Transaxle/ Transmission GENERAL... AUTOMATIC TRANSAXLE SYSTEM .. MANUAL TRANSAXLE SYSTEM .... TRANSFER CASE ASSEMBLY .. NOTE : Overhaul procedures for automatic transaxle| is given in separate manual.TR -2 TRANSAXLE/TRANSMISSION GENERAL ewe SPECIFICATIONS(MIT) Model HTX Type 5 speeds forward, 1 reverse Gear ratio First 3.917 Second 1.950 Third 1.300 Fourth: 0.941 Fifth 0.750, Reverse 3.462 Final gear ratio 4.563 SERVICE STANDARD ewuana20 Standard value mm (in) (Tetightness, L=losseness) Differential side bearing end play Gear backlash in differential Input rear bearing snap ring end play Output rear bearing snap ring end play 0.10T-0.20T (0.0039T-0.0078T) 0.0251-0.150L (0.00095L-0.0057L) 0-0.1L (0-0.0039L) 0.03L-0.1L (0.00114L-0.0039L)GENERAL ae TIGHTENING TORQUE ™ ttem Nm Kg.em Ibst Release bearing sleeve bolt 68 60-80 46 Release cylinder assembly 15-22 150-220 11-46 Select lever 20-27 200-270 15-20 Oil drain plug 40-60 400-600 29-43 Interlock bolt 43-50 430-500 32-36 Clutch housing case 44-55 440-550 32-40 ‘Speedometer driven gear 46 40-60 a4 Reverse idler bolt 43-55 430-550 32-40 Rear cover 20-25 200-250 15-18 Shift control cable bracket 20.27 200-270 15-20 Transaxle case bolt 44-55 440-550 26-40 Shift lever mounting bolt 2027 200-270 15-20 Front roll stopper bracket to subframe bolts 40-50 400-500 29-36 Front roll stopper insulator bolt and nut 50-65 500-650 96-47 Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58 Rear roll stopper bracket to subframe bolts 40-55 400-550 29-40 Rear roll stopper insulator bolt and nut 50-65 500-650 36-47 Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58 Transaxle mounting sub bracket nut 60-80 600-800 43-58 Transaxle mounting bracket bolts 40-55 400-550 29-40 Transaxle mounting insulator bolt 90-110 900-1100 65-80 Front bearing retainer & detent body cover bolt 15:22 150-220 10-16 Detent spring lock nut 15-21 150-210 10-16 Output shaft lock nut 150-220 1800-2200 10-16 LUBRICATIONS emsnooeo tem Recommended lubricant Quantity Transaxle gear oil lt. (U.S. Imp.qts.) | Hypoid gear oil, SAE 75W/90, API-GL4 2.3 (2.4, 1.9) Transaxle input shaft spline CASMOLY L9508 As required Transaxle oil seal lip RETINAX AM, MOLYTEX GREASE EP-2 As required La ase ard cich housing | THREE BOND 1216 areata aaa ase and rear cover THREE BOND 1216 ‘As required Bearing retaining bolt (flush bolt only) _| THREE BOND1303 As requiredTR-4 ‘TRANSAXLE/TRANSMISSION SPECIAL TOOLS enn ‘Tool(Number and Name) Iustration Use (09431-39000 Oil seal installer Installation of differential oil seal (use with 09500— 11000) 09455-33200 Bearing installer Installation of output gear, bearing, sleeve (09433-21000 Removal of differential bearing Bearing plate 99455-88200, Removal of input shaft bearing jearing installer Removal of output shaft bearing 09457-22100 Bearing installer Installation of input shaft bearing (09432-21500 Oil seal installer Installation of input shaft oil seal (09532-11500 Outer race installer Installation of differential bearing race (use with (09500 11000) (09500-11000 Driver Installation of bearing outer raceGENERAL TR-5 ‘Tool(Number and Name) Ilustration Use (09495-33000 Bearing and gear puller Removal of ball bearing and gear (0900-21000 Installation of input shaft bearing Driver 1. Released 2. Gradually rises 2. Half depressed from (1) 3._Depressed 3._ 4,500-5,000 mv Brake pedal Stop lamp switch * Depressed + Released 3 _| larition switch ST | Starting test with lever P | Starting should be pos- | Starting possible or imposst Engine Stopped _| or N range sible ble Warming up Drive for 15 minutes or | Gradually rises to 70- | Oil temperature sensor ‘ more so thatthe auto- | 90°C matic fuid temperature becomes 70-00°C Engine ling NG switch 1. ON TTiple pressure switch Selector lever posi: |. ON 2. OFF tion N 2._OFF ‘Accelerator pedal 1. ON idle poston 1. Released 2._ OFF 2 Hat depressed —Son-000 mm 5 2. Gradually rises form (1) 1. Data changes ‘Communication with engine- Ecu Selector lever position 1.N=D 2 NR Should be no abnormal shift shock Time lag should be within 2 seconds Malfunction when starting Malfunction when startingAUTOMATIC TRANSAXLE SYSTEM RE TR -29 No Condition ‘Operation Judgement : Value Check item Selector lever posi- | Selector lever position | (2) 1st, (4) 3rd, (3) 2nd, | Shift condition tion D (Carry out on a | and vehicle speed () 4th ali t fat and straight road) | 1." lang in tst gear [Oy oon gay 100% @) | Low and reverse solonodd (ehicle stopped) | (07% (0) tor ; 2. Driving at constant » (6) wan) speed of 20 krvh | (2) 096, (4) 0%, (3) 0% | Underdrive solenoid valve 1st gear 3, Driving at constant | (1)100%, (20%, (8) | Second solenoid valve 6 speed of 30 kmh in | 10096 2nd gear (2) 100%, (3) 100%, | Overdrive solenoid valve 4. Driving at 50 kmh | (4)0%, in Grd gear with ac- celerator fully closed | (1) 0 kmvh Vehicle speed sensor 5. Driving at constant | (4) 50 km/h ee ot 50 km/h in | (4) 1,800-2,100 rpm _| Input shaft speed sensor (4) 1,800-2,100 rpm _| Output shaft speed sensor ‘Seletor lever position | 1. Accelerator to 4th | For (1),(2), and (3), the | Malfunction when shifting D gear at a throttle po- | reading should be the (Carry out on a flat sition sensor output | same as the specified and straight road) of 15V Output shaft torque, | Displaced shitt points (accelerator opening | and no abnormal angle of 30 %) shocks should occur, | Does not shift 2. Gently For (4),(5), and (6), | Does not shift from 1 to 2 or decelerate to a downshitting should oc- | 2 to 1 standstill cur immediately after 3. Accelerate to 4th | the shifting operation is | Does not shift from 2 to 3 or ‘gear at a throttle po- | made. 3102 eMonleenson cue Does not shift from 3 to 4 or of 25V 408 7 (accelerator opening angle of 50%). 4. While driving at 40 kmvh in 4th gear, shift down to Grd gear. 5. While driving at 30 kmh in 3rd gear, shift down to 2nd gear. 6. While driving at 20 krvh in 2nd gear, shift down to tst gear. Selector lever posi- | Move selector lever to R | The ratio between in- | Does not shift tion N range drive at constant | put and output speed 8 | (Carry out on a fiat | speed of 10 kmvh sensor data should be and straight road), the same as the gear ratio when reversing.TR -30 DIAGNOSTIC TROUBLE CODE TRANSAXLE/TRANSMISSION Probable cause ‘TPS output > 4.8 V with engine idling TPS output<0.2V with engine not idling TPS output < 0.2V or >1.2V with engine idling il temperature sensor output > 4.57 V for 1 second or longer (oil temperature does not increase) Output < 0.49V for 1 second No crank angle sensor output detected for § seconds at a vehicle speed of 25, knvh No input speed sensor output pulse detected for > 1 second at vehicle speed of > 30 km/h At vehicle speed of > 30 knvh, output speed sensor output < 50% of vehicle speed sensor output for > 1 second. At vehicle speed of 6 km/h, stop lamp switch is ON continuously for § minutes. With relay voltage>10V, open or short circuit is continuous for 5 minutes. After gear shift, output shaft speed sensor output x gear ratio of new gear= input shaft speed sensor output With ignition ON, battery voltage > 10V, and engine speed > 450 r/min, ‘communication is continuously irregular for 1 second or communication error signal is received for > 4 seconds continuously DCC solenoid valve drive duty ratio is, 100% for 4 seconds continuously DESCRIPTION DTC No Diagnosis item P1704 _| Throttle position sensor Short circuit P1703 Open circuit pi7oe ‘Sensor Faulty Fluid temperature sensor | Open circuit PO713 Po7t2 Short circuit ‘CKP sensor Open circuit P0725 Input speed sensor ‘Short circuivopen circuit PO71S ‘Output speed sensor ‘Short circuiopen circuit P0720 Po703 _| Stop lamp switch ‘Short circuitvopen circuit P0750__| LR solenoid valve ‘Short circuitfopen circuit P0755 _| UD solenoid valve ‘Short circuitfopen circuit P0760 _| 2nd solenoid valve ‘Short circuitfopen circuit P0765 _| UD solenoid valve ‘Short circuitfopen circuit P0743 _| TCC solenoid valve Short circuitvopen circuit P0731 _| Gear shift incomplete 1st P0732 2nd P0733 3rd P0734 4th P0736 Reverse Serial communication Short circuitvopen circuit P1749 po749 _ | TOC solenoid valve System defect/stuck on. P1723 | AT control relay Earth short circuitopen circuit After ignition ON, A/T control relay voltage <7VAUTOMATIC TRANSAXLE SYSTEM TR -31 DTC No Diagnosis item Probable cause P0707 _| Transaxle range switch Open circuit No signal for > 30 seconds parte Short circuit More than 2 kinds signals are continuous for 30 seconds Pie3o | CAN-BUS OFF TCU FaiVopenvshort —_| Receive BUS-OFF information from CAN CONTROLLER P1631 | CAN-TIME OUT ECU ECU FaiVopen/short__| No output signal for 1.5 second p17ea__| CAN CONTROLLER cuit matfunetion ‘Communication error output is CIRCUIT continuously for > 1 secondTR -32 TRANSAXLE/TRANSMISSION INSPECTION CHART FOR DIAGNOSIS CODES Code Diagnosis item P1704 P1703 P1702 Throttle position sensor systemif the TPS ‘output voltage is 4.8 V or higher when the ‘engine is idling, the output is judged to be too high and diagnosis code P1704 is the output. It the TPS output voltage is 0.2 V or lower at times other than when the engine is idling the ‘output is judged to be too low and diagnosis code P1703 is the output. If the TPS output voltage is 0.2 V or lower orif itis 1.2 V or higher when the engine is idling, the TPS adjustment is judged to be incorrect and diagnosis code P1702 is the output P0713 Po7t2 P0725 Fluid temperature sensor systemif the fluid temperature sensor output voltage is 4.57 V ‘or more even after driving for 10 minutes or more (ifthe fluid temperature does not in- crease), itis judged that there is an open circuit in the fluid temperature sensor and di- agnosis code P0713 is the output CKP sensor systemitf no output pulse is de- tected from the crank angle sensor for 5 seconds or more while driving at 25 km/h or more, it is judged that there is an open circuit in the crank angle sensor and diagnosis code P0725 is the output Probable cause Short circuit Malfunction of the throttle ; position sensor Open cxout Malfunction of connector Sensor Malfunction of the TCM Maladjustment ‘Open circuit Malfunction of the oil tempera- ture sensor Malfunction of connector Malfunction of the TCM ‘Open circuit Matfunction of the erank angle sensor ‘Malfunction of connector Malfunction of the TOM