AT-3
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CONSULT-II Reference Value .............................. 167
Diagnostic Procedure ........................................... 167
TROUBLE DIAGNOSIS FOR SYMPTOMS ............ 168
Wiring Diagram — AT — NONDTC ...................... 168
A/T CHECK Indicator Lamp Does Not Come On . 173
Engine Cannot Be Started in “P” and “N” Position . 175
In “P” Position, Vehicle Moves Forward or Backward
When Pushed ....................................................... 176
In “N” Position, Vehicle Moves ............................. 176
Large Shock. “N” → “R” Position .......................... 177
Vehicle Does Not Creep Backward in “R” Position . 179
Vehicle Does Not Creep Forward in “D”, “3”, “2” or
“1” Position ........................................................... 181
Vehicle Cannot Be Started From D
1 ..................... 182
A/T Does Not Shift: D
1 → D2 or Does Not Kickdown:
D
4 → D2 ............................................................... 184
A/T Does Not Shift: D
2 → D3 ............................... 186
A/T Does Not Shift: D
3 → D4 ............................... 188
A/T Does Not Perform Lock-up ............................ 191
A/T Does Not Hold Lock-up Condition ................. 193
Lock-up Is Not Released ...................................... 195
Engine Speed Does Not Return To Idle (Light Brak-
ing D
4 → D3 ) ....................................................... 195
A/T Does Not Shift: D
4 → 33 , When A/T Selector
Lever “D” → “3” .................................................... 197
A/T Does Not Shift: 3
3 → 22 , When Selector Lever
“3” → “2” Position ................................................. 198
A/T Does Not Shift: 2
2 → 11 , When Selector Lever
“2” → “1” Position ................................................. 200
Vehicle Does Not Decelerate By Engine Brake (D
4
→ 3
3 ) ................................................................... 203
Vehicle Does Not Decelerate By Engine Brake (3
3
→ 2
2 ) ................................................................... 205
Vehicle Does Not Decelerate By Engine Brake (2
2
→ 1
1 ) ................................................................... 208
TCM Self-diagnosis Does Not Activate ................ 210
TRANSMISSION CONTROL MODULE ..................211
Removal and Installation ....................................... 211
SHIFT CONTROL SYSTEM ................................... 213
Control Device Removal and Installation ............. 213
Adjustment of A/T Position ................................... 215
Checking of A/T Position ...................................... 215
A/T SHIFT LOCK SYSTEM .................................... 216
Description ........................................................... 216
Shift Lock System Electrical Parts Location ......... 216
Wiring Diagram — AT — SHIFT ........................... 217
Shift Lock Control Unit Reference Values ............ 221
Component Inspection ......................................... 222
ON-VEHICLE SERVICE ......................................... 225
Control Valve Assembly and Accumulators .......... 225
Park/Neutral Position (PNP) Switch ..................... 230
Differential Side Oil Seal Replacement ................ 231
Revolution Sensor Replacement .......................... 233
Turbine Revolution Sensor (Power Train Revolution
Sensor) Replacement .......................................... 234
AIR BREATHER HOSE .......................................... 236
Removal and Installation [Air Breather Hose (Oil
Catch Tank to Air Duct)] ....................................... 236
Removal and Installation [Oil Catch Tank and Air Breather Hose (A/T assembly to Oil catch tank)] . 239
TRANSAXLE ASSEMBLY ......................................241
Removal and Installation ......................................241
OVERHAUL ............................................................246
Components .........................................................246
Oil Channel ...........................................................252
Locations of Adjusting Shims, Needle Bearings and
Thrust Washers ....................................................253
Locations of Snap Rings .......................................254
DISASSEMBLY .......................................................255
Disassembly .........................................................255
REPAIR FOR COMPONENT PARTS .....................272
Manual Shaft ........................................................272
Oil Pump ...............................................................275
Control Valve Assembly ........................................280
Control Valve Upper Body ....................................289
Control Valve Lower Body ....................................293
Reverse Clutch .....................................................296
High Clutch ...........................................................301
Forward and Overrun Clutches ............................307
Low & Reverse Brake ...........................................315
Rear Internal Gear, Forward Clutch Hub and Over-
run Clutch Hub ......................................................319
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................323
Band Servo Piston Assembly ...............................329
Final Drive ............................................................335
ASSEMBLY .............................................................339
