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A140E AUTOMATIC TRANSAXLE

1. DIAGNOSTIC TROUBLE CODE CHECK 1 Turn the ignition switch ON but do not start the engine 2 Push in the O D main switch to ON HINT Warning and diagnostic trouble codes can be read only when the O D main switch is ON If it is OFF the 0 D OFF indicator light up will light continu ously and will not blink 3 Using SST connect terminals TE1 and El of the DLC1 or DLC2 SST 09843 18020 AX1 45 AUTOMATIC TRANSAXLE TROUBLESHOOTING 4 Read the diagnostic trouble code indicated by the number of times the O D OFF indicator light blinks HINT If the system is operating normally the light will blink 2 times per second Diagnostic trouble code 42 is shown as an example 0 5 seconds 2 5 seconds pe di HINT When 2 more trouble codes are stored ON memory the lower numbered code is displayed first BR If no diagnostic trouble code is output or if diagnos tic trouble code is output even though no diagnostic py pont trouble code output operation is performed check the TE1 terminal circuit on page AX1 110 DIAGNOSTIC TROUBLE CODE CHECK BY USING TOYOTA HAND HELD TESTER 1 Hook up the TOYOTA hand held tester to the DLC2 2 Read the diagnostic trouble codes by following the prompts on the tester screen Please refer to the TOYOTA hand held tester operator s manual for further details CANCELLING DIAGNOSTIC TROUBLE CODE After repair of the trouble area
2. Proceed to next circuit inspection shown on matrix chart See page 1 68 eck harness and connector between ECM and throttle position sensor See page IN 31 Check and replace ECM Repair or replace harness or connector AX1 92 AUTOMATIC TRANSAXLE TROUBLESHOOTING Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION The park neutral position switch detects the shift lever position and sends signals to the ECM The ECM receives signals NSW 2 and L from the park neutral position switch When the signal is not sent to the ECM from the park neutral position switch the ECM judges that the shift lever is in the D position DIAGNOSTIC CHART Check voltage between terminals NSW 2 L Proceed to next circuit inspection of ECM connector and body ground shown on matrix chart See page Q AX 00 NG Check park neutral position switch OK Check harness and connector between ECM and park neutral position switch park neutral position switch and battery See page IN 31 Repair or replace harness or con nector AX1 93 AUTOMATIC TRANSAXLE TROUBLESHOOTING WIRING DIAGRA Combination Meter we A T Indicator Light JB o EN E hoja 07 En Te Ignition Switch Park Neutral a Position Switch 1731 gt J B _ AX1 94 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals NSW 2 L of ECM con
3. Steel magnetic bearing gear and plate wear Brass non magnetic bushing wear 5 REMOVE OIL STRAINER AND APPLY TUBE BRACKET a Remove the 3 bolts and the oil strainer NOTICE Be careful as oil will come out of the strainer when it is removed b Remove the 2 bolts and the apply tube bracket i 6 DISCONNECT SOLENOID CONNECTORS E Shift Solenoid Valve No 1 Shift Solenoid Valve No 2 AX1 14 AUTOMATIC TRANSAXLE ON VEHICLE REPAIR 7 REMOVE OIL TUBES Pry up the both tube ends with a large screwdriver and remove the four tubes 8 REMOVE MANUAL DETENT SPRING 9 REMOVE MANUAL VALVE AND MANUAL VALVE BODY 10 REMOVE VALVE BODY Remove the 12 bolts 11 REMOVE THROTTLE CABLE a Disconnect the throttle cable b Remove the valve body 12 REMOVE SECOND BRAKE APPLY GASKET AX1 15 AUTOMATIC TRANSAXLE _ON VEHICLE REPAIR VALVE BODY INSTALLATION 1 INSTALL SECOND BRAKE APPLY GASKET 2 INSTALL VALVE BODY a While holding the cam down with your hand slip the cable and into the slot b Bring valve body into place NOTICE Be careful not to entangle the solenoid wire 3 INSTALL BOLTS IN VALVE BODY Hand tighten the 12 bolts first then torque with a torque wrench Torque 10 100 kgf cm 7 ft lbf Bolt length A 20 mm 0 79 in B 25 mm 0 98 in C 36 mm 1 42 in D50mm 1 97in 4 CONNECT SOLENOID WIRING a Connect the shift solenoid valve No 1 connector white and
4. Throttle F Position Sensor Detects the throttle valve opening angle Engine Coolant Temp Sensor Detects the engine coolant temperature Detect the vehicle speed Ordinarily transaxle control uses signals from the Vehicle Speed Sensor vehicle speed sensor Park Neutral Position Switch Detects the shift lever position Shift Solenoid Valves Control the hydraulic pressure applied to each shift valve and control the gear shift No 1 and No 2 position and timing Controls the and transaxle actuators based on signals from each sensor Shift Solenoid Valves SL de For lock up control pressure modulation Stop Light Switch Controls the hydraulic pressure applied to the lock up clutch and controls lock up timing Detects if the brake pedal is depressed 1 11 AUTOMATIC TRANSAXLE PREPARATION PREPARATION SST SPECIAL SERVICE TOOLS 09043 38100 Hexagon 10 mm Wrench Remove and install oil pan drain plug 09308 00010 Oil Seal Puller Remove side gear shaft oil seal 09350 32014 TOYOTA Automatic Transmission Tool Set 09351 32010 One way Clutch Test Toot 09351 32020 Stator Stopper 09351 32130 Handle 09351 32150 Oil Seal Replacer 09843 18020 Diagnosis Check Wire 09992 00094 Automatic Transmission Oil Line pressure Pressure Gauge Set RECOMMENDED TOOLS E 09082 00050 TOYOTA Electrical Tester
5. 2 450 150 rpm pup ee Parking Brake AX1 58 AUTOMATIC TRANSAXLE TROUBLESHOOTING EVALUATION Problem e Engine output may be insufficient e Stator one way clutch is operating properly HINT If more than 600 rpm below the specified value the torque converter clutch could be faulty a Stall speed low in D and R posi tions Line pressure too low e Forward clutch slipping e No 2 one way clutch not operating properly 4 D one way clutch not operating properly b Stall speed high in D position Line pressure too low Direct clutch slipping First and reverse brake slipping O D clutch slipping Line pressure too low d Stall speed high in D and R posi e Improper fluid level tion 0 D one way clutch not operating properly c Stall speed high in R posi tion AX1 59 AUTOMATIC TRANSAXLE TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling there will be a certain time lapse or lag before the shock can be felt This is used for checking the condition of the 4 D direct clutch forward clutch direct clutch and first and reverse brake NOTICE e Perform the test at normal operating fluid temperature 50 80 C 122 176 F e Be sure to allow a one minute Interval between tests e Make 3 measurements and take the average value e MEASURE TIME LAG a Fully apply the parking brake b Start the engine and check idle speed Idle speed 750 rpm
6. GON Accel pedal is released Below 1 V IDL E LESER Accel pedal is depressed em 14 Accel pedal is released IG ON Accel pedal i 5 depressed venen GON OD main SW OFF Balow 1 V Standing still Balow 1 V connectors Turn one front Plus signal is output Cruise control ECU wheel slowly Balaw 1 V 4 5 5 5 V P or N position E V B W BR IG ON P and N position Below 1 1Y 2 ata 2 On BR IG ON position 10 14 V Except 2 position Below 1 V ee Except L position Below 1 V Disconnect following AX1 67 AUTOMATIC TRANSAXLE TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting The Matrix Chart is divided into 3 chapters Chapter 1 Electronic Circuit Matrix Chart Chapter 2 On vehicle Repair Matrix Chart Chapter 3 Off vehicle Repair Matrix Chart When troubleshooting check Chapter 1 first If instructions are given in Chapter 1 to proceed to Chapter 2 or 3 proceed as instructed 1 If the instruction Proceed to next circuit inspection shown on matrix chart is given in the flow chart for each circuit proceed to the circuit with the next highest number in the table to continue the check 2 If the
7. 39 N m 400 kgf cm 29 ft lbf b Connect the connector and nut AX1 33 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 31 CONNECT VEHICLE SPEED SENSOR CONNECTOR 32 INSTALL GROUND TERMINAL w Cruise Control System 33 CONNECT CONNECTOR TO CRUISE CONTROL ACTUATOR 34 INSTALL CRUISE CONTROL ACTUATOR COVER 35 INSTALL THROTTLE CABLE TO ENGINE a Torque the nuts Torque 15 N m 150 kgf cm 11 ft Ibf b Adjust the throttle cable See page AX1 55 36 INSTALL AIR CLEANER ASSEMBLY 37 CONNECT NEGATIVE TERMINAL CABLE TO BATTERY AX1 34 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 38 FILL TRANSAXLE WITH ATF Fluid type ATF DEXRON II Capacity 5 6 liters 5 9 US gts 4 9 Imp gts ATH 39 CHECK FLUID LEVEL See page AX1 64 Add if hot 40 INSPECT FRONT WHEEL ALIGNMENT See page SA 40 41 PERFORM ROAD TEST Check for abnormal noise and smooth shifting TORQUE CONVERTER CLEANING If the transaxle is contaminated the torque converter and transmission cooler should be thoroughly flushed with ATF TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION 1 INSPECT ONE WAY CLUTCH a Install SST into the inner race of the one way clutch SST 09350 33014 09351 32010 AX1 35 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION b Install SST so that it fits in the notch of the converter hub and outer race of the one way clutch SST 09350 32
8. 62 42 48 28 30 50 56 31 36 PWR Mode Shift position Shifting point Throttle valve fully openad D position Vehicle speed km h mph 58 85 38 40 110 120 88 75 147 157 181 88 138 148 86 93 101 111 63 89 51 58 32 36 Thrattla valve fully closed 30 45 24 28 17 24 11 15 Throtile valve fully opened 58 65 38 40 2 position B8 88 55 62 42 40 26 30 rota vane fuly opened 2 1 50 58 31 35 D position AX1 53 AUTOMATIC TRANSAXLE TROUBLESHOOTING LOCK UP POINT NORM Mode D position Lock up ON km h mph Lock up OFF km h mph Throttle valve opening 596 M 3rd Gear 85 92 53 57 78 88 48 53 O D Gear 87 74 42 48 64 71 35 38 PWR Mode D position Lock up OFF km h mph Throttle valve opening 596 3rd Gear O D Gear Lock up km h mph B5 82 53 57 73 80 45 50 79 88 49 53 _ _ O D main switch OFF HINT 1 In the 2 and L positions all stages lock up is OFF 2 In the following cases the lock up will be released regardless of the lock up pattern e When the throttle valve is completely closed e When the brake light switch is ON AX1 54 AUTOMATIC TRANSAXLE TROUBLESHOOTING PRELIMINARY CHECK 1 CHECK FLUID LEVEL HINT e Drive the vehicle so that the engine and transaxle are at normal operating temperature Fluid tem
