MT-48
TRANSAXLE ASSEMBLY
37. Remove differential side bearing outer race from clutch housing
using the puller.
38. Remove input shaft oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Install input shaft oil seal to clutch housing using the drift.
CAUTION:
Do not reuse input shaft oil seal.
2. Install differential side oil seal until it become flush with end face
of clutch housing using the drift.
CAUTION:
Do not reuse differential side oil seal.
Apply multi-purpose grease onto oil seal lip. (For 4WD
models)
SCIA1069J
SCIA0398E
Dimension A: 1.8 - 2.8 mm (0.071 - 0.110 in)
PCIB0873E
SCIA1070J
MT-54
TRANSAXLE ASSEMBLY
37. Apply recommended sealant to threads of park/neutral position
switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-40, "
Case
and Housing Components" .
38. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-40, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
39. Install O-ring onto plug (for 2WD models) or gasket onto filler
plug (for 4WD models), and then install it into clutch housing.
Tighten plug mounting bolt or filler plug to the specified torque.
Refer to MT-40, "
Case and Housing Components" .
CAUTION:
Do not reuse O-ring or gasket.
After oil is filled, tighten plug mounting bolt or filler plug to specified torque.
ADJUSTMENT
Differential Side Bearing Preload
When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. Refer to MT-108, "
DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.
Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
1. Using depth micrometer and straightedge, measure dimension
“L
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
SCIA0895E
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face
and mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
PCIB0795E
SCIA1078E
AT-10
PRECAUTIONS
After performing each TROUBLE DIAGNOSIS, perform
“DTC (Diagnostic Trouble Code) CONFIRMATION PROCE-
DURE”.
The DTC should not be displayed in the “DTC Confirmation
Procedure” if the repair is completed.
Before proceeding with disassembly, thoroughly clean the out-
side of the transaxle. It is important to prevent the internal parts
from becoming contaminated by dirt or other foreign matter.
Disassembly should be done in a clean work area.
Use lint-free cloth or towels for wiping parts clean. Common
shop rags can leave fibers that could interfere with the operation
of the transaxle.
Place disassembled parts in order for easier and proper assembly.
All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
Gaskets, seals and O-rings should be replaced any time the transaxle is disassembled.
It is very important to perform functional tests whenever they are indicated.
The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
After overhaul, refill the transaxle with new ATF.
When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
to “Changing A/T Fluid”, AT- 1 6 , "
A/T FLUID" .
Service Notice or PrecautionsECS004Q3
FAIL -SAF E
The TCM has an electronic Fail-Safe (limp home 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” or “D”. The cus-
tomer may complain of sluggish or poor acceleration.
Always follow the “WORK FLOW”, refer to AT- 2 5 5 , "
Work Flow" (EXCEPT FOR Euro-OBD) or AT- 6 1 , "Work
Flow" (Euro-OBD).
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.
TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:
External leaks in the hub weld area.
Converter hub is scored or damaged.
Converter pilot is broken, damaged or fits poorly into crankshaft.
Steel particles are found after flushing the cooler and cooler lines.
Pump is damaged or steel particles are found in the converter.
Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
Converter is contaminated with engine coolant containing antifreeze.
Internal failure of stator roller clutch.
Heavy clutch debris due to overheating (blue converter).
SAT652J
AT-40
[EURO-OBD]
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
[EURO-OBD]ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONPFP:00000
IntroductionECS004QH
The A/T system has two self-diagnostic systems.
The first is the emission-related on board diagnostic system (EURO-OBD) performed by the TCM in combina-
tion with the ECM. The malfunction is indicated by the MI (malfunction indicator) and is stored as a DTC in the
ECM memory but not the TCM memory.
The second is the TCM original self-diagnosis indicated by the O/D OFF indicator lamp. The malfunction is
stored in the TCM memory. The detected items are overlapped with EURO-OBD self-diagnostic items. For
detail, refer to AT- 4 5 , "
SELF-DIAGNOSTIC RESULT TEST MODE" .
