Introduction to the Trouble Diagnosis of Transmission, Transaxle Page 1 of 13

Introduction to the Trouble Diagnosis of Transmission, Transaxle

1. Introduction to the Trouble Diagnosis of Transmission, Transaxle

1. System diagnostic method

The system diagnosis method is a standardized method applied for repairing all electric/electronic systems. Failures in
electric and electronic systems differ from regular vehicle failures in that they often occur in the following stages.

1) Initial stage of failure

The failure occurs sporadically and for a short time, and often the customer does not notice it. At this stage, the customer's
complaint is unclear, and the malfunction cannot be reproduced. However, the control unit may have stored the failure.
(Past malfunctions)

2) Intermediate stage of failure

The failure occurs sporadically and for a short time, but may occur repeatedly at intervals, and invariably occurs under
specific conditions. The customer's complaint and the failure content are clear, but the failure conditions are unclear.
Therefore, the person performing diagnosis on the vehicle can reproduce the failure by understanding its conditions.
(Intermittent failures, intermittent conditions)

3) Stage where failure is realistic

The failure occurs regularly, and the customer's complaint is real and clear. Therefore, the person performing diagnosis on
the vehicle can reproduce the failure. However, there may sometimes be multiple causes for the failure. (Current
malfunctions)

2. Diagnosis procedure

The diagnostic procedure is always used to solve problems with the electric and electronic systems, and is the starting
point if a repair is required. The following items indicate how to proceed through the diagnosis.

1) Verify the customer's complaint.

In order to verify the customer's complaint, the person performing the diagnosis on the vehicle must know how the system
normally operates.

2) Perform a preliminary inspection.

 Overall visual inspection

 Maintenance history review
 Detection of abnormal conditions such as abnormal noises or smells
 Information collection for DTCs, data, etc., using a scan tool

3) Inspect for related Service Bulletins.

4) Refer to Diagnosis by symptom.

Diagnosis by symptom includes information regarding systems not displayed in the DTC. Therefore, because Diagnosis by
symptom enables the appropriate system operation to be verified, the appropriate diagnosis method can be discovered.

5) Refer to related topics such as mechanical.

3. If a DTC is stored

Accurately perform the repair according to the specified DTC chart.

4. If there is no DTC

Select the symptom from Diagnosis by symptom. Complete the repair according to the diagnostic procedure. It is also
possible to perform the inspection by referring to the functional inspection.

5. If there are no applicable symptoms

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1) Investigate the complaint in detail.

2) Create a diagnosis plan.

3) Utilize the schematics and operation principles.

When repair history for similar cases is available, request technical assistance. Combine technical knowledge and effective
utilization of available Service Bulletins.

6. If the condition is intermittent

Failures that do not always appear are referred to as being intermittent. Take the following steps to resolve intermittent
problems.

1) Check the DTC information and the system data.

2) Evaluate the symptoms and conditions described by the customer.

3) Use the check sheet or another method to check the circuit or electrical system components.

7. If no trouble is detected

This situation indicates that the vehicle is operating normally. The condition reported by the customer may be normal.
Check the customer complaint by comparing to another vehicle that is operating normally. However, depending on the
condition, it may be an intermittent failure. Before returning the vehicle, check the complaint under the conditions given by
the customer.

1) Investigate the complaint again.

If the complaint cannot be adequately detected or determined, it is necessary to perform the diagnosis again to verify the
complaint. The complaint may be intermittent, or it may be a normal condition.

2) Repair and verify.

Perform the repair when the cause has been determined. Verify that the vehicle is operating normally and that the
symptom has been corrected. This includes a road test and other methods to verify that the complaint has been resolved
under the following conditions.

 Verify by testing under the conditions given by the customer.

 If a DTC is diagnosed, check the data to verify that the malfunction has been repaired by duplicating the conditions
when the DTC was set.

8. Vehicle repair verification

After performing electronic control system repairs, it is necessary to check that the repair is accurate. If this check is not
adequate, the Smoother warning light may illuminate again or drivability problems may occur when the vehicle is returned
to the customer. Especially in the case of intermittent conditions, it is necessary to check by reproducing the conditions of
the customer complaint.

