SERVICE DATA AND SPECIFICATIONS (SDS)
MT-97
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS008CE
TRANSAXLE
Engine QR20DE QR25DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Model code number 8H500 9H608 8H868
Number of speed 5 6
Synchromesh typeWarner
Shift pattern
5 speed
6 speed
Gear ratio 1st 3.500 3.416 3.500
2nd 1.944
3rd 1.258
4th 0.947
5th 0.772 0.733 0.772
6th — 0.630
Reverse 3.374 3.252 3.374
Number of teeth Input gear 1st 14 12 14
2nd 18
3rd 31
4th 38
5th 444544
6th — 46
Reverse 14 12 14
Main gear 1st 49 41 49
2nd 35
3rd 39
4th 36
5th 343334
6th — 29
Reverse 38
Reverse idler
gearFront 37
Rear 46 38 46
Oil capacity
(Imp pt)2.3 (4)
SCIA0821E
SCIA0955E
AT-3
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AT TION ........................................................................ 287
Symptom Chart .................................................... 287
TCM Terminals and Reference Value ................... 306
CAN COMMUNICATION ........................................ 309
System Description .............................................. 309
TROUBLE DIAGNOSES FOR SYMPTOMS .......... 310
Wiring Diagram — AT — NONDTC ...................... 310
O/D OFF Indicator Lamp Does Not Come On ..... 312
Engine Cannot Be Started In “P” and “N” Position . 314
In “P” Position, Vehicle Moves Forward Or Back-
ward When Pushed .............................................. 315
In “N” Position, Vehicle Moves ............................. 315
Large Shock. “N” → “R” Position .......................... 317
Vehicle Does Not Creep Backward In “R” Position . 318
Vehicle Does Not Creep Forward In “D”, “2” Or “1”
Position ................................................................ 321
Vehicle Cannot Be Started From D
1 ..................... 323
A/T Does Not Shift: D
1→ D2 Or Does Not Kick down:
D
4→ D2 ............................................................... 326
A/T Does Not Shift: D
2→ D3 ............................... 328
A/T Does Not Shift: D
3→ D4 ............................... 330
A/T Does Not Perform Lock-up ............................ 332
A/T Does Not Hold Lock-up Condition ................. 333
Lock-up Is Not Released ...................................... 335
Engine Speed Does Not Return To Idle (Light Brak-
ing D
4→ D3 ) ....................................................... 336
Vehicle Does Not Start From D
1 ........................... 338
A/T Does Not Shift: D
4→ D3 , When Overdrive Con-
trol Switch “ON” → “OFF” ..................................... 339
A/T Does Not Shift: D
3→ 22 , W h e n S e l e c t o r L e v e r
“D”→ “2” Position ................................................ 340
A/T Does Not Shift: 2
2→ 11 , W h e n S e l e c t o r L e v e r
“2” → “1” Position ................................................. 341
Vehicle Does Not Decelerate By Engine Brake ... 343
TCM Self-diagnosis Does Not Activate ................ 344
ALL
MAIN POWER SUPPLY AND GROUND CIRCUIT . 350
Wiring Diagram — AT — MAIN ............................ 350
Diagnostic Procedure ........................................... 351
VEHICLE SPEED SENSOR·A/T (REVOLUTION
SENSOR) ................................................................ 353
Description ........................................................... 353
Wiring Diagram — AT — VSSA/T ........................ 355
Diagnostic Procedure ........................................... 356
DTC VEHICLE SPEED SENSOR MTR .................. 358
Description ........................................................... 358
Wiring Diagram — AT — VSSMTR ...................... 360
Diagnostic Procedure ........................................... 361
ACCELE RATOR PEDAL POSITION (APP) SEN-
SOR ........................................................................ 362
Description ........................................................... 362
Wiring Diagram — AT — TPS .............................. 364
Diagnostic Procedure ........................................... 365
SHIFT SOLENOID VALVE A .................................. 367
Description ........................................................... 367
Wiring Diagram — AT — SSV/A .......................... 369Diagnostic Procedure ...........................................370
Component Inspection ..........................................371
SHIFT SOLENOID VALVE B ..................................372
Description ............................................................372
Wiring Diagram — AT — SSV/B ...........................374
Diagnostic Procedure ...........................................375
Component Inspection ..........................................376
OVERRUN CLUTCH SOLENOID VALVE ...............377
Description ............................................................377
Wiring Diagram — AT — OVRCSV ......................378
Diagnostic Procedure ...........................................379
Component Inspection ..........................................380
TORQUE CONVERTER CLUTCH SOLENOID
VALVE .....................................................................381
Description ............................................................381
Wiring Diagram — AT — TCV ..............................383
Diagnostic Procedure ...........................................384
Component Inspection ..........................................385
BATT/FLUID TEMP SEN (A/T FLUID TEMP SEN-
SOR CIRCUIT AND TCM POWER SOURCE) .......386
Description ............................................................386
Wiring Diagram — AT — BA/FTS .........................388
Diagnostic Procedure ...........................................389
Component Inspection ..........................................391
ENGINE SPEED SIGNAL .......................................392
Description ............................................................392
Wiring Diagram — AT — ENGSS .........................393
Diagnostic Procedure ...........................................394
LINE PRESSURE SOLENOID VALVE ..................