EURO-OBD Function for A/T SystemECS004QI
The ECM provides emission-related on board diagnostic (EURO-OBD) functions for the A/T system. One
function is to receive a signal from the TCM used with EURO-OBD-related parts of the A/T system. The signal
is sent to the ECM when a malfunction occurs in the corresponding EURO-OBD-related part. The other func-
tion is to indicate a diagnostic result by means of the MI (malfunction indicator) on the instrument panel. Sen-
sors, switches and solenoid valves are used as sensing elements.
The MI automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation
to A/T system parts.
One or Two Trip Detection Logic of EURO-OBDECS004QJ
ONE TRIP DETECTION LOGIC
If a malfunction is sensed during the first test drive, the MI will illuminate and the malfunction will be stored in
the ECM memory as a DTC. The TCM is not provided with such a memory function.
TWO TRIP DETECTION LOGIC
When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC
(diagnostic trouble code) or 1st trip freeze frame data. At this point, the MI will not illuminate. — First Trip
If the same malfunction as that experienced during the first test drive is sensed during the second test drive,
the MI will illuminate. — Second Trip
A/T-related parts for which the MI illuminates during the first or second test drive are listed below.
The “trip” in the “One or Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed
during vehicle operation.
EURO-OBD Diagnostic Trouble Code (DTC)ECS004QK
HOW TO READ DTC AND 1ST TRIP DTC
DTC and 1st trip DTC can be read by the following methods.
( With CONSULT-II or GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710,
P0720, P0725, etc.
These DTCs are prescribed by SAE J2012.
(CONSULT-II also displays the malfunctioning component or system.)
1st trip DTC No. is the same as DTC No.
Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. How-
ever, in case of the Mode II and GST they do not indicate whether the malfunction is still occurring
or occurred in the past and returned to normal.
CONSULT-II can identify them as shown below. Therefore, using CONSULT-II (if available) is rec-
ommended.
ItemsMI
One trip detection Two trip detection
Shift solenoid valve A — DTC: P0750 X
Shift solenoid valve B — DTC: P0755 X
Throttle position sensor — DTC: P1705 X
Except aboveX
AT-42
[EURO-OBD]
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
HOW TO ERASE DTC
The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as
described following.
If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours.
When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode
selector on the ECM.
The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC
related to EURO-OBD. For details, refer toEC-53, "
Emission-related Diagnostic Information" (WITH EURO-
OBD) or EC-565, "
Emission-related Diagnostic Information" (WITHOUT EURO-OBD).
Diagnostic trouble codes (DTC)
1st trip diagnostic trouble codes (1st trip DTC)
Freeze frame data
1st trip freeze frame data
System readiness test (SRT) codes
Test values
HOW TO ERASE DTC (WITH CONSULT-II)
If a DTC is displayed for both ECM and TCM, it needs to be erased for both ECM and TCM.
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Turn CONSULT-II “ON” and touch “A/T”.
3. Touch “SELF DIAGNOSIS”.
4. Touch “ERASE”. (The DTC in the TCM will be erased.) Then touch “BACK” twice.
5. Touch “ENGINE”.
6. Touch “SELF DIAGNOSIS”.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
AT-43
[EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
7. Touch “ERASE”. (The DTC in the ECM will be erased.)
HOW TO ERASE DTC (WITH GST)
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”. Refer to AT- 5 2
. (The engine warm-up
step can be skipped when performing the diagnosis only to erase the DTC.)
3. Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC-113, "
Generic Scan Tool (GST)
Function" .
HOW TO ERASE DTC (NO TOOLS)
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”. Refer to AT- 5 2
. (The engine warm-up
step can be skipped when performing the diagnosis only to erase the DTC.)
3. Perform “EURO-OBD SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”. Refer to AT- 5 2
.
SCIA5680E
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
AT-47
[EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
DTC WORK SUPPORT MODE WITH CONSULT-II
For details, refer to the separate “CONSULT-II Operations Manual”.
CONSULT-II Setting Procedure
1. Turn ignition switch “OFF”.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector, which is located in instrument lower panel on
driver side.
