STARTER MOTOR
STR-35
< ON-VEHICLE REPAIR >[K9K]
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ON-VEHICLE REPAIR
STARTER MOTOR
Removal and InstallationINFOID:0000000001689441
REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove “S” terminal nut and “S” terminal harness.
3. Remove “B” terminal nut and “B” terminal harness.
4. Remove starter motor bolts.
5. Remove starter motor upward from the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
1. “S” terminal nut 2. “B” terminal nut 3. Starter motor
4. Starter motor bolt Vehicle front
JPBIA0519GB
TM-4
Vehicle Speed When Performing and Releasing
Complete Lock-up .................................................
188
ON-VEHICLE REPAIR ...............................189
TRANSMISSION CONTROL MODULE ..........189
Exploded View .......................................................189
Removal and Installation .......................................189
CONTROL SYSTEM ........................................191
Control Valve Assembly and Accumulators ...........191
PARK/NEUTRAL POSITION (PNP) SWITCH .195
Park/Neutral Position (PNP) Switch ......................195
REVOLUTION SENSOR ..................................197
Revolution Sensor .................................................197
Turbine Revolution Sensor (Power Train Revolu-
tion Sensor) ...........................................................
197
DIFFERENTIAL SIDE OIL SEAL ....................199
Differential Side Oil Seal ........................................199
SHIFT CONTROL SYSTEM ............................200
Control Device Removal and Installation ...............200
Control Device Disassembly and Assembly ..........203
Selector Lever Knob Removal and Installation ......203
Adjustment of A/T Position ....................................204
Checking of A/T Position .......................................204
KEY INTERLOCK CABLE ...............................206
Removal and Installation .......................................206
AIR BREATHER HOSE ...................................209
Removal and Installation .......................................209
REMOVAL AND INSTALLATION ..............210
TRANSAXLE ASSEMBLY ..............................210
Exploded View .......................................................210
Removal and Installation .......................................210
DISASSEMBLY AND ASSEMBLY ............213
OVERHAUL .....................................................213
Component ............................................................213
Oil Channel ............................................................219
Location of Adjusting Shims, Needle Bearings and
Thrust Washers .....................................................
220
Location of Snap Rings .........................................221
DISASSEMBLY ...............................................222
Disassembly ..........................................................222
REPAIR FOR COMPONENT PARTS ..............237
Manual Shaft .........................................................237
Oil Pump ................................................................240
Control Valve Assembly ........................................243
Control Valve Upper Body .....................................252
Control Valve Lower Body .....................................255
Reverse Clutch ......................................................258
High Clutch ............................................................262
Forward and Overrun Clutches .............................267
Low & Reverse Brake ...........................................273
Rear Internal Gear and Forward Clutch Hub ........278
Output Shaft, Output Gear, Idler Gear, Reduction
Pinion Gear and Bearing Retainer ........................
281
Band Servo Piston Assembly ................................287
Final Drive .............................................................292
ASSEMBLY ......................................................297
Assembly (1) .........................................................297
Adjustment (1) .......................................................298
Assembly (2) .........................................................303
Adjustment (2) .......................................................307
Assembly (3) .........................................................311
SERVICE DATA AND SPECIFICATIONS
(SDS) .........................................................
319
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................
319
General Specification ............................................319
Vehicle Speed at Which Gear Shifting Occurs .....319
Vehicle Speed at When Lock-up Occurs/Releases
.
319
Stall Speed ............................................................319
Line Pressure ........................................................319
Adjusting shims, Needle Bearings, Thrust Wash-
ers and Snap Rings ..............................................
320
Control Valves .......................................................321
Accumulator ..........................................................321
Clutches and Brakes .............................................321
Final Drive .............................................................323
Planetary Carrier ...................................................323
Oil Pump ...............................................................323
Input Shaft .............................................................323
Reduction Pinion Gear ..........................................323
Band Servo ...........................................................323
Output Shaft ..........................................................323
Bearing Retainer ...................................................324
Total End Play .......................................................324
Reverse Clutch End Play ......................................324
Removal and Installation .......................................324
Shift Solenoid Valves ............................................324
Solenoid Valves ....................................................324
A/T Fluid Temperature Sensor ..............................325
Revolution Sensor .................................................325
Dropping Resistor .................................................325
Turbine Revolution Sensor (Power Train Revolu-
tion Sensor) ...........................................................
