MT-104
SERVICE DATA AND SPECIFICATIONS (SDS)
Gear End PlayECS008CF
Unit: mm (in)
Baulk Ring ClearanceECS00CV4
Unit: mm (in) Number of
teethReverse
idler gearFront 37
Rear 46 38 46
Final gear Final gear/
Pinion76/16 62/14
Side gear/
Pinion
mate gear14/10
Oil level mm (in)55.0 - 61.0
(2.17 - 2.40)168.0 - 174.0 (6.61 - 6.85)55.0 - 61.0
(2.17 - 2.40)168.0 - 174.0
(6.61 - 6.85)
Oil capacity (Reference)
(Imp pt)Approx. 2.2 (3-7/8)
Remarks Reverse synchronizer Installed
Double-cone synchro-
nizer3rd
Triple-cone synchronizer 1st and 2nd Engine type QR20DE QR25DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Axle type 2WD 4WD 2WD 4WD
Model code number EQ500 EQ000 EQ008 EQ078 EQ068
Gear End play
1st main gear0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear0.18 - 0.31 (0.0071 - 0.0122)
4th input gear0.20 - 0.30 (0.0079 - 0.0118)
5th input gear0.06 - 0.16 (0.0024 - 0.0063)
6th input gear (For RS6F51A models) 0.06 - 0.16 (0.0024 - 0.0063)
Measurement point Standard value Limit value
3rd
(Double-cone synchronizer)Clearance between synchronizer cone and
inner baulk ring end face “A” 0.6 - 0.8 (0.024 - 0.031) 0.2 (0.008)
Clearance between outer baulk ring pawl
and synchronizer cone “B”0.6 - 1.1 (0.024 -0.043) 0.2 (0.008)
1st and 2nd
(Triple-cone synchronizer)Clearance between synchronizer cone and
clutch gear end face “A”0.6 - 1.2 (0.024 - 0.047) 0.3 (0.012)
Clearance between outer baulk ring pawl
and synchronizer cone “B”0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008)
Clearance between inner baulk ring and
clutch gear end face “C”0.7 - 1.1 (0.028 - 0.043) 0.3 (0.012)
PCIB0249E
PCIB0835J
OVERALL SYSTEM
AT-39
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Control ValveECS004QG
FUNCTION OF CONTROL VALVES
Valve name Function
Pressure regulator valve, plug and sleeve
plugRegulates oil discharged from the oil pump to provide optimum line pressure for all driv-
ing conditions.
Pressure modifier valve and sleeve Used as a signal supplementary valve to the pressure regulator valve. Regulates pres-
sure-modifier pressure (signal pressure) which controls optimum line pressure for all
driving conditions.
Pilot valve Regulates line pressure to maintain a constant pilot pressure level which controls lock-up
mechanism, overrun clutch, shift timing.
Accumulator control valve Regulates accumulator back-pressure to pressure suited to driving conditions.
Manual valve Directs line pressure to oil circuits corresponding to select positions.
Hydraulic pressure drains when the shift lever is in Neutral.
Shift valve A Simultaneously switches three oil circuits using output pressure of shift solenoid valve A
to meet driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th →
3rd → 2nd → 1st gears) in combination with shift valve B.
Shift valve B Simultaneously switches two oil circuits using output pressure of shift solenoid valve B in
relation to driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th →
3rd → 2nd → 1st gears) in combination with shift valve A.
Overrun clutch control valve Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously
with application of the brake band in D
4 . (Interlocking occurs if the overrun clutch
engages during D
4 .)
1st reducing valve Reduces low & reverse brake pressure to dampen engine-brake shock when downshift-
ing from the 1st position 1
2 to 11 .
Overrun clutch reducing valve Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock.
In the 1st and 2nd positions, line pressure acts on the overrun clutch reducing valve to
increase the pressure-regulating point, with resultant engine brake capability.
Torque converter relief valve Prevents an excessive rise in torque converter pressure.
