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-26
A/T CONTROL SYSTEM
TCM FunctionBCS000ZP
The function of the TCM is to:
Receive input signals sent from various switches and sensors.
Determine required line pressure, shifting point, lock-up operation, and engine brake operation.
Send required output signals to the respective solenoids.
CONTROL SYSTEM OUTLINE
The automatic transmission senses vehicle operating conditions through various sensors or signals. It always
controls the optimum shift position and reduces shifting and lock-up shocks.
CONTROL SYSTEM DIAGRAM
SWITCHES & SENSORS
TCM
ACTUATORS
PNP switch
Accelerator pedal position signal
Closed throttle position signal
Wide open throttle position signal
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Turbine revolution sensor (power
train revolution sensor)
Vehicle speed signal
3rd position switch signal
Stop lamp switch signalShift control
Line pressure control
Lock-up control
Overrun clutch control
Timing control
Fail-safe control
Self-diagnosis
CONSULT-II communication line
control
CAN systemShift solenoid valve A
Shift solenoid valve B
Overrun clutch solenoid valve
Torque converter clutch solenoid
valve
Line pressure solenoid valve
A/T CHECK indicator lamp
SCIA7869E
A/T CONTROL SYSTEM
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CAN CommunicationBCS000ZQ
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-49,
"CAN System Specification Chart" .
Input/Output Signal of TCMBCS000ZR
*1: Spare for vehicle speed sensor·A/T (revolution sensor)
*2: Spare for accelerator pedal position signal
*3: If these input and output signals are different, the TCM triggers the fail-safe function.
*4: Used as a condition for starting self-diagnostics; if self-diagnostics are not started, it is judged that there is some kind of error.
*5: Input by CAN communications.
*6: Output by CAN communications.Control itemLine
pressure
controlVehicle
speed
controlShift
controlLock-up
controlEngine
brake
controlFail-safe
functionSelf-diag-
nostics
function
InputAccelerator pedal position signal
(*5)XXXXX(*3) XX
Vehicle speed sensor A/T
(Revolution sensor)XXXXX(*3) XX
Vehicle speed sensor MTR
(*1)XXXX X
Closed throttle position signal
(*5)(*2) X(*2) XXX(*4) X
Wide open throttle position signal
(*5)(*2) X (*2) X (*4) X
Turbine revolution sensor (Power
train revolution sensor)XX X XX
Engine speed signal X X X X
PNP switch XXXXX(*3) X(*4) X
Stop lamp switch signal
(*5)XX (*4) X
A/T fluid temperature sensors X X X X X X
3rd position switch signal
(*5)XXXX (*4) X
TCM power supply voltage signal X X X X
Out-
putShift solenoid valve A/B X (*3) X X
Line pressure solenoid X (*3) X X
Torque converter clutch solenoid
valveX(*3) XX
Overrun clutch solenoid valve X X (*3) X X
A/T CHECK indicator lamp
(*6)X
A/T CONTROL SYSTEM
AT-29
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AT LOW FLUID TEMPERATURE
A/T fluid viscosity and frictional characteristics of the clutch facing change with A/T fluid temperature.
Clutch engaging or band-contacting pressure is compensated for, according to A/T fluid temperature, to
stabilize shifting quality.
The line pressure is reduced below 60°C (140°F) to prevent
shifting shock due to low viscosity of A/T fluid when temperature
is low.
Line pressure is increased to a maximum irrespective of the
throttle opening when A/T fluid temperature drops to −10°C
(14°F). This pressure rise is adopted to prevent a delay in clutch
and brake operation due to extreme drop of A/T fluid viscosity at
low temperature.
Shift ControlBCS000ZT
The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine opera-
tions. This is accomplished by electrical signals transmitted by the revolution sensor and the ECM (accelerator
pedal position sensor). This results in improved acceleration performance and fuel economy.
CONTROL OF SHIFT SOLENOID VALVES A AND B
The TCM activates shift solenoid valves A and B according to sig-
nals from the accelerator pedal position sensor and revolution sen-
sor to select the optimum gear position on the basis of the shift
schedule memorized in the TCM.
The shift solenoid valve performs simple ON-OFF operation. When
set to “ON”, the drain circuit closes and pilot pressure is applied to
the shift valve.
RELATION BETWEEN SHIFT SOLENOID VALVES A AND B AND GEAR POSITIONS
SCIA4829E
SCIA4830E
SAT008J
Gear position 1 2 3 4
Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed)
Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open)
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
TROUBLE DIAGNOSIS
AT-47
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5. Start engine and measure line pressure at idle and stall speed.
CAUTION:
Keep the brake pedal pressed all the way down during
measurement.
When measuring line pressure at stall speed, refer to AT-
43, "STALL TEST" .
Line Pressure
Judgement of Line Pressure Test
SAT493G
Engine speed rpmLine pressure kPa (bar, kg/cm2 , psi)
“D”, “3”, “2” and “1” positions “R” position
Idle 500 (5.00, 5.1, 73) 778 (7.78, 7.9, 113)
Stall 1,233 (12.33, 12.6, 179) 1,918 (19.18, 19.6, 278)
Judgement Suspected parts
At idleLine pressure is low in all positions.
