumulator pistons and springs from

transmission case.

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9. Accumulator piston (B-0)

Applying compressed air to the oil hole, remove the B-0

accumulator piston and spring.

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10. Accumulator piston (C-0)

Remove the C-0 accumulator piston.

11. Second brake drum gasket

12. Solenoid wiring

Turn over transmission, remove the solenoid wiring

stopper plate from the case.

Pull the wiring out of the transmission case.

247R200002

13. Snap ring, rotor, key (4 4)

Remove the snap ring from the output shaft.

Remove the rotor and key.

247L100001

14. Snap ring, speedometer sensor drive gear, ball

(4 2)

Remove the snap ring from the output shaft.

Remove the speedometer sensor drive gear, and ball.

15. Spacer, rotor, key, snap ring (4 2)

Remove the spacer, rotor and key.

Remove the snap ring from the output shaft.

REASSEMBLY OF MAJOR

COMPONENTS (2)

242R200007

Reassembly steps

1. Converter housing

2. Snap ring, key, rotor (4 2)

3. Spacer, ball, speedometer sensor drive

gear, snap ring (4 2)

4. Key, rotor, snap ring (4 4)

5. Second brake drum gasket

6. Accumulator piston

7. Check valve, spring

8. Valve body

9. Solenoid wiring

10. Oil strainer assembly

11. Oil pan

240R200022

Reassembly steps

1. Converter housing

Torque:

M10 - 34 N m (3.5 kg m/25 Ib ft)

M12 - 57 N m (5.8 kg m/42 Ib ft)

247L100001

2. Snap ring, key, rotor (4 2)

Install the snap ring to the output shaft.

Install the key and rotor.

3. Spacer, ball, speedometer sensor drive gear, snap

ring (4 2)

Install the spacer, ball and speedometer sensor drive

gear.

Install the snap ring to the output shaft.

247R200002

4. Key, rotor, snap ring (4 4)

Install the key and rotor.

Install the snap ring to the output shaft.

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5. Second brake drum gasket

Install a new second brake drum gasket to the

transmission case.

Individual piston operation inspection

Check for the sound of operation while injecting

compressed air into the oil hole indicated in the figure.

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1: OD direct clutch

2: Direct clutch

3: Forward clutch

4: OD brake

5: Second coast brake

6: Second brake

7: First and reverse brake

: C-0 Accumulator piston

hole

NOTE:

When inspecting the direct clutch, check with the

C-0 accumulator piston hole closed. If there is no

noise, disassemble and check the condition of the

parts.

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6. Accumulator piston

Coat the O-ring with ATF and install it to the piston.

Install the three springs and four accumulator pistons to

the bore as shown in th figure.

Piston Outer diameter Height

B-2 36.8 mm (1.449 in) 62.5 mm (2.461 in)

C-2 36.8 mm (1.449 in) 56.6 mm (2.228 in)

B-0 31.8 mm (1.252 in) 52.0 mm (2.047 in)

C-0 29.8 mm (1.173 in) 44.0 mm (1.732 in)

UBS

Spring Free length Outer diameter

B-2 75.8 mm (2.984 in) 20.1 mm (0.791 in)

C-2 (Outer) 64.0 mm (2.520 in) 20.2 mm (0.795 in)

C-2 (Inner) 42.1 mm (1.658 in) 14.7 mm (0.579 in)

B-0 63.6 mm (2.504 in) 16.0 mm (0.630 in)

C-0 (Outer) 74.6 mm (2.937 in) 20.9 mm (0.823 in)

C-0 (Inner) 46.0 mm (1.811 in) 14.0 mm (0.551 in)

TFR/S

Spring Free length Outer diameter

B-2 73.4 mm (2.890 in) 19.9 mm (0.783 in)

C-2 (Outer) 70.3 mm (2.768 in) 20.2 mm (0.795 in)

C-2 (Inner) 42.1 mm (1.658 in) 14.7 mm (0.579 in)

B-0 62.0 mm (2.441 in) 16.0 mm (0.630 in)

C-0 (Outer) 74.6 mm (2.937 in) 20.9 mm (0.823 in)

C-0 (Inner) 46.0 mm (1.811 in) 14.0 mm (0.551 in)

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7. Check valve, spring

Install new check valve and spring.

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8. Valve body

Align the groove of the manual valve to the pin of the

lever.

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Install the twenty bolts.

NOTE:

Each bolt length (mm) is indicated in the figure.

Torque: 10 N m (1.0 kg m/87 Ib in)

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9. Solenoid wiring

Coat a new O-ring with ATF, and install it to the

solenoid wiring.

Insert the solenoid wiring to the case and install the

stopper plate.

Connect the connectors to the solenoid S1 (1), S2 (2),

lock-up solenoid (3), and pressure control solenoid (4).

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UBS and TFR/S

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10. Oil strainer assembly

Install a new oil strainer assembly with gaskets.

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Install the oil strainer with the gaskets to the valve body.

Tighten the four bolts.

Torque: 10 N m (1.0 kg m/87 Ib in)

244L100001

11. Oil pan

Install two magnets in oil pan.

Remove any gasket material and be careful not to drop

oil on the contacting surfaces of the transmission case

and oil pan.

Apply liquid gasket (TB1281 or its equivalent) to the oil

pan as shown in the figure.

NOTE:

Install the oil pan as soon as the seal gasket is

applied.

240RY00020

Install and tighten the nineteen bolts.

Torque: 8 N m (0.8 kg m/69 Ib in)

DISASSEMBLY OF MAJOR

COMPONENTS (3)

248L100001

Disassembly steps

1. Oil pump

2. Race

3. OD planetary gear and OD direct clutch

4. Race

5. OD planetary ring gear

6. Snap ring

7. Flange, plate and disc (B-0)

8. Bearing and race

9. Snap ring

10. OD support

11. Race

12. Snap ring

13. Second coast brake piston assembly

14. Direct clutch and forward clutch

15. E-ring and pin

16. Second coast brake band

17. Front planetary ring gear

18. Bearing and race

19. Race

20. Snap ring

21. Front planetary gear

22. Drum and one-way clutch

23. Snap ring

24. Flange, plate and disc (B-2)

25. Snap ring

26. Rear planetary gear, second brake

drum and output shaft

27. Bearing

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Disassembly steps

1. Oil pump

Remove seven bolts fixing the oil pump to the

transmission case.

Remove the oil pump.

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2. Race

Remove race from oil pump.

252L100001

3. OD planetary gear and OD direct clutch

Remove the overdrive planetary gear and overdrive

direct clutch with thrust needle bearing from the

transmission case.

252L100017

4. Race

Remove the race from OD planetary gear.

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5. OD planetary ring gear

Remove the overdrive planetary ring gear from the

transmission case.

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Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake piston as

shown in the figure.

Measure the stroke applying and releasing the

compressed air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 –

114 psi) as shown in the figure.

Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)

If the values are nonstandard, select another flange.

Available flange sizes

3.3 mm (0.130 in) 3.8 mm (0.150 in)

3.5 mm (0.138 in) 3.9 mm (0.154 in)

3.6 mm (0.142 in) 4.0 mm (0.158 in)

3.7 mm (0.146 in)

244RY00001

246RY00001

6. Snap ring

Remove the snap ring.

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7. Flange, plate and disc (B-0)

Remove two flange, three plates and four discs.

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8. Bearing and race

Remove the thrust bearing and two races.

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9. Snap ring

Using snap ring pliers, remove the snap ring.

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10. OD support

Remove two bolts fixing the overdrive support assembl

to the transmission case.

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Install two removed bolts to the OD support, and pull

out the OD support assembly.

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11. Race

Remove the race from OD support.

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Check piston stroke of second coast brake (B-1)

Place a mark on the second coast brake piston rod as

shown in the figure.

Using feeler gauge, measure the stroke applying the

compressed air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 –

114 psi) as shown in the figure.

Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)

If the values are nonstandard, replace piston rod and

recheck piston stroke.

If piston stroke is nonstandard, replace brake band.

There are two piston rods.

71.4 mm

(

2.811 in

)

Rod length

72.9 mm

(

2.870 in

)

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12. Snap ring

Using snap ring pliers, remove the snap ring.

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13. Second coast brake piston assembly

Applying compressed air to the oil hole, remove the

second coast brake piston assembly.

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14. Direct clutch and forward clutch

Remove the direct clutch and forward clutch from the

transmission case.

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15. E-ring and pin

Remove the E-ring from the pin.

Remove the pin from the brake band.

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16. Second coast brake band

Remove the second coast brake band from the

transmission case.

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17. Front planetary ring gear

Remove the front planetary ring gear from the

transmission case.

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18. Bearing and race

Remove the bearing and race.

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19. Race

Remove the race.

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20. Snap ring

Using snap ring pliers, remove the snap ring.

NOTE:

Hold the output shaft to prevent it from falling.

The output shaft falls when the snap ring is

removed.

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21. Front planetary gear

Remove the front planetary gear from the transmission

case.

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22. Drum and one-way clutch

Remove sun gear input drum and one-way clutch.

248RY00014

23. Snap ring

Using two screwdrivers, remove the snap ring.

248RY00015

24. Flange, plate and disc (B-2)

Remove the flange, five discs and five plates.

248RY00016

Check pack clearance of first and reverse brake (B-3)

Using a feeler gauge, measure the clearance between

the plate and second brake drum as shown in the

figure.

Clearance: 0.7 – 1.0 mm (0.0276 – 0.0394 in) (UBS)

: 0.6 – 0.9 mm (0.0236 – 0.0354 in) (TFR/S)

If the values are nonstandard, replace the discs.

Available flange sizes

4.0 mm (0.158 in) 4.8 mm (0.189 in)

4.2 mm (0.165 in) 5.0 mm (0.197 in)

4.4 mm (0.173 in) 5.2 mm (0.205 in)

4.6 mm (0.181 in) 5.4 mm (0.213 in)

248RY00017

25. Snap ring

Using snap ring pliers, remove the snap ring.

247R200001

26. Rear planetary gear, second brake drum and output

shaft

Remove the rear planetary gear, second brake drum

and output shaft as an assembly.

248RY00018

27. Bearing

Remove the assembled thrust bearing and race from

the transmission case.