Item Item Purpose Method

1 DTC check Check the DTC display Delete the previous DTC. Fully
after the repair. warm up the engine by idling,
then test running and make sure
of the test condition.
2 Check the scan Make a basic check of Monitor the scan tool data list
tool data list the state of engine and use the representative
control and values sheet to check.
communications. Check the representative values
for the scan tool data list.
3 Check other This is to check whether Check whether control of the
systems each control is normal. engine, ABS, etc. have any
abnormalities.
4 Check strong If a transceiver or other Check whether the idle engine
electromagnetic strong electromagnetic speed varies when the
emitting emitter is attached to the transceiver or other

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machines and vehicle, check that it is electromagnetic emitter is turned

tools. not emitting harmful ON and OFF. If any problem is
waves. discovered at this stage, notify
the customer that the mounting
position and output of the
electromagnetic emitter must be
modified.

*: If a problem is detected among the check items for powerful electromagnetic transmitters, convey the following check
items to the customer as necessary.

 Install the antenna in a location as far away as possible from the vehicle electronic systems such as the control
units and sensors.
 Install the antenna cord at least 20 cm away from the vehicle electronic systems, such as the control units and
sensors.
 Do not place the antenna cord with other wiring. Also, place the antenna cord as far away from other wiring as
possible.
 Make sure to install aftermarket equipment in accordance with their respective installation manuals.
 Do not attach high-output mobile communication devices.

Caution:
 Failure to follow these steps when checking a repair may result in unnecessary repairs.
 Review the data relating to the DTC that was diagnosed and make a record.
 Clear the DTC.
 Run the vehicle while checking the related data.

9. Non-OEM parts

In all failure diagnoses, the system is adjusted to perform with genuine parts. Therefore, if a general aftermarket sensor,
switch, etc., is installed, it may make a false diagnosis and illuminate the Smoother warning light.
Aftermarket electronics, such as mobile phones, stereos, and anti-theft devices, may emit electromagnetic interference into
the control system if improperly installed. This may result in generation of incorrect sensor information, causing the
Smoother warning light to illuminate. Before performing failure diagnoses, either turn off the power to aftermarket parts, or
remove them.

10. Improper vehicle maintenance

The high sensitivity of system check will cause the Smoother warning light to illuminate if the vehicle is not properly
maintained.
Clogged oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger vehicle
malfunctions. Poor vehicle maintenance cannot be classified as a non-vehicle fault, but because of the high sensitivity of
the failure diagnosis, vehicle maintenance schedules must be more closely followed.

11. Related system malfunctions

Many system trouble diagnoses will stop operating if the control unit detects a malfunction in a related system or
component.

12. Related component visual inspection

When performing the diagnostic procedure, carefully make a visual inspection of the transmission, etc. This inspection can
often lead to solving a problem without taking extra steps. Use the following guidelines when implementing a visual
inspection.

 Inspect all air hoses, etc., for punched holes, cuts, disconnections, and appropriate routing.
 Inspect hoses that are difficult to see behind other components.
 Inspect all harnesses for being properly connected, for burned or worn areas, and for improper fastening or contact
with sharp edges, the hot exhaust manifold, or pipes.

13. Basic knowledge of tools required

When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result in an incorrect
diagnosis or damage to the powertrain components. Do not attempt to diagnose a problem related to the powertrain
without having basic knowledge.
Basic understanding of hand tools is necessary to effectively use the service manual.

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14. Regarding on-board diagnostic tests

Check the diagnostic results of problems using the following contents.

 Completion of the diagnostic tests of the previous ignition cycle

 The diagnostic tests of the current ignition cycle were passed.
 Problems identified through the diagnostic tests do not currently exist.

If the failure result arises in the diagnostic test, check the following and record the data.

 Completion of the diagnostic tests of the previous ignition cycle

 Currently existing problems identified through the diagnostic tests
 Problems existing in this ignition cycle
 Operation status when the failure occurs

15. Ignition cycle

An ignition cycle is defined as a cycle of turning the key ON, running the engine, then turning the key OFF performed in a
manner that meets the predetermined diagnostic criteria for operating the vehicle.

16. General diagnostic operations of components monitor

To run the engine normally, a general diagnosis of the components is required.

Input components
Check the input components to inspect for an open circuit or whether the reading is within the range. This includes a
rationality inspection. A rationality inspection indicates a malfunction if the signal from a sensor is not thought to be
appropriate.
Although not limited to the following, input components consist of the following sensors.

 Clutch pedal stroke sensor

 Clutch stroke sensor
 Input shaft speed sensor
 Vehicle speed sensor (VSS), etc.

Output components
The output components are inspected to diagnose whether responses to commands from the control unit are appropriate.
If monitoring of functions cannot be executed, check the components, where applicable, for an open circuit or whether the
reading is within the range.
Although not limited to the following, output components to be checked consist of the following circuits.