9. Full Open NOTICE Perform the test at normal ATF operating tem perature 50 80 C 122 176 F 1 D POSITION TEST Shift into the D position and keep the accelerator pedal constant at the full throttle valve opening posi tion and check the following points a Check up shift operation Check that 1 2 2 3 3 O D up shift takes place at the shift point shown in the automatic shift schedule See page AX1 52 HINT 1 0 D Gear Up shift Prohibition Control Coolant temp is 50 C 122 F or less e fthere is a 10 km h 6 mph difference between the set cruise control speed and vehicle speed 0 0 main switch is pushed ON During the O D OFF indicator light lights up 2 0 D Gear Lock up Prohibition Control e Brake pedal is depressed e Coolant temp is 50 C 122 F or less D Position b Check for shift shock and slip Check for shock and slip at the 1 2 2 3 and 3 0 D up shifts AX1 50 AUTOMATIC TRANSAXLE TROUBLESHOOTING c Check for abnormal noise and vibration Abnormal Noise Run at the D position lock up or O D gear and check Vibration for abnormal noise and vibration O D HINT The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also be due to loss of balance in the torque converter clutch etc d Check kick down operation While running in the D position 2nd 3rd and O D gears check to see that the possible kick d
10. 105 AUTOMATIC TRANSAXLE TROUBLESHOOTING Measure voltage between terminal 1 of O D main switch connector and body ground a 1 Disconnect O D main switch connector 2 Turn IG switch ON ES Measure voltage between terminal 1 of O D main switch harness side connector and body ground En K Voltage 10 14 V Repair or replace harness or connector be tween combination meter and O D main switch Check continuity of O D main switch Disconnect O D main switch connector Check continuity between terminals 1 and 3 of O D main switch connector ON Position No continuity More than 10 kQ OFF Position Continuity Below 10 Replace O D main switch epair or replace harness or connector betwee O D main switch and body ground AX1 106 AUTOMATIC TRANSAXLE TROUBLESHOOTING Check O D OFF indicator ight when you disconnect O D main switch connector _ Turn IG switch ON Check that the O D OFF indicator light goes off when you disconnect the O D main switch con nector Replace O D main switch Check 0 D OFF indicator light when you disconnect ECM connector including OD2 terminal EB Turn IG switch ON Check that the O D OFF indicator light goes off when you disconnect the ECM connector includ ing OD2 terminal Replace ECM NG Repair or replace harness Repair or replace combination meter See page 65 AX1 107 AUTOMATIC TRANSAXLE TROUBLESHOO
11. 6 3 8 1 kgf cm 50 115 pai D position R position 750 697 kPa 7 7 8 1 kgt cm 108 130 1 373 1 808 kPa 14 0 18 4 kgf tem 199 233 pai Engine stall revolution 244505 150 rnm Time lag position D position Loss than 1 2 seconds HN position position Less than 1 5 seconds Engine idle speed Cooling fan and A C OFF N position Torque converter runout 0 0118 in Drive plate runout 0 0079 in SHIFT POINT Shift position Shifting point Throttle valve fully opened 58 85 38 40 110 120 BB 75 147 157 81 88 139 149 66 93 98 108 61 67 42 48 2630 Throttle valve fully closad 38 46 24 28 17 24 11 15 Throttie valve fully opened BB 85138 40 _ 2 position 89 99 55 82 42 49 28 30 A 50 60 31 35 LOCK UP POINT D position km h mph Throttle valve opening 596 Lock up Lock up OFF Gear O D switch OFF 85 92 83 67 _ 79 88 49 53 O D Gear NORM 87 74 42 46 84 71 40 44 PWR 73 80 45 50 70 77 43 48 O D switch OFF D position AX1 114 AUTOMATIC TRANSAXLE SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened Engine rear mounting bracket x Front suspention member Engine rear mounting bracket x Front suspention member LH transaxle mounting Nm L a PEE Transaxle x Engine 12 mm bolt I 2 Torque conver
12. AX1 77 AUTOMATIC TRANSAXLE TROUBLESHOOTING Location of Connectors in Instrument Panel amp 05 a Combination Meter Combination Meter Combination Metar pI IA pi i Pattern Select Switch 216 Cruise Control ECU 1 006900000 5 099009000 n T 1 221 AX1 78 Ignition Switch se 14 1 Stop Light Switch AUTOMATIC TRANSAXLE TROUBLESHOOTING Gn 2 Junction Connector Junction Connector 1 ASS AX1 79 AUTOMATIC TRANSAXLE TROUBLESHOOTING J B No 1 J B No 3 p Hc pem HH AX1 80 AUTOMATIC TRANSAXLE TROUBLESHOOTING CIRCUIT INSPECTION Diag Trouble Code 42 No 1 Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The No 1 vehicle speed sensor outputs a 4 pulse signal for every revolution of the differential case After this signal has been converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter it is then transmitted to the ECM 4 Pulse Signal 4 Pulsa Signal Speed Sensor Vehicle Speed Sensor 1 Meter L If the vehicle speed sensor signal is not input for 2 e Vehicle speed sensor seconds or longer after condition A or B described Combination meter below occurs DTC
13. Set AX1 12 AUTOMATIC TRANSAXLE PREPARATION EQUIPMENT Straight edge Check torque converter clutch installation Vernier calipers Dial indicator or dial indicator with magnetic base Torque wrench LUBRICANT Item 7 Capacity _ Classification l Automatic transaxle fluid w o Differential oil ATF DEXRON 6 Q Dry fill 5 6 liters 5 9 US qts 4 9 Imp qts Drain and refill 2 5 liters 2 6 US qts 2 2 Imp qts Differential oil w Automatic transaxle 1 6 liters 1 7 US qts 1 4 Imp qts ATF DEXRON 6 Q ike SSM SPECIAL SERVICE MATERIALS 08833 00070 Adhesive 1311 Torque converter clutch mounting THREE BOND 1311 or equivalent bolt AX1 13 AUTOMATIC TRANSAXLE ON VEHICLE REPAIR ON VEHICLE REPAIR VALVE BODY REMOVAL 1 CLEAN TRANSAXLE EXTERIOR To help prevent contamination clean the exterior of the transaxle 2 DRAIN TRANSAXLE FLUID Remove the drain plug with SST and drain the fluid into a suitable container SST 09043 38100 3 REMOVE OIL PAN AND GASKET NOTICE Some fluid will remain in the oil pan Remove all pan bolts and carefully remove the pan assembly discarding the gasket 4 EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle
14. speed and throttle position and send this data to the ECM in the form of electronic signals b ECM This determines the shift and lock up timing based upon the signals from the sensors c Actuators Solenoid valves divert hydraulic pressure from one circuit of the hydraulic control unit to another thus controlling shifting and lock up timing SENSORS ACTUATORS SHIFT SOLENOID i VALVE NO 1 SHIFT SOLENOID I VALVE NO 2 SHIFT SOLENOID VALVE SL PATTERN SELECT ECM SWITCH itt Control of shift timing PARK NEUTRAL POSITION SWITCH THROTTLE POSITION SENSOR VEHICLE SPEED SENSOR BRAKE LIGHT SWITCH O D MAIN SWITCH CRUISE CONTROL ECU ENGINE COOLANT TEMPERATURE SENSOR Control of lock up timing O D OFF INDICATOR LIGHT Self diagnostic system Back up system AX1 9 SYSTEM DIAGRAM AX1 10 AUTOMATIC TRANSAXLE OPERATION ARRANGEMENT OF COMPONENTS Throttle Position Sensor Engine Coolant Temperatura Sensor Vehicle Speed Sansor Shift Solenoid Valve SL Park Neutral Position Switch y Blinks and warns the driver while the 0 D main switch is pushed in when the O D OFF Indicator Light electronic control circuit is malfunctioning G Pattern Select Switch Selects the Power mode or the Normal mode for shift and lock up timing al 0 D Switch Prevents up shift to the O D gear if the O D switch is off
15. the diagnostic trouble code retained in the ECM memory must be cancelled out by removing the EM fuse for 10 seconds or more with the ignition switch off Check that the normal code is output after connecting the fuse AX1 46 AUTOMATIC TRANSAXLE TROUBLESHOOTING ECM TERMINALS STANDARD VALUE ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK OUT BOX AND TOYOTA HAND HELD TESTER 1 Hook up the TOYOTA break out box and TOYOTA hand held tester to the vehicle 2 Read the ECM input output values by following the prompts on the tester screen HINT TOYOTA hand held tester has a Snapshot function This records the measured values and is effective in the diagnosis of intermittent problems Please refer to the TOYOTA hand held tester TOYOTA break out box operator s manual for fur ther details gt A u 8 5 E 7131 AX1 47 AUTOMATIC TRANSAXLE TROUBLESHOOTING close Throtde Valve Opening Angle Open 0868 CHECK TERMINAL TT OUTPUT VOLTAGE When a voltmeter is connected to the DLC2 the following items can be checked 1 Throttle position sensor signal 2 Brake signal 3 Shift position signal 1 VOLTMETER CONNECTION Connect the positive probe of the voltmeter to terminal Tt and the negative probe to terminal E1 of the DLC2 HINT If a voltmeter with small internal resistance is used the correct voltage will not be indicated so use a voltmeter with an internal
16. 014 09351 32020 With the torque converter clutch standing its side the clutch locks when turned counterclockwise and rotates freely and smoothly clockwise If necessary clean the converter clutch and retest the clutch Replace the converter clutch if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure the drive plate runout If runout exceeds 0 20 mm 0 0079 in or if the ring gear is damaged replace the drive plate If installing a new drive plate note the orientation of spacers and tighten the bolts Torque 83 N m 850 kgf cm 61 ft Ibf 3 MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT a Temporarily mount the torque converter clutch to the drive plate Set up a dial indicator If runout exceeds 0 30 mm 0 0118 in try to correct by reorienting the installation of the converter If ex cessive runout cannot be corrected replace the torque converter clutch HINT Mark the position of the converter clutch to ensure correct installation b Remove the torque converter clutch AX1 36 AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM COMPONENT PARTS LOCATION Shift Lack Override Cover Shift Lock Override Button Shift Lock Solenoid Shift Lock Control Switch WIRING DIAGRAM AX1 37 AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEM ELECTRIC CONTROL COMPONENTS INSPECTION 5156 5158 1 INSPECT SHIFT L
