AT-4
DTC Confirmation Procedure ................................152
Diagnosis Procedure .............................................152
DTC P1845 ATF PRESSURE SWITCH 5 ........154
Description .............................................................154
CONSULT-II Reference Value in Data Monitor
Mode ......................................................................
154
On Board Diagnosis Logic .....................................154
Possible Cause ......................................................154
DTC Confirmation Procedure ................................154
Diagnosis Procedure .............................................154
DTC P1846 ATF PRESSURE SWITCH 6 ........156
Description .............................................................156
CONSULT-II Reference Value in Data Monitor
Mode ......................................................................
156
On Board Diagnosis Logic .....................................156
Possible Cause ......................................................156
DTC Confirmation Procedure ................................156
Diagnosis Procedure .............................................156
MAIN POWER SUPPLY AND GROUND CIR-
CUIT .................................................................
158
Wiring Diagram - AT - MAIN ..................................158
Diagnosis Procedure .............................................159
CLOSED THROTTLE POSITION AND WIDE
OPEN THROTTLE POSITION CIRCUIT .........
161
CONSULT-II Reference Value in Data Monitor
Mode ......................................................................
161
Diagnosis Procedure .............................................161
BRAKE SIGNAL CIRCUIT ..............................162
CONSULT-II Reference Value in Data Monitor
Mode ......................................................................
162
Diagnosis Procedure .............................................162
TOW MODE SWITCH ......................................163
Description .............................................................163
Wiring Diagram - AT - TMSW ................................163
Diagnosis Procedure .............................................164
TROUBLE DIAGNOSIS FOR SYMPTOMS .....165
Wiring Diagram - AT - NONDTC ............................165
A/T Check Indicator Lamp Does Not Come On .....167
Engine Cannot Be Started in "P" or "N" Position ...168
In "P" Position, Vehicle Moves When Pushed .......168
In "N" Position, Vehicle Moves ..............................169
Large Shock ("N" to "D" Position) ..........................170
Vehicle Does Not Creep Backward in "R" Position ..172
Vehicle Does Not Creep Forward in "D" Position ..175
Vehicle Cannot Be Started from D1 .......................177
A/T Does Not Shift: D1→ D2 ..................................179
A/T Does Not Shift: D2→ D3 ..................................181
A/T Does Not Shift: D3→ D4 ..................................183
A/T Does Not Shift: D4→ D5 ..................................185
A/T Does Not Perform Lock-up .............................187
A/T Does Not Hold Lock-up Condition ...................189
Lock-up Is Not Released .......................................190
Engine Speed Does Not Return to Idle .................191
A/T Does Not Shift: 5th gear → 4th gear ..............192
A/T Does Not Shift: 4th gear → 3rd gear ..............194
A/T Does Not Shift: 3rd gear → 2nd gear .............196
A/T Does Not Shift: 2nd gear → 1st gear .............197
Vehicle Does Not Decelerate By Engine Brake ....199
A/T SHIFT LOCK SYSTEM ..............................202
Description ............................................................202
Shift Lock System Electrical Parts Location ..........202
Wiring Diagram - AT - SHIFT ................................203
Shift Lock Control Unit Reference Value ..............204
Component Inspection ..........................................204
SHIFT CONTROL SYSTEM .............................207
Control Device Removal and Installation ..............207
Adjustment of A/T Position ....................................208
Checking of A/T Position .......................................208
ON-VEHICLE SERVICE ...................................209
Oil Pan ..................................................................209
Control Valve with TCM and A/T Fluid Tempera-
ture Sensor 2 ........................................................
210
Rear Oil Seal .........................................................219
AIR BREATHER HOSE ....................................221
Removal and Installation .......................................221
TRANSMISSION ASSEMBLY ..........................223
Removal and Installation (2WD) ...........................223
Removal and Installation (4WD) ...........................225
OVERHAUL ......................................................228
Component ...........................................................228
Oil Channel ...........................................................235
Location of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................
237
DISASSEMBLY ................................................240
Disassembly ..........................................................240
REPAIR FOR COMPONENT PARTS ..............258
Oil Pump ...............................................................258
Front Sun Gear, 3rd One-Way Clutch ...................260
Front Carrier, Input Clutch, Rear Internal Gear .....262
Mid Sun Gear, Rear Sun Gear, High and Low Re-
verse Clutch Hub ..................................................
267
High and Low Reverse Clutch ..............................272
Direct Clutch .........................................................274
ASSEMBLY ......................................................277
Assembly (1) .........................................................277
Adjustment ............................................................290
Assembly (2) .........................................................292
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................