Po715 Input speed sensor systemif no output pulse is detected from the input shaft speed ‘sensor for 1 second or more while driving in 3rd or 4th gear at a speed of 30 kmh or more, there is judged to be an open circuit or short. Circuit in the input shaft speed sensor and diagnosis code P0715 is the output. If di- agnosis code P0715 is the output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure. Short circuitopen circuit Malfunction of the input shaft speed sensor Malfunction of the underdrive clutch retainer Matfunction of connector Maifunction of the TCM P0720 Output speed sensor systemif the output from the output shaft speed sensor is continu- ‘ously 50% lower than the vehicle speed for 1 second or more while driving in Srd or 4th ‘gear at a speed of 30 knv/h or more, there is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnosis code P0720 is output. If diagnosis code P0720 is output four times, the transmission is locked into Srd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.Malfunction of the input shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of connector Malfunction of the TCM Short circuitvopen circuit Malfunction of the wide open throttle switch Malfunction of connector Malfunction of the TCM Malfunction of solenoid valve Malfunction of connector Malfunction of the TCMAUTOMATIC TRANSAXLE SYSTEM TR -33 Code | Diagnosis itern Probable cause ‘Stop lamp switch systemif the stop lamp | Short circuitiopen | Malfunction of the stop lamp switch is on for § minutes or more while driv- | circuit switch P0703 _| ing, itis judged that there is a short circuit in Matfunction of connector the stop lamp switch and diagnosis code Matfunction of the TCM P0703 is the output. 0750 | Low and reverse solenoid vaive system | Short circuivOpen | Malfunction of solenoid valve circuit Malfunction of connector po7ss | Underdrive solenoid valve system Short cicuivOpen | Malfunction of the TCM circuit P0760 | Second solenoid valve system Short circuivOpen circuit P0765 | Overdrive solenoid valve systemif the re- | Short circuitOpen sistance value for a solenoid valve is tool | circuit large or too small it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into Srd gear as a fail-safe measure. P0743 | Torque converter clutch solenoid valve sys- | Short circul/Open | Malfunction of solenoid valve tem circuit Malfunction of connector P0740 _| I the resistance value for a solenoid valve is | Defective system _ | Malfunction of the TCM tool large or too small it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure. P0731 | 1st gear ratio does not meet the specificationif the output from | Malfunction of the input shaft the output shaft speed sensor multiplied by the 1st gear ratio is not | speed sensor the same as the output from the input shaft speed sensor after shift- | Malfunction of the output shaft ing to 1st gear has been completed, diagnosis code P0731 is the | speed sensor ‘output. If diagnosis code P0731 is output four times, the transmis- | Malfunction of the underdrive sion is locked into Srd gear as a fail-safe measure. clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the low ad re- verse brake system Malfunction of the underdrive clutch system Noise generated P0732 | 2nd gear ratio does not meet the specificationif the output from | Malfunction of the input shaft the output shaft speed sensor multiplied by the 3rd gear ratio is not | speed sensor the same as the output from the input shaft speed sensor afer shft- | Malfunction of the output shaft ing to 3rd gear has been completed, diagnosis code P0732 is the | speed sensor ‘output. If diagnosis code P0732 is the output four times, the trans- | Malfunction of the underdrive mmission is locked into 3rd gear as a fail-safe measure. clutch retainer Malfunction of the transfer drive gear or driven gear malfunction of the underdrive clutch system Matfunction of the overdrive clutch system Noise generatedTR -34 TRANSAXLE/TRANSMISSION Code Diagnosis item Probable cause P0733 3rd gear ratio does not meet the specificationit the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shit- ing to 3rd gear has been completed, diagnosis code P0733 is the output. If diagnosis code P0733 is the output four times, the trans- mission is locked into 3rd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer alfunction of the transfer drive gear or driven gear maifunction of the second brake system Malfunction of the overdrive clutch system Noise generated P0734 ‘4th gear ratio does not meet the specificationit the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from the input shaft speed sensor afer shift- ing to 4th gear has been completed, diagnosis code P0734 is the output. If diagnosis code P0734 is the output four times, the trans- mmission is locked into 3rd gear as a fail-safe measure, Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Matfunction of the transfer drive gear or driven gear Matfunction of the low and re- verse brake system Malfunction of the reverse clutch system Noise generated P0736 Reverse gear ratio does not meet the specificationif the output from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output from the input shaft speed sen- sor after shifting to reverse gear has been completed, diagnosis ‘code P0736 is the output. If diagnosis code P0736 is the output four times, the transmission is locked into 3rd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Matfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Maffunction of the transfer drive gear or driven gear Malfunction of the low and re- verse brake system Malfunction of the reverse brake system Malfunction of the reverse clutch system Noise generated P1749 Serial communicationif normal communication is not possible for a continuous period of 1 second or more when the ignition switch is at the ON position, the battery voltage is 10 V ore more and the engine speed is 450 r/min or more, diagnosis code No.51 is the out- put. Diagnosis code No.51 is also output if the data being received is abnormal for a continuous period of 4 seconds under the same conditions, Malfunction of connector Malfunction of the engine-ECU Malfunction of the TCM P1723 AIT control relay systemif the A/T control | Short circuit to relay voltage is less than 7 V after the ignition | earth/ Open circuit switch has been turned ON, itis judged that there is an open circuit or a short-circuit in the AT control relay earth and iagnosis code P1723 is the output. Then the transmission is locked into 3rd gear as a fail-safe measure. Malfunction of the A/T control relay ‘Malfunction of connector ‘Malfunction of the TCMAUTOMATIC TRANSAXLE SYSTEM TR -35 Code _| Diagnosis item Probable cause P0707 | Transaxle range switch Open circuit No signal is continuous for > 30 seconds P0708 Short circuit ‘Above 2 kinds signals are con- tinuous for 30 seconds P1630 | CAN-BUS OFF + TOM Fail * No 3 speed hold fail + TCM side open & short + No PGA, B fail * Batty voltage > 10V continuously for 0.5 second * No engine stop * Receive BUS OFF information from CAN CONTROLLER P1631 | CAN-TIME OUT ECM + ECM fail * No 3 speed hold fail * ECM side open & short + No PGA, B fail o Battry voltage > 10V continuously for 0.5 sec- ond + No engine stop + No output signal for 1.5 second P1764 | TCM CAN CAN CONTROLLER * CAN CONTROLLER circuit *+ No 3 speed hold fai ‘matfunction + No PGA, B fail * Battry voltage > 10V continuously for 0.5 second * No engine stop + Communication error output is continuously for > 1 secondTR -36 TRANSAXLE/TRANSMISSION INSPECTION CHART FOR THROUBLE EKAAOIOO SYMPTOMS Trouble symptom Probable cause ‘Communication with H/SCAN PRO is not possible ‘Malfunction diagnosis line lf communication with the HI-SCAN PRO is not possible, the Matfunction of connector cause is probably a defective diagnosis line or the ECM or TCM | Matfunction of the TCM or ECM is not functioning, Driving im- | Starting impossible Malfunction of the engine system possible Starting is not possible when the selector lever is. | Malfunction of the torque converter in P of N range. In such cases, the cause is prob- | Malfunction of the oil pump ably a defective range switch, engine system, | Malfunction of the rauge switch torque converter or oil pump. Does not move forward ‘Abnormal line pressure If the vehicle does not move forward when the se- | Malfunction of the underdrive solenoid valve lector lever is shifted from N to D while the engine | Malfunction of the underdrive clutch. is idling, the cause is probably abnormal line pres- | Malfunction of the valve body sure or a maifunction of the underdrive clutch or | Malfunction of the torque converter valve body. No transmission fluid Matfunction of the end clutch Does not reverse ‘Abnormal reverse clutch pressure If the vehicle does not reverse when the selector} Abnormal low and reverse brake pressure lever is shifted from N to R range while the engine | Malfunction of the low and reverse brake is idling, the cause is probably abnormal pressure | solenoid valve in the reverse clutch or low and reverse brake, or | Malfunction of the reverse clutch ‘a malfunction of the reverse clutch, low and re- | Malfunction of the low and reverse brake verse brake or valve body. Malfunction of the valve body Does not move (forward or reverse) Abnormal line pressure If the vehicle does not move forward or reverse _| Maifunction of power train when the selector lever is shifted to any position | Malfunction of the oil pump while the engine is idling, the cause is probably | Malfunction of the valve body abnormal line pressure or a malfunction of the ower train, oil pump or valve body. Matfunction | Engine stalling when shifting Malfunction of the engine system when starting | If the engine stalls when the selector lever is Malfunction of the damper clutch control shifted from N to D of R range while the engine is | solenoid valve idling, the cause is probably a malfunction of the | Malfunction of the valve body engine system, damper clutch solenoid valve, | Malfunction of the torque converter valve body or torque converter (damper clutch | Malfunction of the damper clutch malfunction). Shift shock when changing from N to D and | Abnormal underdrive clutch pressure large time lag ‘Abnormal low and reverse brake pressure If abnormal shocks or a time