Power flow in automatic transmission N-position Starting clutch: off Forward clutch: off Reverse brake: off Hydraulic pressure is not supplied to the starting clutch, forward clutch and reverse brake. Power is not transmitted to the output shaft drive...
Electronic control system The electronic control system consists of a power train control module (RSM), sensors, three linear control solenoids and one shift lock solenoid. Electronic shift control provides convenience in all driving modes. The...
Grade Logic Control System Operating principle To control gear shifting while driving uphill or downhill, the PCM compares the current driving conditions with data stored in memory, based on signals received from the vehicle speed sensor,...
General layout of hydraulic pressure distribution № PRESSURE DESCRIPTION SS CLUTCH CONTROL COL ATF COOLER CR RESET IN THE CLUTCH DN DRIVEN PULLEY DR DRIVE PULLEY FWD FORWARD CLUTCH HLC REGULATION PH-PL LUB LUBRICATION PH HIGH PRESSURE RNS PH REGULATION PL LOW PRESSURE...
Parking brake mechanism The mechanism locks the transmission by engaging the parking brake latch with the parking gear, which is integral with the output shaft drive gear. The drive gear of the output shaft engages with the driven gear of the...
Location of automatic transmission control components Left hand drive model: 1. driving mode switch; 2. power train control module (rsm); 3. automatic transmission selector switch; 4. brake light switch Right hand drive model: 1. power train control module (RSM); 2. shift...
PCM terminal voltage — measurement conditions Automatic transmission control system The voltage at the contacts of the PCM module and the measurement conditions are given for the contacts of the connectors related to the automatic transmission control system. The...
Troubleshooting procedures When the PCM module detects a deviation in one or another input or output signal from various systems, the signal lamp D flashes in the instrument cluster. If the diagnostic connector is bridged (located under the...
Fault code table Electrical equipment DTC*: This is the number of flashes (blinking) signal lamp D with the diagnostic socket bridged. If the self-diagnosis warning light D does not flash, check according to the following table. sign...
Linear control solenoids and blocking solenoid Testing 1. Disconnect the 8-pin harness connector from the solenoid. 2. Measure the resistance of the linear shift control solenoid between pins #3 and #7 of the solenoid harness connector. Standard: 3.8-6.8 ohms 3....
Speed sensors for drive pulley, driven pulley and output shaft Replacement Warning! When replacing the speed sensor, do not allow dust or other foreign objects to enter the gearbox. 1. Disconnect the connector from the speed sensor of the drive pulley, driven pulley, or output...
Starting clutch control Starter Calibration Procedure When replacing the following components, the clutch control feedback signal must be entered into the PCM's memory: PCM module Gearbox assembly Starting clutch assembly Lower valve box...
AT selector switch Testing 1. Remove the front console (see ch. « Body »), then disconnect the 14-track automatic transmission selector switch connector. 2. Check the continuity between the contacts in each position according to the...
Range indicator; automatic transmission gear Testing signals at the indicator input This area contains components of an additional security system with an airbag (SRS). Review the SRS component locations, precautions, and procedures before attempting any repair or...
Locking system (models KQ and KU) Key Interlock Solenoid Test This area contains components of an additional security system with an airbag (SRS). Review the SRS component locations, precautions, and procedures before attempting any repair or service....
Automatic transmission malfunction table Hydraulic system sign Check these items in the list of probable causes The engine runs but the vehicle does not move in any position of the selector lever. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 34, 35, 36, 38, 41 The...
Road test automatic transmission Note: Warm up the engine to normal operating temperature (the radiator fan should turn on). 1. Apply the parking brake and chock the wheels. Start the engine, then shift to position D while depressing the brake pedal....
Engine revs on a stationary vehicle Trial Warning! To avoid damage to the transmission, do not test the engine speed with the vehicle stationary for more than 10 seconds at a time. Do not shift the lever while increasing engine speed. Before carrying out...
Fluid level — check and replace Examination Warning! When checking, do not allow dust or other foreign objects to enter the gearbox. Note: Check the fluid level with the engine warmed up to normal operating temperature (radiator fan turns on twice)....
Lower valve box — replacement 1. O-ring. Replace 2. SOLENOID HARNESS CONNECTOR 3. 6x1.0 mm 4. REFERENCE PIN 5. 8x1.25 mm, 26 Nm (2.7 kgf/m) 6. ATF FEED PIPE BRACKET 7.6x1.0mm 8. ATF PAN 9. GASKET UNDER THE PAN FOR ATF LIQUID. Replace 10. 6x1.0 mm...
ATF fluid filter — removal and installation 1. 6x1.0 mm, 12 Nm (1.2 kgf/m) 2. ATF COOLER SUPPLY PIPE 3. 8x1.25mm, 26Nm (2.7 kgf/m) 4. O-ring. Replace 5.ATF FILTER 6. O-ring. Replace 7. 6x1.0 mm, 12 Nm (1.2 kgf/m) 8. ATF PAN 9. ATF PAN GASKET. Replace 10....
Transfer case — check Warning! Make sure the lifts, jacks and safety stands are installed correctly ( see chapter 1 ). Apply the parking brake and block the rear wheels so that the vehicle does not roll off the bed and fall on you while you...
Transfer case — removal Warning! Make sure the lifts, jacks and safety stands are installed correctly. Apply the parking brake and block the rear wheels so that the vehicle does not roll off the bed and fall on you while you are working under...