325
TYPE 2 (4AT: RE4F03B)
BASIC INSPECTION .................................
326
DIAGNOSIS AND REPAIR WORKFLOW ........326
Work Flow .............................................................326
Diagnostic Work Sheet .........................................327
FUNCTION DIAGNOSIS ...........................329
A/T CONTROL SYSTEM ..................................329
TM-7
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P Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
465
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
465
Precaution for On Board Diagnosis (OBD) System
of A/T and Engine (For Type1 Only) .....................
465
Precaution .............................................................466
Service Notice or Precaution .................................467
Wiring Diagram and Trouble Diagnosis ................467
PREPARATION .........................................468
PREPARATION ................................................468
Special Service Tool .............................................468
Commercial Service Tool ......................................471
ON-VEHICLE MAINTENANCE ..................473
A/T FLUID .........................................................473
Checking A/T Fluid ................................................473
Changing A/T Fluid ...............................................473
A/T Fluid Cooler Cleaning .....................................474
STALL TEST ....................................................477
Inspection and Judgment ......................................477
LINE PRESSURE TEST ...................................480
Inspection and Judgment ......................................480
ROAD TEST .....................................................482
Description ............................................................482
Check Before Engine Is Started ............................482
Check at Idle .........................................................483
Cruise Test - Part 1 ...............................................485
Cruise Test - Part 2 ...............................................487
Cruise Test - Part 3 ...............................................488
Vehicle Speed When Shifting Gears .....................490
Vehicle Speed When Performing and Releasing
Complete Lock-up .................................................
490
ON-VEHICLE REPAIR ...............................491
TRANSMISSION CONTROL MODULE ...........491
Exploded View ......................................................491
Removal and Installation .......................................491
SHIFT CONTROL SYSTEM .............................493
Control Device Removal and Installation ..............493
Control Device Disassembly and Assembly ..........496
Selector Lever Knob Removal and Installation .....496
Adjustment of A/T Position ....................................497
Checking of A/T Position .......................................497
KEY INTERLOCK CABLE ...............................499
Removal and Installation .......................................499
AIR BREATHER HOSE ....................................502
Removal and Installation .......................................502
REMOVAL AND INSTALLATION .............503
TRANSAXLE ASSEMBLY ..............................503
Exploded View .......................................................503
Removal and Installation .......................................503
DISASSEMBLY AND ASSEMBLY ............506
OVERHAUL .....................................................506
Component ............................................................506
Oil Channel ............................................................512
Location of Adjusting Shims, Needle Bearings and
Thrust Washers .....................................................
513
Location of Snap Rings .........................................514
DISASSEMBLY ...............................................515
Disassembly ..........................................................515
REPAIR FOR COMPONENT PARTS .............530
Manual Shaft .........................................................530
Oil Pump ................................................................533
Control Valve Assembly ........................................536
Control Valve Upper Body .....................................545
Control Valve Lower Body .....................................548
Reverse Clutch ......................................................551
High Clutch ............................................................555
Forward and Overrun Clutches .............................560
Low & Reverse Brake ............................................566
Rear Internal Gear and Forward Clutch Hub .........571
Output Shaft, Output Gear, Idler Gear, Reduction
Pinion Gear and Bearing Retainer .........................
574
Band Servo Piston Assembly ................................580
Final Drive .............................................................585
ASSEMBLY .....................................................590
Assembly (1) ..........................................................590
Adjustment (1) .......................................................591
Assembly (2) ..........................................................596
Adjustment (2) .......................................................600
Assembly (3) ..........................................................604
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
612
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
612
General Specification ............................................612
Vehicle Speed at Which Gear Shifting Occurs ......612
Vehicle Speed at When Lock-up Occurs/Releases
..