lag of 2 seconds or | Malfunction of the underdrive solenoid valve more occur when the selector lever is shifted from | Malfunction of the valve body Nto D range while the engine is idling, the cause | Malfunction of the idle position switch is probably abnormal underdrive clutch pressure ‘or a malfunction of the underdrive clutch, valve body or idle position switch.AUTOMATIC TRANSAXLE SYSTEM a TR -37 Trouble symptom Probable cause Malfunction | Shift shock when changing from N to Rand | Abnormal reverse clutch pressure when starting | large time lag. ‘Abnormal low and reverse brake pressure | abnormal shock or a time lag of 2 seconds or _| Malfunction of the low and reverse solenoid ore occur when the selector lever is shifted from | valve Nto R range while the engine is idling, the cause | Malfunction of the reverse clutch is probably abnormal reverse clutch pressure or | Malfunction of the low and reverse brake low and reverse brake pressure, or a malfunction | Malfunction of the valve body of the reverse clutch, low and reverse brake, valve | Malfunction of the idle position switch body or ile position switch. Shift shock when changing from N to D, N to R | Abnormal line pressure and large time lag. Malfunction of the oil pump If abnormal shock or a time lag of 2 seconds or _| Malfunction of the valve body ‘more occur when the selector lever is shifted from N to D range and from N to R range while the en- gine is idling, the cause is probably abnormal line Pressure or a malfunction of the oil pump or valve body. Malfunction | Shift shock and rpm increase. ‘Abnormal line pressure when shifting | If shocks occur when driving due to upshitting or | Malfunction of each solenoid valve downshifting and the transmission speed be- Malfunction of the oil pump ‘comes higher than the engine speed, the cause is | Malfunction of the valve body probably abnormal line pressure or a malfunction | Malfunction of each brake or each clutch of a solenoid valve, oll pump, valve body or of a brake or clutch. Displaced —_ All points. Malfunction of the output shaft speed sensor shifting points | If all shift points are displaced while driving, the _ | Malfunction of the throttle position sensor ‘cause is probably a malfunction of the output _| Malfunction of each solenoid valve shaft speed sensor, TPS or a solenoid valve. Abnormal line pressure Malfunction of the valve body Maitunction of the TCM ‘Some points. Malfunction of the valve body If'some of the shift points are displaced while driv- ing, the cause is probably a malfunction of the valve body, or itis related to adaptive control and is not an abnormality, Does not shift | No diagnosis codes. Malfunction of the transaxle range | shifting does not occur while driving and no di- | Malfunction of the TCM ‘agnosis codes are output, the cause is probably a rmaifunction of the transaxle range switch, or TCM Malfunction | Poor a acceleration. Malfunction of the engine system while driving | If acceleration is poor even if downshifting occurs | Malfunction of the brake of clutch while driving, the cause is probably a malfunction of the engine system, Transaxle in fail-safe a brake or clutch or the transaxle is in fail-safe. Malfunction | Vibration. ‘Abnormal damper clutch pressure while driving | If vibration occurs when driving at constant speed | Malfunction of the engine system ‘or when accelerating and deceleration in top range, the cause is probably abnormal damper clutch pressure or a malfunction of the engine system, damper clutch control solenoid valve, torque converter or valve body. Malfunction of the damper clutch control solenoid valve Malfunction of the torque converter Malfunetion of the valve bodyTR -38 TRANSAXLE/TRANSMISSION Trouble symptom Probable cause Transaxle range switch system. The cause is probably a matfunction of the inhibitor switch circuit, ignition switch circuit or a defective TCM. Malfunction of the transaxle range switch Malfunction of the ignition switch Matfunction of connector Malfunction of the TCM Idle position switch system. The cause is probably a defective idle position switch circuit, or a defective TCM Malfunction of the triple pressure switch Malfunction of connector Matfunction of the TCM Triple pressure switch system. The cause is probably a defective triple pressure switch circuit or a detective TCM. Malfunction of the triple pressure switch Matfunction of connector Matfunction of A/C system Matfunction of the TCM Vehicle speed sensor system. ‘The cause is probably a defective vehicle speed sensor circuit or a detective TCM, Malfunction of the vehicle speed sensor Malfunction of connector Malfunction of the cMAUTOMATIC TRANSAXLE SYSTEM a ELEMENT IN USE AT EACH POSITION OF EKAGo140 SELECTOR LEVER TR -39 Coerating clement _| Underdve | Reverse | Overdrive | LOAN | Second | One way Selector lever position | clutch (UD) | clutch (REV) | clutch (OD) rye brake (2nd) | clutch(Owe) Parking : : : ° : : Reverse : ° : ° 5 : Neutral : 3 : ° : : ist ° : : ° 5 ° > 2nd ° 5 : : ° : ard ° ° : : : ath : 5 ° : ° : ist ° 5 : ° : ° 3 2nd ° 5 : : ° : ard ° : ° : 5 : 1st ° : : ° 5 ° , 2nd ° : : : ° u 4st ° 5 : ° : ° OPERATING ELEMENT AND THEIR FUNCTIONS ‘Operating element Code Function Underdrive clutch UD___| Connects the input shaft to the underdrive sun gear Reverse clutch REV | Connects the input shaft and reverse sun gear Overdrive clutch (©D___| Connects the input shaft and overdrive planetary carrier Low-and-reverse brake LR | Locks lowand-reverse annulus gear and overdruve planetary cartier ‘Second brake 2ND___| Locks reverse sun gearTR -40 TRANSAXLE/TRANSMISSION INSPECTION PROCESS FOR DIAGNOSTIC xuaae7o TROUBLE CODES Code P1704, P1703, P1702 (throttle position sensor) _| Probable cause If the TPS output voltage is 4.8 V or higher when the engine is idling, the output is judged to be too high and diagnostic trouble code P1704 is output. If the TPS out- put voltage is 0.2 V or lower at times other than when the engine is idling, the output is judged to be too low and diagnostic trouble code P1703 is output. If the TPS. ‘output voltage is 0.2 V or lower or if itis 1.2 V or higher when the engine is idling, the TPS adjustment is judged to be incorrect and diagnostic trouble code P1702 is output. Malfunction of the throttle position sensor Malfunction of connector Malfunction of the TCM Throttle position check |S. eptace lo ' NG ‘Check the connector »NS__. Repair lox ¥ Harness check NG ‘Throttle position sensor-TCM — [-———> Repair loK 1 Check the trouble symptoms |8e__[ Repace Tom anorAUTOMATIC TRANSAXLE SYSTEM ‘TR -41 Code PO710,0il temperature sensor system Probable cause If the oil temperature sensor output voltage is 2.6 V or | Malfunction of the oil temperature sensor more even after driving for 10 minutes or more (If the oil | Malfunction of connector temperature does not increase), it is judged that there is | Malfunction of the TCM an open circuit in the oil temperature sensor and diagnostic trouble code P0710 is output. Ifthe oil tem- erature sensor output detects the voltage which. corresponds to 200°C(392"F) or more for more than one ‘second, it is judged that there is an open circuit in oil temperature sensor and diagnostic trouble code P0710 is output. ‘Oienpertre chow |. eriaco ox * NS. eps ‘Check connector ; C09 a ox t Tames check Ne ‘0 Oil position sensor - TCM [>> Repair ox 1 NG Ghoakite oie ampiom NS Repica na TO Code No. P0725 Crankshaft position sensor system Probable cause If no output pulse is detected from the crankshaft posi- | Malfunction of the crankshaft position sensor tion sensor for 5 seconds or more while driving at 25 Malfunction of connector krV/h (16 mph) or more, it is judged that there is an Malfunction of the TCM. open circuit in the crankshaft position sensor and diag- nostic trouble code P0725 is output. wa Ghockihe comecer ces NS natace ox t areas chook | No. repair Crake pest ansor-TOM lox { Canta postin sensor check ox | No | Check he Weblo ormpions NS + Repco ne TomTR -42 TRANSAXLE/TRANSMISSION Code P0715 input shaft speed sensor system (Pulse generator 'A’) Probable cause | no output pulse is detected from the input shaft speed sensor for 1 second or more while driving in Srd or 4th gear at a speed of 30 km/h (19 mph) or more, itis judged to be an open circuit or short-circuit in the input shaft speed sensor and diagnostic trouble code PO715 is output. If diagnostic trouble code P0715 is the output four times, the transaxle is locked into 3rd gear or 2nd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Malfunction of underdrive clutch retainer Malfunction of connector ‘Malfunction of the TCM (OK: Approx. 5V Continuity betwen 1 and ground ‘OK : Continuity sensor andTCM [x Check rouble symptoms ox p< Replace the TOM 1 NG Measure the output waveform from the iniput shaft « speed sensor. N 7 ‘0 Engine : 2,000 r/min [approx. 50 km/h (31 mph)} Fieplnoe Sie pat she speed senso) © Selector over poston =D I ox Check wouble symptoms x NG Check rouble symptoms ¥ ‘AT overhaul” Na ‘0 Replace the transfer drive gear and driven gear plac the TOM 1 Chock rouble symptoms ne , Measure at the np shalt sensor connector O42 No ODiconnedt ihe connector andchock atthe Ramess | —=-e[ _Gheckthecomnector 633 | NS» repair oe = Votago between 3 and ground tion etch :ON) | Ox Betoryvtage ——__1 \otage bamaen 2 and ground (itlon switch :ON) heck te fling hamase re ‘© Between input shaft speed [> Repair sensor and ignition switch ‘0 Betwoen input shaft speed Eliminate the cause of the noiseAUTOMATIC TRANSAXLE SYSTEM TR -43 Code P0720 Output shaft sensor system (Pulse genera- tor’B’) Probable cause If the output from the output shaft speed sensor is con- tinuously 50% lower than the vehicle speed for 1 second of more, itis judged to be an open circuit or short circuit in the output shaft speed sensor and diagnostic trouble code P0720 is output. Malfunction of the throttle position sensor Matfunction of connector Malfunction of the TCM Measure at the output shaft sensor connector C43 © Disconnect the connector and check at the harness side, Voltage between 3 and ground (Ignition switch : ON) OK : Battery voltage Voltage between 2 and ground (Ignition switch : ON) OK : Approx. 5V Continuity betwen 1 and ground ‘OK : Continuity oK Measure the output waveform from the output shaft speed sensor. © Engine : 2,000 min [approx. 