 Lights, relay control

 Magnetic valves, solenoid actuator, etc.

17. Common self-diagnosis terms

When diagnosis is used as a noun, it means that it is an arbitrary onboard test implemented using a vehicle diagnosis
method. Since a diagnosis determines whether the system or components are operating according to specification, it is a
test that is implemented on the system or components. There are many diagnoses shown in the list below.

 Vehicle speed
 Gear shift control
 Malfunction indicator light
 Magnetic valves, solenoid actuator, etc.

18. Diagnosis executive

The diagnosis executive not only adjusts the diagnosis procedure and specifies the priority, but also records and displays
the results. The following shows the main items of the diagnosis executive.

 Smoother warning light ON/OFF command

 DTC recording and clearing
 Recording of scan tool data
 Current status information relating to each diagnosis

19. Diagnostic information

This refers to detecting malfunctions of the circuits or components through the diagnosis procedures. Charts are created
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under conditions where the vehicle is functioning normally during assembly, and multiple malfunctions are not currently
occurring.
A continuous self-diagnosis function is provided in specific control functions. This diagnosis function is supplemented by
the diagnosis procedures described in this manual. The DTC system acts as a language to convey the cause of
malfunctions. If functional problems are detected by the control unit, a DTC is set and the Smoother warning light
illuminates.

20. Malfunction indicator light

It refers to the Smoother warning light, etc.

Basically, the Smoother warning light illuminates when a DTC is set due to a failure in the electronic control system, such
as in the TCM.

21. DLC

The equipment for communicating with the control unit is the DLC. The DLC is also designed to establish connections with
a scan tool. The general uses of the scan tool are indicated below.

 Stored DTC identification

 DTC clearing
 Output control test implementation
 Reading of serial data

22. Regarding vehicle repair verification

After the repair is complete, perform the following steps to verify the vehicle repair.

1) Review either the data or the DTC that was diagnosed, or both, and make a record.

2) Clear the DTC.

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3) Operate the vehicle based on the data.

4) Observe the information for the specified DTC that was diagnosed until the diagnostic test related to that DTC is
implemented by the control unit.

The implementation of these steps is extremely important when checking a repair. Neglecting to implement these steps
may result in unnecessary repairs.

2. Diagnostic Trouble Codes (DTCs)

Every time the ignition switch is turned ON, the TCM performs a self-test on most of the wiring and components, records any
detected system failure in the memory of the TCM, and performs a backup control, depending on the DTC. Also, if a failure that
will affect the running of the vehicle occurs in the system, the Smoother warning light in the IP cluster illuminates to notify the
driver.

1. DTC reading

1) Turn ON the ignition switch and check whether the Smoother warning light illuminates.

2) Turn the ignition switch ON, but leave the engine OFF.

3) Short-circuit the No. 12 pin and No. 4 pin or No. 5 pin of the DLC.

4) Read the DTC displayed on the multi information display.

5) The DTC determines the failure contents from the DTC list.

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If the scan tool is connected, the DTC can be read by operating the scan tool.

2. If no DTC is stored

Code 01 is displayed, indicating that no DTC is stored.

3. If a DTC is stored

The stored trouble codes are displayed.

If 2 or more trouble codes have been stored, the DTCs are displayed in ascending order of DTC number.
After displaying all codes, the codes will be displayed again. This display continues while the DLC terminals are short-
circuited.

4. Condition for clearing the DTC

DTCs can be cleared by operating the memory clear switch (connector) installed to the inspection cover of the vehicle.

Caution:
 Electrical system DTCs, except those for some electrical systems (ABS/ASR, Smoother-G, SRS, etc.), will be
cleared collectively through the operation of this switch. Handle with care.

1. Memory clear switch (Connector: white)

2. Diagnostics common connector (Connector: green)

5. Method for clearing only the DTC

1) Turn ON the ignition switch.

2) After 3 or more seconds have passed since turning ON the ignition switch, connect the memory clear connector to the
diagnostic common connector, leave for 1.5 seconds or more, then disconnect it.

The DTC is cleared shortly after disconnection.

Note:
 If the scan tool is connected, the DTC can be cleared with the delete operation on the scan tool.

6. Method for clearing the DTC and learning value

1) Turn ON the ignition switch.

2) Keep the brake pedal fully depressed.

3) After 3 or more seconds have passed since turning ON the ignition switch, connect the memory clear connector to the
diagnostic common connector, leave for 1.5 seconds or more, then disconnect it.

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The DTC is cleared shortly after disconnection.