17. 27 280 kgf cm 20 ft Ibf HINT First install dark green colored bolt and then the 5 bolts 6 INSTALL REAR END PLATE Install the rear end plate with the 4 bolts 7 INSTALL STIFFENER PLATE a Install the stiffener plate with the 3 bolts b Torque the 3 bolts Torque 37 N m 380 kgf cm 27 ft lbf 8 INSTALL FRONT FRAME ASSEMBLY a Hold the front frame assembly with a jack b Install the front frame assembly with the 6 bolts and 4 nuts c Torque the bolts 19 mm head bolt Torque 181 N m 1 850 kgf cm 134 ft lbf 12 mm head bolt Torque 32 N m 330 kgf cm 24 ft lbf AX1 29 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION d Torque the nuts Nut Torque 36 N m 370 kgf cm 27 ft lbf c Install the 2 set screws in the right and left fender liners 9 INSTALL STEERING GEAR HOUSING a Install the steering gear housing to the front frame assembly b Install and torque the 2 bolts and nuts Torque 181 N m 1 850 kgf cm 134 ft lbf c Connect the stabilizer bar bushing bracket with the 4 bolts Torque 19 195 kgf cm 14 ft lbf 10 INSTALL 4 TRANSAXLE MOUNTING BOLTS Torque 52 N m 530 kgf cm 38 ft lbf AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 11 INSTALL 3 REAR SIDE ENGINE MOUNTING NUTS Torque 66 N m 670 kgf cm 48 ft lbf 12 INSTALL FRONT SIDE ENGINE MOUNTING NUT Torque 80 N m 820 kgf cm 59 ft lbf 13 INSTALL DRIVE SHAFT See p
18. 42 is recorded and the OD OFF hic d indicator light lights up simultaneously arness or connector between vehicle spee CONDITION A sensor and ECM 001558 Trouble Area e 30 seconds or more elapses after the park e neutral position switch goes OFF e The throttle opening ratio and engine RPM are within the shadded area E i 25 50 100 CONDITIONB Throttle Opening Ratio e 1second or more elapses after the park neutral position switch goes OFF Avehicle speed sensor signal of 14 km h 7 mph or more was input e The stop light switch is OFF brake pedal is released voi 547 e Waveform between terminals SPD and E1 when vehicle speed is approx 20 km h 12 MPH HINT The greater the vehicle speed the greater the number of vehicle speed sensor signals produced Reference gt 1 81 AUTOMATIC TRANSAXLE TROUBLESHOOTING CIRCUIT DESCRIPTION Fail Safe Function If the vehicle speed sensor fails shift control takes place so that the throttle opening ratio and RPM are controlled according to the shift control map Shift Control Map Raterence A Zone Shift down 2 gears B Zone Shift down 1 gear C Zune Ma change D Zone Shift up 1 gear Zone Shift up 2 gears amp hift up 3 gears 5 V Fixed Check speedometer circuit See combination meter troubleshooting o
19. AX1 1 AUTOMATIC TRANSAXLE A140E AUTOMATIC TRANSAXLE AX1 2 AUTOMATIC TRANSAXLE DESCRIPTION DESCRIPTION PRECAUTIONS When working with FIPG material you must observe the following e Using a razor blade and gasket scraper remove all the old FIPG material from the gasket surfaces e Thoroughly clean all components to remove all the loose material e Clean both sealing surfaces with a non residue solvent Apply the FIPG in approx 1 mm 0 04 in wide bead along the sealing surface e Parts must be assembled within 10 minutes of application Otherwise the FIPG material must be removed and reapplied If the vehicle is equipped with a mobile communication system refer to the precaution in the IN section GENERAL DESCRIPTION The A140E Electronically Controlled automatic transaxle described in this AX section is a lock up four speed automatic transaxle developed exclusively for use with transversely mounted engines Sectional View AX1 3 AUTOMATIC TRANSAXLE DESCRIPTION SPECIFICATIONS Type of Transaxle __ 4 of Engine 85 FE Torque Converter Clutch Stall Torque Ratio 20 1 Torque Converter Clutch Lock up Mechanism Gear Ratio 1 st Gear 2nd Gear 3rd Gear 0 D Gear Reverse Gear Number of Discs Plates O D Direct Clutch Co Forward Clutch C Direct Clutch Ct 2nd Brake Bz 1 st amp Reverse Brake B O D Brake Bo Transaxle nd Coast Brake Band W
20. No lock up OFF Y E EE Li nnl Large shock during lock up E G stalls when starting off and stopping 1 st gt 2nd 2nd 3rd 2 c 3 e Q No down shift 2nd 4 st Harsh engagement 1 st 2nd D position Forward and reverse After warm up em z 411 2 S 4 2 Forward and reverse Directly after E G start Slip or shudder DODGE ae ens No engine braking Poor acceleration EZ LH En AX1 73 AUTOMATIC TRANSAXLE TROUBLESHOOTING Aem ou0 pue 1 Leg AX1 74 AUTOMATIC TRANSAXLE TROUBLESHOOTING ATLA LOCATION OF CONNECTORS Location of Connectors in Engine Compartment vs 01 N 3613 pi E2 Cen Data Link Connector 1 Shift Solenoid Valve Shift Solenoid Valve SL Park Neutral and No 2 Position Switch a 7 im la 3 1 8 la 2 1 x ia 10 1 8 Position Sensor AX1 75 AUTOMATIC TRANSAXLE TROUBLESHOOTING Location of Connectors in Body Sedan DAD E am db Light Failura Sansor Stop Light LH RH Stop Light LH RH NOSE e ool E CT A E 11 1 REDE He Ea idi Light Failure Sensor AX1 76 Light Failure Sensor Stop Light LH RH Stap Light LH 12 AUTOMATIC TRANSAXLE TROUBLESHOOTING
21. OCK CONTROL ECU i Using a voltmeter measure the voltage at each termi nals HINT Do not disconnect the ECU connector Wire Harness Side ek 5 7 1 5 3 2 D Connector Terminal d Measuring condition Voltage V Ignition switch ACC position 10 14 Ignition switch ON position 10 14 epress brake pedal Ee a Ignition switch ACC position and except P position Approx after 1 second Ignition switch ON position and P position SLS 515 2 Shift except P position under conditions above 2 INSPECT SHIFT LOCK SOLENOID a Disconnect the solenoid connector b Using an ohmmeter measure the resistance between terminals Standard resistance 21 272 c Apply the battery positive voltage between terminals Check that an operation noise can be heard from the solenoid AX1 38 AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEM 3 INSPECT KEY INTERLOCK SOLENOID a Disconnect the solenoid connector b Using an ohmmeter measure the resistance between terminals Standard resistance 12 5 16 50 c Apply the battery positive voltage between terminals Check that an operation noise can be heard from the solenoid 4 INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each termi nal Terminal Shift Position P position Release button is not pushed E P position Release button is pushed CF D 2 Posi
22. Remove the 3 nuts AX1 24 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION b Remove the 2 bolts and nuts from rear exhaust pipe 21 REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET 22 DRAIN DIFFERENTIAL FLUID INTO A SUITABLE CONTAINER 23 REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO 2 24 REMOVE ENGINE UNDER FRONT COVER NO 1 AND NO 2 25 REMOVE DRIVE SHAFT See page SA 38 26 REMOVE FRONT SIDE ENGINE MOUNTING NUT 27 REMOVE 3 REAR SIDE ENGINE MOUNTING NUTS AX1 25 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 28 REMOVE ENGINE 4 TRANSAXLE MOUNTING BOLTS 29 REMOVE STEERING GEAR HOUSING a Remove the 4 bolts and disconnect stabilizer bar bus hing bracket from the front frame assembly b Remove the 2 bolts and nuts from the steering gear housing c Remove the steering gear housing 30 REMOVE FRONT FRAME ASSEMBLY a Hold the front frame assembly with a jack b Remove the 2 set screws from the right and left fender liners c Remove the 6 bolts and 4 nuts d Remove the front frame assembly AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 31 REMOVE STIFFENER PLATE a Hold the transaxle with a jack b Remove the 3 bolts and stiffener plate 32 REMOVE REAR END PLATE a Remove the 4 bolts b Remove the rear end plate 33 REMOVE TORQUE CONVERTER CLUTCH MOUNT ING BOLT a Turn the crankshaft to gain access to each bolt b Hold the cra
23. TING EM Turn IG switch ON Check indicator lights on combination meter other than O D OFF indicator light 2 Check the following indicator lights on combination meter e Check Engine Light Low Oil Pressure Warning Light e ABS Warning Light etc Above indicator lights light up Check and repair power source circuit to combination meter or combination meter 1 Turn ignition switch ON Ful 2 Check O D OFF light when O D main switch iF 7 is pushed in to ON b ET _ 3 Start the engine O D OFF light goes off E3 3 Check O D OFF light when O D main switch is pushed again to OFF O D OFF light lights up If the O D OFF light blinks when the O D main switch is pushed in to ON a malfunction is occur ing in the system Check the diagnostic trouble code Check and repair harness between O D main switch and combination meter Check harness and connector between combination meter and ECM SS Replace ECM Repair or replace harness or connector AX1 108 AUTOMATIC TRANSAXLE TROUBLESHOOTING O D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving with cruise control activated in order to minimize gear shifting and provide smooth cruising uphill overdrive may be prohibited temporarily in some conditions The cruise control ECU sends OD cut signals to the ECM as necessary and the ECM cancels overdrive shifting unt
24. afe Function If the ECM detects a malfunction it turns the lock up solenoid valve OFF A Diag Trouble Code Detection Condition Trouble area a Solenoid resistance is 80 or lower short Shift solenoid valve SL circuit when solenoid energized Harness or connector between shift solenoid b Solenoid resistance is 100 kQ or higher valve SL and ECM open circuit when solenoid is not e energized ECM memorizes diag trouble code 64 if above a or b condition is detected once or more but ECM does not start O D OFF indicator light blinking DIAGNOSTIC CHART Repair or replace malfunctioned part Repair or replace harness or connector Check shift solenoid valve SL _ Check harness and connector between electronically controlled transaxle solenoid connector and ECM Replace ECM WIRING DIAGRAM Transaxle Shift Solenoid Valve SL AX1 89 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check shift solenoid valve SL 1 Check shift solenoid valve SL connector connection 2 Measure resistance between shift solenoid valve SL connector terminals and body ground Resistance 11 150 Check that shift solenoid valve SL makes opera tion sound when apply battery voltage shift so lenoid valve SL connector terminal and body ground Check continuity of solenoid wire Continuity Below 10 Repair or replace malfunctio