60 knvh (30 mph] 0 Selector lever position: D OK ¥ Check trouble symptoms |r Replace the TCM Noe Repair Check the connector C33, Harness check ‘© Betwoen output shaft speed ‘sensor and ignition switch ‘© Between output shatt speed sensor and TCM NC Repair loK —L Check trouble symptoms lok ¥ Replace the TCM ING ¥ Replace the output shaft speed sensor ‘Check trouble symptoms i ‘© Replace the transfer drive gear and ‘AT overhaul driven gear | ‘Check trouble symptoms ps Eliminate the cause of the noiseTR -44 TRANSAXLE/TRANSMISSION Code P0703 Stop light switch system Probable cause Hf the stop light switch is on for § minutes or more while | Malfunction of the stop light switch driving, itis judged that there is a short circuit in the stop | Malfunction of connector light switch and diagnostic trouble code P0703 is output. | Malfunction of the TOM ‘Stoplight switch check |S replace }OK e NS. repair Check the connector ver ox ! Tamoss chook Ne ‘0 Between stoplight switch andTcM = |-———> Repair lox Ghecktve voto ommpione NS] Fopace na Tom woreAUTOMATIC TRANSAXLE SYSTEM TR -~45 ee Code P0750 Low and reverse solenoid valve system Code P0755 Underdrive solenoid valve system Code P0760 Second solenoid valve system Code P0765 Overdrive solenoid valve system Probable cause Hf the resistance value for a solenoid valve is too large or too small, it is judged that there is a shortcircuit or an ‘open circuit in the solenoid valve and the respective di- agnostic trouble code is output. The transaxle is locked into Srd gear as a fail-safe measure. Malfunction of the solenoid valve Malfunction of connector Malfunction of the TCM Harness check ‘Solencid valve check } YS replace lox ~ SS Repair (Check the connector C09 a lox ’ NG ‘© Between solenoid valve and Tom — [-———* Repair ok + Replace the solenoid valve lok , ‘Check the trouble eymptoms | SSF Reptace the TOMTR ~46 TRANSAXLE/TRANSMISSION Code P0743, P0740 Torque converter clutch solenoid systern Probable cause Ifthe resistance value for the torque converter clutch solenoid is too large or too small, it is judged that there is a short-circuit or an open circuit in the torque con- verter clutch solenoid and diagnostic trouble code P0743 is output. If the drive duty rate for the torque converter clutch solenoid is 100% for a continuous pe- riod of 4 seconds or more, itis judged that there is an abnormality in the torque converter clutch system and tic trouble code P0743 is output, the transaxle is locked into 3rd gear as a fail-safe measure. If the lock-up clutch remains engaged for a continuous period of 10 seconds when the TCM is attempting to P0740 is output. diagnostic trouble code P0740 is output. When diagnos- disengage the lock-up clutch, it is judged that the torque converter clutch is stuck on and diagnostic trouble code Malfunction of the torque converter clutch solenoid Malfunction of connector ‘Malfunction of the TCM “Torque converter clutch solenoid check [> ‘Check the connector ; C09 lok ¥ Harness check ‘© Between torque converter clutch solenoid oK ¥ Replace the torque converter clutch solenold lox NG [> Replace SS. Repair LNS_, Repair ‘Check the trouble symptoms NG. Replace the TCM {| ‘Only when code No.P0740 is the output, check INSPECTION PROCEDURE 6 Engine staling when shiftingAUTOMATIC TRANSAXLE SYSTEM TR -47 ]————— quem Code P0731 1st gear incorrect ratio Probable cause If the output from the output shaft speed sensor mutti- plied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd ‘gear has been completed, and diagnostic trouble code P0782 is output four times, the transaxle is locked into Srd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the low and reverse brake system Malfunction of the underdrive clutch system Noise generated id ‘Measure the output waveform from the input shaft speed sensor. (Using an oscilloscope) (9 Engine = 2,000 rimin [approx. S0kmvh (31 mph) © Selector lever position :D ‘SCANTOOL DTC Yes i Is the diagnostic trouble code P0715 output? [> LCode P0715 input shatt speed sensor system check Po ‘SCANTOOL DTC yes Is the dlagncatic trouble code PO720 output? [YES [Code P0720 culput shaft speed sensor system check [Nef Replace the input shaft speed sensor lok “Measure the output waveform from the output shaft speed sensor. (Using an oscilloscope) © Engine : 2,000 r/min (approx. 50 kr (30 mph] © Selector lever postion :D NG r— Replace the| =e shaft speed sensor ‘Check the trouble symptoms NG ‘ATT overhaul (© Replace the underdrive clutch retainer | (Check the trouble symptoms ee Eliminate the cause of the noise Check the trouble symptoms po ‘AIT overhaul ‘© Replace the underdrive clutch ‘0 Replace the low and reverse clutch ‘ATT overhaul (© Replace the transfer drive gear and driven gear ————_— ‘Check the trouble symptoms Eliminate the cause of the noiseTR -48 TRANSAXLE/TRANSMISSION (Code P0732 2nd gear incorrect ratio Probable cause If the output from the output shaft speed sensor multi- plied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd gear has been completed, diagnostic trouble code 0732 is output. If diagnostic trouble code P0732 is out- pput four times, the transaxle is locked into 3rd gear as a fail-safe measure. Matfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the second brake system Malfunction of the underdrive clutch system Noise generated Is the diagnostic trouble code P0720 output? ee ‘Measure the output wavetorm from the input shaft speed sensor. (Using an oscilloscope) (© Engine = 2,000 r/min [approx. Sokmv/h (31 mph)] (© Selector lever position : D ‘SCAN TOOL DTC. Yes Is the diagnostic trouble code P0716 output? fr feo ‘SCANTOOL DTC. LSS Code P0720 output shaft speed sensor system check |SS_{ Replace the input shalt speed sensor (Code P0715 input shaft speed sensor system check lok ‘Measure the output waveform from the output shaft ‘speed sensor. (Using an oscilloscope) © Engine: 2,000 rimin [approx. 50 krvh (31 mph) 0 Selector lever position: OK : A waveform (Inspection Procedure Using an ‘Check the trouble symptoms ig ‘AIT overhaul™ (© Replace the underdrive clutch retainer ee ‘Check the trouble symptoms NG Eliminate the cause of the noise © Replace the second clutch. Oseiloscope) is output (lasing between | NG (0 €> 6V) and here ino noise appearing in. | >| place the ouput shat speed sensor the wavetorn, peo Check the trouble symptoms TAT overhaul T (© Replace the underdive clutch. aaa © Replace the transfer drive gear and driven gear (Ghack the trouble symptoms Eliminate the cause of the noiseAUTOMATIC TRANSAXLE SYSTEM TR ~49 Code P0733 3rd gear incorrect ratio Probable cause If the output from the output shaft speed sensor multi- plied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 3rd ‘gear has been completed, diagnostic trouble code P0733 is output. If diagnostic trouble code P0733 is out- put four times, the transaxle is locked into 3rd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the overdrive clutch syste Malfunction of the underdrive clutch system Noise generated © Engine : 2,000 r/min [approx. Sokm/h (31 mph) © Selector lever position: D (OK: A waveform (Inspection Procedure Using an Osciloscope) is output ashing between 0 <> 5V) and there is no noise appearing in the wavetorm. loK ‘Measure the output waveform from the output shaft ‘speed sensor. (Using an oscilloscope) (© Engine : 2,000 r/min [approx. 50 knvh (31 mph)] (© Selector lever position : D OK: A waveform (inspection Procedure Using an PES sf Code P0720 output shaft speed sensor system check ‘SCANTOOL DTC Yes Is the diagnostic trouble code P0715 output? fr Fo ‘SCANTOOL DTC. Is the diagnostic trouble code P0720 output?” ig ‘Measure the output waveform from the input shaft speed sensor. (Using an oscilloscope) NG Oscilloscope) is output (lashing between Na 0€> 5V_) and there is no noise appearing in | "I eeplace the output shaft speed sensor the waveform ‘Code PO715 input shaft speed sensor system _ check Replace the input shaft speed sensor Check the trouble symptoms NG ‘ATT overhaul ® (© Replace the underdrive clutch retainer ‘Check the trouble symptoms NG Eliminate the cause of the noise 1 yo ‘ATT overhaul (© Replace the underdrive clutch. © Replace the overdrive clutch, Check the rouble symptoms ] WT overhaul” ‘0 Replace the transfer drive gear and driven gear ——_____ (Check the trouble symptoms 1 Eliminate the cause of the noiseTR -50 TRANSAXLE/TRANSMISSION (Code P0734 4th gear incorrect ratio Probable cause If the output from the output shaft speed sensor multi plied by the 4th gear ratio is not the same as the output, from the input shaft speed sensor after shifting to 4th {gear has been completed, diagnostic trouble code P0734 is output. If diagnostic trouble code P0734 is out- put four times, the transaxle is locked into Srd gear as a fail-safe measure. Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear ‘Malfunction of the second brake system Matfun« Noise generated of the overdrive clutch system ‘SCAN TOOL DTC. Yes Is the diagnostic trouble code P0715 output? ‘Code PO715 input shaft speed sensor system check _ fe ‘'SCANTOOL DTC Is the diagnostic trouble code P0720 output? Po ‘Measure the output waveform from the input shaft speed sensor. (Using an osciloscope) © Engine : 2,000 rin fapprox. km/h (31 mph)] © Selector lever position :D OK : A waveform (Inspection Procedure Using an Oscilloscope) is the output (flashing between 0 > 5V) and there is no noise appearing in PES of Code P0720 output shaft speed sensor system check Replace the input shaft speed sensor Check the trouble symptoms NG the waveform. lok ‘AIT overhaul * (© Replace the underdrive clutch retainer ‘Measure the output waveform from the output shaft speed sensor. (Using an oscilloscope) ‘© Engine :2,000 rimin (approx. 