612
Stall Speed ............................................................612
Line Pressure ........................................................612
Adjusting shims, Needle Bearings, Thrust Wash-
ers and Snap Rings ...............................................
613
Control Valves .......................................................614
Accumulator ...........................................................614
Clutches and Brakes .............................................614
Final Drive .............................................................616
Planetary Carrier ...................................................616
Oil Pump ................................................................616
Input Shaft .............................................................616
Reduction Pinion Gear ..........................................616
TM-8
Band Servo ............................................................616
Output Shaft ..........................................................616
Bearing Retainer ....................................................617
Total End Play .......................................................617
Reverse Clutch End Play .......................................617
Removal and Installation .......................................617
Shift Solenoid Valves .............................................617
Solenoid Valves .....................................................617
A/T Fluid Temperature Sensor ..............................618
Revolution Sensor .................................................618
Dropping Resistor ..................................................618
Turbine Revolution Sensor (Power Train Revolu-
tion Sensor) ...........................................................
618
5MT: RS5F91R
FUNCTION DIAGNOSIS ............................
619
M/T SYSTEM ...................................................619
System Diagram ....................................................619
System Description ................................................620
COMPONENT DIAGNOSIS .......................621
POSITION SWITCH .........................................621
BACK-UP LAMP SWITCH .......................................621
BACK-UP LAMP SWITCH : Component Parts Lo-
cation .....................................................................
621
BACK-UP LAMP SWITCH : Component Inspec-
tion .........................................................................
621
PARK/NEUTRAL POSITION (PNP) SWITCH .........621
PARK/NEUTRAL POSITION (PNP) SWITCH :
Component Parts Location ....................................
621
PARK/NEUTRAL POSITION (PNP) SWITCH :
Component Inspection ...........................................
621
SYMPTOM DIAGNOSIS ............................623
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ..........................
623
NVH Troubleshooting Chart ..................................623
PRECAUTION ............................................624
PRECAUTIONS ...............................................624
Service Notice or Precautions for Manual Tran-
saxle ......................................................................
624
PREPARATION ..........................................625
PREPARATION ...............................................625
Special Service Tools ..........................................625
Commercial Service Tools ...................................627
ON-VEHICLE MAINTENANCE ..................628
GEAR OIL ........................................................628
Exploded View .......................................................628
Draining .................................................................628
Refilling ..................................................................628
Inspection ..............................................................628
ON-VEHICLE REPAIR ..............................629
SIDE OIL SEAL ................................................629
Exploded View ......................................................629
Removal and Installation .......................................629
CONTROL LINKAGE .......................................630
Exploded View ......................................................630
Removal and Installation .......................................630
Inspection ..............................................................631
AIR BREATHER HOSE ....................................632
Exploded View ......................................................632
Removal and Installation .......................................632
REMOVAL AND INSTALLATION .............633
TRANSAXLE ASSEMBLY ...............................633
Exploded View ......................................................633
Removal and Installation .......................................633
DISASSEMBLY AND ASSEMBLY ...........635
TRANSAXLE ASSEMBLY ...............................635
Exploded View ......................................................635
Disassembly ..........................................................639
Assembly ..............................................................645
INPUT SHAFT AND GEAR ..............................653
Exploded View ......................................................653
Disassembly ..........................................................653
Assembly ..............................................................653
Inspection ..............................................................653
MAINSHAFT AND GEAR .................................655
Exploded View ......................................................655
Disassembly ..........................................................655
Assembly ..............................................................656
Inspection ..............................................................657
FINAL DRIVE ....................................................659
Exploded View ......................................................659
Disassembly ..........................................................659
Assembly ..............................................................659
Inspection ..............................................................659
SHIFT CONTROL .............................................661
Exploded View ......................................................661
Disassembly ..........................................................661
Assembly ..............................................................661
Inspection ..............................................................661
SERVICE DATA AND SPECIFICATIONS
(SDS) .........................................................
662
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................
662
General Specification ............................................662
6MT: RS6F94R
FUNCTION DIAGNOSIS ...........................