25. age SA 40 14 INSTALL RIGHT AND LEFT ENGINE SIDE COVER N 0 2 15 INSTALL ENGINE UNDER FRONT COVER NO 1 AND NO 2 16 INSTALL DIFFERENTIAL FLUID DRAIN PLUG WITH A NEW GASKET 17 FILL DIFFERENTIAL FLUID Fluid Type ATF DEXRON Capacity Differential 1 6 liters 1 7 US qts 1 4 Imp qts 18 CHECK DIFFERENTIAL FLUID LEVEL 19 INSTALL EXHAUST PIPE a Install and torque the 3 nuts Torque 62 N m 630 kgf cm 46 ft lbf AX1 31 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION b Install the rear exhaust pipe with the 2 bolts and nuts Torque 103 N m 1 050 kgf cm 76 ft Ibf 20 INSTALL FRONT WHEEL AND LOWER VEHICLE Torque 103 N m 1 050 kgf cm 76 ft lbf 21 UNTIE STEERING GEAR HOUSING TO ENGINE SUP PORT FIXTURE BY CORD OR EQUIVALENT 22 REMOVE ENGINE SUPPORT FIXTURE 23 INSTALL 3 UPPER TRANSAXLE TO ENGINE BOLTS Torque 64 N m 650 kgf cm 47 ft Ibf 24 INSTALL 2 BOLTS AND CLAMP FROM TO FRAME ASSEMBLY 25 INSTALL 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque 80 N m 1820 kgf cm 59 ft Ibfj AX1 32 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 26 CONNECT SHIFT CONTROL CABLE a Install the clip to the control cable b Install the nut c Adjust the control cable See page AX1 55 27 CONNECT OIL COOLER HOSE 28 CONNECT SOLENOID CONNECTOR 29 CONNECT PARK NEUTRAL POSITION SWITCH CONNECTOR 30 INSTALL STARTER a Install the starter with 2 bolts Torque
26. al shown on matrix chart See page _ 1 50 6 NG Check harness and connector between ECM HG Repair or replace harness of con and stop light switch See page 31 nector OK Check and replace ECM WIRING DIAGRAM JB J B _ JB 3 Stop i 621 is equipped on 570 only B21 la not equipped on W G 2 5D CYP G R Wis GW AX1 97 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check operation of stop light Check if the stop light goes on and off normally when the brake pedal is depressed and released Check and repair stop light circuit See page BE 50 Check stop light signal 1 Connect voltmeter to terminals TT and E of the DLC2 2 Turn ignition switch ON Do not start the engine 3 Fully depress the accelerator pedal until the voltmeter indicates 8 v and hold it 4 Depress and release the brake pedal and check iG ON OK Brake pedal Voltage Depressed Dv Released g Ve Brake Pedal Accelerator Pedal Proceed to next circuit inspection shown on matrix chart See page 1 68 Check harness and connector between ECM and stop light switch See page IN 31 Repair or replace harness or connector Check and replace ECM AX1 98 AUTOMATIC TRANSAXLE TROUBLESHOOTING Pattern Select Switch Circuit The ECM has stored in its mem
27. eck and repair harness between O D main switch and combination meter OK 58 5 pe Check harnesses between connector between R epair or replace harness or con OK Replace ECM Proceed to next circuit inspection 1 shown on matrix chart See page 1 68 Repair or replace harness or connec tor between combination meter and O D main switch NO 330 Check O D main switch operation AX1 104 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check 0 D OFF indicator light when engine starting E en starting the engine check the operating con dition of the O D OFF indicator light O D OFF indicator lights immediately after the engine is started Remains ON NG 1 Remains OFF NG2 the O D OFF indicator light keeps blinking check the diag trouble code and repair the problem 1 Turn ignition switch ON 2 Check O D OFF light when O D main switch is pushed in to ON 3 Start the engine O D OFF light goes off 3 Check O D OFF light when O D main switch is pushed again to OFF O D OFF light lights up If the O D OFF light blinks when the O D main EU switch is pushed in to ON a malfunction is occur ing in the system Check the diagnostic trouble code Proceed to next circuit inspection shown on matrix chart See page 1 68 AX1
28. ect electronically controlled transaxle so lenoid connector Measure resistance between terminals of elec tronically controlled transaxle solenoid connector and body ground as shown in the illustration Resistance 1 2 Body ground 11 15 0 1 Jack up the vehicle 2 Remove oil pan 1 Check shift solenoid valve No 1 and No 2 connector connection 2 Measure resistance between shift solenoid valve No 1 and No 2 connector terminals and body ground Resistance 11 150 Check for operation sound of solenoids sound when you apply battery voltage to shift solenoid valve No 1 and No 2 connector terminals and body ground Check continuity of solenoid wire Continuity Below 10 Repair or replace malfunctioned part Check harness and connector between electronically controlled transaxle solenoid connector and ECM NG Repair or replace harness or connector Replace ECM AUTOMATIC TRANSAXLE TROUBLESHOOTING Memo AX1 88 AUTOMATIC TRANSAXLE TROUBLESHOOTING Diag Trouble Code 64 Shift Solenoid Valve SL Circuit CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock up relay valve which then controls operation of the lock up clutch If a malfunction occurs in this circuit and diagnostic trouble code 64 is stored in memory the O D OFF indicator light does not blink Fail S
29. fter completing repairs confirm not only that the malfunction is eliminated but also conduct a test drive etc to make sure the entire electronically controlled transaxle system is operating correctly AX1 42 AUTOMATIC TRANSAXLE TROUBLESHOOTING Items insidef 7 are titles of pages in this man Vehicle Brought to Workshop ual with the page number indicated in the bot tom portion See the indicated pages for detailed Customer Problem Analysis j explanations P AX1 43 00 Step 2 5 12 15 Diagnostic steps permitting n t the use of the TOYOTA Check and Clear Diagnostic Trouble Codes Precheck j hand held tester or TOYOTA P AX1 44 AX1 46 Precheck brake out box Symptom does not occur 4 Symptom Simulation P AX1 48 Symptom occurs NG Diagnostic Trouble Code Check NG Bf Shift Position Signal Check P AX1 64 i Manual Shifting Test ji li i Y ji Matrix Chart of Problem Symptoms P AX1 67 Chapteri Chapter 2 Electronic On Vehicle OFF Vehicle P AX1 68 P AX1 70 P AX1 72 NG mmu Main Throttle Signal Check y Parts Inspection jl e Stop Light Signal Check 12 Inspection if Identification of Problem P AX1 8000 AX1 112 END AX1 43 AUTOMATIC TRANSAXLE TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS Electronica
30. idth 25 0 98 MER es UI IAM CEN zu ATF DEXRON I Capacity liter US gts Imp qts Drain M is ES q AX1 4 AUTOMATIC TRANSAXLE OPERATION OPERATION Planetary Gear Unit First and Aloverse O D Direct Brake B4 Clutch C4 O D Brake Ba UU AAA j opor ry O D One Way Count Clutch Fa Drive O D Planetary Intermediate Gear Shaft Down shift only no up shift One Way Clutch deett ttt MD eee 22 2922 2222 Gear Second Coast Brake B Forward Clutch C P CEE EEE YY yy Second Brake B Direct Clutch C4 A Hp Pr 2422 One Way Clutch No 1 F Input Shaft Rear Planetary Front Planetary Gear AX1 5 AUTOMATIC TRANSAXLE OPERATION 1 FUNCTION OF COMPONENTS O D Direct Clutch Co Connects Overdrive sun gear and overdrive carrier 0 D Brake Bo Prevents overdrive sun gear from turning either clockwise or counterclockwise When transaxle is being driven by engine connects overdrive gear and O D One Clutch Fo overdrive carrier Front Clutch C4 Connects input shaft and intermediate shaft Rear Clutch Co Connects input shaft and front amp rear planetary gear Prevents front amp rear planetary sun gear from turning either clockwise or No 1 Brake B4 counterclockwise No 2 Brake Bo Prevents outer race of F from turning either cloc
31. il these signals are disconnected IAGNOSTIC CHART Check voltage between terminals OD 1 of Proceed to next circuit inspection shown on matrix chart See page ECM connector and body ground AX1 68 NG Check voltage between terminal OD of cruise control ECU harness side connector and body Check and replace cruise control ground ECU Check harness and connector between cruise Repair on replace harness or con control ECU and ECM See page IN 31 nector OK Check and replace ECM WIRING DIAGRAM Cruise Control ECU AX1 109 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal OD1 of ECM connector and body ground Turn ignition switch ON Measure voltage between terminal 01 31 of ECM connector and body ground Voltage 10 14 V Proceed to next circuit inspection shown on matrix chart See page 1 68 Check voltage between terminal OD of cruise control ECU harness side co nector and body ground i De m 1 Disconnect cruise control ECU connector oC CTUM SS 2 Turn ignition switch ON Measure voltage between terminal OD of cruise control ECU harness side connector and body ground Voltage 10 14 V Repair or replace harness or connector Check and replace ECM AX1 110 AUTOMATIC TRANSAXLE TROUBLESHOOTING CIRCUIT DESCRIPTION The ECM displays diagnostic trouble codes using the O D OFF indicato