50 knvh (31 mph)] © Selector lever position : D NG 1 (Check the rouble symptoms ING Eliminate the cause of the noise Replace the output shaft speed sensor 1 ‘Check the trouble symptoms: po ‘ATT overhaul (0 Replace the overdrive clutch, ‘Replace the second clutch. ‘ATT overhaul ™ (© Replace the transfer drive gear and driven gear (Check the trouble symptoms Eliminate the cause of the noiseAUTOMATIC TRANSAXLE SYSTEM TR -51 a Code P0736 reverse gear incorrect ratio Probable cause If the output from the output shaft speed sensor multi- plied by the reverse gear ratio is not the same as the ‘output from the input shaft speed sensor after shifting to reverse gear has been completed, diagnostic trouble ‘code P0736 is output. If diagnostic trouble code P0736 is output four times, the transaxle is locked into 3rd gear as a fail-safe measure Malfunction of the input shaft speed sensor Malfunction of the output shaft speed sensor Malfunction of the underdrive clutch retainer Malfunction of the transfer drive gear or driven gear Malfunction of the low and reverse brake system Malfunction of the reverse clutch systme Noise generated 0€ 5 and theres no noise appearing in SeaNTOOL OTe ves a Ca POS ap cat peo aa en Sak To ca ves SEANTOOL Oe coun P0r20 npr S| Sado POE op a ped sonar ONE] Ri Tease he cpa waa Fone Hp dal Stood conor {Gong ances ra 0 Engine : 2,000 r/min (approx. 50km/h (31 mph)} Replace the input shaft speed sensor ‘0 Selector lever position : D x Avwavtr napecton Procedure Using an Oscilloscope) is output (lashing between Check the trouble symptoms: 0 €> SV) and there is no noise appearing in ye tho weet a ¢ lcs he undo heh etna ox : Graco ompions xs Speed conor (Ucng an osaoscne) ne minal the cause ofthe roee np 200 tn aopon 20 enh (3 mp 8 Soot ver ont D Ox "A wav rapecton Procedure Using an Oscilloscope) is output (flashing between NG Replace the output shaft speed sensor ‘0 Replace the low and reverse brake, ‘© Replace the reverse clutch, the waveform. 1 ro ‘Check the trouble symptoms. ‘AT overhaul * t "ATT overhaul = © Replace the transfer drive gear and driven gear (Check the trouble symptoms Eliminate the cause of the noiseTR -52 TRANSAXLE/TRANSMISSION Code P1723 A/T Control relay system Probable cause Ifthe relay voltage is less than 7 V after the ignition | Malfunction of the A/T control relay switch has been turned to ON, it is judged that there is Malfunction of connector an oped circuit or a short-circuit in the AT control relay | Malfunction of the TCM earth and diagnostic trouble code P1723 is output. The transaxle is locked into Srd gear as a fail-safe measure. Check the A/T control relay | YS + piace lok t NG NS. Replace Check the connectors ; C36 loK ¥ Harness check NG © Between control relay and body ground | ———* Replace (© Between control relay and battery © Between control relay and TCM 0K ¥ (Check the trouble symptoms || Replace the TOMAUTOMATIC TRANSAXLE SYSTEM TR -53 a. INSPECTION PROCESS FOR TROUBLE SYMPTOMS exnc20 INSPECTION PROCEDURE 1 No communication with the scan tool Probable cause f communication with the scan tool is not possible, the | Malfunction of diagnostic trouble line cause is probably a defective diagnostic trouble line or | Malfunction of connector the TOM is not functioning. Malfunction of the TCM is commulcation wih other eystome ma {Check the dlagnostic trouble ino wth possibio using he scan toot | Sot ene opal ocosony ves ' he I Check the conruity and votage N° +1 cheac tne comecorss ca ES Repair of the TCM connector OK NG t Hamess check LS + Repair NSS pepsi o Between th power supply andthe TOM Check the connectors pel 0 Between the ground and the TCM. ox lox ' Harness check No 7 "lames chec Fi = |o Between data link trouble connector] Repai ice the ou Svat enaToM 7 t 7 Replace tho TOM i NG. Check the rouble symptoms -——NS__t Foplace the TOMTR -54 TRANSAXLE/TRANSMISSION _S.. INSPECTION PROCEDURE 2 Starting impossible Probable cause N range. In such cases, the cause is probably a defec- tive engine, torque converter or oil pump. ‘Starting is not possible when the selector lever is in P or ‘Malfunction of the engine Malfunction of the torque converter Malfunction of the oil pump |s communication with other systems Possible using the scan tool [> Repair, Replace ‘Torque converter check (© Check for incorrect installation (Inserted at an angle, etc.) and for ‘damaged splines. __ | Replace the oll pump assembly. * (the oil pump cannot be disassembled) INSPECTION PROCEDURE 3 Repair if possible. the splines are damaged and repairs are not possible, replace the torque converter asembly. Vehicle cannot move Probable cause If the vehicle does cannot move forward when the selec- tor lever is shifted from N to D or L range while the ‘engine is idling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body. ‘Abnormal line pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body ‘SCAN TOOL Actuator Test No Underdrive solenoid valve {+——> Replace the solenoid valve * OK : Sound of operation can be heard. Pe Fiydraulc pressure test NG Valve body disassembly, cleaning and ‘© Measure the hydraulic pressure for each |___] reassembly * element © Pay particular attention to loosening of botts, and valve bodies. ie [>| cif the damage cannot be repaired, replace on the valve body assembly. Underdrive clutch system check” (© Remove the transaxle assembly © Piston should operate and pressure NG ‘Underdrive Gutch check = ‘should be maintained when airis blown |»! 9 Check for burning ofthe facing, defective through the underdrive clutch oil hole in piston seal rings, and interference at the the transaxle case, retainer.AUTOMATIC TRANSAXLE SYSTEM TR -55 INSPECTION PROCEDURE 4 Vehicle does not reverse Probable cause I the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low reverse brake or a malfunction of the re- verse clutch, low reverse brake or valve body. ‘Abnormal reverse clutch pressure ‘Abnormal low reverse brake pressure Malfunction of the low reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low reverse brake Malfunction of the valve body SCANTOOL Actuator Test ee © No.1 Low reverse solenoid valve OK : Sound of operation can be heard loK pee ‘SCAN TOOL Actuator Test ae ‘© Measure the hydraulic pressure for each ‘element when in L range Replace the low reverse solenoid valve through the reverse clutch oil hole and the low reverse brake oil hole in the transaxle case. lox. Y “Hydraulic pressure check NG ‘Valve body disassembly, cleaning and ‘© Measure the reverse clutch pressure in R | >| reassembly. range. © Pay particular attention to loosening of bots, and to damage and slippage of O-rings joK [| valves and valve bodies. 1 oe o Ifthe damage cannot be repeited, replace averse cic system and low reverse the valve body assembly. brake system chock" a ‘Remove the transaxle assembly, vave | N° ___.-Raverae chtch and low reverse brake check body cover and valve body © Check or burning ofthe facing, defective © Pistons should operate and pressure piston seal ings and interference athe should be maintained when aii blown retainerTR -56 TRANSAXLE/TRANSMISSION oe INSPECTION PROCEDURE 5 Vehicle does not move (forward or reverse) Probable cause If the vehicle does not move forward or reverse when. the selector lever is shifted to any position while the en- gine is idling, the cause is probably abnormal line Pressure, or a malfunction of the power train, oil pump or valve body. ‘Abonormal line pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Malfunction of the power train Tiyaraule pressure chock oK ‘© Measure the hydraulic pressure for each ‘element when moving forward and back. ING Replace the transaxle * INSPECTION PROCEDURE 6 | —*__,. [ Check power train Of OK, replace transaxle Engine stalls when shifting Probable cause If the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine, torque converter clutch soledoid, valve body or torque con- verter (torque converter clutch malfunction). Matfunction of the engine Malfunction of the torque converter clutch solenoid ‘Malfunction of the valve body ‘Malfunction of the torque converter (Malfunction of the torque converter clutch) [Engine system check N@ land main system. oK Y Replace the torque converter clutch solenoid NG Replace the torque convert Jo Check the control systemignition, fuel ten —— Repair, Replace erasAUTOMATIC TRANSAXLE SYSTEM TR -57 INSPECTION PROCEDURE 7 ‘Shock or delay when changing from N to D Probable cause Hf abnormal shocks or a time lag of 2 second or more ‘occurs when the selector lever is shifted from N to D range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve body or closed throttle posi- tion switch, ‘Abnormal line pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Malfunction of the closed throttle position switch ISCAN TOOL Actuator Test NG Jo Underdrive solenoid valve [OK : Sound of operation can be heard. lox Y Replace the underdrive solenoid valve * When does the shock occur? Replace the underdrive solenoid valve * When siting Ne Is t Tiydrauiic pressure test Na [SCAN TOOL Data list 0 Measure the undoraive clic pressure fox: Tums tom Onto Off when the accelerator when shifting from N to D. pedal is slightly depressed from the Glosed postion |_—ror 2] piace he ransaxe, EmmonsTR -58 ‘TRANSAXLE/TRANSMISSION ee INSPECTION PROCEDURE 8 ‘Shock or delay when changing from N to R Probable cause If abnormal shock or a time lag of 2 seconds or more ‘occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction or the reverse clutch, low and reverse brake, valve body. ‘Abnormal reverse clutch pressure ‘Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body [SCAN TOOL Data list NG }o Low and reverse solenoid valve |OK : Sound of operation can be heard. J |_ “© | Replace the low and reverse solenoid valve * ‘When does the shock oocur? When starting }-——+ Schock sometimes occur Jin shiting Ne [= Fiydraulie pressure fost we ‘0 Measure the reverse clutch pressure in R range. |_—ToK [SCAN TOOL Data lst /OK : Turns from on to off when the accelerator pedal is slightly depressed from the Closed positon, BaoAUTOMATIC TRANSAXLE SYSTEM TR -59 ——— INSPECTION PROCEDURE 9 ‘Shock or delay when changing from N to D,NtoR __| Probable cause lf abnormal shock or a time lag of 2 seconds or more | Abnormal line pressure ‘occurs when the selector lever is shifted from N to D, N | Malfunction of the oil pump to R range while the engine is idling, the cause is proba- | Malfunction of the valve body bly abnormal line pressure or a malfunction of the oil ump or valve body. Hydraulic pressure test NG ‘0 Measure the hydraulic pressure for each || Replace the transaxle element when in range D and range A. [o« When starting ‘When does the shack occur? | [ Replace the transaxle | When shifting Replace the oll pump assembly * (The oil pump cannot be disassembled) INSPECTION PROCEDURE 10 ‘Shocks and transaxle flare Probable