Assembly (1) .........................................................339
Adjustment (1) ......................................................340
Assembly (2) .........................................................345
Adjustment (2) ......................................................352
Assembly (3) .........................................................355
SERVICE DATA AND SPECIFICATIONS (SDS) ....362
General Specifications ..........................................362
Vehicle Speed Which Gear Shifting Occurs .........362
Vehicle Speed at When Lock-up Occurs/Releases .362
Stall Revolution .....................................................363
Line Pressure .......................................................363
Adjusting shims, Needle Bearings, Thrust Washers
and Snap Rings ....................................................363
Control Valves ......................................................364
Accumulator ..........................................................365
Clutch and Brakes ................................................366
Final Drive ............................................................367
Planetary Carrier and Oil Pump ............................367
Input Shaft ............................................................367
Reduction Pinion Gear .........................................367
Band Servo ...........................................................368
Output Shaft .........................................................368
Bearing Retainer ...................................................368
Total End Play .......................................................368
Reverse Clutch End Play ......................................368
Removal and Installation ......................................368
Shift Solenoid Valves ............................................368
Solenoid Valves ....................................................368
A/T Fluid Temperature Sensor ..............................368
Revolution Sensor ................................................369
AT-14
A/T FLUID
A/T FLUIDPFP:KLE40
Checking A/T FluidBCS000ZL
1. Warm up engine.
2. Check for A/T fluid leakage.
3. Before driving, A/T fluid level can be checked A/T at fluid tem-
peratures of 30 to 50°C (86 to 122°F) using “COLD” range on A/
T fluid level gauge.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check A/T fluid level with engine idling.
d. Remove A/T fluid level gauge and wipe clean with lint-free
paper.
CAUTION:
When wiping away the A/T fluid level gauge, always use
lint-free paper, not a cloth one.
e. Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using a stopper attached.
f. Remove A/T fluid level gauge and note reading. If reading is at
low side of range, add ATF to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Recheck A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T
fluid level gauge.
CAUTION:
When wiping away the A/T fluid level gauge, always use lint-free paper, not cloth one.
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.
SMA146B
SCIA3451E
SMA051D
AT-28
A/T CONTROL SYSTEM
Line Pressure ControlBCS000ZS
TCM has various line pressure control characteristics to match the driving conditions.
An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics.
Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid
valve to accommodate engine torque. This results in smooth shift operation.
NORMAL CONTROL
The characteristics of line pressure to throttle opening.
BACK-UP CONTROL (ENGINE BRAKE)
If the selector lever is shifted to “2” position while driving in D4 , D3
or 33 , great driving force is applied to the clutch inside the transmis-
sion. Clutch operating pressure (line pressure) must be increased to
deal with this driving force.
DURING SHIFT CHANGE
The line pressure is temporarily reduced corresponding to a change
in engine torque when shifting gears (that is, when the shift solenoid
valve is switched for clutch operation) to reduce shifting shock.
SCIA4826E
SCIA4827E
SCIA4828E
AT-30
A/T CONTROL SYSTEM
CONTROL OF SHIFT VALVES A AND B
Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift
valves A and B.
The figure above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure
applied to the end face of the shift valve overcomes spring force, moving the valve upward.
Lock-up ControlBCS000ZU
The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip to
increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from
the TCM. The signal is converted to an oil pressure signal which controls the torque converter clutch piston.
CONDITIONS FOR LOCK-UP OPERATION
When vehicle is driven in 3rd and 4th gear position, vehicle speed and throttle opening are detected. If the
detected values fall within the lock-up zone memorized in the TCM, lock-up is performed.
TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL
Lock-up Control System Diagram
SAT009J
Selector lever “D” position “3” position
Gear position D
4 , D333
Vehicle speed sensor More than set value
accelerator pedal position sensor Less than set opening
Closed throttle position signal OFF
A/T fluid temperature sensor More than 20°C (68°F)
SCIA5623E
A/T CONTROL SYSTEM
AT-31
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Lock-up Released
In the lock-up released state, the torque converter clutch control valve is set into the unlocked state by drain-
ing the torque converter clutch piston applying pressure and the torque converter clutch piston release pres-
sure is generated.