298
General Specification ............................................298
Vehicle Speed When Shifting Gears .....................298
Vehicle Speed When Performing and Releasing
Complete Lock-up .................................................
299
Stall Speed ............................................................299
PRECAUTIONS
AT-9
< SERVICE INFORMATION >
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•After performing each TROUBLE DIAGNOSIS, perform “DTC
(Diagnostic Trouble Code) CONFIRMATION PROCEDURE”.
If the repair is completed the DTC should not be displayed in
the “DTC CONFIRMATION PROCEDURE”.
• Always use the specified brand of ATF. Refer to MA-10
.
• Use paper rags not cloth rags during work.
• After replacing the ATF, dispose of the waste oil using the methods prescribed by law, ordinance, etc.
• Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to pre-
vent 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 transmission.
• 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 transmission 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.
• Clean or replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Refer to AT-
15, "A/T Fluid Cooler Cleaning".
• After overhaul, refill the transmission 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 con-
verter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer to
AT-13, "
Changing Automatic Transmission Fluid (ATF)", AT-13, "Checking Automatic Transmission Fluid
(ATF)".
Service Notice or PrecautionINFOID:0000000003532221
ATF COOLER SERVICE
If A/T fluid contains frictional material (clutches, bands, etc.), or if an A/T is repaired, overhauled, or replaced,
inspect and clean the A/T fluid cooler mounted in the radiator or replace the radiator. Flush cooler lines using
cleaning solvent and compressed air after repair. For A/T fluid cooler cleaning procedure, refer to AT-15, "
A/T
Fluid Cooler Cleaning". For radiator replacement, refer to CO-13.
CHECKING AND CHANGING A/T FLUID SERVICE
Increase ATF temperature by 80°C (176°F) once, and then check ATF level in 65°C (149°F) when adjusting
ATF level.
NOTE:
JA60 uses both systems of a water-cooling and of an air-cooling. Air-cooling system has a by-pass valve.
When ATF temperature is not over 50°C (122°F) with water-cooling system OFF, it does not flow to air-cooling
system. If ATF level is set without the flow of ATF, the level will be 10mm lower than the standard. Therefore,
piping should be filled with ATF when adjusting level.
OBD-II SELF-DIAGNOSIS
• A/T self-diagnosis is performed by the TCM in combination with the ECM. Refer to the table on AT-83,
"CONSULT-II Function (A/T)" for the indicator used to display each self-diagnostic result.
SEF217U
A/T FLUID
AT-13
< SERVICE INFORMATION >
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A/T FLUID
Changing Automatic Transmission Fluid (ATF)INFOID:0000000003532224
1. Drive the vehicle to warm up the ATF to 80° C (176° F).
2. Stop the engine.
3. Remove the ATF level gauge bolt.
4. Drain the ATF from the drain plug hole and then install the drain
plug with a new gasket. Refill the transmission with new ATF.
Always refill with the same volume as the drained ATF. Use the
ATF level gauge to check the ATF level as shown. Add ATF as
necessary.
• To flush out the old ATF from the coolers, pour new ATF into the charging pipe with the engine idling and
at the same time drain the old ATF from the auxiliary transmission oil cooler hose return line.
• When the color of the ATF coming out of the auxiliary transmission oil cooler hose return line is about
the same as the color of the new ATF, flushing out the old ATF is complete. The amount of new trans-
mission ATF used for flushing should be 30% to 50% increase of the specified capacity.
CAUTION:
• Use only the specified ATF. Do not mix with other fluids.
• Using an ATF other than the specified ATF will cause deterioration in driveability and automatic
transmission durability, and may damage the automatic transmission, which is not covered by
the warranty.
• When filling the transmission with ATF, do not spill the ATF on any heat generating parts such as
the exhaust manifold.
• Do not reuse the drain plug gasket.
5. Install the ATF level gauge in the ATF charging pipe and tighten the ATF level gauge bolt to specification.
6. Drive the vehicle to warm up the ATF to 80° C (176° F).
7. Check the ATF level and condition. Refer to AT-13, "
Checking Automatic Transmission Fluid (ATF)". If the
ATF is still dirty, repeat steps 2 through 5.
Checking Automatic Transmission Fluid (ATF)INFOID:0000000003532225
1. Remove the ATF level gauge bolt.Drain plug : Refer to AT-228, "
Component".
WLIA0014E
ATF type and capacity : Refer to MA-10, "Fluids and Lubricants".