REASSEMBLY OF MAJOR

COMPONENTS (3)

248L100002

Reassembly steps

1. Bearing

2. Rear planetary gear, second brake

drum and output shaft

3. Snap ring

4. Second brake piston sleeve

5. One-way clutch

6. Flange, plate and disc (B-2)

7. Snap ring

8. Drum

9. Front planetary gear and bearing

10. Snap ring

11. Race

12. Second coast brake band

13. E-ring and pin

14. Bearing and race

15. Race

16. Front planetary ring gear

17. Bearing and race

18. Direct clutch and forward clutch

19. Second coast brake piston assembly

20. Snap ring

21. Race

22. OD support

23. Snap ring

24. Flange, plate and disc (B-0)

25. Snap ring

26. Bearing and race

27. OD planetary ring gear

28. Bearing and race

29. Race

30. OD planetary gear and OD direct clutch

31. Bearing

32. Race

33. Oil pump

Reassembly steps

1. Bearing

Coast the assembled bearing and race with petroleum

jelly and install it onto the transmission case.

Assembled bearing and race

(Reference)

Bearing and race Diameter

Inside 39.2 mm (1.543 in)

Outside 57.7 mm (2.272 in)

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2. Rear planetary gear, second brake drum and output

shaft.

Align the teeth of the second brake drum, flanges, discs

and plates as shown in the figure.

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Align the splines of the transmission case and the

assembled rear planetary gear, second brake drum and

output shaft, indicated by A in the figure.

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3. Snap ring

Using snap ring pliers, install the snap ring.

248RY00016

Check pack clearance of first and reverse brake

Using a thickness gauge, measure the clearance

between the plate and second brake drum as shown in

the figure.

Clearance: 0.7 – 1.0 mm (0.0276 – 0.0394 in) (UBS)

0.6 – 0.9 mm (0.0236 – 0.0354 in) (TFR/S)

If the values are nonstandard, check for an improper

installation.

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4. Second brake piston sleeve

Install second brake piston sleeve.

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5. One-way clutch

Install one-way clutch.

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6. Flange, plate and disc (B-2)

Install flange, discs and plates.

Install the 2.5 mm (0.098 in) thick plate with the

rounded edge side of the plate facing the disc.

Alternately install five discs and five plates (Disc first)

Install the flange with the rounded edge of the flange

facing the disc.

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7. Snap ring

Install the snap ring.

248RY00020

8. Drum

While turning the sun gear input drum clockwise.

Install it into the one-way clutch.

NOTE:

Confirm the thrust washers are installed correctly.

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9. Front planetary gear and bearing

Install the front planetary gear to the sun gear.

NOTE:

Confirm the bearing and race is installed correctly.

247RY00013

With wooden blocks under the output shaft, stand the

transmission on the output shaft.

248RY00011

10. Snap ring

Using snap ring pliers, install the snap ring.

11. Race

Coat the bearing race with petroleum jelly and install it

onto the front planetary gear.

Bearing race diameter (Reference)

Bearing race Diameter

Inside 34.3 mm (1.350 in)

Outside 47.8 mm (1.882 in)

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12. Second coast brake band

Insert the second coast brake band to the transmission

case.

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13. E-ring and pin

Install the pin through the brake band.

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Install the E-ring to the pin.

14. Bearing and race

Coat the bearing and race with petroleum jelly and

install them onto the forward clutch.

Bearing and race diameter (Reference)

Inside Outside

Bearing 26.0 mm (1.024 in) 46.7 mm (1.839 in)

Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)

248RY00023

15. Race

Coat the race with petroleum jelly and install it onto the

front planetary ring gear.

Race diameter (Reference)

Inside Outside

Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)

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Align the flukes of the discs in the forward clutch.

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16. Front planetary ring gear

Align the spline of the front planetary gear with the

flukes of the discs and install the front planetary gear to

the forward clutch.

17. Bearing and race

Coat the bearing and race with petroleum jelly and

install them onto the ring gear.

Bearing and race diameter (Reference)

Inside Outside

Bearing 32.6 mm (1.283 in) 47.7 mm (1.878 in)

Race 30.6 mm (1.205 in) 53.6 mm (2.110 in)

247RY00019

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18. Direct clutch and forward clutch

Install the assembled direct clutch, forward clutch and

front planetary ring gear into the transmission case.

248RY00024

Using vernier calipers, measure the distance between

the sun gear input drum and direct clutch drum as

shown in the figure.

Height: 9.8 – 11.8 mm (0.386 – 0.465 in)

If the values are nonstandard, check for an improper

installation.

Coat the assembled bearing and race with petroleum

jelly and install it onto the forward clutch.

Assembled bearing and race diameter

(Reference)

Inside Outside

Bearing

and race 33.7 mm (1.327 in) 47.8 mm (1.882 in)

248RY00025

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19. Second coast brake piston assembly

Coat the oil seal ring with ATF and install it to the

second coast brake piston.

Install the washer, spring and piston to the piston rod.

Install the E-ring.

: Second coast brake piston

: Oil seal

: Piston rod

248RY00027

20. Snap ring

Coat two new oil seals with ATF and install them to the

piston cover.

Install the spring, second coast brake piston assembl

and piston cover to the transmission case.

Using snap ring pliers, install the snap ring.

248RY00005

Check piston stroke of second coast brake

Place a mark on the second coast brake piston rod as

shown in the figure.

248RY00004

Using wire gauge, measure the stroke by applying the

compressed air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 –

114 psi) as shown in the figure.

Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in)

If the values are nonstandard, check for an improper

installation.

21. Race

Coat the race with petroleum jelly and install it onto the

overdrive support assembly.

Race diameter (Reference)

Inside Outside

Race 36.8 mm (1.449 in) 50.9 mm (2.004 in)

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22. OD support

Aim the bolt and oil holes of the overdrive support

toward the valve hole side, and align them with the bolt

hole of the transmission case and insert.

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23. Snap ring

Using snap ring pliers, install the snap ring as shown in

the figure.

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Install and tighten the two bolts.

Torque: 25 N m (2.6 kg m/19 Ib ft)

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Check end of output shaft

Using a dial indicator, measure the end play of the

output shaft by hand.

End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)

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24. Flange, plate and disc (B-0)

Install the (flat ring) 4.0 mm (0.157 in) thick flange with

the rounded edge side of the flange facing the disc.

Alternately install four discs and three plates. (Disc first)

25. Snap ring

Install the (stepped ring) flange with the flat side of the

flange facing the disc.

Install the snap ring.

Snap ring (Reference)

Inside diameter 167.9 mm (6.61 in)

246RY00001

252RY00003

Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake piston as

shown in the figure.

Measure the stroke by applying and releasing the

compressed air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 –

114 psi) as shown in the figure.

Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)

If the values are nonstandard, check for an improper

installation.

Available flange size

3.3 mm (0.130 in) 3.8 mm (0.150 in)

3.5 mm (0.138 in) 3.9 mm (0.154 in)

3.6 mm (0.142 in) 4.0 mm (0.158 in)

3.7 mm (0.146 in)

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246RY00001

Remove the snap ring.

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Remove two flanges, three plates and four discs.

26. Bearing and race

Coat the bearing and races with petroleum jelly and

install them onto the overdrive support.

Bearing and races diameter (Reference)

Inside Outside

Bearing 36.5 mm (1.437 in) 48.4 mm (1.906 in)

Race (Front) 37.2 mm (1.465 in) 58.8 mm (2.315 in)

Race (Rear) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

252RY00010

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27. OD planetary ring gear

Install the overdrive planetary ring gear.

28. Bearing and race

Coat the bearing and race with petroleum jelly and

install them onto the planetary ring gear.

Bearing and race diameter (Reference)

Inside Outside

Bearing 26.0 mm (1.024 in) 46.8 mm (1.843 in)

Race 24.2 mm (0.953 in) 47.8 mm (1.882 in)

252RY00011

29. Race

Coat the race with petroleum jelly and install it onto the

planetary gear.

Race diameter (Reference)

Inside Outside

Race 27.3 mm (1.075 in) 41.8 mm (1.646 in)

252RY00001

252L100001

30. OD planetary gear and OD direct clutch

Install the overdrive planetary gear and direct clutch.

31. Bearing

Coat the assembled bearing and race with petroleum

jelly and install it onto the direct clutch.

Bearing and race diameter (Reference)

Inside Outside

Bearing

and race 28.9 mm (1.138 in) 50.2 mm (1.976 in)

252L100018

252RY00009

Install the (flat ring) 4.0 mm (0.157 in) thick flange with

the rounded edge side of the flange facing the disc.

Alternately install four discs and three plates. (Disc first)

246RY00001

Install the (stepped ring) flange with the flat side of the

flange facing the disc.

Install the snap ring.

32. Race

Coat the race with petroleum jelly and install it onto the

oil pump.

Race diameter (Reference)

Inside Outside

Race 28.1 mm (1.106 in) 47.3 mm (1.862 in)

252RY00014

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33. Oil pump

Coat the O-ring with ATF and install it around the pump

body.

Place the oil pump through the input shaft, and align the

bolt holes of the pump body with the transmission case.

Hold the input shaft, and lightly press the oil pump bod

to slide the oil seal rings on the stator shaft through the

direct clutch drum.

CAUTION:

Do not push on the oil pump strongly or the oil seal

ring will stick to the direct clutch drum.

Install the seven bolts.

Torque: 22 N m (2.2 kg m/16 Ib ft)

Check input shaft rotation

Make sure the input shaft rotates smoothly.

DISASSEMBLY, INSPECTION AND

REASSEMBLY OF MINOR COMPONENTS

NOTE:

The instructions here are organized so that you work on

only one component group at a time.

This will help avoid confusion from similar-looking parts of

different subassemblies being on your workbench at the

same time.

The component groups are inspected and repaired from

the converter housing side.

As much as possible, complete the inspection, repair and

reassembly before proceeding to the next component

group. If a component group cannot be reassembled

because parts are being ordered, be sure to keep all parts

of that group in separate container while proceeding with

disassembly, inspection, repair and reassembly of other

component groups.

Recommended ATF type BESCO ATF .

GENERAL CLEANING NOTES:

1. All disassembled parts should be washed clean and an

fluid passages and holes blown through with compressed

air.

2. When using compressed air to dry parts, always aim

away from yourself to prevent accidentally spraying

automatic transmission fluid in your face.

3. The recommended automatic transmission fluid should be

used for cleaning.

PARTS ARRANGEMENT:

1. After cleaning, the parts should be arranged in prope

order to allow performing inspection, repairs, and

reassembly with efficiency.

2. When disassembling a valve body, be sure to keep each

valve together with the corresponding spring.

3. New brakes and clutches that are to be used fo

replacement must be soaked in transmission fluid for at

least thirty minutes before assembly.

GENERAL ASSEMBLY:

1. All oil seal rings, clutch discs, clutch plates, rotating parts,

and sliding surfaces should be coated with transmission

fluid prior to reassembly.

2. All gaskets and rubber O-ring should be replaced.

3. Make sure that the ends of a snap ring are not aligned

with one of the cutouts and are installed in the groove

correctly.