GEAR — XGear position recognized by the TCM
updated after gear-shifting
SLCT LVR POSI — XSelector lever position is recognized by
the TCM.
For fail-safe operation, the specific value
used for control is displayed.
VEHICLE SPEED (km/h) — X Vehicle speed recognized by the TCM.
THROTTLE POSI (0.0/8) — XDegree of opening for accelerator recog-
nized by the TCM
For fail-safe operation, the specific value
used for control is displayed.
LINE PRES DTY (%) — X
TCC S/V DUTY (%) — X
SHIFT S/V A (ON/OFF) — X
SHIFT S/V B (ON/OFF) — X
OVERRUN/C S/V (ON/OFF) — X
SELF-D DP LMP (ON/OFF) — X
TC SLIP RATIO (0.000) — —
TC SLIP SPEED (rpm) — —Difference between engine speed and
torque converter input shaft speed
Voltage (V) — —Displays the value measured by the volt-
age probe.
Frequency (Hz) — —
The value measured by the pulse probe
is displayed. DUTY·HI (high) (%) — —
DUTY·LOW (low) (%) — —
PLS WIDTH·HI (ms) — —
PLS WIDTH·LOW (ms) — —Monitor item (Unit)SELECT MONITOR ITEM
Remarks
TCM INPUT
SIGNALSMAIN SIG-
NALSSELEC-
TION FROM
MENU
SCIA0691E
AT-80
[EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
5. CHECK LOCK-UP (D4 TO D4 L/U)
Check lock-up (D
4 to D4 L/U).
Specified speed when lock-up occurs. Refer to AT- 5 3 0 , "
VEHICLE SPEED WHEN PERFORMING LOCK-UP"
.
Read vehicle speed, throttle opening when lock-up duty
becomes 94%. Refer to AT- 4 6 , "
DATA MONITOR MODE (A/T)" .
Does A/T perform lock-up at the specified speed?
YES >> GO TO 6.
NO >>
Mark the box on the “DIAGNOSTIC WORKSHEET”.
Refer to AT- 5 8
.
GO TO AT- 2 2 4 , "A/T Does Not Perform Lock-up" .
Continue “Road Test”.
6. CHECK LOCK-UP HOLD
Check lock-up hold.
When lock-up duty becomes 94%. Refer to AT- 4 6 , "
DATA MONITOR MODE (A/T)" .
Does A/T hold lock-up condition for more than 30 seconds?
YES >> GO TO 7.
NO >>
Mark the box on the “DIAGNOSTIC WORKSHEET”. Refer to AT- 5 8 .
GO TO AT- 2 2 5 , "A/T Does Not Hold Lock-up Condition" .
Continue “Road Test”.
7. CHECK SHIFT-DOWN (D4 L/U TO D4 )
Release accelerator pedal.
When lock-up duty becomes 4%. Refer to AT- 4 6 , "
DATA
MONITOR MODE (A/T)" .
Is lock-up released when accelerator pedal is released?
YES >> GO TO 8.
NO >>
Mark the box on the “DIAGNOSTIC WORKSHEET”.
Refer to AT- 5 8
.
GO TO AT- 2 2 7 , "Lock-Up Is Not Released" .
Continue “Road Test”.
8. CHECK SHIFT-DOWN (D4 TO D3 )
Decelerate vehicle by applying foot brake lightly.
Read gear position and engine speed. Refer to AT- 4 6 , "
DATA
MONITOR MODE (A/T)" .
Does engine speed return to idle smoothly when A/T is shifted from
D4 to D3 ?
YES >> 1. Stop vehicle.
2. Go to AT- 8 1 , "
Cruise Test — Part 2" .
NO >>
Mark the box on the “DIAGNOSTIC WORKSHEET”.
Refer to AT- 5 8
.
GO TO AT- 2 2 8 , "Engine Speed Does Not Return To
Idle (Light Braking D4 → D3 )" .
Continue “Road Test”.
SAT957I
SAT958I
SAT959I