663
TM-9
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M/T SYSTEM ....................................................663
System Diagram ....................................................663
System Description ...............................................664
COMPONENT DIAGNOSIS .......................665
POSITION SWITCH ..........................................665
BACK-UP LAMP SWITCH ......................................665
BACK-UP LAMP SWITCH : Component Parts Lo-
cation .....................................................................
665
BACK-UP LAMP SWITCH : Component Inspec-
tion ........................................................................
665
PARK/NEUTRAL POSITION (PNP) SWITCH .........665
PARK/NEUTRAL POSITION (PNP) SWITCH :
Component Parts Location ....................................
665
PARK/NEUTRAL POSITION (PNP) SWITCH :
Component Inspection ..........................................
665
SYMPTOM DIAGNOSIS ............................667
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ..........................
667
NVH Troubleshooting Chart ..................................667
PRECAUTION ............................................668
PRECAUTIONS ................................................668
Service Notice or Precautions for Manual Tran-
saxle ......................................................................
668
PREPARATION .........................................669
PREPARATION ................................................669
Special Service Tools ..........................................669
Commercial Service Tools ...................................670
ON-VEHICLE MAINTENANCE ..................672
GEAR OIL .........................................................672
Exploded View ......................................................672
Draining .................................................................672
Refilling .................................................................672
Inspection ..............................................................672
ON-VEHICLE REPAIR ...............................673
SIDE OIL SEAL ................................................673
Exploded View ......................................................673
Removal and Installation .......................................673
CONTROL LINKAGE .......................................674
Exploded View ......................................................674
Removal and Installation .......................................674
Inspection ..............................................................677
AIR BREATHER HOSE ..................................678
Exploded View .......................................................678
Removal and Installation .......................................678
REMOVAL AND INSTALLATION .............680
TRANSAXLE ASSEMBLY ..............................680
Exploded View .......................................................680
Removal and Installation .......................................681
DISASSEMBLY AND ASSEMBLY ............683
TRANSAXLE ASSEMBLY ..............................683
Exploded View .......................................................683
Disassembly ..........................................................688
Assembly ...............................................................694
INPUT SHAFT AND GEAR .............................700
Exploded View .......................................................700
Disassembly ..........................................................700
Assembly ...............................................................701
Inspection ..............................................................702
MAINSHAFT AND GEAR ...............................704
Exploded View .......................................................704
Disassembly ..........................................................704
Assembly ...............................................................705
Inspection ..............................................................707
REVERSE IDLER SHAFT AND GEAR ...........709
Exploded View .......................................................709
Disassembly ..........................................................709
Assembly ...............................................................710
FINAL DRIVE ..................................................711
Exploded View .......................................................711
Disassembly ..........................................................711
Assembly ...............................................................711
Inspection ..............................................................712
SHIFT FORK AND FORK ROD ......................714
Exploded View .......................................................714
Disassembly ..........................................................714
Assembly ...............................................................714
Inspection ..............................................................714
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
715
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
715
General Specification ............................................715
TM-12
< BASIC INSPECTION >[TYPE 1 (4AT: RE4F03B)]
DIAGNOSIS AND REPAIR WORKFLOW
DIAGNOSTIC WORK SHEET
Symptoms❏ Vehicle does not move. (❏ Any position❏ Particular position)
❏ No up-shift (❏ 1st → 2nd❏ 2nd → 3rd❏ 3rd → 4th ❏ 4th → 5th)
❏ No down-shift (❏ 5th → 4th ❏ 4th → 3rd❏ 3rd → 2nd❏ 2nd → 1st)
❏ Lock-up malfunction
❏ Shift point too high or too low.
❏ Shift shock or slip (❏ N → D❏ N → R❏ Lock-up❏ Any drive position)
❏ Noise or vibration
❏ No kick down
❏ No pattern select
❏ Others
()
Malfunction indicator lamp (MIL)❏ Continuously lit❏ Not lit
1❏ Read the item on cautions concerning fail-safe and understand the customer's com-
plaint.TM-123
2❏ A/T fluid inspection, stall test and line pressure test
❏ A/T fluid inspection
TM-171❏ Leak (Repair leak location.)