4. If a worn bushing is to be replaced, the subassembl

containing that bushing must be replaced.

5. Check thrust bearings and races for wear or damage.

Replace if necessary.

6. Use petroleum jelly or vaseline to keep parts in place.

OIL PUMP

DISASSEMBLY

241R200003

Disassembly steps

1. Oil seal ring

2. O-ring

3. Stator shaft

4. Oil pump drive gear

5. Oil pump driven gear

6. Oil pump body

241RY00005

Disassembly steps

1. Oil seal ring

Use torque converter as work stand.

Remove 2 oil seal rings from stator shaft.

2. O-ring

Remove O-ring.

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3. Stator shaft

4. Oil pump drive gear

5. Oil pump driven gear

6. Oil pump body

Remove 13 bolts, and then remove the stator shaft from

oil pump body.

Then remove drive and driven gear.

INSPECTION AND REPAIR

Make necessary correction or parts replacement i

wear, damage or any abnormal conditions are found

through inspection.

241RY00007

Check oil pump body bushing

Using a dial indicator, measure the inside diameter o

the oil pump body bushing.

Maximum inside diameter: 38.19 mm (1.5035 in)

If the inside diameter is greater than the maximum,

replace the oil pump body.

241RY00008

Check stator shaft bushing

Using a dial indicator, measure the inside diameter o

the stator shaft bushing.

Maximum inside diameter:

Front side: 21.58 mm (0.8496 in)

Rear side: 27.08 mm (1.0661 in)

If the inside diameter is greater than the maximum,

replace the stator shaft.

241RY00009

Check tip clearance of both gears

Measure between the gear teeth and the cresent-

shaped part of the pump body.

Standard tip clearance: 0.11 – 0.14 mm

(0.0043 – 0.0055 in)

Maximum tip clearance: 0.3 mm (0.012 in)

If the tip clearance is greater than the maximum,

replace the drive gear, driven gear or pump body.

241RY00010

Check body clearance of driven gear

Push the driven gear to one side of the body.

Use a feeler gauge, measure the clearance.

Standard body clearance: 0.07 – 0.15 mm

(0.0028 – 0.0059 in)

Maximum body clearance: 0.3 mm (0.012 in)

If the body clearance is greater than the maximum,

replace the drive gear, driven gear or pump body.

241RY00011

Check side clearance of both gears

Using a steel straightedge and a feeler gauge, measure

the side clearance of both gears.

Standard side clearance: 0.02 – 0.05 mm

(0.0008 – 0.0020 in)

Maximum side clearance: 0.1 mm (0.004 in)

If the side clearance is greater than the maximum,

replace the drive gear, driven gear or pump body.

241RY00012

Check oil seal

Check for wear, damage or cracks.

If necessary, replace oil seal.

Pry off the oil seal with a screwdriver.

241RY00013

Using special tool, install a new oil seal.

The oil seal end should be flush with the outer edge o

the pump body.

Oil seal installer : 5-8840-2256-0 (J-9617)

Coat the oil seal lip with multi purpose grease.

REASSEMBLY

241R200004

Reassembly steps

1. Oil pump body

2. Oil pump driven gear

3. Oil pump drive gear

4. Stator shaft

5. Oil seal ring

6. O-ring

241RY00014

Reassembly steps

1. Oil pump body

2. Oil pump driven gear

3. Oil pump drive gear

Place the oil pump body on the torque converter.

Coat the driven gear and drive gear with ATF.

Install the driven gear and drive gear.

241RY00006

4. Stator shaft

Align the stator shaft with the bolt holes.

Tighten the thirteen bolts.

Torque: 11 N m (1.1 kg m/95 Ib in)

241RY00015

5. Oil seal ring

Coat the oil seal rings with ATF.

Contract the oil seal rings as shown, and install them

onto the stator shaft.

NOTE:

Do not spread the ring ends too much.

6. O-ring

Coat a new O-ring with ATF and install it to the oil pump

body.

O-ring size (Reference)

Inside diameter 204.9 mm (8.067 in)

Thickness 3.5 mm (0.138 in)

241RY00016

241RY00017

Check oil pump drive gear rotation

Make sure the drive gear rotates smoothly when

installed to the torque converter.

OD PLANETARY GEAR AND OD

DIRECT CLUTCH ASSEMBLY (C-0)

DISASSEMBLY

252R200007

Disassembly steps

1. OD direct clutch assembly

2. OD planetary gear assembly

3. Thrust bearing

4. Snap ring

5. Flange, disk and plate

6. Snap ring

7. Piston return spring

8. OD direct clutch piston with O-ring

9. O-ring

10. Thrust bearing

11. Snap ring

12. Ring gear flange

13. OD planetary ring gear

14. Race

15. Snap ring

16. Retaining plate

17. OD one-way clutch

18. Thrust washer

252L100003

Disassembly steps

Check operation of one-way clutch

Hold the OD direct clutch drum and turn the input shaft.

The input shaft should turn freely clockwise and should

lock counterclockwise.

1 : Free

2 : Lock

252L100004

1. OD direct clutch assembly

2. OD planetary gear assembly

Remove OD direct clutch assembly from OD planetar

gear assembly.

3. Thrust bearing

Then remove thrust bearing with the race from OD

direct clutch drum.

252L100005

Check piston stroke of OD direct clutch (C-0)

Place the oil pump onto the torque converter, and then

place the OD direct clutch assembly onto the oil pump.

252L100016

Use a dial indicator, measure the OD direct clutch

piston stroke applying and releasing the compressed ai

(390 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as

shown.

Piston stroke: 1.85 – 2.15 mm (0.0728 – 0.0846 in)

252L100006

4. Snap ring

Remove snap ring from clutch drum.

5. Flange, disc and plate

Remove flange, two discs and two plates.

252L100007

6. Snap ring

Place special tool on the spring retainer and compress

the return spring.

Using snap ring pliers, remove the snap ring.

Spring compressor : 5-8840-0195-0 (J-23327-1)

7. Piston return spring

Remove piston return spring

252L100008

8. OD direct clutch piston with O-ring.

Place the oil pump onto the torque converter and then

place the OD direct clutch onto the oil pump.

Holding the OD direct clutch piston by hand, appl

compressed air to the oil pump to remove the OD direct

clutch piston.

Remove the OD direct clutch piston.

9. O-ring

Remove two O-rings from piston.

252RY00021

10. Thrust bearing

Remove bearing and race from OD planetary ring gear.

252RY00022

11. Snap ring

Remove snap ring.

252RY00023

12. Ring gear flange

13. OD planetary ring gear

Remove ring gear flange from OD planetary ring gear.

252RY00024

14. Race

15. Snap ring

Remove snap ring, using screwdriver.

252RY00025

16. Retaining plate

Remove retaining plate from OD planetary gear.

252RY00026

17. OD one-way clutch

Remove OD one-way clutch with outer race.

18. Thrust washer

252RY00027

INSPECTION AND REPAIR

Check discs

Using a micrometer, measure the thickness of the

discs.

Minimum thickness: 1.84 mm (0.0724 in)

If the thickness is less than the minimum, replace the

disc.

252RY00028

Check piston return spring

Using calipers, measure the free length of the return

spring.

Standard length: 15.8 mm (0.622 in)

252RY00029

Check OD direct clutch piston

Check that the check ball is free by shaking the piston.

Check that the valve does not leak by applying low-

pressure compressed air.

252L100009

Check OD direct clutch drum bushings

Using a dial indicator, measure the inside diameter o

the OD direct clutch drum bushings.

Maximum inside diameter: 27.11 mm (1.0673 in)

If the inside diameter is greater than the maximum,

replace the OD direct clutch drum.

252RY00031

Check OD planetary gear bushing

Using a dial indicator, measure the inside diameter o

replace the OD planetary gear bushing.

Maximum inside diameter: 11.27 mm (0.4437 in)

If the inside diameter is greater than the maximum,

replace the OD planetary gear.

REASSEMBLY

252R200008

Reassembly steps

1. OD planetary gear assembly

2. Thrust washer

3. OD one-way clutch

4. Retaining plate

5. Snap ring

6. Race

7. OD planetary ring gear

8. Ring gear flange

9. Snap ring

10. Thrust bearing

11. O-ring

12. OD direct clutch piston with O-ring

13. Piston return spring

14. Snap ring

15. Flange, disc and plate

16. Snap ring

17. Thrust bearing

18. OD direct clutch assembly

252RY00032

Reassembly steps

1. OD planetary gear assembly

2. Thrust washer

Install the thrust washer to the OD planetary gear,

facing the grooved side upward.

252RY00033

3. OD one-way clutch

Install the one-way clutch into the outer race, with the

flanged side of the one-way clutch facing upward.

252RY00026

Install OD one-way clutch with outer race to overdrive

planetary gear.

252RY00024

4. Retaining plate

5. Snap ring

Install retaining plate, then install snap ring, using a

screwdriver.

6. Race

Coat the race with petroleum jelly and install it to the

planetary gear.

Race diameter (Reference)

Inside diameter 27.3 mm (1.075 in)

Outside diameter 41.8 mm (1.646 in)

252RY00034

252RY00023

7. OD planetary ring gear

8. Ring gear flange

Install ring gear flange to OD planetary ring gear.

252RY00022

9. Snap ring

Install snap ring, using a screwdriver.

10. Thrust bearing

Coat the race and bearing with petroleum jelly and

install them onto the OD planetary ring gear.

Race and bearing diameter (Reference)

Inside Outside

Race 24.2 mm (0.953 in) 47.8 mm (1.882 in)

Bearing 26.0 mm (1.024 in) 46.8 mm (1.843 in)

252RY00035

252L100011

11. O-ring

Coat new O-rings with ATF and install them on the OD

direct clutch piston.

12. OD direct clutch piston with O-ring

Being careful not to damage the O-rings, press in the

OD direct clutch piston into the clutch drum, using both

hands.

252L100012

13. Piston return spring

Install piston return spring.

252L100007

14. Snap ring

Place special tool on the spring retainer, and compress

the return spring.

Spring compressor : 5-8840-0195-0 (J-23327-1)

Install the snap ring with snap ring pliers.

Be sure the end gap of the snap ring is not aligned with

the spring retainer claw.

252L100013

15. Flange, disc and plate

Install two plates and tow discs then install the flange,

with the flat side facing downward.

252L100014

16. Snap ring

Install snap ring.

252L100005

Check piston stroke of OD direct clutch (C-0)

Place the oil pump onto the torque converter, and then

place the OD direct clutch assembly onto the oil pump.

