Page 457 of 2389
Manual Shifting Test
HINT: With this test, it can be determined whether the
trouble lies within the electrical circuit or is a mechani-
cal problem in the transaxle.
1. DISCONNECT SOLENOID WIRE
2. INSPECT MANUAL DRIVING OPERATION
Check that the shift and gear positions correspond
with the table below.
HINT: If the L, 2 and D range gear positions are diffi-
cult to distinguish, perform the following road test.
wWhile driving, shift through the L, 2 and D ranges,
Check that the gear change corresponds to the
shift position.
If any abnormality is found in the above test, the
problem lies in transaxle itself.
3. CONNECT SOLENOID WIRE
Shift position
Gear
positionP
range 2
range
range D
rangeR
range
Pawl
Lock Reverse O/D
O/D1 st
± AUTOMATIC TRANSAXLETroubleshooting (Manual Shifting Test) (A540E and
A540H)AT±202
Page 458 of 2389

Mechanical System Tests
STALL TEST
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
CAUTION:
wPerform the test at normal operation fluid temperature (122 ± 176°F or 50 ± 80°C).
wDo not continuously run this test longer than 5 seconds.
wTo ensure safety, conduct this test in a wide, clear, level area, which provides good traction.
wThe stall test should always be carried out in pairs. One should observe the conditions of wheels
or wheel stoppers outside the vehicle while the other is performing the test.
MEASURE STALL SPEED
(a) Chock the front and rear wheels.
(b) Connect a tachometer to the engine.
(c) Fully apply the parking brake.
(d) Step down strongly on the brake pedal with your left foot.
(e) Start the engine.
(f) Shift into the D range. Step all the way down on the accelerator pedal with your right foot. Quickly
read the stall speed at this time.
Stall speed: A540E (2VZ±FE) 2,450
+150 rpm
A540H (3S±FE) 2,320
+150 rpm
(g) Perform the same test in R range.
EVALUATION
(a) If the stall speed is the same for both ranges without the rear wheels rotating but lower than specified
value:
wEngine output may be insufficient
wStartor one±way clutch is not operating properly
(b) If the stall speed in D range is higher than specified:
wLine pressure too low
wForward clutch slipping
wNo. 2 one±way clutch not operating properly
wO/D one±way clutch not operating properly
(e) If the stall speed in R range is higher than specified:
wLine pressure too low
wDirect clutch slipping
wFirst and reverse brake slipping
wO/D one±way clutch not operating properly
(d) If the stall speed in both R and D ranges are higher than specified:
wLine pressure too low
wImproper fluid level
wO/D one±way clutch not operating properly
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±222
Page 459 of 2389

TIME LAG TEST
If the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward
clutch, direct clutch and first and reverse brake.
NOTICE: .
wPerform the test at normal operating fluid temperature (122 ± 176°F or 50 ± 80°C).
wBe sure to allow one minute interval between tests.
wMake three measurements and take the average value.
MEASURE TIME LAG
(a) Fully apply the parking brake.
(b) Start the engine and check the idle speed.
Idle speed (N range): 700 rpm (A540E and A540H)
(c) Shift the shift lever from N to D position. Using a stopwatch, measure the time it takes from shifting
the lever until the shock is felt.
Time lag: Less than 1.2 seconds.
(d) In the same manner, measure the time lag for N ± R.
Time lag: Less than 1.5 seconds.
EVALUATION
(a) If N ± D time lag is longer than specified:
wLine pressure too low
wForward clutch worn
wO/D one±way clutch not operating properly
(b) If N ± R time lag is longer than specified:
wLine pressure too low
wDirect clutch worn
wFirst and reverse brake worn
wO/D one±way clutch not operating properly
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±223
Page 460 of 2389

HYDRAULIC TEST
PREPARATION
(a) Warm up the transaxle fluid.
(b) Remove the transaxle case test plug and connect the hydraulic pressure gauge.
SST 09992±00094 (Oil pressure gauge)
NOTICE:
wPerform the test at normal operating fluid temperature (122 ± 176°F or 50 ± 80°C)
wThe line pressure test should always be carried out in pairs. One should observe the conditions of
wheels or wheel stoppers outside the vehicle while the other is performing the test.
MEASURE LINE PRESSURE
(a) Fully apply the parking brake and chock the four wheels.
(b) Start the engine and check idling rpm.
(c) Step down strongly on the brake pedal with your left foot and shift into D range.
(d) Measure the line pressure when the engine is idling.
(e) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(f) In the same manner, perform the test in R range.
(A540E)
kg/cm2 (psi, kPa)
Line pressure
D rangeR range
Idling
IdlingStallStall
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±224
Page 461 of 2389
If the measured pressure are not up to specified values, recheck the throttle cable adjustment and
perform a retest.
EVALUATION
(a) If the measured values at all ranges are higher than specified:
wThrottle cable out of adjustment
wThrottle valve defective
wRegulator valve defective
(b) If the measured values at all ranges are lower than specified:
wThrottle cable out of adjustment
wThrottle valve defective
wRegulator valve defective
wOil pump defective
wO/D direct clutch defective
(e) If pressure is low in the D range only:
wD range circuit fluid leakage
wForward clutch defective
(d) If pressure is low in the R range only:
wR range circuit fluid leakage
wDirect clutch defective
wFirst and reverse brake defective
kg/cm2 (psi, kPa)
Line pressure
(A540H)
R rangeD
rang
e Id-
lin
g
IdlingS
t
al
l
Stall
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±225
Page 462 of 2389

