1996 TOYOTA T100 stop start

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AT6683
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm (0 − 0.04 in.)
Q03104No.1 Gear Shifting Rod
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−271
1996 TOYOTA T100 (RM449U)
If the level is at the low side, add new fluid.
Fluid type: ATF DEXRON®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON®II
Capacity:
A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts)
A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature, 70 − 80°C (158 − 176°F), and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transmission.
If there are leaks, it is necessary to repair or replace O−
rings, FIPGs, oil seals, plugs or other parts.
(e) INSPECT AND ADJUST THROTTLE CABLE
(1) Check that the accelerator pedal is fully released.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not standard, adjust the cable by the adjusting
nuts.
(f) Inspect and adjust the shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Remove the nut on the No.1 gear shifting rod.
(2) Push the No.1 gear shifting rod fully downward.

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm

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DI−273
1996 TOYOTA T100 (RM449U)
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D position
Line pressure too low
forward clutch slipping
No.2 one−way clutch not operating properly
O/D one−way clutch not operating properly
(c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D one−way clutch not operating properly
(d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse 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 1st and reverse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
(3) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the
lever is shifted until the shock is felt.
In the same manner, measure the time lag for N → R.
Time lag:
N → D Less than 1.2 seconds
N → R Less than 1.5 seconds
Evaluation (If N → D time or N → R time lag is longer than specified):
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one−way clutch not operating properly

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− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
7. HYDRAULIC TEST
Measure the line pressure.
NOTICE:
Do the test at normal operation fluid temperature 50 − 80°C (122 − 176°F).
The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe.
(1) Warm up the fluid.
(2) Remove the test plug on the transmission case right side and connect SST.
(See page AT−26 and AT−33 for the location to connect SST)
SST 09992−00094 (09992−00150, 09992−00270)
(3) Fully apply the parking brake and chock the 4 wheels.
(4) Start the engine and check idling speed.
(5) Keep your left foot pressed firmly on the brake pedal and shift into D position.
(6) Measure the line pressure when the engine is idling.
(7) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when
engine speed reaches stall speed.
NOTICE:
Release the accelerator pedal and stop test if the rear wheels begin to rotate before the engine speed
reaches specified stall speed.
(8) In the same manner, do the test in R position.
Specified line pressure:
3RZ−FE
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling363 − 422 (3.7 − 4.3, 53 − 61)490 − 588 (5.0 − 6.0, 71 − 85)
Stall932 − 1,177 (9.5 − 12.0, 135 − 171)1,294 − 1,638 (13.2 − 16.7, 188 − 238)
5VZ−FE
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling363 − 422 (3.7 − 4.3, 53 − 61)608 − 696 (6.2 − 7.1, 88 − 101)
Stall902 − 1,147 (9.2 − 11.7, 131 − 166)1,432 − 1,942 (14.6 − 19.8, 208 − 282)
If the measured pressures are not up to specified values, recheck the throttle cable adjustment and retest.
Evaluation
ProblemPossible cause
If the measured value at all positions are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured value at all positions are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective
If pressure is low in the D position onlyD position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective

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DI−282
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On−vehicle Repair Matrix Chart
Chapter 3: Off−vehicle Repair Matrix Chart
If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow
chart for each circuit, proceed to the circuit with the next highest number in the table to continue
the check.
If the trouble still occurs even though there are no abnormalities in any of the other circuits, then
check and replace the ECM.
Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up−shift
(A particular gear, from 1st to 3rd gear, is not up−shifted)1. ECMDI−279
No up−shift (3rd → O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−311
DI−309
DI−279
No down−shift (O/D → 3rd)1. ECMDI−279
No down−shift
(A particular gear, from 1st to 3rd gear, is not up−shifted)1. ECMDI−279
No lock−up1. Stop light swich circuit
2. ECMDI−316
DI−279
No lock−up off1. Stop light swich circuit
2. ECMDI−316
DI−279
Shift point too high or too low1. ECMDI−279
Up−shift to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−311
DI−279
Up−shift to O/D from 3rd while engine is cold1. ECMDI−279
No kick−down1. ECMDI−279
Engine stalls when starting off or stopping1. Stop light swich circuit
2. ECMDI−316
DI−279

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DI−285
1996 TOYOTA T100 (RM449U)
Chapter 3: Off−Vehicle Repair Matrix Chart
(: A340E, A340F, A340H AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM391U)
(: A340F, A343F AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM479U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position and reverse posi-
tion
1. O/D one−way clutch (F0)
2. O/D direct clutch (C
0)
3. O/D planetary gear unit
4. Torque converter clutch



AT−38
Vehicle does not move in R position
1. Front and rear planetary gear unit
2. Direct clutch (C
2)
3. 1st and reverse brake (B
3)
4. O/D direct clutch (C
0)