Using a dial indicator, measure the OD direct clutch

piston stroke by applying and releasing the compressed

air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as

shown.

Piston stroke: 1.85 – 2.15 mm (0.0729 – 0.0847 in)

If the piston stroke is not within specification, replace

the disc and recheck the piston stroke.

If the piston stroke is non standard, select anothe

flange.

Flange sizes

Flange thickness Flange thickness

3.8 mm (0.150 in) 3.4 mm (0.134 in)

3.7 mm (0.146 in) 3.3 mm (0.130 in)

3.6 mm (0.142 in) 3.2 mm (0.126 in)

3.5 mm (0.138 in) 3.1 mm (0.122 in)

252L100016

17. Thrust bearing

Coat the assembled bearing and race with petroleum

jelly and install it with the race side facing downward.

Bearing and race (Reference)

Inside diameter 28.9 mm (1.138 in)

Outside diameter 50.2 mm (1.976 in)

252L100015

252L100004

18. OD direct clutch assembly

Align the flukes of discs in the direct clutch.

Install the OD direct clutch assembly onto the OD

planetary gear.

252L100003

Check operation of one-way clutch

Hold the OD direct clutch drum and turn the input shaft.

The input shaft should turn freely clockwise and should

lock counterclockwise.

1 : Free

2 : Lock

OD SUPPORT ASSEMBLY

DISASSEMBLY

252R200003

Disassembly steps

1. Thrust bearing

2. Race

3. Thrust washer (plastic)

4. Snap ring

5. Piston return spring

6. OD brake piston

7. O-ring

8. Oil seal ring

9. OD support

252RY00042

Disassembly steps

Check OD brake piston movement

Place the OD support assembly onto the direct clutch

assembly.

252RY00043

Apply compressed air into the oil passage as shown,

and be sure that the OD brake piston moves smoothly.

1. Thrust bearing

2. Race

3. Thrust washer (plastic)

252RY00044

4. Snap ring

Place special tool on the spring retainer, and compress

the return spring with a shop press.

Spring compressor : 5-8840-2170-0 (J-37233)

Remove the snap ring with a screwdriver.

5. Piston return spring

252RY00045

6. OD brake piston

Place the OD support onto the direct clutch assembly.

Hold the OD brake piston so it is not slanted and appl

compressed air into the passage to remove the OD

brake piston.

Remove the OD brake piston.

7. O-ring

8. Oil seal ring

9. OD support

INSPECTION AND REPAIR

Make necessary correction or parts replacement i

wear, damage or any abnormal conditions are found

through inspection.

252RY00046

Check piston return spring

Using calipers, measure the free length of the return

spring.

Standard length: 17.2 mm (0.677 in)

REASSEMBLY

252R200004

Reassembly steps

1. OD support

2. Oil seal ring

3. O-ring

4. OD brake piston

5. Piston return spring

6. Snap ring

7. Thrust washer (Plastic)

8. Race

9. Thrust bearing

252RY00047

Reassembly steps

1. OD support

2. Oil seal ring

Coat the two oil seal rings with ATF.

Contract the oil seals as shown, and install them onto

the OD support.

NOTE :

Do not spread the ring ends more than necessary.

252RY00048

3. O-ring

Coat two new O-rings with ATF and install them on the

OD brake piston.

4. OD brake piston

Being careful not to damage the O-rings, press in the

brake piston into the OD support, using both hands.

252RY00049

5. Piston return spring

Install piston return spring.

252RY00050

6. Snap ring

Place special tool on the spring retainer, and compress

the return spring with a shop press.

Spring compressor : 5-8840-2170-0 (J-37233)

Install the snap ring with a screwdriver.

Be sure the end gap of the snap ring is not aligned with

cutout portion of the OD support.

252RY00051

7. Thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it

onto the OD support.

NOTE :

Make sure that the lug fits into the hole on the OD

support.

8. Race

Coat the race with petroleum jelly, and install it onto the

OD support.

Race diameter (Reference)

Inside diameter 36.8 mm (1.450 in)

Outside diameter 50.9 mm (2.004 in)

252RY00052

9. Thrust bearing

Turn over OD support.

Coat the two races with petroleum jelly, and install them

onto the OD support.

Race and bearing diameter (Reference)

Inside Outside

Race (A) 37.2 mm (1.465 in) 58.8 mm (2.315 in)

Bearing 36.5 mm (1.437 in) 48.4 mm (1.906 in)

Race (B) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

252RY00069

252RY00042

Check OD brake piston movement

Place the OD support assembly onto the direct clutch

assembly.

252RY00043

Apply compressed air into the oil passage as shown,

and be sure that the OD brake piston moves smoothly.

DIRECT CLUTCH ASSEMBLY (C-2)

DISASSEMBLY

248R200001

Disassembly steps

1. Clutch drum thrust washer (Plastic)

2. Snap ring

3. Flange

4. Plate and disc

Five plates and five discs (UBS)

Four plates and four discs (TFR/S)

5. Snap ring

6. Piston return spring

7. Direct clutch drum

8. Direct clutch piston

9. O-ring

248RY00028

Disassembly steps

Remove direct clutch drum assembly from forward

clutch assembly.

248RY00029

Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support

assembly.

248RY00061

Using a dial indicator, measure the direct clutch piston

stroke by applying and releasing compressed air (390 –

780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as shown.

Piston stroke: 1.6 – 1.9 mm (0.0630 – 0.0748 in)

(UBS)

Pack clearance: 0.4 – 0.7 mm (0.0157 – 0.0276 in)

(TFR/S)

1. Clutch drum thrust washer (Plastic)

2. Snap ring

3. Flange

4. Plate and disc

248RY00002

5. Snap ring

Place special tool on the spring retainer and compress

the return spring.

Using snap ring pliers, remove the snap ring.

Spring compressor : 5-8840-0254-0 (J-25048)

6. Piston return spring

248RY00030

7. Direct clutch drum

8. Direct clutch piston

9. O-ring

Place the direct clutch drum onto the OD support.

Holding the direct clutch piston by hand, appl

compressed air to the OD support to remove the direct

clutch piston.

Remove the direct clutch piston.

Remove two O-rings from piston.

247RY00034

INSPECTON AND REPAIR

Check piston return spring

Using calipers, measure the free length of the return

spring.

Standard length: 21.3 mm (0.839 in)

252RY00027

Check discs

Using micrometer, measure the thickness of the discs.

Minimum thickness: 1.84 mm (0.0724 in)

If the thickness is less than the minimum, replace the

disc.

248RY00031

Check direct clutch piston

Check that check ball is free by shaking the piston.

Check that the valve does not leak by applying low-

pressure compressed air.

248RY00032

Check direct clutch drum bushing

Using a dial indicator, measure the inside diameter o

the clutch drum bushing.

Maximum inside diameter: 53.99 mm (2.1256 in)

If the inside diamater is greater than the maximum,

replace the clutch drum.

REASSEMBLY

248R200002

Reassembly steps

1. O-ring

2. Direct clutch piston

3. Direct clutch drum

4. Piston return spring

5. Snap ring

6. Disc and plate

Five discs and five plates (UBS)

Four discs and four plates (TFR/S)

7. Flange

8. Snap ring

9. Clutch drum thrust washer (Plastic)

248RY00033

Reassembly steps

1. O-ring

2. Direct clutch piston

3. Direct clutch drum

Coat new O-rings with ATF and install them on the

direct clutch piston.

Install direct clutch piston to direct clutch drum.

Being careful not to damage the O-rings, press in the

direct clutch piston into the clutch drum, using both

hands.

248RY00034

4. Piston return spring

Install piston return spring.

248RY00002

5. Snap ring

Compress piston return spring and install snap ring in

groove.

Place special tool on the spring retainer, and compress

the return spring.

Install the snap ring with snap ring pliers.

Be sure the end gap of the snap ring is not aligned with

the spring retainer claw.

Spring compressor: 5-8840-0254-0 (J-25048)

248RY00062

6. Disc and plate

Install plates and discs.

Install in order : P-D-P-D-P-D-P-D-P-D (UBS)

: P-D-P-D-P-D-P-D (TFR/S)

P : Plate, D : Disc

248RY0035

7. Flange

Install the flange, with the flat side facing downward.

248RY00036

8. Snap ring

Install the snap ring with a screwdriver.

Be sure the end gap of the snap ring is not aligned with

the cutout portion of the direct clutch drum.

248RY00029

Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support

assembly.

Using a dial indicator, measure the direct clutch piston

stroke by applying and releasing compressed air (390 –

780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as shown.

Piston stroke: 1.6 – 1.9 mm (0.0630 – 0.0748 in)

(UBS)

Pack clearance: 0.4 – 0.7 mm (0.0157 – 0.0276 in)

(TFR/S)

If the piston stroke is not within specification, replace

the discs and recheck the piston stroke.

If the piston stroke is non standard, select anothe

flange.

Flange sizes

Flange thickness Flange thickness

3.3 mm (0.130 in) 3.8 mm (0.150 in)

3.4 mm (0.134 in) 3.9 mm (0.154 in)

3.5 mm (0.138 in) 4.0 mm (0.157 in)

3.6 mm (0.142 in) 4.1 mm (0.161 in)

3.7 mm (0.146 in) 4.2 mm (0.165 in)

248RY00061

248RY00037

9. Clutch drum thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it

onto the direct clutch.

NOTE :

Make sure that the lugs fit into the cutout portions

on the direct clutch.

248RY00038

Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward clutch

assembly.

Check that the distance from the direct clutch end to the

forward clutch end is 71.2 mm (2.803 in).

FORWARD CLUTCH ASSEMBLY (C-1)

DISASSEMBLY

248R200003

Disassembly steps

1. Thrust bearing

2. Race

3. Snap ring

4. Flange

5. Disc and plate

Six discs and six plates (UBS)

Five discs and five plates (TFR/S)

6. Cushion plate

7. Snap ring

8. Piston return spring

9. Piston

10. O-ring

11. O-ring

12. Oil seal ring

13. Thrust bearing

14. Forward clutch drum

248RY00039

Disassembly steps

Remove forward clutch assembly from direct clutch

assembly.

248RY00048

1. Thrust bearing

2. Race

Place wooden blocks, etc. to prevent forward clutch

shaft from touching the work stand, and place the OD

support on them.

Place the forward clutch onto the OD support and

remove the bearing and race.

248R200008

Check piston stroke of forward clutch (C-1)

Using a dial indicator, measure the forward clutch

piston stroke by applying and releasing compressed ai

(390 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as

shown.

Pack clearance: 0.6 – 1.0 mm (0.0236 – 0.0394 in)

(UBS)

: 0.5 – 0.9 mm (0.0197 – 0.0354 in)

(TFR/S)

248RY00041

3. Snap ring

Remove snap ring from clutch drum.