MEASURE CENTER DIFFERENTIAL CONTROL PRESSURE (A540H Only)
(a) Warm up the transaxle fluid (122 ± 176°F or 50 ± 80°C)
(b) Measure the line pressure. (See page AT±224)
(e) Remove the transfer case test plug and mount the oil pressure gauge (SST).
SST 09992±00094
(d) Check the parking brake to see that it is fully applied chock the four wheels.
(e) Disconnect the connector from ECT ECU.
(f) Start the engine.
(g) Apply battery voltage to terminal SD1, or SD2 of the wire harness side connector and turn the No. .1
and No. 2 center differential control solenoid valves to either ON or OFF.
(h) Shift into the L range, step down strongly on the brake pedal with your left foot and while manipulating the
accelerator pedal with the right foot, measure the pressure at the engine speeds specified in the table.
kg/cm2 (psi, kPa)
HINT: After inspecting the center differential control pressure, erase the diagnosis codes (No. 73 and 74)
from the memory.
Condition of
Solenoid
ValvesNo. 1 Solenoid
Valve
No. 2 Solenoid
Valve
Engine
RPML range
Range
Idling
Stall
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±226
Page 463 of 2389

ROAD TEST (A540E and A540H)
NOTICE: Perform the test at normal operating fluid temperature
(122 ± 176°F or 50 ± 80°C).
1. D RANGE TEST IN NORM AND PWR PATTERN
RANGES
Shift into the D range and hold the accelerator pedal
constant at the full throttle valve opening position.
Check the following:
(a) 1±2, 2±3 and 3±O/D up±shifts should take place, and shift
points should conform to those shown in the automatic
shift schedule. (See page AT±230)
Conduct a test under both Normal and Power. patterns.
HINT:
wThere is no O/D up±shift and lock±up when the coolant
temp. is below 140
°F (60°C) (A540E) or 122°I= (50°C)
(A540H).
wWhen the coolant temp. is below 140°F (600C) or
122°F (50°C) (A540H), the shift point is lower than specified in
the automatic shift schedule.
EVALUATION
(1) If there is no 1 ± 2 up±shift:
wNo. 2 solenoid is stuck
w1±2 shift valve is stuck
(2) If there is no 2 ± 3 up±shift:
wNo. 1 solenoid is stuck
w2±3 shift valve is stuck
(3) If there is no 3 ± O/D up±shift:
w3±4 shift valve is stuck
(4) If the shift point is defective:
wThrottle valve, 1±2 shift valve, 2±3 shift valve, 3±4
shift valve etc., are defective
(5) If the lock±up is defective:
wLock±up solenoid is stuck .
wLock±up relay valve is stuck
(b) In the same manner, check the shock and slip at the 1
±2, 2 ± 3 and 3 ± O/D up±shifts.
EVALUATION
If the shock is excessive:
wLine pressure is too high
wAccumulator is defective
wCheck ball is defective
(c) Run at the D range lock±up or 0/C) gear and check for abnor-
mal noise and vibration.
HINT: The check for the cause of abnormal noise and vibra-
tion must be make with extreme care as it could also be due
to loss of balance in the drive shaft, tire, torque converter,
etc.
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±227
Page 464 of 2389

2. 2 RANGE TEST
Shift into the 2 range and, while driving with the accel-
erator pedal held constantly at the full throttle valve
opening position, push in one of the pattern selectors
and check or the following points.
(a) Check to see that the 1 ± 2 up±shift takes place and
that the shift point conforms to it shown on the auto-
matic shift schedule. (See page AT±230)
(b) While running in the 2 range and 2nd gear, release
the accelerator pedal and check the engine braking ef-
fect.
EVALUATION
If there is no engine braking effect:
w Second coast brake is defective (f) Check for the lock±up mechanism.
(1) Drive in D range, O/D gear, at a steady speed
(lock±up ON) of about 75 km/h (47 mph).
(2) Lightly depress the accelerator pedal and check
that the engine rpm does not change abruptly.
If there is a big jump in engine rpm, there is no
lock±up. (d) While running in the D range, 2nd, 3rd and O/D
gears, check to see that the possible kick±
down vehicle speed limits for 2 ± 1, 3 ± 2 and
O/D ± 3 kickdowns conform to those indicated
on the automatic shift schedule. (See page
AT±230)
(e) Check for abnormal shock and slip at kick±down.
(c) Check for abnormal noise at acceleration an4
deceleration, and for shock at up±shift and
down shift.
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±228