Torque converter clutch control valve, plug
and sleeveActivates or inactivates the lock-up function.
Also provides smooth lock-up through transient application and release of the lock-up
system.
1-2 accumulator valve and piston Lessens the shock find when the 2nd gear band servo contracts, and provides smooth
shifting.
3-2 timing valve Switches the pace that oil pressure is released depending on vehicle speed; maximizes
the high clutch release timing, and allows for soft downshifting.
Shuttle valve Determines if the overrun clutch solenoid valve should control the 3-2 timing valve or the
overrun clutch control valve and switches between the two.
Cooler check valve At low speeds and with a small load when a little heat is generated, saves the volume of
cooler flow, and stores the oil pressure for lock-up.
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-65
[EURO-OBD]
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Stall TestECS004QR
STALL TEST PROCEDURE
1. Check A/T fluid and engine oil levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature. Refer to AT- 1 6 , "
Checking A/T Fluid" .
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.
6. Accelerate to wide open throttle gradually while applying foot
brake.
7. Quickly note the engine stall revolution and immediately release
throttle.
During test, never hold throttle wide open for more than 5
seconds.
SAT647B
SAT513G
SAT775B
Stall revolution:
QR20DE: 2,450 - 2,950 rpm
QR25DE: 2,300 - 2,750 rpm
SAT514G
AT-68
[EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
Line Pressure TestECS004QS
LINE PRESSURE TEST PORTS
Location of line pressure test ports are shown in the illustration.
Always replace pressure plugs as they are self-sealing
bolts.
LINE PRESSURE TEST PROCEDURE
1. Check A/T fluid and engine oil levels. If necessary, add fluid or
oil.
2. Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature. Refer to AT- 1 6 , "
Checking A/T
Fluid" .
3. Install pressure gauge to corresponding line pressure port.
4. Set parking brake and block wheels.
Continue to depress brake pedal fully while line pressure
test is being performed at stall speed.
SCIA0709E
SAT647B
UAT008
SAT513G
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
AT-85
[EURO-OBD]
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TROUBLE DIAGNOSIS — GENERAL DESCRIPTIONPFP:00000
Symptom ChartECS004QU
Numbers are arranged in order of inspection.
Perform inspections starting with number one and work up.
Symptom Condition Diagnostic Item Reference Page
Engine cannot start in “P” and “N”
positions.
AT- 2 0 6
ON vehicle1. Ignition switch and starterPG-2
, SC-23
2. Control cable adjustmentAT-409
3. PNP switchAT-100
Engine starts in position other than
“N” and “P” positions.
AT- 2 0 6
ON vehicle1. Control cable adjustmentAT-4092. PNP switchAT-100
Transaxle noise in “P” and “N” posi-
tions.ON vehicle1. Fluid levelAT- 6 4
2. Line pressure testAT- 6 8
3. Accelerator pedal position (APP) sensorAT-173
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 11 2,
AT-192
OFF vehicle5. Oil pumpAT-4436. Torque converterAT-423
Vehicle moves when changing into
“P” position, or parking gear does
not disengage when shifted out of
“P” position.
AT- 2 0 7ON vehicle 1. Control cable adjustmentAT-409
OFF vehicle 2. Parking componentsAT- 4 1 6, AT-440
Vehicle runs in “N” position.
AT- 2 0 8
ON vehicle 1. Control cable adjustmentAT-409
OFF vehicle2. Forward clutchAT-4753. Reverse clutchAT-464
4. Overrun clutchAT-475
Vehicle will not run in “R” position
(but runs in “D”, “2” and “1” posi-
tions). Clutch slips.
Very poor acceleration.
AT- 2 1 0
ON vehicle1. Control cable adjustmentAT-409
2. Stall testAT- 6 5
3. Line pressure testAT- 6 8
4. Line pressure solenoid valveAT-154
5. Control valve assemblyAT-404
Vehicle will not run in “R” position
(but runs in “D”, “2” and “1” posi-
tions). Clutch slips.
Very poor acceleration.