32. in N position and air conditioner OFF c Shift the shift lever from N to D position Using a stop watch measure the time it takes from shifting the lever until the shock is felt In same manner measure the time lag for N R Time lag NooD Less than 1 2 seconds NcoR Less than 1 5 seconds TIME LAG TEST AX1 60 AUTOMATIC TRANSAXLE TROUBLESHOOTING EVALUATION If NooD or NooR time lag are longer than specified Problem Possible cause Line pressure too low N D time lag is longer Forward clutch worn O D one way clutch not operating properly Line pressure too low Direct clutch worn First and reverse brake worn O D clutch worn N time lag is longer AX1 61 AUTOMATIC TRANSAXLE TROUBLESHOOTING HYDRAULIC TEST MEASURE LINE PRESSURE NOTICE Perform the test at normal operating fluid temperature 50 80 C 122 176 F The line pressure test should always be carried out in pairs One technician should observe the conditions of the wheels or wheel stoppers outside the vehicle while the other is performing the test a Warm up the transaxle fluid b Remove the test plug on the transaxle case left side and connect the oil pressure gauge SST SST 09992 00094 Curved Adaptor ATBIB3 ATIOTS Fully apply the parking brake and chock the 4 wheels d Start the engine and check idling RPM e Keep your left foot pressed firmly on the brake pedal and shift into D position f Measure the line p
33. ion shown on matrix chart See page AX1 68 ee Check PWR indicator light Turn IG switch 4N Check that the PWR indicator light lights up when you push the pattern select switch to PWR 1 Push pattern select switch to NORMAL 2 Turn IG switch ON E Measure voltage between terminal 6 of pattern select switch connector and body ground Voltage 10 14 V A Check and repair pattern select switch power source circuit AX1 101 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check pattern select switch Disconnect pattern select switch connector Measure resistance between terminals and6 of pattern select switch connector when the select switch is set to PWR and NORMAL positions Check connectors and harness between pattern select switch PWR indicator light and ECM See page IN 31 Repair or replace harness connector Replace ECM AX1 102 AUTOMATIC TRANSAXLE TROUBLESHOOTING O D Main Switch amp O D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O D main switch contacts go off when the switch is pushed in and come on when it is pushed out In O D main switch OFF position the O D OFF indicator lights up and the ECM prohibits shifting to overdrive The ECM also causes the O D OFF indicator light to blink when a malfunction is detected However when the O D main switch is OFF the O D indicator light does not blink but sta
34. kwise or counterclockwise thus preventing front amp rear planetary sun gear from turning counterclockwise No 3 Brake B3 Prevents front planetary carrier from turning either clockwise or counterclockwise When B2 is operating prevents front amp rear planetary sun gear from turning No 1 One Way Clutch F1 counterclockwise No 2 One Way Clutch F5 Prevents front planetary carrier from turning counterclockwise O D Planetary Ring Gear Intermediate Front and Rear Planetary Sun Gear and Counter Drive Gear Shaft Rear Planotary Front Planetary Carrier O D Planetary Carrier Ring Geer nput Shaft O D Planetary Sun Gear QUT E Rear Planetary Carrier AX1 6 AUTOMATIC TRANSAXLE OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch By operation of the brake and one way clutch either the planetary carrier or the planetary sun gear are immobilized altering the speed of revolution of the planetary gear unit Shift change is carried out by altering the combination of clutch and brake operation Each clutch and brake operates by hydraulic pressure Gear position are decided according to the throttle opening angle and vehicle speed and shift change automatically occurs The conditions of operation for each gear position are shown on the following ill
35. ll throttle valve opening position and check the following points a Check no up shift While running in the L position check that there is no up shift to 2nd gear b Check engine braking L Position While running in the L position release the accelera tor pedal and check the engine braking effect c Check for abnormal noises during acceleration and L Position deceleration Abnormal Noise AX1 52 AUTOMATIC TRANSAXLE TROUBLESHOOTING A Position Full Open Slippage P Position Vehicle on Gradient P Parking Lock Paw Acting 4 R POSITION TEST Shift into the R position and while starting at full throttle check for slipping CAUTION Before conducting this rest ensure that the test area is free from personnel and obstructions 5 P POSITION TEST Stop the vehicle on a gradient more than 5 and after shifting into the P position release the parking brake Then check to see that the parking lock pawl holds the vehicle in place AX1 52 AUTOMATIC TRANSAXLE TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE SHIFT POINT NORM Mode Shift position Shifting point Vehicle speed km h mph Throttle valve fully opened 58 65 38 40 110 120 68 75 147 157 81 88 138 150 88 83 988 108 81 87 42 49 26 30 Throttla wnben fully closed 18 45 24 28 17 24 11 16 Throttle valve fully opened 58 85 36 40 2 position 88 99 55
36. lly Controlled Inspector s Transaxle Check Sheet Name Odometer Reading Brought In Data Problem E Occurred How Often Does Problam Occur O Vehicle does not move 0 Any position Ol Particular position O Me up shift O Mo down shift 0 0D 3rd Sd 2nd O 2nd 1st O Lock up malfunction 5 t Lock up O Any drive position ymptoms i 8 O Normal Coda O Malfunction Coda Code O Normal Code O Malfunction Code Code Diagnostic Trouble Coda Chock O D OFF indicator Light d 2nd Time AX1 44 AUTOMATIC TRANSAXLE TROUBLESHOOTING DIAGNOSIS SYSTEM The Electronically Controlled Transaxle has built in self diagnostic functions If the malfunction occurs in the system the ECM stores the diagnostic trouble code in memory and the O D OFF Overdrive OFF indicator light blinks to inform the driver The diagnos tic trouble code stored in memory can be read out by the following procedure O D OFF INDICATOR LIGHT INSPECTION 1 Turn the ignition switch to ON 2 Check if the O D OFF indicator light lights up when the O D main switch is pushed out to OFF and goes off when the O D main switch is pushed in to ON HINT If the O D OFF indicator light does not light up or stay on all the time carry out the check for O D OFF Indicator Light Circuit on page AX 102 If the O D OFF indicator light blinks a trouble code is stored in the ECM memory A EO
37. n B E section Measure voltage between terminal SPD of combination meter connector and body ground Changes 0 V Fixed 0V H5V Replace Measure voltage between terminals SPD 1 of ECM connector Replace ECM Check and repair harness or connector between combination meter and ECM WIRING DIAGRAM From Cruise Control ECU Combination J B No 3 AX1 82 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Measure voltage between terminal S P D of combination meter connector and body ground a Shift the shift lever to position b Jack up one of the front wheels c Disconnect the cruise control ECU and PPS connectors d Turn IG switch ON Measure voltage between terminal SPD of com bination meter connector and body ground when slowly turning the Jack up wheel Voltage Constantly 0 V Go to Next Step Constantly 4 6 V Go to NG 1 Changes OVH4H6V Check combination meter circuit See combination meter troubleshooting E 1 Disconnect combination 1 meer and cruise control ECU connectors 2 Turn IG switch ON 3 Measure voltage between terminals SPD and E of ECM connector Voltage 4 6 V Check and repair harness or connector between co bination meter and ECM AUTOMATIC TRANSAXLE TROUBLESHOOTING Memo AX1 84 AUTOMATIC TRANSAXLE TROUBLESHOOTING Diag Trouble Code 62 63 Shift Solen
38. nector and body ground AA Turn ignition switch ON Measure voltage between terminals NSW 2 L of ECM connector and body ground when the shift lever is put in the following positions rain iem 10 14 V Below 1 V Below 1 V 10 14 V Below 1 V Below 1 V 10 14V 10 14V Below 1 V 2 7 10 14 V Below1V 10 14V The voltage will drop slightly due to lighting up of the back up light Remove position switch Check continuity between each terminal shown be low when the shift lever is put in each position 0 0 Continuity Terminal nee Position Check harness and connector between ECM and park neutral position switch park neutral position switch and battery See page IN 31 Repair or replace harness or connector Check and replace ECM AUTOMATIC TRANSAXLE TROUBLESHOOTING Memo AX1 96 AUTOMATIC TRANSAXLE TROUBLESHOOTING Stop Light Circuit CIRCUIT DESCRIPTION __ The purpose of this circuit is to prevent the engine from stalling when the brakes are suddenly applied while driving in lock up condition When the brake pedal is operated this switch sends a signal to the ECM Then the ECM cancels oper tion of the lock up clutch while braking is in progress DIAGNOSTIC CHART Check and repair stop light circuit See page BE 62 Proceed to next circuit inspection Check stop light sign
39. ned part Check harness and connector between electronically controlled transaxle solenoid connector and ECM Replace ECM Repair or replace harness or connector AX1 90 AUTOMATIC TRANSAXLE TROUBLESHOOTING Throttle Position Sensor Circuit IRCUIT DESCRIPTION The throttle position sensor detects the throttle valve opening angle and sends signals to the ECM DIAGNOSTIC CHART n OK Proceed to next circuit inspection Throttle position signal check shown on matrix chart See page AX1 68 NG Check throttle positi y throttle position sensor Replace throttle position sensor NG Check harness and connector between ECM Repair or replace harness or con and throttle position sensor See IN 31 5 OK Check and replace ECM DIAGRAM ECM Throttle Position Sensor AX1 91 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Throttle position signal check urn ignition switch ON Do not start the engine le Check voltage at terminal TT of the DLC2 while 2 E gradually depressing the accelerator pedal from the fully closed position to the fully opened position Voltage changes from 0 V to 8 V by stages Voltage Terminal Voltage V Clase Throttle Valve Opening Angle Open Emg Do not depress the brake pedal during this test The voltage will stay at O V if it is depressed