In this way, the torque converter clutch piston is not coupled.
Lock-up Applied
In the lock-up applied state, the torque converter clutch control valve is set into the locked state by generating
the torque converter clutch piston applying pressure and the torque converter clutch piston release pressure is
drained.
In this way, the torque converter clutch piston is pressed and coupled.
SMOOTH LOCK-UP CONTROL
When shifting from the lock-up released state to the lock-up applied state, the current output to the torque con-
verter clutch solenoid is controlled with the TCM. In this way, when shifting to the lock-up applied state, the
torque converter clutch is temporarily set to the half-clutched state to reduce the shock.
Half-clutched State
The current output from the TCM to the torque converter clutch solenoid is varied to steadily increase the
torque converter clutch solenoid pressure.
In this way, the lock-up applying pressure gradually rises and while the torque converter clutch piston is put
into half-clutched status, the torque converter clutch piston applying pressure is increased and the coupling is
completed smoothly.
Engine Brake Control (Overrun Clutch Control)BCS000ZV
Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits
engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because
the one-way clutch rotates idle. This means the engine brake is not effective.
The overrun clutch operates when the engine brake is needed.
OVERRUN CLUTCH OPERATING CONDITIONS
SCIA4831E
Selector lever position Gear position Throttle opening
“D” position D
1 , D2 , D3 gear position
Less than 3/16
“3” position 3
1 , 32 , 33 gear position
“2” position 2
1 , 22 gear position
At any position
“1” position 1
1 , 12 gear position
AT-34
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSISPFP:00004
DTC Inspection Priority ChartBCS000ZX
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for
“CAN COMMUNICATION LINE”. Refer to AT- 1 3 3
.
Fail-safeBCS000ZY
The TCM has an electronic Fail-safe mode. This allows the vehicle to be driven even if a major electrical input/
output device circuit is damaged.
Under Fail-safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2”, “3” or “D”. The
customer may complain of sluggish or poor acceleration.
Always follow the AT- 3 7 , "
WORK FLOW" .
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.
FAIL-SAFE FUNCTION
The following fail-safe functions allow vehicles to be driven even when sensor, switch or solenoid malfunction
occurs.
Vehicle Speed Sensor 1 (Revolution Sensor)
Vehicle speed sensor 2 signal is input from combination meter.
Accelerator Pedal Position Sensor Signal
TCM controls the throttle opening angle to a predetermined fixed position to enable driving if a malfunctioning
signal is input to TCM.
Park/Neutral Position (PNP) Switch
When the multiple PNP switch signals are input to TCM, the priority of selector lever position becomes “D”·“3”,
“N”, “R”, “2” and “1” in order by internal TCM determination.
The use of 4th gear is inhibited until normal operation resumes. Because the hydraulic circuit of the control
valve is switched by manual valve according to the selector lever position, however, actual operating condition
of vehicle becomes as follows.
Priority Detected items
1 CAN communication line
2 Except above
Actual lever position PNP switch input signal Running status
“P” “P” position and other position signals P
“R” “R” position and other position signals R
“N” “N” position and other position signals N
“D”·“3” “D” position and other position signals D
1 ⇔D2 ⇔D3
“2”“2” position and other position signals (Except “1” position) 21 ⇔22 ⇔23
“2” position and “1” position signals 21 ⇔22
“1”“1” position and other position signals (Except “2” position) 11 ⇔12 ⇔13
“1” position and “2” position signals 11 ⇔12
AT-40
TROUBLE DIAGNOSIS
4. 4-3.“Cruise Test”AT- 5 0
Part 1
❏ AT-182, "
Vehicle Cannot Be Started From D1" .
❏ AT-184, "
A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" .
❏ AT-186, "
A/T Does Not Shift: D2 → D3" .
❏ AT-188, "
A/T Does Not Shift: D3 → D4" .
❏ AT-191, "
A/T Does Not Perform Lock-up" .
❏ AT-193, "
A/T Does Not Hold Lock-up Condition" .