Drain plug : Refer to AT-228, "
Component".
ATF level gauge bolt : Refer to AT-223, "
Removal and Installation (2WD)",
AT-225, "
Removal and Installation (4WD)".
TROUBLE DIAGNOSIS FOR SYMPTOMS
AT-169
< SERVICE INFORMATION >
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Even though the selector lever is set in the “P” position, the parking mechanism is not actuated,
allowing the vehicle to be moved when it is pushed.
DIAGNOSTIC PROCEDURE
1.CHECK PNP SWITCH CIRCUIT
Perform self-diagnosis. Refer to AT-83, "
CONSULT-II Function (A/T)".
Do the self-diagnosis results indicate PNP switch?
YES >> Check the malfunctioning system. Refer to AT- 9 9.
NO >> GO TO 2.
2.CHECK CONTROL CABLE
Check the control cable.
• Refer to AT-208, "
Checking of A/T Position".
OK or NG
OK >> GO TO 3.
NG >> Adjust control cable. Refer to AT-208, "
Adjustment of A/
T Position".
3.CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sensor 2".
2. Check A/T fluid condition. Refer to AT-13, "
Checking Automatic
Transmission Fluid (ATF)".
OK or NG
OK >>INSPECTION END
NG >> GO TO 4.
4.DETECT MALFUNCTIONING ITEM
• Check the malfunction items. If any items are damaged, repair or replace damaged parts. Refer to AT-60,
"Symptom Chart" (Symptom No.58).
OK or NG
OK >>INSPECTION END
NG >> Repair or replace damaged parts.
In "N" Position, Vehicle MovesINFOID:0000000003532451
SYMPTOM:
Vehicle moves forward or backward when selecting “N” position.
DIAGNOSTIC PROCEDURE
1.CHECK PNP SWITCH CIRCUIT
Perform self-diagnosis. Refer to AT-83, "
CONSULT-II Function (A/T)".
Do the self-diagnostic results indicate PNP switch?
YES >> Check the malfunctioning system. Refer to AT- 9 9.
NO >> GO TO 2.
2.CHECK CONTROL CABLE
LCIA0345E
SCIA5199E
AT-170
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS FOR SYMPTOMS
Check the control cable.
• Refer to AT-208, "
Checking of A/T Position".
OK or NG
OK >> GO TO 3.
NG >> Adjust control cable. Refer to AT-208, "
Adjustment of A/
T Position".
3.CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-13, "
Checking Automatic Trans-
mission Fluid (ATF)".
OK or NG
OK >> GO TO 4.
NG >> Refill ATF.
4.CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sensor 2".
2. Check A/T fluid condition. Refer to AT-13, "
Checking Automatic
Transmission Fluid (ATF)".
OK or NG
OK >> GO TO 5.
NG >> Check the malfunction items. If any items are damaged,
repair or replace damaged parts. Refer to AT-60, "
Symp-
tom Chart" (Symptom No.60).
5.CHECK SYMPTOM
Check again. Refer to AT-55, "
Check at Idle".
OK or NG
OK >>INSPECTION END
NG >> GO TO 6.
6.PERFORM TCM INSPECTION
1. Perform TCM input/output signals inspection. Refer to AT-82, "
TCM Input/Output Signal Reference
Va l u e".
2. If NG, recheck A/T assembly harness connector terminals for damage or loose connection with harness
connector.
OK or NG
OK >>INSPECTION END
NG >> Repair or replace damaged parts.
Large Shock ("N" to "D" Position)INFOID:0000000003532452
SYMPTOM:
A noticeable shock occurs when the selector lever is shifted from the “N” to “D” position.
LCIA0345E
SAT638A
SCIA5199E
AT-172
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS FOR SYMPTOMS
- Oil pump assembly. Refer to AT-258, "Oil Pump".
OK or NG
OK >> GO TO 8.
NG >> Repair or replace damaged parts.
7.DETECT MALFUNCTIONING ITEM
1. Check control valve with TCM. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sen-
sor 2".
2. Disassemble A/T. Refer to AT-240, "
Disassembly".
3. Check the following items:
- Oil pump assembly. Refer to AT-258, "
Oil Pump".
- Power train system. Refer to AT-240, "
Disassembly".
- Transmission case. Refer to AT-240, "
Disassembly".
OK or NG
OK >> GO TO 8.
NG >> Repair or replace damaged parts.
8.CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sensor 2".
2. Check A/T fluid condition. Refer to AT-13, "
Checking Automatic
Transmission Fluid (ATF)".