AT- 2 1 0
OFF vehicle6. Reverse clutchAT-464
7. High clutchAT-469
8. Forward clutchAT-475
9. Overrun clutchAT-475
10. Low & reverse brakeAT-483
Vehicle braked when shifting into
“R” position.ON vehicle1. Fluid levelAT- 6 4
2. Line pressure testAT- 6 8
3. Line pressure solenoid valveAT-154
4. Control valve assemblyAT-404
OFF vehicle5. High clutchAT-4696. Brake bandAT-497
7. Forward clutchAT-475
8. Overrun clutchAT-475
AT-86
[EURO-OBD]
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Sharp shock in shifting from “N” to
“D” position.ON vehicle1. Engine idling rpmEC-45
2. Accelerator pedal position (APP) sensorAT-173
3. Line pressure testAT- 6 8
4. A/T fluid temperature sensorAT-184
5. Engine speed signalAT- 11 9
6. Line pressure solenoid valveAT-154
7. Control valve assemblyAT-404
8. Accumulator N-DAT-404
OFF vehicle 9. Forward clutchAT-475
Vehicle will not run in “D” and “2”
positions (but runs in “1” and “R”
positions).ON vehicle 1. Control cable adjustmentAT-409
OFF vehicle 2. Low one-way clutchAT-416, AT- 4 2 3
Vehicle will not run in “D”, “1”, “2”
positions (but runs in “R” position).
Clutch slips. Very poor acceleration.
AT- 2 1 2
ON vehicle1. Fluid levelAT- 6 4
2. Stall testAT- 6 5
3. Line pressure testAT- 6 8
4. Line pressure solenoid valveAT-154
5. Control valve assemblyAT-404
6. Accumulator N-DAT-404
Vehicle will not run in “D”, “1”, “2”
positions (but runs in “R” position).
Clutch slips. Very poor acceleration.
AT- 2 1 2
OFF vehicle7. Reverse clutchAT-464
8. High clutchAT-469
9. Forward clutchAT-475
10. Forward one-way clutchAT-416
11. Low one-way clutchAT-416, AT- 4 2 3
Clutches or brakes slip somewhat in
starting.ON vehicle1. Fluid levelAT- 6 4
2. Control cable adjustmentAT-409
3. Accelerator pedal position (APP) sensorAT-173
4. Line pressure testAT- 6 8
5. Line pressure solenoid valveAT-154
6. Control valve assemblyAT-404
7. Accumulator N-DAT-404
8. Shift solenoid valve AAT-161
9. Shift solenoid valve BAT-167
10. Overrun clutch solenoid valveAT-178
11. Torque converter clutch solenoid valveAT-148
OFF vehicle12. Forward clutchAT-475
13. Reverse clutchAT-464
14. Low & reverse brakeAT-483
15. Oil pumpAT-443
16. Torque converterAT-423
Excessive creep. ON vehicle 1. Engine idling rpm EC-45
Symptom Condition Diagnostic Item Reference Page
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
AT-87
[EURO-OBD]
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No creep at all.
AT- 2 1 0
and AT-212
ON vehicle1. Fluid levelAT- 6 42. Line pressure testAT-387
3. Control valve assemblyAT-404
OFF vehicle4. Forward clutchAT-4755. Oil pumpAT-443
6. Torque converterAT-423
Failure to change gear from “D1 ” to
“D
2 ”.ON vehicle1. Control cable adjustmentAT-409
2. Shift solenoid valve AAT-161
3. Control valve assemblyAT-404
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 11 2, AT- 1 9 2
5. Accelerator pedal position (APP) sensorAT-173
OFF vehicle 6. Brake bandAT-497
Failure to change gear from “D2 ” to
“D
3 ”.ON vehicle1. Control cable adjustmentAT-409
2. Shift solenoid valve BAT-167
3. Control valve assemblyAT-404
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 11 2, AT- 1 9 2
5. Accelerator pedal position (APP) sensorAT-173
OFF vehicle6. High clutchAT-4697. Brake bandAT-497
Failure to change gear from “D3 ” to
“D
4 ”.ON vehicle1. PNP switchAT-100
2. Overdrive control switchAT-237
3. Shift solenoid valve AAT-161
4. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 11 2, AT- 1 9 2
5. A/T fluid temperature sensorAT-184
OFF vehicle 6. Brake bandAT-497
Too high a gear change point from
“D
1 ” to “D2 ”, from “D2 ” to “D3 ”,
from “D
3 ” to “D4 ”.