❏ AT-195, "
Lock-up Is Not Released" .
❏ AT-195, "
Engine Speed Does Not Return To Idle (Light Braking D4 → D3 )" .
Part 2AT- 5 1
❏ AT-182, "Vehicle Cannot Be Started From D1" .
❏ AT- 1 8 4 , "
A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" .
❏ AT-186, "
A/T Does Not Shift: D2 → D3" .
❏ AT-188, "
A/T Does Not Shift: D3 → D4" .
Part 3AT- 5 2
❏ AT-197, "A/T Does Not Shift: D4 → 33 , When A/T Selector Lever “D” → “3”" .
❏ AT-203, "
Vehicle Does Not Decelerate By Engine Brake (D4 → 33 )" .
❏ AT-198, "
A/T Does Not Shift: 33 → 22 , When Selector Lever “3” → “2” Position" .
❏ AT-205, "
Vehicle Does Not Decelerate By Engine Brake (33 → 22 )" .
❏ AT-200, "
A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position" .
❏ AT-208, "
Vehicle Does Not Decelerate By Engine Brake (22 → 11 )" .
❏ Perform self-diagnostics. Enter checks for detected items. AT- 6 9
, AT- 7 6 .
❏ AT-133, "
CAN COMMUNICATION LINE" .
❏ AT-80, "
VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" .
❏ AT-86, "
VEHICLE SPEED SENSOR MTR" .
❏ AT-120, "
TURBINE REVOLUTION SENSOR" .
❏ AT-90, "
SHIFT SOLENOID VALVE A" .
❏ AT-95, "
SHIFT SOLENOID VALVE B" .
❏ AT-100, "
OVERRUN CLUTCH SOLENOID VALVE" .
❏ AT-105, "
TORQUE CONVERTER CLUTCH SOLENOID VALVE" .
❏ AT-110, "
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)" .
❏ AT-116, "
ENGINE SPEED SIGNAL" .
❏ AT-136, "
A/T 1ST GEAR FUNCTION" .
❏ AT-140, "
A/T 2ND GEAR FUNCTION" .
❏ AT-143, "
A/T 3RD GEAR FUNCTION" .
❏ AT-146, "
A/T 4TH GEAR FUNCTION" .
❏ AT-151, "
A/T TCC S/V FUNCTION (LOCK-UP)" .
❏ AT-126, "
LINE PRESSURE SOLENOID VALVE" .
❏ AT-156, "
CONTROL UNIT (RAM)" .
❏ AT-157, "
CONTROL UNIT (ROM)" .
5.❏ For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
6.❏ Perform “Road Test”.AT- 4 8
7.❏ Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)AT- 5 5
8.❏ Erase DTC from TCM and ECM memories.AT- 6 9AT- 7 9
TROUBLE DIAGNOSIS
AT-43
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Inspections Before Trouble DiagnosisBCS00102
A/T FLUID CHECK
Fluid Leakage and Fluid Level Check
Inspect for A/T fluid leakage and check the A/T fluid level. Refer to AT- 1 4 , "Checking A/T Fluid" .
A/T Fluid Condition Check
Inspect the A/T fluid condition.
STALL TEST
Stall Test Procedure
1. Check ATF and engine oil levels. If necessary, add ATF and oil.
2. Drive vehicle for approximately 10 minutes or until ATF and
engine oil reach operating temperature.
3. Set parking brake and block wheels.
4. Install a tachometer where it can be seen by driver during test.
It is good practice to mark the point of specified engine
rpm on indicator.
5. Start engine, apply foot brake, and place selector lever in “D”
position.
Fluid status Conceivable Cause Required Operation
Varnished (viscous
varnish state)Clutch, brake
scorchedReplace the ATF and check the A/T
main unit and the vehicle for mal-
functions (wire harnesses, cooler
pipes, etc.)
Milky white or
cloudyWater in the ATFReplace the ATF and check for
places where water is getting in.
Large amount of
metal powder mixed
inUnusual wear of
sliding parts within
A/TReplace the ATF and check for
improper operation of the A/T.
SAT638A
ATF operating temperature: 50 - 80°C (122 - 176°F)
SAT647B
SCIA7463E
SCIA5703E