4. Flange

5. Disc and plate

6. Cushion plate

248RY00003

7. Snap ring

Place special tool on the sparing retainer and compress

the return spring.

Using snap ring pliers, remove the snap ring.

Spring compressor : 5-8840-0254-0 (J-25048)

8. Piston return spring

248RY00042

9. Piston

Place the forward clutch drum onto the OD support.

Holding the forward clutch piston by hand, appl

compressed air to the OD support to remove the

forward clutch piston.

10. O-ring

11. O-ring

12. Oil seal ring

13. Thrust bearing

14. Forward clutch drum

248RY00031

INSPECTION AND REPAIR

Check forward clutch piston

Check that check ball is free by shaking the piston.

Check that the valve does not leak by applying low-

pressure compressed air.

248RY00043

Check forward clutch drum bushing

Using a dial indicator, measure the inside diameter o

the forward clutch drum bushing.

Maximum inside diameter: 24.08 mm (0.948 in)

If the inside diameter is greater then the maximum,

replace the forward clutch drum.

248RY00045

Check disc, plate and flange

Check to see if the sliding surface of the disc, plate and

flange are worn or burnt. If necessary, replace them.

If the lining of the disc is peeling off or discolored, o

even if parts of the printed numbers are defaced,

replace all discs.

Before assembling new discs, soak them in ATF fo

at least fifteen minutes.

247RY00034

Check piston return spring

Using calipers, measure the free length of the return

spring.

Standard length: 19.47 mm (0.7665 in)

REASSEMBLY

248R200004

Reassembly steps

1. Forward clutch drum

2. Thrust bearing

3. Oil seal ring

4. O-ring

5. O-ring

6. Forward clutch piston

7. Piston return spring

8. Snap ring

9. Cushion plate

10. Disc and plate

Six discs and six plates (UBS)

Five discs and five plates (TFR/S)

11. Flange

12. Snap ring

13. Race

14. Thrust bearing

Reassembly steps

1. Forward clutch drum

2. Thrust bearing

Coat the assembled bearing and race with petroleum

jelly and install it onto the forward clutch drum, with the

race side facing downward.

Bearing and race (Reference)

Inside diameter 33.7 mm (1.327 in)

Outside diameter 47.8 mm (1.882 in)

248RY00044

248RY00046

3. Oil seal ring

Coat the three oil rings with ATF.

Contract the oil seal rings as shown, and install three oil

seal rings onto the forward clutch drum.

NOTE:

Do not spread the ring ends more than necessary.

248RY00047

4. O-ring

Coat a new O-ring with ATF and install O-ring on the

forward clutch drum.

5. O-ring

Coat new O-rings with ATF and install two O-rings on

the forward clutch piston.

248RY00049

6. Forward clutch piston

Being careful not to damage the O-rings, press the

forward clutch piston into the forward clutch drum.

248RY00065

7. Piston return spring

Install piston return spring.

248RY00003

8. Snap ring

Place special tool on the spring retainer, and compress

the return spring.

Spring compressor: 5-8840-0245-0 (J-25048)

Install the snap ring with snap ring pliers.

Be sure the end gap of the snap ring is not aligned with

the spring retainer claw.

248RY00069

9. Cushion plate

Install cushion plate rounded side down as shown.

248RY00070

10. Disc and plate

Install discs and plates.

Install in order: P-D-P-D-P-D-P-D-P-D-P-D (UBS)

: P-D-P-D-P-D-P-D-P-D (TFR/S)

11. Flange

And then install the flange, with the rounded edge

facing downward.

248RY00041

12. Snap ring

Install the snap ring with a screwdriver.

Be sure the end gap of the snap ring is not aligned with

the cutout portion of the forward clutch drum.

248R200008

Check piston stroke of forward clutch (C-1)

Using a dial indicator, measure the forward clutch

piston stroke by applying and releasing the compressed

air (380 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as

shown.

Pack clearance: 0.6 – 1.0 mm (0.0236 – 0.0394 in)

(UBS)

: 0.5 – 0.9 mm (0.0197 – 0.0354 in)

(TFR/S)

If the piston stroke is not within specification, replace

the discs, and recheck the piston stroke.

Available flange sizes

3.0 mm (0.118 in) 3.4 mm (0.134 in)

4.2 mm (0.165 in) 3.6 mm (0.142 in)

4.4 mm (0.173 in) 3.8 mm (0.150 in)

3.2 mm (0.126 in) 4.0 mm (0.158 in)

13. Race

14. Thrust bearing

Coat the race and bearing with petroleum jelly, and

install them onto the forward clutch drum.

Race and bearing diameter (Reference)

Inside Outside

Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)

Bearing 26.0 mm (1.024 in) 46.7 mm (1.839 in)

248RY00048

248RY00039

Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward clutch

assembly.

248RY00038

Check that the distance from the direct clutch end to the

forward clutch end is 71.2 mm (2.803 in).

FRONT PLANETARY GEAR

DISASSEMBLY

247R200003

Disassembly steps

1. Race

2. Thrust bearing

3. Race

4. Front planetary gear

5. Race (Metal)

6. Thrust bearing

7. Race

8. Front planetary ring gear

Disassembly steps

1. Race

2. Thrust bearing

3. Race

4. Front planetary gear

5. Race (Metal)

6. Thrust bearing

7. Race

8. Front planetary ring gear

247RY00021

INSPECTION AND REPAIR

Check front planetary ring gear bushing

Using a dial indicator, measure the inside diameter o

the front planetary ring gear bushing.

Maximum inside diameter: 24.08 mm (0.9480 in)

If the inside diameter is greater than the maximum,

replace the front planetary ring gear.

REASSEMBLY

247R200004

Reassembly steps

1. Front planetary gear

2. Race

3. Thrust bearing

4. Race (Metal)

5. Front planetary ring gear

6. Race

7. Thrust bearing

8. Race

Reassembly steps

1. Front planetary gear

2. Race

3. Thrust bearing

Coat the race and bearing with petroleum jelly.

Install the race and bearing to the rear side of the front

planetary gear.

Bearing and race diameter (Reference)

Inside Outside

Bearing 35.6 mm (1.402 in) 47.7 mm (1.878 in)

247RY00023

Race 33.7 mm (1.327 in) 47.6 mm (1.874 in)

4. Race (Metal)

Turn over the planetary gear and install the race.

Make sure that the lugs fit into the holes on the front

planetary gear.

Race diameter (Reference)

Inside Outside

Race 34.3 mm (1.350 in) 47.8 mm (1.882 in)

247RY00024

5. Front planetary ring gear

6. Race

7. Thrust bearing

Coat the race and bearing with petroleum jelly.

Install the race and bearing onto the rear side of the

front planetary ring gear.

Race and bearing diameter (Reference)

Inside Outside

Race 30.6 mm (1.205 in) 53.6 mm (2.110 in)

Bearing 32.7 mm (1.287 in) 47.7 mm (1.878 in)

247RY00025

8. Race

Turn over the planetary ring gear and install the race

onto the front side of the front planetary ring gear.

Race diameter (Reference)

Inside Outside

Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)

247RY00026

PLANETARY SUN GEAR AND NO.1

ONE-WAY CLUTCH

DISASSEMBLY

248R200005

Disassembly steps

1. One-way clutch and second brake hub

2. Thrust washer (plastic)

3. Oil seal ring (Metal)

4. Snap ring

5. Sun gear input drum

6. Snap ring

7. Planetary sun gear

248RY00051

Disassembly steps

Check operation of No.1 one-way clutch

Hold the planetary sun gear and turn the second brake

hub.

The second brake hub should turn freely clockwise and

should lock counterclockwise.

: Free

: Lock

1. One-way clutch and second brake hub

2. Thrust washer (plastic)

248RY00052

3. Oil seal ring (Metal)

Remove two oil seal rings.

248RY00053

4. Snap ring

Remove the snap ring with snap ring pliers.

5. Sun gear input drum

6. Snap ring

7. Planetary sun gear

248RY00054

INSPECTION AND REPAIR

Check planetary sun gear bushing

Using a dial indicator, measure the inside diameter o

the planetary sun gear bushing.

Maximum inside diameter: 27.08 mm (1.0661 in)

If the inside diameter is greater than the maximum,

replace the planetary sun gear.

REASSEMBLY

248R200006

Reassembly steps

1. Planetary sun gear

2. Snap ring

3. Sun gear input drum

4. Snap ring

5. Oil seal ring (Metal)

6. Thrust washer (Plastic)

7. One-way clutch and second brake hub

248RY00055

Reassembly steps

1. Planetary sun gear

2. Snap ring

Install snap ring to planetary sun gear.

248RY0056

3. Sun gear input drum

Place a wooden block, etc. as a work stand and place

the planetary sun gear onto it.

Install the sun gear input drum onto the planetary sun

gear.

248RY00053

4. Snap ring

Install snap ring with snap ring pliers.

248RY00052

5. Oil seal ring (Metal)

Coat the two oil seal rings with ATF.

Install the two oil seal rings onto the planetary sun gear.

NOTE:

Do not spread the ring ends too much.

248RY00057

6. Thrust washer (Plastic)

Install thrust washer.

NOTE:

Make sure that the lugs fit into the holes on the sun

gear input drum.

248RY00058

7. One-way clutch and second brake hub

Install assembled No.1 one-way clutch and second

brake hub onto planetary sun gear as shown.

248RY00051

Check operation of No.1 one-way clutch

Hold the planetary sun gear and turn the second brake

hub.

The second brake hub should turn freely clockwise and

should lock counterclockwise.

: Free

: Lock

SECOND BRAKE ASSEMBLY (B-2)

DISASSEMBLY

246R200001

Disassembly steps

1. Second brake assembly

2. Thrust washer (Plastic)

3. Snap ring

4. Spring retainer

5. Piston return spring

6. Piston sleeve

7. Second brake piston

8. O-ring

9. Second brake drum

246RY00007

Disassembly steps

1. Second brake assembly

Remove second brake assembly from output shaft.

247RY00001

2. Thrust washer (Plastic)

3. Snap ring

Place special tool on the spring retainer, and compress

the return spring.

Spring compressor: 5-8840-0254-0 (J-25048)

Remove the snap ring with snap ring pliers.

4. Spring retainer

5. Piston return spring

6. Piston sleeve

246RY00008

7. Second brake piston

Holding the second brake piston by hand, appl

compressed air to the second brake drum to remove

the second brake piston.

Remove the second brake piston.