cause If shocks occur when driving due to upshiting or down- shiting and the transaxle speed becomes higher than the engine speed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch. ‘Abnormal line pressure Malfunction of each solenoid valve Malfunction of the oil pump ‘Malfunction of the valve body Malfunction of each brake or each clutch ‘SCAN TOOL Actuator Test LS Low and reverse solenoid valve Underdrive solenoid valve ‘Second solenoid valve Overdrive solenoid valve ‘Ok : Sound of operation can be heard. \* No Replace the transaxle ‘Abjust the line pressure, I" [otuich and brake check Jo Check for burning ofthe facing, defective seal rings, and interference on the retainer, Replace the oll pump assembly * (The oil pump cannot be disassembled.) Replace the transaxleTR -60 INSPECTION PROCEDURE 11 TRANSAXLE/TRANSMISSION Changed shift points Probable cause TPS or If all shift points are changed while driving, the cause is probably a malfunction of the output shaft speed sensor, ‘a solenoid valve. Malfunction of the output shaft speed sensor Malfunction of the throttle position sensor Malfunction of each solenoid valve ‘Abnormal line pressure Malfunction of the valve body Malfunction of the TCM ‘SCAN TOOL Data list NG (© Output shatt speed sensor [>| Output shatt speed sensor system OK : Increases in proportion to vehicle speed lox Y ‘SCAN TOOL Data list Ne ay - |__——__+ “TPs system check OK : Increases in proportion to accelerator Pedal opening angle OK —__1__ na ‘SCAN TOOL Data lst +[_ Replace the solenoid vave = © Low and reverse solenoid valve duty % (© Underdrive solenoid valve duty % loK © Second solenoid valve duty % 10 Overdrive solenoid valve duty % OK : Refer to the table below fieriece MecM) lok 1 NG ‘Adjust the line pressure [> Replace the transaxleAUTOMATIC TRANSAXLE SYSTEM TR -61 ———_—Y—X——— INSPECTION PROCEDURE 12 Displaced shift points Probable cause If some of the shift points are changed while driving, the cause is probably a malfunction of the valve body, or it is related to adaptive logic control and is not an abnor- ality. Malfunction of the valve body No Do standard shifting occur normally ? temperature is Yes ‘C No Does the problem occur only when} NO, r= a the automatic transaxle fluid = ° 125°C or higher? = 29°C or lower or - control and isn Its related to adaptive logic tan abnormality, INSPECTION PROCEDURE 13 No diagnostic trouble codes (Does not shift) Probable cause If shifting does not occur while driving and no diagnostic trouble codes are given, the cause is probably a mal- function of the Park/Neutral switch, or the TCM. Malfunction of the Park/Neutral switch Malfunction of the TCM Does the transaxle remain in 3rd gear with selector lever in position D? No [= |s backup power being supplied to thoToM? [= No Yes Ts power being supplied to the TOM?) Power supply circuit check © Pay particular attention to an open circuit in the hamesses or poor connector olf there is a blown fuse, investigate why a short circuit has occurred and "TCM input signal and selector lever position should match then replace the fuse.TR -62 INSPECTION PROCEDURE 14 TRANSAXLE/TRANSMISSION Poor acceleration Probable cause fail-safe. If acceleration is poor even if downshifting occurs while | Malfunction of the engine system driving, the cause is probably a maifunction of the en- | Malfunction of the brake or clutch gine system, a brake or clutch, or the transaxle is in _| Transaxle in fail-safe PRESENT Check for DTCs —_ + [oroet conation NONE Engine system check © Check the control system, ignition system, fuel system, and main system NG [}-———— Replace, repair 0K Brake or clutch check ‘© Check for burning ofthe facing, defective piston ‘seal rings, and interference at the retainer.AUTOMATIC TRANSAXLE SYSTEM TR 63 INSPECTION PROCEDURE 15 Vibration Probable cause If vibration occurs when driving at constant speed or when accelerating in top range, the cause is probably abnormal torque converter clutch pressure or a malfunc- tion of the engine, torque converter clutch solenoid, torque converter or valve body. ‘Abnormal torque converter clutch pressure Malfunction of the engine Malfunction of the torque converter clutch solenoid Matfunction of the torque converter Malfunction of the valve body ‘SCAN TOOL Actuator Test (Torque converter clutch solenoid OK : Sound of operation can be heard |e NG Replace the torque converter clutch solenoid valve] [Does the problem occur even when the oil Yes temperature sensor connectors disconnected 7 © Cheek the control system, ignition system, fuel Engine system check system, and main system No oK ¥ Replace the torque converter assembly Hydraulic pressure test, NG ‘0 Measure the torque converter clutch pressure Replace transaxleTR -64 TRANSAXLE/TRANSMISSION SERVICE ADJUSTMENT amount) + thickness of the special tool — 0.79]. (Refer PROCEDURES cous to the “Snap ring and spacer for adjustment”) BRAKE REACTIONPLATE END PLAY ADJUSTMENTReplace the pressure plate of the low-reverse brake with the special tool, and then install the brake disc, brake plate, and snap ring as shown in the figure. Install the reaction plate and the used snap 08456-49100 ring. Move the special tool to measure the end play, and then replace the snap ring to adjust the end play to standard value. Standard value : 0-0.16 mm ae (Refer to the “Snap ring and spacer for adjustment") LOW-REVERSE BRAKE END PLAY ADJUSTMENT Reaction plate Snap ring Reverse the transmission and install the dial gauge. Move the special tool up and down to measure the end play. 08486-56100) Teaaoia SECOND BRAKE END PLAY ADJUSTMENT Replace the pressure plate of the second brake with the ‘special tool, and then install the brake disc and brake eam) plate as shown in the figure. Install the return spring, second brake piston, and snap ring, .95-1.81 mm. ‘Second brako Snap ing Reference Select a pressure plate whose thickness piston is within the following value. [A (moving amount) + Ratu sping thickness of the special tool — 1.81] to [A (moving amount) + thickness of the special tool — 1.35]. (Refer (00456-99100 i) to the “Snap ring and spacer for adjustment’). ‘Standard value : 0.79-1.25 mm Reference Select a pressure plate whose thickness is within the following value. [A (moving amount) + thickness of the special tool — 1.25] to [A (movingAUTOMATIC TRANSAXLE SYSTEM TR -65 — — #87 6 W584 #3 enon IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS OD. 1D. Thickness Symbol OD. 1D. Thickness | Symbol 59 47 1.8 a 48.9 37 1.6 #8 59 a7 2.0 a 48.9 a7 17 #8. 59) a7 2.2 1 48.9 37. 18 #8 59 47 24 A 48.9 37. 19 #8 59 a7 26 1 48.9 7 2.0 #8. 59 a7 28 oo 48.9 37. 24 #8 49 36 36 #2 48.9 37. 22 #8 49 36 36 #3, 48.9 7 23 #8 45.3 3t 3.8 #4 48.9 37. 2.4 #8 49 36 3.6 #5 48.9 37 25 #8 49 36 36 #6 48.9. 37. 26 #8 59 37 28 7 : : : :TR -66 TRANSAXLE/TRANSMISSION UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT Install the used thrust race #8, and then the rear cover. Measure end play of the underdrive sun gear. Replace thrust race #8 to adjust the play to the standard value. ‘Standard value : 0.25-0.45 mm NOTE Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear. DIFFERENTIAL CASE PRELOAD ADJUSTMENT Place a solder (approx. 10 mm in length, 3 mm in diameter) on the torque converter housing as shown in the figure. Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to the specified torque. Loosen the bolts, and remove the solder. Use a micrometer to measure the thickness (T) of the pressed solder. Select a-spare with a thickness that is within the following value. Standard value (T+0.045 mm) to (T+0.105 mm)AUTOMATIC TRANSAXLE SYSTEM TR -67 a) AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT exer PARKING & NEUTRAL i 5 8 LI Hce~ 1A I=} Wm LINE PRESSURE PUMP SUCTION PRESSURE ‘TORQUE CONVERTER AND LUBRICATION PRESSURETR -68 TRANSAXLE/TRANSMISSION FIRST MMM LINE PRESSURE PUMP SUCTION PRESSURE ‘TORQUE CONVERTER AND LUBRICATION PRESSUREAUTOMATIC TRANSAXLE SYSTEM TR -69 SECOND DL a 8 : 5 ik f Wm LINE PRESSURE u PUMP SUCTION PRESSURE TORQUE CONVERTER AND LUBRICATION PRESSURETRANSAXLE/TRANSMISSION TR -70 THIRD (MM _LINE PRESSURE PUMP SUCTION PRESSURE TORQUE CONVERTER AND LUBRICATION PRESSUREAUTOMATIC TRANSAXLE SYSTEM FOURTH i 5 i a i ip a } 5 5 i i : ee tee i ' 5 = . i ; ; i F a i IE z 8 3 : i i 7 j T I : ; i a é a 5 r j y i 8 § lh fmm LINE PRESSURE PUMP SUCTION PRESSURE TORQUE CONVERTER AND LUBRICATION PRESSURETR -72 TRANSAXLE/TRANSMISSION REVERSE IL = (Mmm LINE PRESSURE PUMP SUCTION PRESSURE ‘TORQUE CONVERTER AND LUBRICATION PRESSUREAUTOMATIC TRANSAXLE SYSTEM TCM CIRCUIT DIAGRAM (2.4L) (1) cxromo TOTATON OR STARTTR -74 ‘TRANSAXLE/TRANSMISSION ‘CONNECTORAUTOMATIC TRANSAXLE SYSTEM TR -75 ane‘TR -76 ‘TRANSAXLE/TRANSMISSION ‘TCM CIRCUIT DIAGRAM (2.7L) (1) HOTAT ON OF START BaDAUTOMATIC TRANSAXLE SYSTEM‘TR -78 TRANSAXLE/TRANSMISSION [ROTATALL THES. From Pulse Gonorator onpage S0-101AUTOMATIC TRANSAXLE SYSTEM TR -79 oa AUTOMATIC TRANSAXLE COMPONENTS | cxncew Low-everse brake ur Underrive ltch Reverse chtch wp) (REV) Coneway catch (Owe) Second brake a verdive clutch eon on} Damper cutch © Torque converter Rear cover il pump Output shaft Transfer drive gear DifferentialTR -80 TRANSAXLE/TRANSMISSION REMOVAL | euaczso 1. Remove the drain plug and drain the automatic transaxle fluid, 2, Remove the air cleaner assembly. 3. Remove the control cable. 4. Disconnect the speedometer sensor connector. 5. Disconnect the transaxle range switch connector, solenoid connector, and oil temperature sensor connector. 8. Lift up the vehicle. 9. Remove the gear box, stabilizer bar, tie rod end, lower arm ball joint, and drive shaft. 10. Remove the steering u-joint bolt and return tube mounting bolts. NOTE Mark a mating line on the steering column universal joint and the gear box before disassembling to make the installation easier. 11. Remove the subframe mounting bolts and the sub- frame. 7. Attach the special tool (09200-38001), an engine support fixture to the engine hooks. 12, Remove the starter motor. 13. Remove the automatic tranaxle mounting bolts. 