AT- 2 1 7
, AT- 2 2 0 and AT-222
ON vehicle1. Accelerator pedal position (APP) sensorAT-173
2. Vehicle speed sensor·A/T (Revolution
sensor) and vehicle speed sensor·MTRAT- 11 2, AT- 1 9 2
3. Shift solenoid valve AAT-161
4. Shift solenoid valve BAT-167
Gear change directly from “D1 ” to
“D
3 ” occurs.ON vehicle1. Fluid levelAT- 6 42. Accumulator servo releaseAT-404
OFF vehicle 3. Brake bandAT-497
Engine stops when shifting lever
into “R”, “D”, “2” and “1”.ON vehicle1. Engine idling rpm EC-45
2. Fluid levelAT- 6 4
3. Torque converter clutch solenoid valveAT-148
4. Control valve assemblyAT-404
OFF vehicle 5. Torque converterAT-423
Symptom Condition Diagnostic Item Reference Page
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
AT-89
[EURO-OBD]
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Vehicle braked by gear change from
“D
3 ” to “D4 ”.ON vehicle 1. Fluid levelAT- 6 4OFF vehicle2. Overrun clutchAT-3623. Forward one-way clutchAT-416
4. Reverse clutchAT-464
Maximum speed not attained.
Acceleration poor.ON vehicle1. Fluid levelAT- 6 4
2. PNP switchAT-100
3. Overdrive control switchAT-237
4. Accelerator pedal position (APP) sensorAT-173
5. Shift solenoid valve AAT-161
6. Shift solenoid valve BAT-167
7. Control valve assemblyAT-404
OFF vehicle8. Reverse clutchAT-464
9. High clutchAT-469
10. Brake bandAT-497
11. Low & reverse brakeAT-483
12. Oil pumpAT-443
13. Torque converterAT-423
Failure to change gear from “D4 ” to
“D
3 ”.ON vehicle1. Fluid levelAT- 6 4
2. Accelerator pedal position (APP) sensorAT-173
3. Overrun clutch solenoid valveAT-178
4. Shift solenoid valve AAT-161
5. Line pressure solenoid valveAT-154
6. Control valve assemblyAT-404
OFF vehicle7. Brake bandAT-4978. Overrun clutchAT-475
Failure to change gear from “D3 ” to
“D
2 ” or from “D4 ” to “D2 ”.ON vehicle1. Fluid levelAT- 6 4
2. Accelerator pedal position (APP) sensorAT-173
3. Shift solenoid valve AAT-161
4. Shift solenoid valve BAT-167
5. Control valve assemblyAT-404
OFF vehicle6. High clutchAT-4697. Brake bandAT-497
Failure to change gear from “D2 ” to
“D
1 ” or from “D3 ” to “D1 ”.ON vehicle1. Fluid levelAT- 6 4
2. Accelerator pedal position (APP) sensorAT-173
3. Shift solenoid valve AAT-161
4. Shift solenoid valve BAT-167
5. Control valve assemblyAT-404
OFF vehicle6. Low one-way clutchAT- 4 1 6
, AT-423
7. High clutchAT-469
8. Brake bandAT-497
Gear change shock felt during
deceleration by releasing accelera-
tor pedal.ON vehicle1. Accelerator pedal position (APP) sensorAT-1732. Line pressure testAT- 6 8
3. Overrun clutch solenoid valveAT-178
4. Control valve assemblyAT-404
Symptom Condition Diagnostic Item Reference Page