8. O-ring

9. Second brake drum

247RY00034

INSPECTION AND REPAIR

Check piston return spring

Using calipers, measure the free length of the return

spring.

Standard length: 16.05 mm (0.6319 in)

REASSEMBLY

246R200002

Reassembly steps

1. O-ring

2. Second brake piston

3. Second brake drum

4. Piston sleeve

5. Piston return spring

6. Spring retainer

7. Snap ring

8. Thrust washer (Plastic)

9. Second brake assembly

246RY00009

Reassembly steps

1. O-ring

Coat new O-rings with ATF and install them on the

second brake piston.

2. Second brake piston

3. Second brake drum

Being careful not to damage the O-rings, press in the

second brake piston into the second brake drum.

4. Piston sleeve

Install piston sleeve.

246RY00010

5. Piston return spring

Install piston return spring.

6. Spring retainer

Install spring retainer.

247RY00001

7. Snap ring

Place special tool on the spring retainer, and compress

the return spring.

Spring compressor: 5-8840-0254-0 (J-25048)

Install the snap ring with snap ring pliers.

Be sure the end gap of the snap ring is not aligned with

the spring retainer claw.

246RY00011

Check second brake piston movement

Make sure the second brake piston moves smoothl

when applying and releasing the low compressed air to

the second brake drum.

246RY00012

8. Thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it

to the second brake piston, with the grooved side facing

upward.

NOTE:

Make sure that the cutout portions of the thrust

washer match the teeth of the spring retainer.

246RY00014

9. Second brake assembly

Install second brake assembly to output shaft.

REAR PLANETARY GEAR

ASSEMBLY AND OUTPUT SHAFT

DISASSEMBLY

247R200005

Disassembly steps

1. Second brake assembly

2. Output shaft

3. Oil seal ring

4. Disc, plate and flange (B-3)

Seven discs and seven plates (UBS)

Six discs and six plates (TFR/S)

5. Rear planetary gear assembly

6. One-way clutch inner race

7. Snap ring

8. One-way clutch

9. Thrust washer (Plastic)

10. Thrust washer (Plastic)

11. Rear planetary gear

12. Thrust bearing and race

13. Snap ring

14. Ring gear flange

15. Rear planetary ring gear

246RY00014

Disassembly steps

1. Second brake assembly

2. Output shaft

Remove second brake assembly from output shaft.

247RY00028

3. Oil seal ring

Remove oil seal ring from output shaft.

4. Disc, plate and flange (B-3)

Seven discs and seven plates (UBS)

Six discs and six plates (TFR/S)

247RY00029

5. Rear planetary gear assembly

Remove rear planetary gear from rear planetary ring

gear.

247RY00030

Check operation of No.2 one-way clutch

Hold the planetary gear and turn the one-way clutch

inner race.

The one-way clutch inner race should turn freel

counterclockwise and should lock clockwise.

: Lock

: Free

247RY00031

6. One-way clutch inner race

Remove the one-way clutch inner race from the rea

planetary gear.

247RY00032

7. Snap ring

Remove the snap ring with a screwdriver.

247RY00033

8. One-way clutch

Remove the one-way clutch with retainers from the

planetary gear.

9. Thrust washer (Plastic)

10. Thrust washer (Plastic)

11. Rear planetary gear

12. Thrust bearing and race

13. Snap ring

14. Ring gear flange

15. Rear planetary ring gear

248RY00045

Check disc, plate and flange

Check to see if the sliding surface of the disc, plate and

flange are worn or burnt. If necessary, replace them.

If the lining of the disc is peeling off or discolored, o

even if parts of the printed numbers are defaced,

replace all discs.

Before assembling new discs, soak them in ATF fo

at least fifteen minutes.

REASSEMBLY

247R200006

Reassembly steps

1. Rear planetary ring gear

2. Ring gear flange

3. Snap ring

4. Thrust bearing and race

5. Rear planetary gear

6. Thrust washer (Plastic)

7. Thrust washer (Plastic)

8. One-way clutch

9. Snap ring

10. One-way clutch inner race

11. Rear planetary gear assembly

12. Disc, plate and flange (B-3)

Seven discs and seven plates (UBS)

Six discs and six plates (TFR/S)

13. Oil seal ring

14. Output shaft

15. Second brake assembly

247RY00035

Reassembly steps

1. Rear planetary ring gear

2. Ring gear flange

Install ring gear flange to the rear planetary ring gear.

3. Snap ring

Install snap ring to the rear planetary ring gear.

4. Thrust bearing and race

Coat the races and bearing with petroleum jelly, and

install them onto the rear planetary ring gear.

Races and bearing diameter (Reference)

Inside Outside

Race (A) 28.8 mm (1.134 in) 44.8 mm (1.764 in)

Bearing 30.1 mm (1.185 in) 44.7 mm (1.760 in)

Race (B) 27.8 mm (1.094 in) 44.8 mm (1.764 in)

247RY00036

247RY00037

5. Rear planetary gear

6. Thrust washer (Plastic)

7. Thrust washer (Plastic)

Coat the thrust washers with petroleum jelly.

Install the thrust washers onto both sides of the rea

planetary gear, facing the grooved side upward.

NOTE:

Make sure that the lugs fit into the cutout portions

on the rear planetary gear.

247RY00038

8. One-way clutch

Install the one-way clutch with the flanged side facing

upward onto the rear planetary gear.

247RY00039

9. Snap ring

Install snap ring.

247RY00040

10. One-way clutch inner race

While turning counterclockwise, install one-way clutch

inner race to rear planetary gear.

247RY00041

Check operation of one-way clutch

Hold the planetary gear and turn the one-way clutch

inner race.

The one-way clutch inner race should turn freel

counterclockwise and should lock clockwise.

: Lock

: Free

247RY00029

11. Rear planetary gear assembly

Install rear planetary gear onto rear planetary ring gear.

246RY00013

12. Disc, plate and flange (B-3)

Install a brake flange onto the rear planetary gea

assembly.

Install a clutch plate onto the rear planetary gea

assembly.

NOTE:

The claw interval of the plate should be as shown in

the figure when viewing the clutch plate from the

arrow direction.

247RY00047

Install seven clutch discs and seven brake plates (UBS)

or six clutch discs and six brake plates (TFR/S)

alternately, starting with clutch disc, onto the rea

planetary gear assembly.

247RY00028

13. Oil seal ring

Coat the oil seal ring with ATF and install it to the output

shaft.

NOTE:

Do not spread the ring ends too much.

247RY00042

14. Output shaft

Install output shaft into rear planetary gear assembly.

246RY00014

15. Second brake assembly

Install second brake assembly to output shaft.

FIRST AND REVERSE BRAKE (B-3)

DISASSEMBLY

246RY00024

Disassembly steps

1. Thrust bearing and race

2. Snap ring

3. Piston return spring

4. First and reverse brake piston No.2

5. O-ring

6. Reaction sleeve

7. O-ring

8. First and reverse brake piston No.1

9. O-ring

247RY00043

Disassembly steps

1. Thrust bearing and race

Remove assembled bearing and race from

transmission case.

246RY00016

Check first and reverse brake piston movement

Make sure that first and reverse brake piston moves

smoothly when applying and releasing the compressed

air into the transmission case.

247RY00002

2. Snap ring

Set special tool on the spring retainer, and compress

the return spring.

Spring compressor: 5-8840-0254-0 (J-25048)

Remove the snap ring with snap ring pliers.

3. Piston return spring

246RY00016

4. First and reverse brake piston No.2

Holding the first and reverse brake piston No.2 by hand,

apply compressed air to the transmission case to

remove the first and reverse brake piston No.2.

Remove the first and reverse brake piston No.2.

If the piston does not pop out with compressed air, lift

the piston out with needle-nose pliers.

5. O-ring

246RY00017

6. Reaction sleeve

Insert special tool behind the reaction sleeve and

gradually lift it out of the transmission case.

Reaction sleeve puller: 5-8840-2173-0 (J-37236)

7. O-ring

247RY00044

8. First and reverse brake piston No.1

Insert special tool behind the first and reverse brake

piston No.1 and gradually lift it out of the transmission

case.

Piston puller: 5-8840-2174-0 (J-37237)

9. O-ring

REASSEMBLY

246RY00025

Reassembly steps

1. O-ring

2. O-ring

3. First and reverse brake piston No.1

4. O-ring

5. Reaction sleeve

6. First and reverse brake piston No.2

7. Return spring

8. Snap ring

9. Thrust bearing and race

246RY00018

Reassembly steps

1. O-ring

Coat three new O-rings with ATF.

Install the two O-rings on the No.1 piston.

2. O-ring

Install the O-ring on the reaction sleeve.

3. First and reverse brake piston No.1

Install the first and reverse brake piston No.1 to the

reaction sleeve.

246RY00019

4. O-ring

Coat a new O-ring with ATF and install it on the first and

reverse brake piston No.2.

5. Reaction sleeve

Install the first and reverse brake piston No.1 with

reaction sleeve onto the first and reverse brake piston

No.2.

246RY00020

6. First and reverse brake piston No.2

Align the teeth of the first and reverse brake piston No.2

into the proper grooves.

Being careful not to damage the O-rings, press in the

first and reverse brake piston No.2 with No.1 into the

transmission case.

246RY00021

7. Return spring

Place piston return spring onto first and reverse brake

piston No.2.

247RY00002

8. Snap ring

Set special tool as shown, and compress the return

spring with special tool.

Spring compressor: 5-8840-0254-0 (J-25048)

Install the snap ring with snap ring pliers.

Be sure the end gap of the snap ring is not aligned with

the spring retainer claw.

246RY00022

Check first and reverse brake piston movement

Make sure the first and reverse brake piston moves

smoothly when applying and releasing the compressed

air into the transmission case.

9. Thrust bearing and race

Coat the assembled bearing and race with petroleum

jelly.

Install the assembled bearing and race facing the

bearing side upward.

Bearing and race diameter (Reference)

Inside diameter 39.2 mm (1.543 in)

Outside diameter 57.7 mm (2.272 in)

247RY00043

TRANSMISSION VALVE BODY

ASSEMBLY

DISASSEMBLY

240R200039

Disassembly steps

1. Detent spring

2. Manual shift valve

3. Upper valve body

4. No.1 gasket (Upper valve body side)

5. Valve body plate

6. Clamp

7. Pressure control solenoid

8. No.2 gasket (Lower valve body side)

9. Lower valve body

240R200040

Disassembly steps

1. Detent spring

Remove detent spring from valve body.

2. Manual shift valve

Remove manual shift valve.

244R200049

3. Upper valve body

4. No.1 gasket (Upper valve body side)

5. Valve body plate

Turn over assembly and remove thirty bolts.