40. nkshaft pulley nut with a wrench and remove 6 bolts HINT First remove dark green colored bolt and then remove the others 34 REMOVE 3 TRANSAXLE TO ENGINE BOLTS AX1 27 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 35 REMOVE TRANSAXLE ASSEMBLY Separate transaxle and engine and lower the trans axle 36 REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE TRANSAXLE INSTALLATION 1 INSTALL TORQUE CONVERTER CLUTCH IN TRA NSAXLE If the torque converter clutch has been drained and washed refill with new ATF Fluid Type ATF DEXRON Q 2 CHECK TORQUE CONVERTER CLUTCH INSTALLA TION Using a scale and a straight edge measure from the installed surface to the front surface of the transaxle housing Correct distance 13 0 mm 0 51 in or more 3 ALIGN TRANSAXLE AT INSTALLATION POSITION a Align the 2 knock pins on the block with the converter housing b Temporarily install the bolt 4 INSTALL TRANSAXLE TO ENGINE BOLT Install the transaxle to engine bolts 12 mm head bolt Torque 64 N m 650 kgf cm 47 ft lbf AX1 28 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 10 mm head bolt Torque 46 470 kgf cm 34 ft lbf 5 INSTALL TORQUE CONVERTER CLUTCH MOUNT ING BOLT a Clean the threads of the bolts with the gasoline b Coat the threads of the bolts with sealer Sealer Part No 08833 00070 THREE BOND 1324 or equi valent c Tighten the bolts evenly Torque
41. nsaxle If there are leaks it is necessary to repair or replace O Add hot rings seal packings oil seals plugs or other parts AX1 55 AUTOMATIC TRANSAXLE TROUBLESHOOTING ATa25z 5 INSPECT AND ADJUST THROTTLE CABLE a Check that the throttle valve is fully closed b Check that the inner cable is not slack c Measure the distance between the outer cable end and stopper on the cable Standard distance 0 1 mm 0 0 04 in If the distance is not standard adjust the cable by the adjusting nuts 6 INSPECT AND ADJUST SHIFT CABLE When shifting the shift lever from the N position to other positions check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position If the indicator is not aligned with the correct position carry out the following adjustment procedures a Loosen the swivel nut on the manual shaft lever b Push the manual shaft lever fully toward the right side of the vehicle c Return the control shaft lever 2 notches to U position d Set the shift lever to N position e While holding the shift lever lightly toward the R position side tighten the shift lever nut AX1 56 AUTOMATIC TRANSAXLE TROUBLESHOOTING Neutral A O 7 INSPECT AND ADJUST PARK NEUTRAL POSITION SWITCH Check that the engine can be started with the shift lever only in the N or P position but not in other positions If no
42. oid Valve No 1 and No 2 Circuit IRCUIT DESCRIPTION Shifting from 1 st to O D is performed in combination with ON and OFF of the shift solenoid valves No 1 and No 2 controlled by the ECM If an open or short circuit occurs in either of the solenoid valves the ECM controls the remaining normal solenoid to allow the vehicle to be operated smoothly Fail safe function Fail Safe Function If either of the solenoid valve circuits develops a short or an open the ECM turns the other solenoid ON and OFF to shift to the gear positions shown in the table below The ECM also turns the lock up solenoid valve OFF at this time If both solenoids malfunction hydraulic control cannot be performed electronically and must be done manually Manual shifting as shown in the following table must be done in the case of a short circuit the ECM stops sending current to the short circuited solenoid SOLENOID VALVE NO 1 SOLENOID VALVE NO 2 BOTH SOLENOID VALVES MALFUNCTIONING MALFUNCTIONING MALFUNCTIONING solenoid vayg E Gear when shift selector No 1 is manually operated Check the shift solenoid valve No 1 when diagnostic trouble code 62 is output and check the shift solenoid valve No 2 when diagnostic trouble code 63 is output Diag Trouble Code Detection Condition Trouble area d a Solenoid resistance is 8Q or lower short Shift solenoid valve No 1 or No 2 circuit when solenoid is energized Harness or c
43. on reusable pari 1 21 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL CAUTION Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative terminal cable is discon nected from the battery 1 DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY AT 2 REMOVE AIR CLEANER ASSEMBLY 3 REMOVE THROTTLE CABLE FROM ENGINE w Cruise Control System 4 REMOVE CRUISE CONTROL ACTUATOR COVER 5 DISCONNECT CONNECTOR FROM CRUISE CON TROL ACTUATOR 6 REMOVE GROUND TERMINAL 7 DISCONNECT CONNECTOR FROM VEHICLE SPEED SENSOR AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 8 REMOVE STARTER a Disconnect the connector and nut b Remove the 2 bolts and the starter 9 DISCONNECT PARK NEUTRAL POSITION SWITCH CONNECTOR 10 DISCONNECT SOLENOID CONNECTOR 11 DISCONNECT OIL COOLER HOSE 12 DISCONNECT SHIFT CONTROL CABLE a Remove the clip from the control cable b Remove the nut AX1 23 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION 13 REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLT 14 REMOVE 2 BOLT AND CLAMP FROM FRONT FRAME ASSEMBLY 15 REMOVE 3 UPPER TRANSAXLE TO ENGINE BOLT 16 INSTALL ENGINE SUPPORT FIXTURE 17 TIE STEERING GEAR HOUSING TO ENGINE SUP PORT FIXTURE BY CORD OR EQUIVALENT 18 RAISE AND SUITABLE SUPPORT VEHICLE 19 REMOVE FRONT WHEEL 20 REMOVE EXHAUST PIPE a
44. onnect the cable housing to the bracket 5 ADJUST THROTTLE CABLE See page AX1 55 6 INSTALL PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch b Install the manual shift lever c Adjust the park neutral position switch See page AX1 56 d Connect the transaxle control cable AX1 19 AUTOMATIC TRANSAXLE ON VEHICLE REPAIR DIFFERENTIAL OIL SEAL REMOVAL 1 REMOVE BOTH DRIVE SHAFTS See page SA 38 2 REMOVE BOTH SIDE GEAR SHAFT OIL SEALS Using SST pull out the oil seal SST 09308 00010 DIFFERENTIAL OIL SEAL INSTALLATION 1 INSTALL LEFT SIDE GEAR SHAFT OIL SEAL 1 Using SST drive in a new oil seal SST 09350 32014 09351 32130 08351 32150 Oil seal depth 2 7 0 5 mm 0 11 0 02 in 2 Coat the lip of oil seal with MP grease 2 INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL 1 Using SST drive in a new oil seal SST 09350 32014 09351 32130 09351 32150 Oil seal depth 0 0 5 mm 0 0 02 in 2 Coat the lip of seal with MP grease 3 INSTALL BOTH DRIVE SHAFTS See page SA 40 4 CHECK TRANSAXLE FLUID LEVEL See page AX1 54 AX1 20 AUTOMATIC TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY COMPONENTS Rear End Plate Transaxle Control Cable Assembly 1 150 18 Engine Undercover No 4 Center Exhaust Pipe Engine Front Engine Undercover LH Undercover Specified torque N
45. onnector between shift solenoid b Solenoid resistance is 100 kQ or higher valve No 1 or No 2 and ECM connector open circuit when solenoid is not e ECM energized The ECM checks for an open or short circuit in the shift solenoid valve No 1 and No 2 circuit when it changes gear position The ECM records diag trouble code 62 or 63 if cond tion a or b is detected once but it does not blink th O D OFF indicator light After the ECM detects condition a or b con tinuously 8 times or more it cancels the O D OFF indi cator light to blink until condition a or b disappears After that if the ECM detects condition a or b once it starts blinking the O D OFF indi cator light again AX1 85 AUTOMATIC TRANSAXLE TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between terminals of electronically controlled transaxle solenoid Repair or replace malfunctioned Check shift solenoid valve No 1 or No 2 in transaxle Check harness and connector between electronically controlled transaxle solenoid Replace ECM WIRING DIAGRAM Repair or replace harness or con nector Transaxla Shift Solenoid Valve 1 Cruise Control ECU AX1 86 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Measure resistance between terminals of electronically controlled transaxle solenoid connector and body ground Disconn
46. orque 49 N m 500 kgf cm 36 ft lbf SST 09043 38100 AX1 17 AUTOMATIC TRANSAXLE ON VEHICLE REPAIR 11 FILL TRANSAXLE WITH ATF Add only about 2 liters of ATF NOTICE Do not overfill Fluid type ATF DEXRON 12 CHECK FLUID LEVEL See page AX1 54 THROTTLE CABLE REMOVAL Mid 1 DISCONNECT THROTTLE CABLE a Disconnect the cable housing from the bracket b Disconnect the cable from the throttle linkage 2 REMOVE PARK NEUTRAL POSITION SWITCH a Remove the clips and disconnect the transaxle con trol cable from manual shift lever b Remove the manual shift lever c Remove the park neutral position switch 3 REMOVE VALVE BODY See page AX 13 4 PULL THROTTLE CABLE OUT OF TRANSAXLE CASE a Remove the bolt and retaining plate b Pull the cable out of the transaxle case AX1 18 AUTOMATIC TRANSAXLE _ON VEHICLE REPAIR THROTTLE CABLE INSTALLATION 1 INSTALL CABLE IN TRANSAXLE CASE a Be sure to push it in all the way b Install the retaining plate and the bolt 2 INSTALL VALVE BODY See page AX 15 3 IF THROTTLE CABLE IS NEW STAKE STOPPER ON INNER CABLE a Bend the cable so there is a radius of about 200 mm 7 87 in 7 87 in b Pull the inner cable lightly until a slight resistance is felt and hold it c Stake the stopper 0 8 1 5 mm 0 031 0 059 in from the end of outer cable as shown 4 CONNECT THROTTLE CABLE a Connect the cable to the throttle linkage b C
47. ory the gear shift patterns for D position 2nd position and L position and also the lock up pattern for D position Two types of gear shifting pattern and lock up pattern are recorded for D position for POWER use and NORMAL use The ECM selects the D position gear shift pattern and lock up pattern in accordance with the signal from the pattern select switch Proceed to next circuit inspection shown on matrix chart See page Check shift pattern switch operation NG Check PWR indicator light LEE OK Measure voltage between terminal 6 of m dre ea HG _ Check and repair pattern select pattern select switch connector and body around switch power source circuit Replace pattern select switch Check connectors and harness between pat _ tern select switch PWR indicator light and i Repair or replace connector as harness M OK Replace ECM AX1 99 AUTOMATIC TRANSAXLE TROUBLESHOOTING WIRING DIAGRAM From Ignitian Switch JB Pattern Select Switch w Light we AT Indicator Light Dice oia FWR Indicator Light COMB Mene COMB Mater Junction Conn ctor B m a e J B AX1 100 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check shift pattern switch operation MA Check that the shift point changes when the pattern select switch is operated m Proceed to next circuit inspect