Note:
 If the scan tool is connected, the DTC can be cleared with the delete operation on the scan tool.

3. Performing Diagnosis

1. Performing the trouble diagnosis with a scan tool

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2. Preliminary inspection with a scan tool

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3. Safety precautions

Caution:
 Because exhaust gas is highly poisonous and can lead to fainting and/or death, make sure to adequately
ventilate the area to ensure no exhaust gas is breathed in when performing an inspection using the scan tool
with the engine ON in a closed location such as a garage.
 Before inspecting the vehicle using a scan tool, stabilize the vehicle such as by applying the parking brake
and by placing chock blocks. Also be aware of safety when test driving the vehicle.

4. Reproduction method

The reproduction method is used to reproduce the failure conditions if the customer's complaint is intermittent or the failure
conditions of when those failures were indicated in the past.
The status of the failure and the instant the DTC is displayed can be checked by matching the external conditions, such as
the driving condition, and by monitoring the reproduced failure using a scan tool.
Check the system data using the scan tool at the moment the DTC is displayed.
If no DTC is displayed, the snapshot function is effective.

5. Component and sensor check

1) Connect the scan tool to the vehicle and monitor the data list of the part suspected to be the cause.

2) Knock on the part suspected to be the cause, such as with a gentle tap, and inspect whether the failure occurs.

3) If the vibration causes the values being monitored to change, it can be assumed that the related part is not properly
installed or is a defective product.

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1. Gently vibrate.
2. Gently shake.
3. Gently shake.

Caution:
 Relay parts may become disconnected if they are subjected to a strong impact.

6. Wire harness and connector

1) Connect the scan tool to the vehicle and monitor the data list of the part suspected to be the cause.

2) Gently shake the wire harness vertically and horizontally, and inspect whether a malfunction occurs.

Particularly for wire harnesses, check the base of the connector, the supporting point of the vibration, and the area on the
body where the wire passes through.
If shaking the wire harness causes the values on the data list to change, it can be assumed that an open circuit or short
circuit is present near the wire harness. It is also necessary to check the connection terminal of the connector for looseness
or deformation.

3) With the connector engaged, inspect whether the terminal is loose or disconnected.

4) Gently pull each wire of the connector wire harnesses to check that none are disconnected.

5) Remove the connector, and inspect the male-side terminal for bending or for being misaligned.

6) Remove the connector and inspect the female-side terminal for deformation of connection portions.

7) Inspect the connector contacts of each part for dirt, rust or roughness.

8) The wire harness should not apply excessive force to the connector when the connector is connected to the part.
Verify that the wire harness has an appropriate amount of slack. Also, check for interference with other parts, wear, or
bending.

7. Terminal repair method

If any dirt is found in the connection, clean it using an air gun or shop cloth, etc. At this time, do not polish the contact area

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with sandpaper because the surface of the contact area is sometimes plated and applying a coarse material will remove
the plating.
Replace the female terminal if there is a problem in the contact tension. In this case, use a gold-plated terminal if the male
side terminal is gold plated, or a tin-plated terminal if the part is tin plated.
If no failure is found in the contact area, clean it using an air gun, etc., and apply a small amount of clean, non-absorbent
oil such as engine oil or gear oil to avoid oxidization or wear of the contacts.

4. Oral Consultation

1. Questioning

1) Fully understand the description given by the customer using the Smoother-G control system check sheet.

Reference: When questioning, do not ask random questions. Focus on the system believed to be malfunctioning based on
the malfunction symptom and the facts.

2) Determine failure information accurately.

Have concrete understanding based on 5W1H.

Example: Low air temperature, during startup, on a steady basis, near the transmission area, metallic sound, etc.

2. Key points of questioning

 What: Malfunction symptom
 When: Month and date, time, frequency of occurrence
 Where: Road conditions
 In what kinds of conditions: Driving conditions, operation status, weather conditions
 What happened: What the symptom felt like

3. Smoother-G control system check sheet

When receiving the vehicle from the customer at the service factory, the failure symptoms and the data on the occurrence
of failures must be checked with the customer based on the Smoother-G control system check sheet.

1. Fault symptoms
2. Fault frequency/fault conditions

Reasons:

 Failure symptoms may not be reproducible at the service factory.

 The customer's complaint may not always turn out to be a malfunction.
 Notification of incorrect malfunction conditions to the person in charge of repairs may result in unnecessary man-
hours for repairs.

The check sheet assists in onboard diagnosis, repair, and repair confirmation at the service factory.

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