Oil pump wear
Control piston damage
Pressure regulator valve or plug sticking
Spring for pressure regulator valve damaged
Fluid pressure leakage between oil strainer and pressure regulator valve
Clogged strainer
Line pressure is low in particular posi-
tion.
Fluid pressure leakage between manual valve and particular clutch
For example, line pressure is:
− Low in “R” and “1” positions, but
− Normal in “D”, “3” and “2” positions.
Therefore, fluid leakage exists at or around low and reverse brake circuit.
Refer to AT-18, "
CLUTCH AND BAND CHART" .
Line pressure is high.
Accelerator pedal position signal malfunction
A/T fluid temperature sensor damaged
Line pressure solenoid valve sticking
Short circuit of line pressure solenoid valve circuit
Pressure modifier valve sticking
Pressure regulator valve or plug sticking
Open in dropping resistor circuit
At stall
speedLine pressure is low.
Accelerator pedal position signal malfunction
Line pressure solenoid valve sticking
Short circuit of line pressure solenoid valve circuit
Pressure regulator valve or plug sticking
Pressure modifier valve sticking
Pilot valve sticking
TROUBLE DIAGNOSIS
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Symptom ChartBCS0010B
Numbers are arranged in order of inspection.
Perform inspections starting with number one and work up.
Items Symptom Condition Diagnostic item Reference page
No Lock-up
Engagement/
TCC InoperativeTorque converter
is not locked up.ON vehicle1. Accelerator pedal position sensor
EC-272
*1, EC-652*2
2. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
3. PNP switchAT- 1 6 1
4. Engine speed signalAT- 11 6
5. A/T fluid temperature sensorAT- 11 0
6. Line pressure testAT- 4 6
7. Torque converter clutch solenoid valveAT- 1 0 5
8. Control valve assemblyAT- 2 2 5
OFF vehicle 9. Torque converterAT- 2 5 5
Torque converter
clutch piston slip.ON vehicle1. A/T fluid levelAT- 1 4
2. Accelerator pedal position sensor
EC-272*1, EC-652*2
3. Line pressure testAT- 4 6
4. Torque converter clutch solenoid valveAT- 1 0 5
5. Line pressure solenoid valveAT- 1 2 6
6. Control valve assemblyAT- 2 2 5
OFF vehicle 7. Torque converterAT- 2 5 5
Lock-up point is
extremely high or
low.ON vehicle1. Accelerator pedal position sensor
EC-272
*1, EC-652*2
2. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
3. Torque converter clutch solenoid valveAT- 1 0 5
4. Control valve assemblyAT- 2 2 5
Shift ShockSharp shock in
shifting from “N”
to “D” position.ON vehicle1. Engine idle speed
EC-45
*1, EC-387*2
2. Accelerator pedal position sensor
EC-272*1, EC-652*2
3. Line pressure testAT- 4 6
4. A/T fluid temperature sensorAT- 11 0
5. Engine speed signalAT- 11 6
6. Line pressure solenoid valveAT- 1 2 6
7. Control valve assemblyAT- 2 2 5
8. N-D accumulatorAT- 2 2 5
OFF vehicle 9. Forward clutchAT- 3 0 7
Too sharp a
shock in change
from D
1 to D2 .ON vehicle1. Accelerator pedal position sensor
EC-272
*1, EC-652*2
2. Line pressure testAT- 4 6
3. Accumulator servo releaseAT- 2 2 5
4. Control valve assemblyAT- 2 2 5
5. A/T fluid temperature sensorAT- 11 0
OFF vehicle 6. Brake bandAT- 3 2 9
AT-58
TROUBLE DIAGNOSIS
No Up ShiftFailure to change
gear from D
1 to
D
2 .ON vehicle1. A/T positionAT-215
2. Shift solenoid valve AAT- 9 0
3. Control valve assemblyAT-225
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
5. Accelerator pedal position sensor
EC-272*1, EC-652*2
OFF vehicle 6. Brake bandAT-329
Failure to change
gear from D
2 to
D
3 .ON vehicle1. A/T positionAT-215
2. Shift solenoid valve BAT- 9 5
3. Control valve assemblyAT-225
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
5. Accelerator pedal position sensor
EC-272*1, EC-652*2
OFF vehicle6. High clutchAT-3017. Brake bandAT-329
Failure to change
gear from D
3 to
D
4 .ON vehicle 1. PNP switchAT-161
2. 3rd position switchAT-161
3. A/T positionAT-215
4. Shift solenoid valve AAT- 9 0
5. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
6. A/T fluid temperature sensorAT- 11 0
OFF vehicle 7. Brake band AT-329
A/T does not shift
to D
4 when driv-
ing with changing
lever into “D”
position.ON vehicle1. Accelerator pedal position sensor
EC-272
*1, EC-652*2
2. PNP switchAT-161
3. 3rd position switchAT-161
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 8 0, AT- 8 6
5. Shift solenoid valve AAT- 9 0
6. Overrun clutch solenoid valveAT-100
7. Control valve assemblyAT-225
8. A/T fluid temperature sensorAT- 11 0
9. Line pressure solenoid valveAT-126
OFF vehicle10. Brake bandAT-32911. Overrun clutchAT-307
Items Symptom Condition Diagnostic item Reference page