48. own vehicle speed limits for 2 1 3 2 and O D 3 kick downs conform to those indicated on the auto matic shift schedule See page AX1 52 e Check abnormal shock and slip at kick down D Position Full Opening f Check the lock up mechanism 1 Drive in D position O D gear at a steady speed lock up ON of about 75 km h 47 mph 2 Lightly depress the accelerator pedal and check that the RPM does not change abruptly If there is a big jump in RPM there is no lock up 2 2 POSITION TEST Shift into the 2 position and while driving with the accelerator pedal held constantly at the full throttle valve opening position and check on the following points a Check up shift operation Check to see that the 1 2 up shift takes place and that the shift point conforms to the automatic shift schedule See page AX1 52 HINT There is no O D up shift and lock up in the 2 position amp TzR1z AX1 51 AUTOMATIC TRANSAXLE TROUBLESHOOTING b Check engine braking 2 Position While running in the 2 position and 2nd gear release the accelerator pedal and check the engine braking effect LL Engine Braking i AT2B11 2 Check for abnormal noises during acceleration and deceleration and for shock at up shift and down ws shift Abnormal Noise Shock 0 0 3 L POSITION TEST No Up Shift Shift into the L position and while driving with the Lo accelerator pedal held constantly at the fu
49. p 70 80 C 158 176 F e Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run a Park the vehicle on a level surface and set the parking brake b With the engine idling and the brake pedal depressed shift the shift lever into all positions from P to L position and return to P position c Pull out the oil level gauge and wipe it clean d Push it back fully into the tube e Pull it out and check that the fluid level is in the HOT range If the level is at the low side add fluid Fluid type ATF DEXRON II NOTICE Do not overfill 2 CHECK FLUID CONDITION If the fluid smells burnt or is black replace it 3 REPLACE TRANSAXLE FLUID a Using SST remove the drain plug and drain the fluid SST 09043 38100 b Reinstall the drain plug securely c With the engine OFF add new fluid through the oil filler tube Fluid type ATF DEXRONAII Capacity Total 5 6 liters 5 9 US qts 4 9 Imp qts Drain and refill 2 5 liters 2 6 US qts 2 2 Imp qts d Start the engine and shift the shift lever into all posi tions from P to L position and then shift into P posi tion e With the engine idling check the fluid level Add fluid up to the COOL level on the dipstick f Check the fluid level at the normal operating tempera ture 70 80 C 158 176 F and add as neces sary NOTICE Do not overfill 4 CHECK FLUID LEAKS Check for leaks in the tra
50. r light when terminals TE1 and E1 of the DLC2 or DLC1 are connected Proceed to next circuit inspection shown on matrix chart See page Check harness and connector between ECM and DLC2 DLC1 and body ground See IN 31 IG DIAGRAM 9 1 111 AUTOMATIC TRANSAXLE TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals TE and E of DLCZ or DLC1 Measure voltage between terminals TE and E of DLC2 or D LC1 Voltage 4 6 V 5171 2914 __ _ Proceed to next circuit inspection shown on matrix chart See page 1 68 Check harness and connector between ECM and DLC2 DLC1 and body ground See page IN 31 Check and replace ECM Repair or replace harness or connector AX1 112 AUTOMATIC TRANSAXLE TROUBLESHOOTING Terminal Circuit IRCUIT DESCRIPTION Checks of ECM input and output signals related to the throttle position sensor brakes shift position and other circuits can be performed by measuring the voltages at terminal T of DLC1 DIAGNOSTIC CHART Check harness and connector between ECM and DLC2 DLC1 and body ground See page IN 31 OK Check and replace ECM 1 DIAGRAM AX1 113 AUTOMATIC TRANSAXLE SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Line pressure whell locked lt a Engine idling D position a4 1 3 j position 363 Et kPa 3 7 4 3 53 81 psi AT stall 618 784 kPa
51. red in the memory is output errors could be made in the diagnosis 6 DIAGNOSTIC TROUBLE CODE CHART If a trouble code is confirmed in the diagnostic trouble code check proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code 7 PRELIMINARY CHECK Carry out a preliminary check of the transaxle oil level throttle cable adjustment etc 8 SHIFT POSITION SIGNAL CHECK Carry out the shift position signal check when the transaxle gears do not up shift down shift or lock up This is to check the signal output condition from the ECM to each solenoid If the results are NG then it is likely that the trouble is in the electrical system particularly in the sensors or the ECM Proceed to Part 1 Electrical System under 11 Matrix Chart of Problem Symptoms If all the circuits specified in Part 1 are OK check the ECM and replace it 9 MECHANICAL SYSTEM TEST Stall Test Time Leg Test Line Pressure Test If the malfunction is found in the stall test time lag test or line pressure test check the parts indicated in the respective tests 14 MANUAL SHIFTING TEST If the results of the manual driving test are NG it is likely that the trouble is in the mechanical system or hydraulic system Proceed to Part 2 Mechanical System under the Matrix Chart of Problem Symptoms AX1 41 AUTOMATIC TRANSAXLE TROUBLESHOOTING 11 MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is confirmed in the diagnostic t
52. resistance of at least 10 k Q 2 TURN IGNITION SWITCH TO ON DO NOT START THE ENGINE 3 CHECK THROTTLE POSITION SENSOR SIGNAL Check if the voltage changes from approximately 0 V to approximately 8 V when the accelerator pedal is gradually depressed from the fully closed position 4 CHECK BRAKE SIGNAL LOCK UP CUT SIGNAL a Open the throttle valve fully to apply approximately 8 V to terminal Tt b In this condition check terminal Tr voltage when the brake pedal is depressed and released Tt terminal voltage 0 V When brake pedal is depressed 8 V When brake pedal is released 5 START ENGINE 6 CHECK SHIFT POSITION SIGNAL VEHICLE SPEED ABOVE 10 KM H OR 6 MPH Check up shifting together with terminal TT voltage HINT Check for light shocks from up shifting and for changes in the tachometer Gear Position Terminal TT output voltage Below 0 5 V 15 26V _ 3rd Lock up O D 0 D Lock up If terminal TT output voltage check cannot be perfo rmed check TT terminal circuit on page AX1 112 AX1 48 AUTOMATIC TRANSAXLE TROUBLESHOOTING PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis try to reproduce the symptoms of the trouble If the problem is that the transaxle does not up shift does not down shift or the shift point is too high or too low conduct the following road test to confirm the automatic shift schedule and simulate the problem symptoms ROAD TEST
53. ressure when the engine is idling g Fully depress the accelerator pedal Quickly read the highest line pressure when engine speed reaches stall speed h In the same manner perform the test in R position SPECIFIED LINE PRESSURE Line pressure D position kPa kgf emt psi R position kPa kgf cmt psi 362 422 3 7 4 3 53 61 618 794 6 3 8 1 90 115 750 897 7 7 9 2 109 130 1 373 1 608 14 0 16 4 199 233 If the measured pressures are not up to specified values recheck the throttle cable adjustment and retest AX1 62 AUTOMATIC TRANSAXLE TROUBLESHOOTING HYDRAULIC TEST EVALUATION Problem A Possible cause Throttle cable out of adjustment If the measured values at all positions are higher Throttle valve defective Regulator valve defective Throttle cable out of adjustment Throttle valve defective If the measured values at all positions are lower Regulator valve defective Oil pump defective O D direct clutch defective D position circuit fluid leakage Forward clutch defective _ R position circuit fluid leakage If pressure is low in the R position only Direct clutch defective e First and reverse brake defective If pressure is low in the D position only AX1 63 AUTOMATIC TRANSAXLE TROUBLESHOOTING MANUAL SHIFTING TEST HINT With this test it can be determined whether the trouble is within the electrical circuit or is a mechani cal problem in the transa
54. rouble code check perform inspection according to the inspection order in the matrix chart of problem symptoms Perform diagnosis of each circuit or part in the order shown in the Matrix Chart The Matrix Chart contains 3 chapters Electronically Controlled Circuits in Chapter 1 On vehicle Inspection in Chapter 2 and Off vehicle Inspection in Chapter 3 If all the circuits indicated in Chapter 1 are normal proceed to Chapter 2 If all the parts indicated in Chapter 2 are normal proceed to Chapter 3 If all the circuits and parts in Chapter 1 Chapter 3 are normal and the trouble still occurs check and replace the ECM 12 CIRCUIT INSPECTION Perform diagnosis of each circuit in accordance with the inspection order confirmed in steps 6 and 11 Judge whether the cause of the problem is in the sensor actuators wire harness and connectors or the ECM In some cases the Flow Chart instructs that a throttle signal check brake signal check or kick down signal check in test mode be performed These are diagnosis functions used to check if signals are being input correctly to the ECM 13 PART INSPECTION Check the individual parts of the mechanical system and hydraulic system in the order of the numbers indicated in the Matrix Chart 14 REPAIRS After the cause of the problem is located perform repairs by following the inspection and replacement procedures in this manual or 94 Al 40E AUTOMATIC TRANSAXLE Repair Manual 15 CONFIRMATION TEST A