.396
Description ............................................................396
Wiring Diagram — AT — LPSV ............................398
Diagnostic Procedure ...........................................399
Component Inspection ..........................................401
CAN COMMUNICATION LINE ...............................403
Description ............................................................403
On Board Diagnosis Logic ....................................403
Self-Diagnosis Code Confirmation Procedure ......403
Wiring Diagram — AT — CAN ..............................404
Diagnostic Procedure ...........................................405
A/T SHIFT LOCK SYSTEM ....................................406
Description ............................................................406
Shift Lock System Electrical Parts Location .........406
Wiring Diagram — SHIFT — ................................407
Diagnostic Procedure ...........................................408
KEY INTERLOCK CABLE ......................................412
Components .........................................................412
Removal ...............................................................412
Installation ............................................................413
ON-VEHICLE SERVICE ..........................................414
Control Valve Assembly and Accumulators ..........414
Control Cable Adjustment .....................................416
Park/Neutral Position (PNP) Switch Adjustment ..416
Differential Side Oil Seal Replacement ................417
Revolution Sensor Replacement ..........................417
REMOVAL AND INSTALLATION ...........................418
Removal ...............................................................418
Installation ............................................................419
OVERHAUL ............................................................421
Components .........................................................421
AT-4
Oil Channel ...........................................................424
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................425
DISASSEMBLY .......................................................426
Disassembly .........................................................426
REPAIR FOR COMPONENT PARTS ......................441
Manual Shaft ........................................................441
Oil Pump ...............................................................444
Control Valve Assembly ........................................448
Control Valve Upper Body ....................................457
Control Valve Lower Body ....................................461
Reverse Clutch .....................................................463
High Clutch ...........................................................466
Forward and Overrun Clutches ............................471
Low & Reverse Brake ...........................................476
Rear Internal Gear, Forward Clutch Hub and Over-
run Clutch Hub ......................................................479
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................483
Band Servo Piston Assembly ...............................488
Final Drive ............................................................493
ASSEMBLY .............................................................498
Assembly (1) .........................................................498
Adjustment (1) ......................................................499
Assembly (2) .........................................................504Adjustment (2) .......................................................510
Assembly (3) .........................................................514
SERVICE DATA AND SPECIFICATIONS (SDS) ....521
General Specifications ......................................... .521
Shift Schedule .......................................................521
Stall Revolution .....................................................522
Line Pressure ........................................................522
Control Valves .......................................................522
Accumulator ..........................................................523
Clutch and Brakes .................................................524
Final Drive .............................................................526
Planetary Carrier and Oil Pump ............................527
Input Shaft .............................................................528
Reduction Pinion Gear ..........................................528
Band Servo ...........................................................529
Output Shaft ..................................................
........529
Bearing Retainer ...................................................529
Total End Play .......................................................529
Reverse Clutch End Play ......................................530
Removal and Installation .......................................530
Shift Solenoid Valves ............................................530
Solenoid Valves ....................................................530
A/T Fluid Temperature Sensor ..............................531
Revolution Sensor .................................................531
Dropping Resistor .................................................531
PREPARATION
AT-9
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PREPARATIONPFP:00100
Special Service ToolsECS004Q5
Tool number
Tool nameDescription
KV381054S0 Puller
●Removing differential side oil seals
●Removing differential side bearing outer race
●Removing idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33400001 Drift
●Installing differential side oil seal
F04B
● Installing oil seal on oil pump housing
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST2505S001 Oil pressure
gauge set
1. ST25051001 Oil pressure
gauge
2. ST25052000 Hose
3. ST25053000 Joint pipe
4. ST25054000 Adapter
5. ST25055000 Adapter
●Measuring line pressure
ST27180001 Puller
●Removing idler gear
a: 100 mm (3.94 in)
b: 110 mm (4.33 in)
c: M8 x 1.25P
ST23540000 Pin punch
●Removing and installing parking rod plate and
manual plate pins
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
ST25710000 Pin punch
●Aligning groove of manual shaft and hole of
transmission case
a: 2 mm (0.08 in) dia.