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.
9.DETECT MALFUNCTIONING ITEM
• Check the malfunction items. If any items are damaged, repair or replace damaged parts. Refer to AT-60,
"Symptom Chart" (Symptom No.1).
OK or NG
OK >> GO TO 10.
NG >> Repair or replace damaged parts.
10.CHECK SYMPTOM
Check again. Refer to AT-55, "
Check at Idle".
OK or NG
OK >>INSPECTION END
NG >> GO TO 11.
11 .PERFORM TCM INSPECTION
1. Perform TCM input/output signals inspection. Refer to AT-82, "
TCM Input/Output Signal Reference
Va l u e".
2. If NG, recheck A/T assembly harness connector terminals for damage or loose connection with harness
connector.
OK or NG
OK >>INSPECTION END
NG >> Repair or replace damaged parts.
Vehicle Does Not Creep Backward in "R" PositionINFOID:0000000003532453
SYMPTOM:
The vehicle does not creep in the “R” position. Or an extreme lack of acceleration is observed.
DIAGNOSTIC PROCEDURE
SCIA5199E
AT-178
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS FOR SYMPTOMS
NO >> GO TO 3.
3.CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR
Check accelerator pedal position (APP) sensor. Refer to AT- 11 7
OK or NG
OK >> GO TO 4.
NG >> Repair or replace accelerator pedal position (APP) sensor.
4.CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-13, "
Checking Automatic Trans-
mission Fluid (ATF)".
OK or NG
OK >> GO TO 5.
NG >> Refill ATF.
5.CHECK LINE PRESSURE
Check line pressure at the engine stall point. Refer to AT-51,
"Inspections Before Trouble Diagnosis".
OK or NG
OK >> GO TO 8.
NG - 1 >> Line pressure high. GO TO 6.
NG - 2 >> Line pressure low. GO TO 7.
6.DETECT MALFUNCTIONING ITEM
1. Check control valve with TCM. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sen-
sor 2".
2. Disassemble A/T. Refer to AT-240, "
Disassembly".
3. Check the following items:
- Oil pump assembly. Refer to AT-258, "
Oil Pump".
OK or NG
OK >> GO TO 8.
NG >> Repair or replace damaged parts.
7.DETECT MALFUNCTIONING ITEM
1. Check control valve with TCM. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sen-
sor 2".
2. Disassemble A/T. Refer to AT-240, "
Disassembly".
3. Check the following items:
- Oil pump assembly. Refer to AT-258, "
Oil Pump".
- Power train system. Refer to AT-240, "
Disassembly".
- Transmission case. Refer to AT-240, "
Disassembly".
OK or NG
OK >> GO TO 8.
NG >> Repair or replace damaged parts.
8.CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sensor 2".
SAT638A
SAT494G
AT-180
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS FOR SYMPTOMS
Do the self-diagnostic results indicate ATF pressure switch 5, direct clutch solenoid valve, accelerator pedal
position sensor, vehicle speed sensor A/T (revolution sensor) and vehicle speed sensor MTR?
YES >> Check the malfunctioning system. Refer to AT-154' AT-138' AT- 11 7' AT-105, AT-124.
NO >> GO TO 3.
3.CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-13, "
Checking Automatic Trans-
mission Fluid (ATF)".
OK or NG
OK >> GO TO 4.
NG >> Refill ATF.
4.CHECK LINE PRESSURE
Check line pressure at the engine stall point. Refer to AT-51,
"Inspections Before Trouble Diagnosis".
OK or NG
OK >> GO TO 7.
NG - 1 >> Line pressure high. GO TO 5.
NG - 2 >> Line pressure low. GO TO 6.
5.DETECT MALFUNCTIONING ITEM
1. Check control valve with TCM. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sen-
sor 2".
2. Disassemble A/T. Refer to AT-240, "
Disassembly".
3. Check the following items:
- Oil pump assembly. Refer to AT-258, "
Oil Pump".
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.
6.DETECT MALFUNCTIONING ITEM
1. Check control valve with TCM. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sen-
sor 2".
2. Disassemble A/T. Refer to AT-240, "
Disassembly".
3. Check the following items:
- Oil pump assembly. Refer to AT-258, "
Oil Pump".
- Power train system. Refer to AT-240, "
Disassembly".
- Transmission case. Refer to AT-240, "
Disassembly".
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.
7.CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-210, "
Control Valve with TCM and A/T Fluid Temperature Sensor 2".
SAT638A
SAT494G