55. shorter wire b Connect the shift solenoid valve No 2 connector black and longer wire 5 INSTALL MANUAL VALVE BODY DETENT SPRING a Align the manual valve with the pin on the manual shaft lever b Lower the manual valve body into place c Hand tighten the 4 bolts first Then tighten them with a torque wrench Torque 10 N m 100 kgf cm 7 ft lbf 20 0 787 1 aren 1 AX1 16 AUTOMATIC TRANSAXLE ON VEHICLE REPAIR 38 1 417 d Place the detent spring on the manual valve body and O hand tighten the 2 bolts first Then tighten them with a torque wrench Torque 10 N m 100 kgf cm 7 ft Ibf e Check that the manual valve lever is touching the center of the detent spring tip roller 6 INSTALL OIL TUBES Tap the tubes with a plastic hammer to install them into the positions indicated in the illustration NOTICE Be careful not to bend or damage the tubes 7 INSTALL OIL STRAINER AND APPLY TUBE BRACK ET a Install the oil strainer and torque the 3 bolts b Install the apply tube bracket and the 2 bolts Torque 10 N m 100 kgf cm 7s ft lbf 8 INSTALL MAGNETS IN PAN Install the 2 magnets in the indentations of the pan 9 INSTALL OIL PAN WITH NEW GASKET NOTICE Make sure that the magnet does not interfere with the oil tubes Torque 4 9 N m 50 kgf cm 43 in Ibf 10 INSTALL DRAIN PLUG WITH NEW GASKET Using SST install the drain plug with a new gasket and tighten it T
56. t as started above carry out the following adjust ment procedure a Loosen the park neutral position switch bolt and set the shift lever to the N position b Align the groove and neutral basic line c Hold in position and tighten the bolt Torque 5 4 N m 55 kgf cm 48 in Ibf 8 INSPECT IDLE SPEED N POSITION Idle speed 750 rpm In N position and air conditioner OFF AX1 57 AUTOMATIC TRANSAXLE TROUBLESHOOTING STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions NOTICE Perform the test at normal operating fluid temperature 50 80 C 122 176 F Do not continuously run this test longer than 5 seconds To ensure safety conduct this test in a wide clear level area which provides good traction The stall test should always be carried out in pairs One technician should observe the conditions of the wheels or wheel stoppers outside the vehicle while the other is performing the test MEASURE STALL SPEED a Chock the 4 wheels b Connect a tachometer to the engine c Fully apply the parking brake d Keep your left foot pressed firmly on the brake pedal e Start the engine f Shift into the D position Fully depress the accelerator pedal with your right foot Quickly read the stall speed Stall speed 2 450 150 rpm g Perform the same test in R position Quickly read the stall speed Stall speed
57. t valve 2 3 shift valve 3 4 shift valve accumulator C2 No engine brakin 1st 2nd 2nd 3rd O D 3rd 3rd 2nd 2nd 1st No up shift No down shift zlz 5 gt Iz L 2 2 a D position 1 st 2nd 2 position mo Harsh engagement e 1st22nd 3rd O D mb 3 o eo Y a Ki a IUXTA 0 ala Sliper shudder in forward and reverse Directry after E G start AX1 71 TROUBLESHOOTING AUTOMATIC TRANSAXLE yeyo Jredai 440 119 110441 dn 201 Joje npouu ep1oJu puz SAJBA JOJe nuINDIY 4Joje nuuno9e OD Jojejnuunooe _ _ _ me LES EN TE AX1 72 AUTOMATIC TRANSAXLE TROUBLESHOOTING Chapter 3 Off Vehicle Repair 794 A140E AUTOMATIC TRANSAXLE Repair Manual See page AX1 34 Suspect Area Torque Parking lock pawl Co O D direct C Forward clutch C Direct clutch Vehicle does not move in any forward position Vehicle does not move in reverse position Vehicle does not move in any forward position and reverse position No lock up E Esa E PS
58. ter clutch x Drive plate 27 Valve body x Transaxle case Oil strainer _ 4 110 so sao EE a a a a FIM QE ERE Tames ea E Park neutral position switch x Transaxle case bolt 1 Park neutral position switch nut minw
59. tion AUTOMATIC TRANSAXLE TROUBLESHOOTING TROUBLESHOOTING AX1 40 AUTOMATIC TRANSAXLE TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING For troubleshooting using a volt ohm meter see page AX1 400042 HOW TO PROCEED WITH TROUBLESHOOTING USING VOLT OHM METER 1 CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference ask the customer in as much detail as possible about the problem 2 CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES PRECHECK Before confirming the problem symptom first check the diagnostic trouble code if there are any trouble codes stored in memory When there are trouble codes make a note of them then clear them and proceed to 3 Problem Symptom Confirmation 3 PROBLEM SYMPTOM CONFIRMATION Confirm the problem symptoms 4 SYMPTOM SIMULATION If the problem does not reappear be sure to simulate the problem by mainly checking the circuits indicated by the diagnostic trouble code in step 2 using Problem Simulation method 5 DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes Check if there is abnormality in the sensors or the wire harness If a trouble code is output proceed to 6 Diagnostic Trouble Code Chart If the normal code is output proceed to 7 Matrix Chart of Problem Symptoms Be sure to proceed to 6 Diagnostic Trouble Code Chart after steps 2 and 3 are completed If troubleshooting is attempted only by following the trouble code sto
60. trouble still occurs even though there are no abnormalities in any of the other circuits then check or replace the ECM AX1 68 AUTOMATIC TRANSAXLE TROUBLESHOOTING Chapter 1 Electronic Circuit e 5 Suspect Area us lt o m 2 9 3 Ge luo a 25 5 0 5 5 o 3 o og ZN di 95 za o oz oo De 3 o o 2 912 192 a e2le 5 52 5 2 e Cil E s 28152 9 esl Vehicle does not move in any forward position and reverse position L E X d P Vehicle does not move in a particular position or positions er a 365 I No up shift 2nd 3rd sjaj KS t J peu Slip or Shudder a E er LI E EN diae ECL A A 71 23 Large shift shock or engine stalls when starting off or stopping AX1 69 TROUBLESHOOTING AUTOMATIC TRANSAXLE yeyo Jredai epiuSA 44O0 Jredai epiusA uo 108095 aunyesodwe euis 440 Q O pue yams q o ynouo youms 09 AX1 70 AUTOMATIC TRANSAXLE TROUBLESHOOTING Chapter 2 On Vehicle Repair 794 A140E AUTOMATIC TRANSAXLE Repair Manual See page a Suspect Area C accumulator B2 accumulator Oil strainer 1 2 shif
61. ustrations D or 2 Position 1st Gear 2 Position 2nd Gear 1 7 AUTOMATIC TRANSAXLE OPERATION 2 Hydraulic Control System The hydraulic control system is composed of the oil pump the valve body the solenoid valves the accumulator the clutches and brakes and the governor valve as well as the fluid passages which connect all of these components Based on the hydraulic pressure created by the oil pump the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch clutches and brakes in accordance with the vehicle driving conditions There are three solenoid valves on the valve body The shift solenoid valves No 1 and No 2 are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position The No 3 solenoid valve is operated by signals from the ECM to engage or disengage the lock up clutch of the torque converter clutch HYDRAULIC CONTROL SYSTEM 34 r VALVEBODY OIL PUMP Hydr pressure contral CLUTCHES amp BRAKES Planetary gear unit i Torque converter L SOLENOID VALVES AX1 8 AUTOMATIC TRANSAXLE OPERATION 3 Electronic Control System The electronic control system for controlling the shift timing and the operation of the lock up clutch is composed of the following three parts a Sensors These sense the vehicle
62. xle 1 DISCONNECT SOLENOID WIRE 2 INSPECT MANUAL DRIVING OPERATION Check that the shift and gear positions correspond with the table below Shift Position Gear Position D Position O D 2 Position 3rd _ Reverse P Position _ Pawl Lock HINT If the L 2 and D position gear positions are difficult to distinguish perform the following road test e While driving shift through the L 2 and D positions Check that the gear change corresponds to the shift position If any abnormality is found in the above test the problem is in the transaxfe itself 3 CONNECT SOLENOID WIRE 4 CANCEL OUT DIAGNOSTIC TROUBLE CODE See page AX1 45 AUTOMATIC TRANSAXLE TROUBLESHOOTING Memo AUTOMATIC TRANSAXLE TROUBLESHOOTING Memo AX1 66 AUTOMATIC TRANSAXLE TROUBLESHOOTING STANDARD VALUE OF ECM TERMINAL ECM Terminals 12206009008 ejer 4 IDL NSW 0D L 2 Standard Value 11 150 10 14 V 10 14V Symbols Wiring Color I Condition IG OFF Vehicle driving in 2nd gear position IG OFF P L GON Se Vehicle driving in 2nd gear position BA Balow 1 V 10 14 V 11 15 Below 1 Vv Vehicle driving under lock up position 10 1 V es Pattern select SW NORM Below 1 V r Brake pedal is depressed G W BA IG ON Brake pedal is released IG ON Engine Coolant temp 80 C 1 76T
63. ys on In this case connecting the terminals in the DLC2 or DLC1 can display the malfunction code DIAGNOSTIC CHART a See next page WIRING DIAGRAM From bgnition Switch Junction Connector m G O D e a 1 XL O D OFF a Indicator Light 2 t 4 A gt El z L cern Junction Connector O D Main Junction B 5 Connector 0 0 Main Switch Contacts go off with switch pushed in Contacts go on with switch pushed out AX1 103 AUTOMATIC TRANSAXLE TROUBLESHOOTING DIAGNOSTIC CHA Check O D OFF indicator light while engine starting Check O D main switch operation Measure voltage between terminal 1 of O D main switch and body ground j Repair or replace harness or connec Check O D main switch tor between O D main switch and body ground zw NG Replace O D switch Check O D OFF indicator light when O D main O D mai itch switch connector is disconnected Check O D OFF indicator light when ECM inc OD2 terminal is disconnected Replace ECM NE E E Check harness between combination meter NG Repai h O D main switch and ECM m OK ms Repair replace combination meter Check indicator lights on combination meter NG Check and repair power source cir other than O D OFF indicator light cuit to combination meter h

A140E AUTOMATIC TRANSAXLE

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