❏ State
❏ Amount
3❏ Stall test
TM-175
❏ Torque converter one-way clutch
❏ Front brake
❏ High and low reverse clutch
❏ Low coast brake
❏ Forward brake
❏ Reverse brake
❏ Forward one-way clutch❏ 1st one-way
clutch
❏ 3rd one-way
clutch
❏ Engine
❏ Line pressure low
❏ Except for input
clutch and direct
clutch, clutches and
brakes OK
❏ Line pressure test - Suspected part:TM-178
4❏ Perform self-diagnosis. — Check detected items to repair or replace malfunctioning
part.TM-35 or TM-38
5❏ Perform road test.
5-1❏ Check before engine is startedTM-180
5-2❏ Check at idleTM-181
5-3 Cruise test❏ Part 1TM-183❏ Part 2TM-185
❏ Part 3TM-186
❏ Check malfunction phenomena to repair or replace malfunctioning part after completing all road test.
Refer to TM-127
.
5❏ Drive vehicle to check that the malfunction phenomenon has been resolved.
6❏ Erase the results of the self-diagnosis from the TCM and the ECM.TM-35
or TM-38
A/T CONTROL SYSTEM
TM-13
< FUNCTION DIAGNOSIS >[TYPE 1 (4AT: RE4F03B)]
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FUNCTION DIAGNOSIS
A/T CONTROL SYSTEM
Cross-Sectional ViewINFOID:0000000001694420
1. Converter housing 2. Oil pump 3. Brake band
4. Reverse clutch 5. High clutch 6. Front planetary gear
7. Low one-way clutch 8. Rear planetary gear 9. Forward clutch
10. Overrun clutch 11. Low & reverse brake 12. Output gear
13. Band servo piston 14. Reverse clutch drum 15. Side cover
16. Idler gear 17. Forward one-way clutch 18. Transaxle case
19. Reduction pinion gear 20. Final gear 21. Differential case
22. Input shaft 23. Torque converter
SCIA6171J
TM-14
< FUNCTION DIAGNOSIS >[TYPE 1 (4AT: RE4F03B)]
A/T CONTROL SYSTEM
Shift Mechanism
INFOID:0000000001694421
CONSTRUCTION
FUNCTION OF CLUTCH AND BRAKE
CLUTCH AND BAND CHART
1. Torque converter 2. Oil pump 3. Input shaft
4. Brake band 5. Reverse clutch 6. High clutch
7. Front sun gear 8. Front pinion gear 9. Front internal gear
10. Front planetary carrier 11. Rear sun gear 12. Rear pinion gear
13. Rear internal gear 14. Rear planetary carrier 15. Forward clutch
16. Forward one-way clutch 17. Overrun clutch 18. Low one-way clutch
19. Low & reverse brake 20. Parking pawl 21. Parking gear
22. Output shaft 23. Idle gear 24. Output gear
SAT998I
Clutch and brake components Abbr. Function
5Reverse clutch R/C To transmit input power to front sun gear 7.
6High clutch H/C To transmit input power to front planetary carrier 10.
15Forward clutch F/C To connect front planetary carrier 10 with forward one-way clutch 16.
17Overrun clutch O/C To connect front planetary carrier 10 with rear internal gear 13.
4Brake band B/B To lock front sun gear 7.
16Forward one-way clutch F/O.CWhen forward clutch 15 is engaged, to stop rear internal gear 13 from rotating in
opposite direction against engine revolution.
18Low one-way clutch L/O.CTo stop front planetary carrier 10 from rotating in opposite direction against en-
gine revolution.
19Low & reverse brake L & R/B To lock front planetary carrier 10.
Shift posi-
tionR/C
5H/C
6F/C
15O/C
17Band servo
F/O.C
16L/O.C
18L&R/B
19Lock-
upRemarks
2nd
apply3rd re-
lease4th ap-
ply
PPA R K
POSITION
RREVERSE
POSITION