Page 2385 of 2870

4AT-72
AUTOMATIC TRANSMISSION
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
2) Tighten the bolt and nut.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect the harness connectors.
Connect the connectors of same color, and con-
nect the connectors to control valve body using
clips.4) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
5) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
6) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
7) Pour ATF from the ATF charge pipe.
4AT-30, Automatic Transmission Fluid.>
8) Check the ATF level.
ic Transmission Fluid.>
2. ATF TEMPERATURE SENSOR
For installation procedure of the ATF temperature
sensor, refer to “Front Vehicle Speed Sensor”.
Speed Sensor.>
Bolt length mm (in)
(A) 12 (0.47)
(B) 40 (1.57)
(C) 45 (1.77)
(D) 62 (2.44)
(E) 73 (2.87)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-02126
E
AD
EE
D
D
B
CC
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
AT-00051
AT-02123
Page 2386 of 2870

4AT-73
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
20.Transfer Duty Solenoid and
Valve Body
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the air cleaner case. (Non-turbo mod-
el).
Case.>
4) Remove the intercooler. (Turbo model)
er.>
5) Remove the pitching stopper.
6) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model).
Pipe.>
7) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
8) Remove the rear exhaust pipe and muffler.
(Non-turbo model).
Pipe.>
fler.>
(Turbo model)
haust Pipe.>
AL, Muffler.>9) Raise the vehicle and drain the ATF.
10) Remove the heat shield cover. (If equipped)
11) Remove the propeller shaft.
12) Remove the transmission rear crossmember.
(1) Support the transmission using a transmis-
sion jack and raise slightly.
(2) Remove the bolts and nuts as shown in the
figure.
13) Remove the rear vehicle speed sensor.
AT-00023
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential oil drain plug
AT-00016
(A) (B)
(C)
AT-00024
AT-00082
Page 2387 of 2870

4AT-74
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
14) Remove the select cable nut.
15) Move the gear select cable so that extension
case securing bolts can be removed.
16) Remove the bolt.
17) Remove the extension case.
NOTE:
Use a container to catch oil flowing from extension.
18) Disconnect the transfer duty solenoid connec-
tor.
19) Remove the transfer duty solenoid and transfer
valve body.B: INSTALLATION
1) Install the transfer duty solenoid and transfer
valve body.
(1) Install the transfer duty solenoid and trans-
fer valve body.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
2) Replace the gasket with a new one, and then in-
stall the extension case to transmission case.
(1) Tighten eleven bolts.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable.
JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00083
AT-00084
AT-00085
(A)
(C)
(B)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00086
(A)
(C)
(B)
TT
AT-00087
T
Page 2388 of 2870

4AT-75
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
4) Install the transmission rear crossmember.
(1) Tighten the bolt.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
(2) Remove the transmission jack.
5) Install the propeller shaft.
6) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
haust Pipe.>
TION, Rear Exhaust Pipe.>
INSTALLATION, Muffler.>
7) Install the center, rear exhaust pipe and muffler.
(Turbo model)
Exhaust Pipe.>
STALLATION, Rear Exhaust Pipe.>
EX(H4DOTC)-16, INSTALLATION, Muffler.>
8) Connect the transmission harness connector.9) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
10) Install the air cleaner case. (Non-turbo model)
Case.>
11) Install the intercooler. (Turbo model)
cooler.>
12) Pour ATF from the ATF charge pipe.
4AT-30, Automatic Transmission Fluid.>
13) Check the ATF level.
matic Transmission Fluid.>
AT-00088
T2T2T1
AT-00089
AT-00025
T1
T2
Page 2389 of 2870

4AT-76
AUTOMATIC TRANSMISSION
ATF Filter
21.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
1) Lift-up the vehicle.
2) Using ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing formula.
T2 = L2/ (L1+L2) ×T1
T1: 14 N⋅m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
NOTE:
Align the ST with torque wrench while tightening
the ATF filter.
ST 498545400 OIL FILTER WRENCH
4) Fill ATF.
5) Check the level of the ATF.
tomatic Transmission Fluid.>
C: INSPECTION
Replace the part if any defect is found from the
inspection.
Check for rust, hole, ATF leaks and other dam-
age.
(A) ATF filter
Torque wrench length
mm (in)Tightening torque
N⋅m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 9.8 (1.0, 7.2)
AT-00091
(A)ST
Page 2390 of 2870
4AT-77
AUTOMATIC TRANSMISSION
Transmission Control Module (TCM)
22.Transmission Control Mod-
ule (TCM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower cover and then disconnect
the connector.
3) Disconnect the connectors from TCM.
LHD model
RHD model
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM.
LHD model
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
RHD model
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Connect the connectors to TCM.
3) Install in the reverse order of removal.
(A) Transmission control module (TCM)
(B) Brake pedal
(A) Transmission control module (TCM)
(B) Steering column
AT-00041
(A)
(B)
AT-00748
AT-00749
(A)(B)
(A) Transmission control module (TCM)
(B) Brake pedal
(A) Transmission control module (TCM)
(B) Steering column
(A)
(B)
AT-00748
AT-00749
(A)(B)
Page 2391 of 2870
4AT-78
AUTOMATIC TRANSMISSION
Dropping Resistor
23.Dropping Resistor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from dropping resis-
tor.
3) Remove the dropping resistor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
(A) Dropping resistor
AT-00041
AT-00313
(A)
(A) Dropping resistor
AT-00313
(A)
Step Check Yes No
1 CHECK RESISTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from dropping
resistor.
3) Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 9 — 15 Ω? Go to step 2.Replace the drop-
ping resistor.
to 4AT-78, Drop-
ping Resistor.>
2 CHECK RESISTOR.
Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 3 — No. 4:Is the resistance 9 — 15 Ω? Dropping resistor
is normal.Replace the drop-
ping resistor.
to 4AT-78, Drop-
ping Resistor.>
Page 2392 of 2870

4AT-79
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
24.ATF Cooler Pipe and Hose
A: REMOVAL
1. EXCEPT WITH ATF COOLER MODEL
(WITH WARMER FUNCTION)
1) Set the vehicle on a lift.
2) Remove the battery and washer tank.
3) Lift-up the vehicle.
4) Remove the under cover.
5) Disconnect the ATF cooler hose from radiator.
(Turbo model)
AL, Radiator.>
6) Disconnect the ATF cooler hose from radiator.
(Non-turbo model)
NOTE:
Do not use a screwdriver or other pointed tools.
When hard to remove the hose, wrap the hose
with cloth to prevent from damaging, and then turn
with pliers and pull out with hand straightly.
7) Disconnect the ATF cooler hoses from pipes.
NOTE:
Do not use a screwdriver or other pointed tools.
When hard to remove the hose, wrap the hose
with cloth to prevent from damaging, and then turn
with pliers and pull out with hand straightly.8) Disconnect the ATF cooler pipe from frame.
9) Remove the ATF cooler inlet and outlet pipes.
CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used with retain-
ing screw.
2. WITH ATF COOLER MODEL (WITH
WARMER FUNCTION)
1) Set the vehicle on a lift.
2) Remove the air cleaner case.
IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
AT-00455
AT-00450
(A) ATF cooler inlet pipe
(B) ATF cooler outlet pipe
AT-00456
AT-00806
(A)
(B)