STR-16
< BASIC INSPECTION >[MR18DE]
DIAGNOSIS AND REPAIR WORKFLOW
9.CHECK MAGNETIC SWITCH OPERATION SOUND
Check that a magnetic switch operation sound can be heard when the ignition switch is set at the starting posi-
tion.
Does magnetic switch operation sound occur?
YES >> GO TO 10
NO >> Replace magnetic switch.
10.PINION AND RING GEAR ENGAGEMENT CHECK
Check condition of pinion and ring gear mesh.
Is the inspection result normal?
YES >> GO TO 12
NO >> GO TO 11
11 .CHECK STARTER MOTOR UNIT
Check the following.
Adjust pinion movement.
Check pinion moving mechanism.
Check ring gear.
Are these inspection results normal?
YES >> INSPECTION END
NO >> Repair or replace, if necessary.
12.CHECK STARTER MOTOR UNIT
Check that the starter motor runs when connecting the positive ter-
minal (12 V) to starter motor terminal M and the negative terminal
(ground) to starter motor body.
Does the starter motor run?
YES >> Replace magnetic switch.
NO >> Repair starter motor.
SEL009Z
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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(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-30
< FUNCTION DIAGNOSIS >[TYPE 1 (4AT: RE4F03B)]
A/T CONTROL SYSTEM
Component Parts Location
INFOID:0000000001694446
1. OD OFF indicator lamp 2. Shift position indicator 3. Accelerator pedal position (APP)
4. Turbine revolution sensor (Power
train revolution sensor)5. PNP switch 6. Terminal body (Terminal cord assem-
bly connector)
7. Revolution sensor 8. Dropping resistor 9. TCM (LHD)
10. TCM (RHD) 11. Overdrive control switch
AWDIA0072ZZ
DTC P0725 ENGINE SPEED SIGNAL
TM-57
< COMPONENT DIAGNOSIS >[TYPE 1 (4AT: RE4F03B)]
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NG >> Check ignition signal circuit for engine control. Refer to EC-319, "Diagnosis Procedure".
2.CHECK INPUT SIGNAL
With CONSULT-III
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-III.
3. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position.
Without CONSULT-III
1. Start engine.
2. Check voltage between TCM harness connector terminal and
ground.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.
3. CHECK HARNESS BETWEEN TCM AND ECM
1. Turn ignition switch OFF.
2. Disconnect ECM connector and TCM connector.
3. Check continuity between ECM connector and TCM connector.
4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between body ground and transaxle
assembly.
6. Reinstall any part removed.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
4.CHECK DTC
Perform TM-56, "
DTC Confirmation Procedure".
OK or NG
OK >>INSPECTION END
NG >> GO TO 5.
5.CHECK TCM
1. Check TCM input/output signal. Refer to TM-119, "
Reference Value".
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
Item name Condition Display value
ENGINE SPEED (rpm) Engine runningApproximately matches the tachome-
ter reading.
itemConnec-
torTerminal ConditionJudgement standard (Ap-
prox.)
Engine
speed signalE3239 -
Ground
and Refer to EC-328
.
SCIA3265E
Item Connector Terminal Continuity
TCM E32 39
Ye s
ECM F10 13
SCIA7173E
TM-164
< PRECAUTION >[TYPE 1 (4AT: RE4F03B)]
PRECAUTIONS
Be sure to turn the ignition switch OFF and disconnect battery negative cable from battery negative
terminal before any repair or inspection work. The open/short circuit of related switches, sensors,
solenoid valves, etc. will cause the MIL to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to an open circuit. (Be sure the connectors are free from water, grease,
dirt, bent terminals, etc.)
Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MIL to light up due to a short circuit.
Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
PrecautionINFOID:0000000001696267
Before connecting or disconnecting the TCM harness connec-
tor, turn ignition switch OFF and disconnect the battery cable
from the negative terminal. Failure to do so may damage the
TCM. Because battery voltage is applied to TCM even if igni-
tion switch is turned off.
When connecting or disconnecting pin connectors into or
from TCM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on TCM pin
terminal, when connecting pin connectors.
Before replacing TCM, perform TCM input/output signal
inspection and make sure whether TCM functions properly or
not. (See page XX-XX, "*****"
.)
After performing each TROUBLE DIAGNOSIS, perform “DTC
(Diagnostic Trouble Code) Confirmation Procedure”.
The DTC should not be displayed in the “DTC Confirmation
Procedure” if the repair is completed.
Before proceeding with disassembly, thoroughly clean the outside
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 A/T.
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 A/T 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.
SEF289H
AAT470A
MEF040DA
CONTROL SYSTEM
TM-193
< ON-VEHICLE REPAIR >[TYPE 1 (4AT: RE4F03B)]
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- Remove O-rings (1) from servo release accumulator piston (2) and
N-D accumulator piston (3).
CAUTION:
Wrap the removed servo release accumulator piston (2) and
N-D accumulator piston (3) in a lint-free paper.
INSPECTION
Inspect the sliding surfaces of each accumulator piston and tran-
saxle case, and replace if damaged or dented.
(1): Servo release accumulator piston
(2): N-D accumulator piston
Inspect the sliding surfaces of manual valve and valve body, and
replace if damaged or dented.
Inspect each return spring, and replace if damaged, deformed or
worn. Refer to TM-321, "
Accumulator" for free length (L1) and
length (L
2).
(1): Return spring (Servo release accumulator)
(2): Return spring (N-D accumulator)
CAUTION:
Do not remove spring retainer (3).
INSTALLATION
Install is in the reverse order of removal.
CAUTION:
Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of
transaxle case and oil pan.
Do not reuse O-rings, lip seals, oil pan gasket and oil pan bolts.
Apply ATF to manual valve, O-rings, lip seals and sliding surfaces transaxle case.
SCIA6033J
SCIA6035J
SCIA6955E
TM-224
< DISASSEMBLY AND ASSEMBLY >[TYPE 1 (4AT: RE4F03B)]
DISASSEMBLY
14. Remove control valve assembly according to the following pro-
cedures.
a. Remove snap ring (1) from terminal body (2).
CAUTION:
Do not expand snap ring (1) excessively.
b. Push terminal body (2) into transaxle case.
c. Remove control valve assembly bolts (A), (B) and (C).
Bolt length, number and location:
d. Remove control valve assembly from transaxle case.
CAUTION:
Do not drop manual valve.
15. Remove manual valve from control valve assembly.
Inspect the sliding surfaces of manual valve and valve
body, and replace if damaged or dented.
CAUTION:
Do not drop manual valve.
16. Remove O-ring from terminal body.
17. Remove return spring from servo release accumulator piston.
SCIA6030J
Bolt symbol A B C
Bolt length “ ” [mm (in)]
40.0 mm
(1.575 in)33.0 mm
(1.299 in)43.5 mm
(1.713 in)
Number of bolts 5 6 2
SCIA5911J
SCIA3150E
SCIA3477E