14, Remove the engine to automatic transaxle bolts. "15, Remove the automatic transaxle assembly by jack.AUTOMATIC TRANSAXLE SYSTEM CAUTION a. Engine and transmission mounting insulators should be installed as specified them. b. Mounting bracket installation procedures. + Engine mounting bracket. + T/M mounting bracket. + Rear roll stopper mounting bracket. + Front roll stopper mounting bracket. ¢. When installing the front roll stopper mounting bracket, be especially careful not to crush the insulator. If crushed, idle vibration will most probably occur.. INSTALLATION | exisco00 1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine. CAUTION If the torque conveter is mounted first on the engine, the oil seal on the transaxle may be damaged. Therefore, first be sure to assemble the torque converter to the transaxle. 2. Install the transaxle control cable and adjust as follows: @. Move the shift lever and the transaxle range swth to the "N" position and install the control cale. b. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts to the control cable. . Remove any free-play in the control cable by adjusting the nut and then check to see that the selected lever moves smoothly. d. Check to see that the control cable has been adjusted correctly 3. Installation is the reverse of removal. NOTE For Automatic Transaxle overhaul, please refer to the “Overhaul Manual”.TR -82 ‘TRANSAXLE/TRANSMISSION a AUTOMATIC TRANSAXLE SHIFT CONTROL AUTOMATIC TRANSAXLE CONTROL SYSTEM cxroxeo AUTOMATIC TRANSAXLE SHIFT CONTROL » 13(130, 9) ® 1" 2 - 1. Shift knob 8. Shaft 2. Indicator pane! 9. Cable lever 3. Switch bracket 10. Detent spring 4. Magnetic switch 11. Lever assembly 5. Dotent 42. Switch lever 6 Bolt 18. Clevis pin 7. Parking brake cable bracket 14. Cam spring 418. Lock cam 16. Bracket assembly TORQUE : N-m (kg-cm, Ib-ft)AUTOMATIC TRANSAXLE SYSTEM TR -83 INSTALLATION | cxisc2o0 PROCEDURE TO INSTALL THE LOCK CAM BaDoTe 1. Move A/T lever to “P* position to set the key lock ‘cam and the shift lock cam as shown in the figure. ‘+ Check that the key lock cam is located at “B’by the detent pin. ‘* Check that the shift lock cam is located at “A”. 2. Check that the key cylinder is at “LOCK”. PROCEDURE FOR ADJUSTING SHIFT LOCK AND KEY LOCK CABLE 1. Check that each lock cam is as shown in the figure. 2. Install the shift lock and key lock cable in position. In this case, the shift lock cable must be fixed to the brake pedal and the key lock cable must be fixed to the key cylinder. 3. Temporarily install each cable to the AT lever assembly as shown in the figure. Securely insert the cable end into the fixing pin of each cam. 4. Slightly pull the shift lock cable in the direction “E” 5. After checking that the portion of the cable end touches the cable fixing pin, fix with the self-tapping bolt. 6. Slightly push the key lock cam to direction “Q”, 7. Slightly pull the key lock cable in the direction *G"to stretch the cable. Then fix the cable with the self- tapping bolt. 8. Check that the key lock and the shift lock cable are secure, PROCEDURE FOR CHECKING THE SHIFT Lock 1. When the brake pedal is not depressed, the push button of the shift lever at “P” position must not be operable. (Shift lever cannot be shifted at the other positions from “P.) 2, When the brake pedal stroke is 15~22mm (with shift lever at “P" position), the push button should be ‘operable without catching and the shift lever should be shift smoothly to other positions. 3. When the brake pedal is not depressed, the shift lever should shift smoothly to *P” position from all heading other positions. 4, The brake pedal must operate smoothly without catching. 5. When the ignition key is at the “LOCK" position, although brake pedal is depressed, the push button should be operable. 6. The Ignition key must not be able to be turned to the “LOCK" position except in the “P" position. 7. If the shift lever is shifted to the “P* position, the ignition key must turn to the “LOCK” position smoothly.TR -84 TRANSAXLE/TRANSMISSION DOUBLE DIFFERENTIAL UNIT DOUBLE DIFFERENTIAL UNIT-4WD SECTION VIEW 1150-250(1500-2500, 110-180) Final drive cartier Planetary gear set (LH) Annulus gear Planetary gear set (RH) Ball bearing Oil seal ‘Sun gear Differential drive gear installation '350-450(8500-4500, 260-320) TORQUE : /-m (kg-cm, Ib-ft)AUTOMATIC TRANSAXLE SYSTEM TR -85 SK DOUBLE DIFFERENTIAL UNIT-4WD cx0300 COMPONENTS Final drive cartier Oil seal ‘Sun gear Gear planetary set Planetary gear set ‘Sun gear Annulus gearTR -86 TRANSAXLE/TRANSMISSION REASSEMBLY exo 1, When reassembling the planetary gear (LH, RH), apply LOCTITE 242e or equivalent. 2. Be careful not to damage on the oil sealMANUAL TRANSAXLE SYSTEM TR -87 MANUAL TRANSAXLE SYSTEM SERVICE ADJUSTMENT PROCEDURES noone TRANSAXLE GEAR OIL INSPECTION Inspect each component for evidence of leakage. Check the gear oil level by removing the speedometer driven gear. If the oil is contaminated, replace it with new oil 1. Remove the speedometer driven gear and check the level with your finger. 2. Verity that the oil level is between 'F” and speedometer driven gear. ! on the 3. {foil level is 'L’ fill wth the specified type of oil until the level reaches 'F’. REPLACEMENT OF TRANSAXLE GEAR OIL Use HP Gear Oil SAE 75W/90 (API-GL-4). 1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil. 2. Replace the gasket with a new one and install the drain plug. 3. Remove the speedometer gear. 4, Add the specified amount and type of oil into the speedometer gear hole unti the level reaches 'F’ on the speedometer driven gear. Capacity : 2.43 US qt (2.3 lit, 2.1 Imp at) 5. Verify that the cil level is between 'F" and 'L’ on the speedometer gear. 6. Install the speedometer gear on the clutch housing of the transaxle. 7. Warm up the vehicle until the transaxle oil reaches its normal temperature, then check for leakage of transaxle oil DRIVE SHAFT OIL SEAL REPLACEMENT 1 Disconnect the drive shaft form the transaxle (Refer to "DS" group). Using a flat-tip screwdriver, remove the oil seal. Using the special too! (09431-21200), tap the drive shaft oil seal into the transaxle. Apply a coating of gear oil to the oil seal. Transaxle gear oll : Hypoid gear oll, SAE 75W/ 90 conforming to API GL-4 or higher. Disconnect the drive shaft form the transaxle (Refer to "DS" group).TR -88 TRANSAXLE/TRANSMISSION MANUAL TRANSAXLE COMPONENTS | euios 180 == Torn Ri pe oe F)MANUAL TRANSAXLE SYSTEM TR -89 REMOVAL aus 1. Remove the battery (-) cable. 2. Remove the air cleaner duct. 3. Remove the air cleaner and airflow hose assembly. 4. Disconnect the backup light switch connector. 5. Disconnect the clutch line and clip. 6. Remove the clutch release cylinder. 7. Remove the speedometer cable. 8. Remove the select or cable and shift cable. eR 9. Remove the starter motor mounting bolts, and remove the transaxle assembly upper connecting bolts. 10. Attach engine hooks using special tool (09200- 38001). 11. Remove the transaxle mounting bracket and insula- tor. 42. Lift the vehicle up. 18. Remove the front tire. 14, Remove the drain plug and drain the transaxle gear oil. 15. Disconnect the tie rod end, lower arm ball joint and drive shaft. (Refer to "DS" Group). 16. Remove the gear box u-joint bolt and the return tube ‘mounting bolts. 17. Remove the front muffler. 18. Remove the sub-frame mounting bolts and the sub- frame. 19. Remove the transaxle front and rear mounting bracket. 20. Remove the transaxle side mounting bolts. 21. Lower the transaxle assembly, supporting it with a Jack. NOTE ‘When supporting the transaxle assembly, make sure that the lifting force is applied to a wide area and, not to a small localized area.TR -90 TRANSAXLE/TRANSMISSION 2) CAUTION 1. Engine and transmission mounting insulators should be installed in the following order : 1) Engine mounting bracket. 2) TM mounting bracket. 3) Rear roll stopper mounting bracket. 4) Front roll stopper mounting bracket. 2. When installing the front roll stopper mounting bracket, be especially careful not to crush the insulator. If crushed, idle vibration will most probably result. INSTALLATION | cvs 1. Installation is the reverse of removal.MANUAL TRANSAXLE SYSTEM TR -91 COMPONENTS = aunoz0 4-6 (40-60, 3-4) a i, B J ~ Do not reuse 29.25 (200-250, 15-18) 4. Rear cover 9. Reverse lever spring 16. 1/2 shit fork 25. 5/R shit rod end 2. Lock nut set 17. We shit rod end 26, Input shaft 3. Retainer ring 10, Reverse shit lever 18.Foll pins 27. Output shaft 4, Transaxle case 11. Change rod 19.4 shit od 28, Bearing cover 5. Detent plug & spring, 12. Back lamp switch 20.314 shit fork 29, Differential assembly steel bal 13.Speedometer diven 21. /4 shit rod end 30. Magnet 6. Reverse ido shaft gear 22. Roll pins 31. Oil seal 7. Reverse 14 Roll pine 23.5/R shift rod 32, Clutch housing 8 Gontrolcase assembly 15. 1/2 shit rod 24. 5IR shit fork TORQUE : N-m (kg-cm, Ib-ft)TR -92 TRANSAXLE/TRANSMISSION DISASSEMBLY 1. Remove the rear cover, lock nut and retainer ring. Far cover 2. Remove the detent plug, spring and stee! ball. 3, Remove the back-up lamp switch. Detent plug Back lamp switch Bane 4, Remove the bolts holding the rear case to the main case. 5. Remove the reverse idler shaft and gear. 6. Remove the reverse lever spring set. 7. Remove the change rod and the control case. 8. Carefully remove the roll pins from the rod/fork assembly with a pin punch. 9. Refer to the order of removal in the figure. Discard the used pins. 10. Remove the S/R shift rod, 5/R shift fork and 6/R shift rod end. 11. Remove the 3/4 shift rod, 3/4 shift fork, 3/4 shift rod end,MANUAL TRANSAXLE SYSTEM rod end, 13. Remove gears and clutch hub assemblies of the input and output shaft in order and then remove the primary shaft (Remove the gears and hubs from both the input shaft and output shaft), 14, Remove the rings, bearings, and clutch hub assem- blies of the input shaft. Loosen the four bearing cover screws and then remove the output shaft. 16. Remove the speedometer driven gear after loosen- ing the bolt. 17. Remove the input shaft oil seal with a screwdriver or suitable tool BAe 18. Remove the sealing cap. 19. Remove the change rod oil seal with a screwdriver or suitable tool. 20, Remove the differential oil seal with a screwdriver or suitable tool. ena 21. Remove the output shaft bearing outer race of the transaxle case with a screwdriver or suitable tool.TR -94 TRANSAXLE/TRANSMISSION cor ‘enone 5. Install the speedometer driven gear. aucun 6. Apply transaxle oil to the input shaft oil seal, and install it to transaxle case using the special tool REASSEMBLY 1. Install the drive shaft oil seal. 7. Set the differential into the clutch housing. 