6. Clamp

7. Pressure control solenoid

244R200061

Hold the valve body plate to the upper valve body.

Lift off upper valve body and plate as a single unit.

NOTE:

Be careful that the check balls and strainers do not

fall out.

8. No.2 gasket (Lower valve body side)

9. Lower valve body

REASSEMBLY

240R200041

Reassembly steps

1. No.1 gasket (Upper valve body side)

2. Valve body plate

3. No.2 gasket (Lower valve body side)

4. Upper valve body

5. Lower valve body

6. Pressure control solenoid

7. Clamp

8. Manual shift valve

9. Detent spring

244R200073

Reassembly steps

1. No.1 gasket (Upper valve body side)

Position a new No.1 gasket (1) on upper valve body.

Align the No.1 gasket at each bolt hole.

2. Valve body plate

Position valve body plate (2) on No.1 gasket (1).

Align the plate at each bolt hole.

3. No.2 gasket (Lower valve body side)

Position a new No.2 gasket (3) on valve body plate (2).

Align the No.2 gasket at each bolt hole.

244R200074

4. Upper valve body

5. Lower valve body

Place upper valve body with plate and gaskets on top

lower valve body.

Align each bolt hole and gasket in the valve body.

6. Pressure control solenoid

7. Clamp

Install thirty bolts to upper valve body.

Each bolt is indicated in the figure.

Length (mm) Quantity

A 20 7

B 28 12

C 40 11

Torque: 6.4 N m (0.65 kg m/57 Ib in)

244R200050

240R200040

8. Manual shift valve

Install manual shift valve.

9. Detent spring

Install detent spring.

Torque: 10 N m (1.0 kg m/87 Ib in)

LOWER VALVE BODY

DISASSEMBLY

244R200046

244R200075

Disassembly steps

1. By-pass valve

2. Spring

3. Strainer

4. Shift solenoid S1

5. Shift solenoid S2

6. Lock-up solenoid SL

7. Clamp

8. Accumulator sub-assembly

9. Retainer

10. Spring

11. Ball

12. Retainer

13. Plug

14. Spring

15. 1-2 shift valve

16. Retainer

17. Spring

18. Low coast modulator valve

19. Retainer

20. Plug

21. Spring

22. Accumulator control valve

23. Retainer

24. Spring

25. Coast modulator valve

26. Retainer

27. Plug

28. Spring

29. Cut back valve

30. Retainer

31. Sleeve

32. Plunger

33. Plunger

34. Spring

35. Washer

36. Primary regulator valve

37. Lower valve body

244R200063

Disassembly steps

1. By-pass valve

2. Spring

Remove by-pass valve and spring.

244R200064

3. Strainer

Remove three strainers.

244R200066

NOTE:

Confirm six retainers are installed correctly.

4. Shift solenoid S1

5. Shift solenoid S2

Remove the fixing bolt.

Remove the shift solenoid S1 (2) and S2 (1) from each

bore.

Remove the O-rings from each solenoid.

6. Lock-up solenoid SL

Remove the fixing bolt.

Remove the lock-up solenoid SL (3) from the bore.

Remove the O-ring from solenoid.

7. Clamp

8. Accumulator sub-assembly

Remove the clamp.

Remove the accumulator sub-assembly (4) from the

bore.

244R200052

9. Retainer

10. Spring

11. Ball

Remove the retainer (5).

Remove the spring and ball from the valve body.

240R200042

244R200067

12. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

13. Plug

14. Spring

15. 1-2 shift valve

Remove the plug, spring and 1-2 shift valve.

244R200054

244R200068

16. Retainer

Remove the retainer by pushing in the spring with a

screwdriver.

17. Spring

18. Low coast modulator valve

Remove the spring and low coast modulator valve.

244R200056

244R200069

19. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

20. Plug

21. Spring

22. Accumulator control valve

Remove the plug, spring and accumulator control valve.

244R200057

244R200070

23. Retainer

Remove the retainer by pushing in the spring with a

screwdriver.

24. Spring

25. Coast modulator valve

Remove the spring and coast modulator valve.

244R200058

244R200071

26. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

27. Plug

28. Spring

29. Cut back valve

Remove the plug, spring and cut back valve.

244R200065

244R200072

244R200059

30. Retainer

Place a mark on the bevel when the retainer is

positioned.

NOTE:

When reassembling, position the retainer in the

same position.

Remove the retainer with a magnetic finger by pushing

in the sleeve.

31. Sleeve

32. Plunger

33. Plunger

34. Spring

35. Washer

36. Primary regulator valve

Remove the sleeve with the plungers, spring and

washer.

Remove the two plungers from the sleeve.

244R200060

Remove the primary regulator valve from the valve

body.

37. Lower valve body

244R200051

INSPECTION AND REPAIR

Inspect strainer

Inspect strainer for residual adhesive and damage, and

clean and replace as necessary.

Inspect valve springs

Check for damage, squareness, rust and distorted coils.

Measure the spring free height and replace if less than

shown below.

Spring Free length

(1) By-pass valve 21.3 mm (0.839 in)

(2) Steel ball 20.5 mm (0.807 in)

(3) 1-2 shift valve 30.8 mm (1.213 in)

(4) Low coast modulator valve 30.4 mm (1.197 in)

(5) Accumulator control valve 33.8 mm (1.331 in)

(6) Coast modulator valve 26.6 mm (1.047 in)

(7) Cut back valve 34.0 mm (1.339 in)

(8) Primary regulator valve 41.6 mm (1.638 in)

244R200077

REASSEMBLY

244R200046

244R200076

Reassembly steps

1. Lower valve body

2. Washer

3. Primary regulator valve

4. Plunger

5. Plunger

6. Spring

7. Sleeve

8. Retainer

9. Cut back valve

10. Spring

11. Plug

12. Retainer

13. Coast modulator valve

14. Spring

15. Retainer

16. Accumulator control valve

17. Spring

18. Plug

19. Retainer

20. Low coast modulator valve

21. Spring

22. Retainer

23. 1-2 shift valve

24. Spring

25. Plug

26. Retainer

27. Ball

28. Spring

29. Retainer

30. Accumulator sub-assembly

31. Clamp

32. Lock-up solenoid SL

33. Shift solenoid S2

34. Shift solenoid S1

35. Strainer

36. Spring

37. By-pass valve

244R200060

Reassembly steps

1. Lower valve body

2. Washer

3. Primary regulator valve

Install the washer onto the primary regulator valve.

Install the primary regulator valve with the washer into

the bore.

4. Plunger

5. Plunger

Install the two plungers into the sleeve.

6. Spring

7. Sleeve

Install the sleeve with the two plungers and spring into

the bore.

244R200072

8. Retainer

Install the retainer to the bevel by pushing in the sleeve.

NOTE:

Install the retainer to the same position on the

sleeve, as when disassembling.

244R200059

244R200065

9. Cut back valve

10. Spring

11. Plug

Install the cut back valve, spring and plug into the bore.

12. Retainer

Install the retainer by pushing in the plug.

244R200071

244R200058

13. Coast modulator valve

14. Spring

15. Retainer

244R200070

244R200057

16. Accumulator control valve

17. Spring

18. Plug

Install the accumulator control valve, spring and plug

into the bore.

19. Retainer

Install the retainer by pushing in the plug.

244R200069

244R200056

20. Low coast modulator valve

21. Spring

Install the low coast modulator valve and spring into the

bore.

22. Retainer

Install the retainer by pushing in the spring.

244R200068

244R200054

23. 1-2 shift valve

24. Spring

25. Plug

Install the 1-2 shift valve, spring and plug into the bore.

26. Retainer

Install the retainer by pushing in the plug.

244R200067

244R200052

27. Ball

28. spring

29. Retainer

Install the ball, spring and retainer (5) to the valve body.

Torque: 10 N m (1.0 kg m/87 Ib in)

30. Accumulator sub-assembly

31. Clamp

Install the accumulator sub-assembly (4) and clamp to

the valve body.

Torque: 10 N m (1.0 kg m/87 Ib in)

32. Lock-up solenoid SL

Install a new O-ring to the solenoid (3).

Install the solenoid to the valve body.

Torque: 10 N m (1.0 kg m/87 Ib in)

33. Shift solenoid S2

34. Shift solenoid S1

Install a new O-ring to the solenoids (1) and (2).

Install the solenoids to the valve body.

Torque: 10 N m (1.0 kg m/87 Ib in)

240R200042

244R200066

NOTE:

Make sure six retainers are installed correctly.

244R200064

35. Strainer

Install the three strainers to the valve body as shown.

244R200063

36. Spring

37. By-pass valve

Install the spring and by-pass valve to the valve body as

shown.

UPPER VALVE BODY

DISASSEMBLY

243R200052

243R200074

Disassembly steps

1. Check ball

2. Retainer

3. Check valve NO.2

4. Ball

5. Check valve NO.1

6. Retainer

7. Check valve NO.2

8. Ball

9. Check valve NO.1

10. Retainer

11. Plug

12. Secondary regulator valve

13. Spring

14. Retainer

15. Plug

16. Spring

17. 2-3 shift valve

18. Retainer

19. Plug

20. Spring

21. Reverse control valve

22. Retainer

23. Plug

24. Second coast modulator valve

25. Spring

26. Retainer

27. Plug

28. 3-4 shift valve

29. Spring

30. Retainer

31. Sleeve

32. Plunger

33. Spring

34. Lock-up relay valve

35. Upper valve body

UBS

243R200053

Disassembly steps

1. Check ball

Remove the two types of check balls from the valve

body.

Number of check ball : UBS 11

TFR/S 10

TFR/S

243L200001

243R200054

NOTE:

Confirm eight retainers are installed correctly.

243R200066

2. Retainer

3. Check valve NO.2

4. Ball

5. Check valve NO.1

Remove the check valve NO.2 ball and check valve

NO.1 from the valve body.

243R200062

243R200067

6. Retainer

7. Check valve NO.2

8. Ball

9. Check valve NO.1

Remove the check valve NO.2, ball and check valve

NO.1 from the valve body.

243R200062

243R200070

10. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

11. Plug

12. Secondary regulator valve

13. Spring

Remove the plug, secondary regulator valve and spring.

243R200056

243R200069

14. Retainer

Remove the trainer with a magnetic finger by pushing in

the plug.

15. Plug

16. Spring

17. 2-3 shift valve

Remove the plug, spring and 2-3 shift valve.

243R200058

243R200068

18. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

19. Plug

20. Spring

21. Reverse control valve

Remove the plug, spring and reverse control valve.

243R200060

243R200073

22. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

23. Plug

24. Second coast modulator valve

25. Spring

Remove the plug, second coast modulator valve and

spring.