NT414
NT086
NT097
NT424
NT442
NT410
AT-12
PREPARATION
Commercial Service Tools
ECS004Q6
Tool name Description
Puller
●Removing idler gear bearing inner race
●Removing and installing band servo piston
snap ring
Puller
●Removing reduction gear bearing inner
race
a: 60 mm (2.36 in) dia.
b: 35 mm (1.38 in) dia.
Drift
●Installing differential side oil seal
a: 90 mm (3.54 in) dia.
Drift
●Installing needle bearing on bearing
retainer
a: 36 mm (1.42 in) dia.
Drift
●Removing needle bearing from bearing
retainer
a: 33.5 mm (1.319 in) dia.
Drift
●Installing differential side bearing outer
race
a: 75 mm (2.95 in) dia.
Drift
●Installing differential side bearing outer
race
a: 100 mm (3.94 in) dia.
NT077
NT411
NT083
NT083
NT083
NT083
NT083
AT-16
OVERALL SYSTEM
Cross-Sectional View
ECS004QB
SCIA0688E
1. Band servo piston 9. Low one-way clutch 17. Pinion reduction gear
2. Reverse clutch drum 10. Rear planetary gear 18. Final gear
3. Converter housing 11. Forward clutch 19. Differential case
4. Oil pump 12. Overrun clutch 20. Input shaft
5. Brake band 13. Low & reverse brake 21. Torque converter
6. Reverse clutch 14. Output gear 22. Side cover
7. High clutch 15. Idler gear
8. Front planetary gear 16. Forward one-way clutch
AT-18
OVERALL SYSTEM
Shift Mechanism
ECS004QD
CONSTRUCTION
FUNCTION OF CLUTCH AND BRAKE
1. Torque converter 2. Oil pump 3. Input shaft
4. Brake band 5. Reverse clutch 6. High clutch
7. Front sun gear 8. Front pinion gear 9. Front internal gear
10. Front planetary carrier 11. Rear sun gear 12. Rear pinion gear
13. Rear internal gear 14. Rear planetary carrier 15. Forward clutch
16. Forward one-way clutch 17. Overrun clutch 18. Low one-way clutch
19. Low & reverse brake 20. Parking pawl 21. Parking gear
22. Output shaft 23. Idle gear 24. Output gear
SAT998I
Clutch and brake components Abbr. Function
5 Reverse clutch R/C To transmit input power to front sun gear 7 .
6 High clutch H/C To transmit input power to front planetary carrier 10 .
15 Forward clutch F/C To connect front planetary carrier 10 with forward one-way clutch 16 .
17 Overrun clutch O/C To connect front planetary carrier 10 with rear internal gear 13 .
4 Brake band B/B To lock front sun gear 7 .
16 Forward one-way clutch F/O.C When forward clutch 15 is engaged, to stop rear internal gear 13 from rotatin g in
opposite direction against engine revolution.
18 Low one-way clutch L/O.C To stop front planetary carrier 10 from rotating in opposite direction against
engine revolution.
19 Low & reverse brake L & R/B To lock front planetary carrier 10 .
OVERALL SYSTEM
AT-19
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CLUTCH AND BAND CHART
●*1: Operates when overdrive control switch is set in “OFF” position.
●*2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not con-
tract because oil pressure area on the “release” side is greater than that on the “apply” side.
●*3: Oil pressure is applied to 4th “apply” side in condition *2 above, and brake band contracts.
●*4: A/T will not shift to 4th when overdrive control switch is set in “OFF” position.
●: Operates.
●A: Operates when throttle opening is less than 3/16, activating engine brake.
●B: Operates during “progressive” acceleration.
●C: Operates but does not affect power transmission.
●D: Operates when throttle opening is less than 3/16, but does not affect engine brake. Shift positionRever
se
clutch
5High
clutch
6For-
ward
clutch
15Over-
run
clutch
17Band servo
Forward
one-way
clutch
16Low
one-
way
clutch
18Low &
revers
e
brake
19Lock-
upRemarks
2nd
apply3rd
releas
e4th
apply
PPA R K
POSITION
RREVERSE
POSITION
NNEUTRAL
POSITION
D*41st *1D B B
Automatic
shift
1⇔ 2 ⇔ 3 ⇔
4 2nd *1A B
3rd *1A *2C C B
*1
4th C *3C C
21stBBAutomatic
shift
1⇔ 2 2ndB
11stBLocks (held
stationary) in
1st speed
1⇐ 2 2ndB