2. Apply transaxle oil to the bearing, and install in the differential case using the special tool. 8. Install the input and output shafts in the clutch housing. saver 9. Install the gears and clutch hub assemblies into the 3. Apply transaxle oil to each bearing race, and install them to the transaxle case using the special tool. 4, Install the oil seal input and output shaft in order.MANUAL TRANSAXLE SYSTEM TR -95, 10. Install the 1/2 shift rod, 1/2 shift fork and 1/2 shift rod end. rod end. Bane rod end. 14. Install the control case assembly and the change rod and then tighten the two control case assembly bolts. 16, Install the reverse shift lever and tighten the two reverse shift lever bolts. 16. Install the reverse lever spring set. 17. Install the reverse idler shaft and gear. 18. Install the roll pins to the rod/fork assembly with a | pin punch in the order shown in the figure. 18. Attach the magnet to the clutch housing. 19. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case. 20. Tighten the transaxle installation bolts. 21. Install the backup lamp switch.TR -96 TRANSAXLE/TRANSMISSION 22. Install the detent plug, spring and steel ball. 23. Install the output shaft lock nut. Dotent plug Back lamp switch Bane 24, Install the rear cover.MANUAL TRANSAXLE SYSTEM INPUT SHAFT COMPONENTS | emsccs0 TR -97 1. 2. 3. 4. 5. 6. 2 8 8. 10. 11 12, Retainer ring Shim Bearing Reverse cone sleeve Reverse cone ‘Synchronizer ring Clutch hub sleeve ‘Syncgronizer key Clutch hub Synchronizer ring sth gear Needle bearing 18. Gear sleeve 14, Needle bearing 15. 4th gear 416. Synchronizer ing 17. Retainer riog 18. Clutch hub sleeve 19. Synegronizer ring 20. 3rd gear 21. Needle bearing 22. Input shaft 23. BearingTR -98 TRANSAXLE/TRANSMISSION INSPECTION = cmscze0 1. Measure the clearance between 8rd gear and 2nd gear. 2. If the clearance exceeds the maximum specified, check the contact surface of 3rd gear, 2nd gear and clutch hub (Srd/4th). Replace worn and damaged parts. 3. Measure the clearance between 4th gear and Sth gears. If the clearance exceeds the maximum, check the contact surfaces of 4th gear, Sth gear, clutch hub (Gra/ath), and clutch hub(Sth). Replace worn and damaged parts. DISASSEMBLY 1. Remove the Sth clutch hub assembly, 5th synchro- nizer ring, and 5th gear using the SST. 2, Remove 3rd/4th clutch hub assembly, 3rd synchro- nizer ring, and 3rd gear using the SST. REASSEMBLY ewsc20 1 Install a new bearing using the SST. 9455-33200 Install the Sth synchronizer ring, Sth gear, and a new bearing using the SST.MANUAL TRANSAXLE SYSTEM TR -99 OUTPUT SHAFT COMPONENTS | eaoooo 1 2. 3, 4. 5. 6. 7 8. Spacer Retainer ring Sth gear 4th gear 3rd gear 2nd gear Needle bearing Sleeve 9. Synchronizer inner ring 10. Double cone 11. Synchronizer ring 12. Synchronizer key spring 18, Reverse gear 14, Clutch hub sleeve 18. Synchronizer key spring 16. Synchronizer ring 17. Double cone 18. Synchronizer inner ring 19. 1st gear 20. Needle bearing 21. Cap bearing 22. Cone bearing 23. Output shaftTR -100 TRANSAXLE/TRANSMISSION INSPECTION 1. Measure the clearance between the output shaft and its bearing. 2. If the clearance exceeds the maximum, check the contact surface of the output shaft 1st gear, bearing of shaft, and 1st/2nd clutch hub assembly. Replace worn and damaged parts. 3, Measure the clearance between 2nd gear and Srd gear. 4, If the clearance exceeds the maximum, check the contact surfaces of 2nd gear, 3rd gear, and the tst2nd clutch hub assembly. Replace worn.and damaged parts. 2, Remove the 1st/2nd clutch hub assembly, 1st syn- chronizer ring, and ‘st gear, using a press. Press REASSEMBLY 1. Assemble the 1st gear, 1st synchronizer ring, and ‘1s¥/2nd clutch hub assembly, as shown in the figure. 2. Align the synchronizer ring grooves and synchro- nizer keys. 3. Press on the 1st/2nd clutch hub assembly. DISASSEMBLY 1. Remove the bearing and 5th gear using the SST. 09493-21000 4, Measure the clearance between 1st gear and the differential drive gear.MANUAL TRANSAXLE SYSTEM TR -101 5. Measure the clearance between 2nd gear and 3rd gear. BanooTR -102 TRANSAXLE/TRANSMISSION MANUAL TRANSAXLE SHIFT CONTROL COMPONENTS | emaoro (ime Shift lever 9-14 (80-140, 7-10) TORQUE : N-m (kg-cm, Ib-ft) 4MANUAL TRANSAXLE SYSTEM ).— REMOVAL aucor0 1. Remove the console assembly. Remove the cotter pins and clips (shift lever side). Remove the shift lever assembly. Remove the retainer and bolts. Remove the cotter pins and clips (Transaxle side). Remove the shift cable and select cable, INSPECTION awo0:s0 1 Check the select cable for proper operation and for damage. Check the shift cable for proper operation and for damage. Check the boot for damage. ‘Check each bushing for wear, abrasion, sticking, restricted movement or damage. Check for a weak or damaged return spring. REASSEMBLY | ewsouo 1 2. Install the shift lever assembly. Install the shift lever and select cable.TR -104 TRANSAXLE/TRANSMISSION SHIFT LEVER COMPONENTS | ewno:s0 ()- ‘Shiftiever 9-14 (90-140, 7-10) TORQUE : N-m (kg-cm, Ib-ft) INSPECTION | suso:co 1. Inspect the bushing for wear or damage, 2. Inspect the return spring for damage or deteriora- tion, REASSEMBLY = ewsor0 1. Apply multi-purpose grease to the sliding parts of the bushings. 2. Reassembly is reverse of disassembly.TRANSFER CASE ASSEMBLY TR -105 TRANSFER CASE ASSEMBLY PEPLACEMENT OF TRANSFER CASE OIL SYSTEM DESCRIPTION 1. The transfer case is a fulltime four-wheel drive system developed for stable driving in the worst conditions. It improves not only driving safety on a normal road but also the performance of the vehicle in a slippery road by distributing the power to both, front and rear wheels. 2. A driver may not control front or rear wheel drive directly like a four-wheel drive vehicle. 3. When the front or rear wheels slip, the viscous generates the effect of differential limitation made by viscosity torque of silicon oil inside the viscous coupling, caused by relative revolution difference among interior plates. 4. This system secures optimum drive performance and vehicle safety according to a road by transmit- ting viscous torque to the side there is a litle slip- age between front wheels and rear wheels. 5. Rear wheel power set by the above system is transmitted to the rear wheel through the hypoid gear, TRANSFER CASE OIL INSPECTION Check the gear cil level by removing the filler plug. If the oil is contaminated, it is necessary to replace it with new oil. 1. With the vehicle parked on a level surface, remove the oil filler plug. 2, Inspect the oil level. PEPLACEMENT OF TRANSFER CASE OIL USE SHELL SPIRAX AX (SAE 80W/90, API GL-5) 1. With the vehicle parked on a levell surface, remove the drain plug and drain the transfer case cil. 2. Install the drain plug. 3. Remove the oil filler plug. 4, Add the specified amount and type of oil into the oil filler hole Install the oil filler plug.TR -106 TRANSAXLE/TRANSMISSION TRANSFER CASE SECTION VIEW exo Inner hotow shaft Viecous couping Te ‘Outer holiow shat ranster cover Inner drive shaft ‘a Hypoid gear Ball bearing Pinion shaft Rear flange‘TRANSFER CASE ASSEMBLY OUTSIDE VIEW exo 1h ©) pF eei0.1.29 '34-37(340-370, 25-38) '34-98(340-380, 25-38) 20.8mm 180-210(1800-2100, 133-155) TORQUE : N-m (kg-cm, Ib-ft)TR -108 TRANSAXLE/TRANSMISSION TRANSFER CASE cxiaosso COMPONENTS ‘Transfer housing Viscous coupiing Transfer cover Hollow shaft Pinion case Hypoid gear Inner drive shaft REMOVAL cxsoxo 1. Attach the, engine support fixture (09200-38001) to the engine (if necessary). 2. Remove the transfer case andithe sub-frame mount- ing bracket. 8. Raise the vehicle and remove the tires. 4. Remove the front muffler. 5. Drain the transfer case oil. cary 6. Remove the engine lower cover and side cover. 7. Remove the brake calipers, the shock-absorbers and the drive shaft. 8. Remove the alternator, exhaust manifold and the + rear propeller shaft.TRANSFER CASE ASSEMBLY TR -109 TT 9. Remove the steering tube attached to the sub- frame. 10. Remove the bolts of the sub-frame and the sub- frame assembly. 11. Support the transfer case with a jack. 12, Remove the transfer case mounting bolts. 13, Remove the transfer case assembly.TRANSAXLE/TRANSMISSION TR -110 TRANSFER CASE cxao COMPONENTS ‘Transfer cover (Outer hollow shaft Inner drive shaft Inner hollow shaft | Transfer housing Ball bearing @ S @S eS a 180-210 (1800-2100, 139-155) BaNOTA TORQUE : Nm (kg-cm, Ib-ft)TRANSFER CASE ASSEMBLY ‘TR -111 — VISCOUS COUPLING VISCOUS COUPLING cxnouo COMPONENTS Viscous coupling Taper roller bearing ‘Taper roller beari Ps ing NOTE The viscous coupling is not serviceable REASSEMBLY | exo 1. Reassemble the taper roller bearing using special Tool. tm ww 2. Reassemble the taper roller bearing (larger size) in ‘opposite side using special Tool.TRANSAXLE/TRANSMISSION TR -112TRANSFER CASE ASSEMBLY TR -113, — HYPOID GEAR xno COMPONENTS Hypoid gear Taper roller bearing ‘Taper roller bearingTR -114 TRANSAXLE/TRANSMISSION HYPOID GEAR REASSEMBLY cunsio 1. Reassemble two (front & rear side) taper roller bearings using the special tool.TRANSFER CASE ASSEMBLY TR -115 as PINION SHAFT AND CASE PINION SHAFT AND CASE | cxsos0 COMPONENTS 180-210(1800-2100, 193-155) Pinion case Oring Pinion shaft TORQUE : Nem (kg-cm, Ib-ft) nea REASSEMBLY cxiaces0 1. Reassemble the oil seal on the pinion case using special Tool. OoTR -116 TRANSAXLE/TRANSMISSION TRANSFER HOUSING AND COVER TRANSFER HOUSING AND COVER exis COMPONENTS Inner drive shaft Inner hollow shaft ‘Transfer housing Outer hollow shaft ‘Snap ring 00 0) 00 ‘Snap ring ‘Transfer cover REASSEMBLY cuss REMOVAL OF INNER DRIVE SHAFT 1. Reassemble the oil seal on the transfer housing 1. Remove the oil seal. using the special tool.TRANSFER CASE ASSEMBLY TR -117 2, Remove the snap ring. 3. Remove the inner drive shaft. REMOVAL OF INNER DRIVE SHAFT BEARING. 1. Remove the inner drive shaft bearing using the special tool. Tne REASSEMBLY OF BEARING AND SNAP RING 1. Reassemble the snap ring on the inner drive shaft. 2. Reassemble the ball bearing and the hoop ring. ‘09485-33200 REASSEMBLY OF HOLLOW SSHAFT 1. Apply grease to the spline surface. GREASE : KLUBER MICROLUBE GNY202equivalent 2. Reassemble the outer hollow shaft.TR -118 ‘TRANSAXLE/TRANSMISSION 3. Reassemble the inner hellow shaft. eA