243R200063

243R200072

26. Retainer

Remove the retainer with a magnetic finger by pushing

in the plug.

27. Plug

28. 3-4 shift valve

29. Spring

Remove the plug, 3-4 shift valve and spring.

243R200064

243R200071

243R200065

30. Retainer

Remove the retainer with a magnetic finger by pushing

in the sleeve.

31. Sleeve

32. Plunger

33. Spring

34. Lock-up relay valve

Remove the sleeve with the plunger, spring and lock-up

relay valve.

Remove the lock-up relay valve, spring and plunge

from the sleeve.

35. Upper valve body

INSPECTION AND REPAIR

Inspect valve springs

Check for damage, squareness, rust and distorted coils.

Measure the spring free height and replace if less than

that down below.

Spring Free length

(1) secondary regulator valve 32.9 mm (1.295 in)

(2) 2-3 shift valve 30.8 mm (1.213 in)

(3) Reverse control valve 25.6 mm (1.008 in)

(4) Second coast modulator

valve 30.9 mm (1.217 in)

(5) 3-4 shift valve 30.8 mm (1.213 in)

(6) Lock-up relay valve 23.4 mm (0.912 in)

243R200076

REASSEMBLY

243R200052

243R200075

Reassembly steps

1. Upper valve body

2. Plunger

3. Spring

4. Lock-up relay valve

5. Sleeve

6. Retainer

7. Spring

8. 3-4 shift valve

9. Plug

10. Retainer

11. Spring

12. Second coast modulator valve

13. Plug

14. Retainer

15. Reverse control valve

16. Spring

17. Plug

18. Retainer

19. 2-3 shift valve

20. Spring

21. Plug

22. Retainer

23. Spring

24. Secondary regulator valve

25. Plug

26. Retainer

27. Check valve NO.1

28. Ball

29. Check valve NO.2

30. Retainer

31. Check valve NO.1

32. Ball

33. Check valve NO.2

34. Retainer

35. Check ball

243R200065

243R200071

Reassembly steps

1. Upper valve body

2. Plunger

3. Spring

4. Lock-up relay valve

5. Sleeve

Install the plunger and spring into the sleeve.

Install the lock-up relay valve into the sleeve.

Install the sleeve with the plunger, spring and lock-up

relay valve into the bore.

6. Retainer

Install the retainer.

243R200064

7. Spring

8. 3-4 shift valve

9. Plug

Install the spring, 3-4 shift valve and plug into the bore.

10. Retainer

Install the retainer by pushing in the plug.

243R200072

243R200063

11. Spring

12. Secondary regulator valve

13. Plug

Install the spring, second coast modulator valve and

plug into the bore.

14. Retainer

Install the retainer by pushing in the plug.

243R200073

243R200060

15. Reverse control valve

16. Spring

17. Plug

Install the reverse control valve, spring and plug into the

bore.

18. Retainer

Install the retainer by pushing in the plug.

243R200068

243R200058

19. 2-3 shift valve

20. Spring

21. Plug

Install the 2-3 valve, spring and plug into the bore.

22. Retainer

Install the retainer by pushing in the plug.

243R200069

243R200056

23. Spring

24. Secondary regulator valve

25. Plug

Install the spring, secondary regulator valve and plug

into the bore.

26. Retainer

Install the retainer by pushing in the plug.

243R200070

243R200062

27. Check valve NO.1

28. Ball

29. Check valve NO.2

Install the check valve NO.1, ball and check valve NO.2

to valve body.

30. Retainer

243R200067

243R200062

31. Check valve NO.1

32. Ball

33. Check valve NO.2

Install the check valve NO.1, ball and check valve NO.2

to the valve body.

34. Retainer

243R200066

243R200054

NOTE:

Make sure eight retainers are installed correctly

35. Check ball

Install the two types of check balls to the valve body.

Number of check ball : UBS – 11

TFR/S – 10

Check ball Diameter

(A) Rubber ball 5.535 mm (0.2179 in)

(B) Rubber ball 6.35 mm (0.2500 in)

UBS

243R200053

TFR/S

243L200001

TRANSMISSION CASE

DISASSEMBLY

249RY00001

Disassembly steps

1. Spacer

2. Pin

3. Manual valve lever shaft

4. Manual valve lever

5. Oil seal

6. Oil seal

249RY00002

Disassembly steps

1. Spacer

Using a chisel, cut off the spacer and remove it from the

shaft.

249RY00003

2. Pin

Using a punch, drive out the pin.

3. Manual valve lever shaft

4. Manual valve lever

Pull the manual valve lever shaft out through the case

by the threads.

249RY00004

5. Oil seal

6. Oil seal

Using a screwdriver, remove the oil seal.

REASSEMBLY

249RX00001

Reassembly steps

1. Oil seal

2. Oil seal

3. Spacer

4. Manual valve lever

5. Manual valve lever shaft

6. Pin

240RY00021

Reassembly steps

1. Oil seal

2. Oil seal

Coat a new oil seal lip with multi purpose grease.

Using special tool, drive in the oil seal.

Oil seal installer : 5-8840-2169-0 (J-37232-2)

249RY00005

3. Spacer

4. Manual valve lever

Assemble a new spacer to the manual valve lever.

5. Manual valve lever shaft

Install the manual valve lever shaft to the transmission

case through the manual valve lever by the threads.

249RY00006

6. Pin

Drive in the pin with the slot at a right angle to the shaft.

249RY00003

Match the spacer hole to the lever staking hollow and

stake the spacer to the lever.

Make sure the manual valve lever shaft turns smoothly.

241RY00018

TORQUE CONVERTER

INSPECTION AND REPAIR

Insert special tool in end of torque converter.

Insert a turning tool into the inner race of the one-wa

clutch.

One-way clutch testing tool : 5-8840-2168-0

(J-35467)

Insert the stopper so that it fits in the notch of the

converter hub and outer race of the one-way clutch.

One-way clutch test

The clutch should lock when turned counterclockwise,

and rotate freely and smoothly clockwise. Less than 25

kg cm (22 Ib in) of torque should be required to rotate

the clutch clockwise. If necessary, clean the converte

and retest the clutch. Replace the converter if the clutch

still fails the test.

ADAPTER HOUSING (44)

DISASSEMBLY

241R200005

Disassembly steps

1. Oil seal

2. Adapter housing

Disassembly steps

1. Oil seal

2. Adapter housing

Using a screwdriver, remove the oil seal.

REASSEMBLY

241R200006

Reassembly steps

1. Adapter housing

2. Oil seal

240RY00003

Reassembly steps

1. Adapter housing

2. Oil seal

Using oil seal installer, install the new oil seal to the

adapter housing.

Oil seal installer : 5-8840-2282-0

EXTENSION HOUSING (42)

DISASSEMBLY

241R200007

Disassembly steps

1. Gasket

2. Tube

3. Tube packing

4. Oil seal

5. Dust deflector

6. Extension housing

Disassembly steps

1. Gasket

2. Tube

3. Tube packing

4. Oil seal

Using a screwdriver, remove the oil seal.

NOTE:

The oil seal can be removed without removing the

dust deflector.

5. Dust deflector

6. Extension housing

REASSEMBLY

241R200008

Reassembly steps

1. Extension housing

2. Oil seal

3. Tube

4. Tube packing

5. Dust deflector

6. Gasket

249L100005

Reassembly steps

1. Extension housing

2. Oil seal

Using oil seal installer, install the new oil seal to the

extension housing.

Oil seal installer : 5-8840-2702-0

NOTE:

The oil seal can be installed without removing the

dust deflector.

3. Tube

4. Tube packing

5. Dust deflector

6. Gasket

MAIN DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

Remaks

Model AW30-40LE

Engine

’02 UBS 4JX1-TC

’02 TFR/S 4JH1-TC

Electronic control, planetary gear type

Type 3-element 1-stage 2-phase type

(with lock-up mechanism)

1st 2.804

2nd 1.532

3rd 1.000

4th (O/D) 0.705

Gear ratio

Reverse 2.394

Name

ATF DEXRON III

Oil used Q’ty (l) UBS and TFR/S 8.7

Torque converter

UBS 2450150

TFR/S ???? 150

Stall speed (rpm)

Forward clutch C-1 UBS 6, TFR/S 5

Direct clutch C-2 UBS 5, TFR/S 4

OD direct clutch C-0 2

Number of discs

Second coast brake B-1 40 mm Band width or

Number of discs

Second brake B-2 5

First and reverse brake B-3 UBS 7, TFR/S 6

Friction element

Overdrive brake B-0 4

Number of discs

One-way clutch No.1 F-1 22

One-way clutch No.2 F-2 28

Clutch

OD one-way clutch F-0 24

Number of sprage

Sun gear 42

Pinion gear 19

Front planetary

Ring gear 79

Sun gear 33

Pinion gear 23

Rear planetary

Ring gear 79

Sun gear 33

Pinion gear 23

Planetary gear

O/D planetary

Ring gear 79

Number of teeth

TORQUE SPECIFICATIONS

UBS N m (kg m/Ib ft)

E07R200015

TFR/S N m (kg m/Ib ft)

E07L200005

Nm (kg m/Ib ft)

E07R200016

Nm (kg m/Ib ft)

E07R200017

SPECIAL TOOLS

ILLUSTRATION PART NO. PART NAME

Tech 2 scan tool

5884000930

5-8840-0093-0 Oil pressure gauge

901RY00018

5-8840-2152-0

(J-37227) Holding fixture

901RT096

5-8840-0003-0

(J-2389-20) Holding fixture base

901RY00019

5-8840-2153-0

(J-37228) Oil pan seal cutter

901RY00028

5-8840-0195-0

(J-23327-1) Spring compressor

ILLUSTRATION PART NO. PART NAME

901RY00020

5-8840-2256-0

(J-9617) Oil seal installer; oil pump

901RY00021

5-8840-2170-0

(J-37233) OD brake piston spring compressor

901RY00022

5-8840-0254-0

(J-25048) Spring compressor (snap ring)

901RY00023

5-8840-2173-0

(J-37236) 1st/reverse brake puller

901RY00024

5-8840-2174-0

(J-37237) 1st/reverse brake puller

901RY00025

5-8840-2169-0

(J-37232-2) Manual valve shaft seal installer & remover

901RY00026

5-8840-2168-0

(J-35467)

One-way clutch testing tool;

torque converter

ILLUSTRATION PART NO. PART NAME

901RY00027

5-8840-2282-0 Oil seal installer;

adapter housing (4 4)

5884027020

5-8840-2702-0 Oil seal installer;

extension housing (4 2)