No up−shift (1st → 2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


No up−shift (2nd → 3rd)1. Direct clutch (C2)
No up−shift (3rd → O/D)1. O/D brake (B0)
No lock−up or No lock−up off1. Torque converter clutchAT−38
Harsh engagement (N → D)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → R)
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)



Harsh engagement (N → 2)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → L)
1. Forward clutch (C1)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)
4. No. 2 one−way clutch (F
2)




Harsh engagement (Lock−up)1. Torque converter clutchAT−38
Slip or shudder (Forward and reverse: After warm−up)
1. Torque converter clutch
2. O/D one−way clutch (F
0)
3. O/D direct clutch (C
0)
AT−38


Slip or shudder (Particular position: Just after engine starts)1. Torque converter clutchAT−38
Slip or shudder (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip or shudder (1st)1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)


Slip or shudder (2nd)
1. 2nd brake (B2)
2. 2nd coast brake (B
1)
3. No. 1 one−way clutch (F
1)



Slip or shudder (3rd)1. Direct clutch (C2)
Slip or shudder (O/D)1. O/D brake (B0)
No engine braking (1st ∼ 3rd: D position)1. 2nd brake (B2)
No engine braking (1st: L position)1. 1st and reverse brake (B3)
No engine braking (2nd: 2 position)1. 2nd coast brake (B1)
Poor acceleration (All position)1. Torque converter clutchAT−38
Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear unit

Engine stalls when starting off or stopping1. Torque converter clutchAT−38

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NORMALSHIFT SOLENOID NO.1
MALFUNCTIONING
Solenoid valveNo.1 No.2GearSHIFT SOLENOID NO.2
MALFUNCTIONINGBOTH SOLENOIDS
MALFUNCTIONINGSolenoid valve
No.1 No.2GearSolenoid valve
No.1 No.2GearGear when shift selector is
manually operated
D
2
LON
ONOFF
ON
ON
OFF
OFF OFF
ON
ONOFF
ON
ON OFF
ON
ON ONOFF1st
2nd
3rd
O/D
1st
2nd
3rd
1st
2ndX
X
X
X
X
X
X
X
XON
ON
OFF
OFFON
ON
ON3rd 3rd
O/D
3rd
3rd
1st
2ndX
X
X
X
X
X
X
X
X OFF
OFF
ON
ON OFF OFF
OFF
ON
ON1st
O/D
3rd1st O/D O/D
3rd
1st
1stO/D O/D O/D
O/D
3rd 3rd
3rd
1st
1st
X: MalfunctionsON
ON3rd
3rd
DI−290
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunc-
tion (Shift Solenoid Valve No.1/No.2)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and
No.2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM con-
trols the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe func-
tion).
Fail safe function:
If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid
ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid
valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be performed
electronically and must be done manually.
Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops
sending current to the short circuited solenoid).
HINT:
Check the shift solenoid valve No.1 when DTC P0753 is output and check the shift solenoid valve No.2 when
DTC P0758 is output.
DTC No.DTC Detecting ConditionTrouble Area
P0753
P0758
ECM checks for open or short circuit in shift solenoid valves
No.1 and No.2 circuit when it changes
ECM records DTC P0753 or P0758 if condition (a) or (b) is
detected once, but it does not light up MIL
After ECM detects condition (a) or (b) continuously 2 times or
more in one−trip, it causes MIL light up until condition (a) or (b)
disappears
After that, if ECM detects condition (a) or (b) once, it starts
lighting up MIL again:
(a) Solenoid resistance is 8 Ω or less (short circuit) when sole-
noid is energized
(b) Solenoid resistance is 100 kΩ or more (open circuit) when
solenoid is not energized
Open or short in shift solenoid valve No.1/No.2 circuit
Shift solenoid valve No.1/No.2
ECM
DI0VP−02

Downloaded from www.Manualslib.com manuals search engine BR3904
0.13 sec. 0.13 sec.
ON
OFF
BR3893
Malfunction Code (Example Code 72, 76)
7
26
7
ON
OFF
0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.1.5 sec. 2.5 sec.4 sec.
Repeat
A00778DLC1 E
1
Ts
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−323
1996 TOYOTA T100 (RM449U)
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−354).
(5) Drive vehicle straight forward.
HINT:
Drive vehicle faster than 45 km/h (28 mph) for several seconds.
(6) Stop the vehicle.
(7) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(8) Read the number of blinks of the ABS warning light.
HINT:
See the list of DTC on page DI−326.
If every sensor is normal, a normal code is output (A cycle
of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunction are indicated at the same time,
the lowest numbered code will be displayed 1st.
(9) After doing the check, disconnect terminals Ts and
E
1, Tc and E1 of the DLC1, and ignition switch
turned OFF.
(b) Check the deceleration sensor detection point.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E
1 of the
DLC1.
SST 09843−18020
(3) Start the engine.