Transfer case — installation Warning! When removing and installing the transfer case assembly, do not allow dust or other foreign matter to enter the transmission. 1. Install a new O-ring on the transfer case assembly. 2. Thoroughly clean the areas...
Gearbox — removal Warning! Make sure the jacks, jacks and safety stands are properly installed and the jack brackets are installed in the proper locations on the engine. Apply the parking brake and block the rear wheels so that the... There is 1 a comment
Right cover, intermediate case 1. Right cover; 2. ATF supply pipe; 3. Reference pin; 4. O-ring. Replace; 5. Feed tube flange; 6. Feed tube flange plate; 7. Gasket under the right cover. Replace; 8. Roller; 9. Intermediate crankcase assembly; 10....
Removing the gearbox housing, lower valve box 1. O-ring. Replace 2. SOLENOID HARNESS CONNECTOR 3. 6x1.0 mm, BOLT 4. REFERENCE PIN 5. 6x1.0 mm, 8 BOLTS 6. REFERENCE PIN 7. BOLT FOR FEED PIPE BRACKET ATF COOLER, 8x1.25 mm 8. COOLER SUPPLY PIPE ATF ASSEMBLY 9. ATF PAN...
Removing the gearbox housing, flywheel housing 1. 10x1.25 mm, 3 bolts 2. ATF FEED PIPE HOLDER ASSEMBLY 3. 6x1.0 mm, 2 bolts 4. FLYWHEEL CASE 5. CONNECTOR BRACKET 6. O-ring. Replace 7. FLYWHEEL CASE FIXING BOLTS, 18 bolts 8. REFERENCE PIN 9. GASKET FOR FLYWHEEL CASE....
Removing the right cover, intermediate crankcase 1. 8x1.25 mm, 11 bolts 2. 6x1.0 mm, 3 bolts 3. RIGHT COVER 4. GASKET UNDER THE RIGHT COVER. Replace 5. REFERENCE PIN 6. 8x1.25mm, 4 bolts 7. INTERCASE ASSEMBLY 8. ROLLER 9. GASKET UNDER GEARBOX CASE. Replace 10. CONTROL...
Manual valve body Disassembly/Inspection/Assembly Note: Thoroughly clean all parts with solvent or carburetor cleaner and dry with compressed air. Purge all channels. Apply transmission fluid to all components when reassembling. 1....
Forward Clutch — Disassembly 1. DRUM CLUTCH 2. O-rings. Replace 3. BELLELEE SPRING 4. RETURN SPRING 5. SPRING HOLDER 6. RETAINING RING 7. CLUTCH PLATES. Standard thickness: 2.00 mm. 8. CLUTCH END CAP 9. RETAINING RING 10. CLUTCH DISKS. Standard...
Forward Clutch — Assembly Note: Thoroughly clean all parts with solvent or carburetor cleaner and dry with compressed air. Purge all channels. Lubricate all components with transmission fluid before assembly. 1. Check check valve, if it is...
Output Shaft — Thrust shim selection 25x35mm 1. Measure the distance between the surface of the flywheel housing and the ball bearing as shown in the figure, then record the measurement (dimension A). 1. FLYWHEEL CASE 2. Measure distance A 3. BALL BEARING 4....
Differential — design description 2WD (LEFT) 1. 10x1.5 mm, BOLT, 98.0 Nm (10.0 kgf/m) Left hand thread 2. LEADING GEAR FINAL DRIVE. Check for excessive wear. 3. BALL BEARING 4. DIFFERENTIAL CUP 5. BALL BEARING 6. RETAINING RING, 80 mm. Selected by...
Differential — checking and replacing elements Checking gear engagement clearance 1. Fix differential in gathering on prisms and establish both semiaxes. 2. Install the indicator. 3. Measure the clearance between both side gears and satellites. Standard: 0.05-0.15...
Flywheel housing drive shaft oil seal — replacement 1. Drive the input shaft seal out of the flywheel housing. 1. SEAL 2. Using the special tool, press the oil seal into the flywheel housing. 1. DRIVE HANDLE, 07749-0010000 2. FLYWHEEL CASE 3. DRIVER, 32x35 mm,...
Bearings in the gearbox housing — replacement Replacing the driven pulley shaft bearing 1. In order to remove the driven pulley shaft bearing from the gearbox housing, spread the ends of the retaining ring with pliers, then press the bearing out using the special...
Bearings in the flywheel housing — replacement Replacing the output shaft bearing 1. Using a special tool, press out the output shaft bearing as shown in the figure. 1. ADJUSTABLE BEARING PULLER, 07JAC-PH80000 2. OUTPUT SHAFT BEARING 3. FLYWHEEL CASE 2. Using the...
Ring gear bearing — replacement 1. Knock out the ring gear bearing. 1. RING BEARING 2. RING GEAR 2. Using the special tool, press in the new ring gear bearing until it contacts the bottom of the ring gear as shown. 1. DRIVE HANDLE, 07749-0010000 2....
Control shaft assembly — removal and installation 1. Loosen the bolt and remove the lock washer, then remove the roller. 2: Remove the control lever from the shaft. 3. Remove the control shaft assembly. 4. Install the control shaft assembly into the transmission case....
Transfer case — design description 1. Carter transfer case; 2. O-ring. Replace; 3. Roller bearing of the transfer box housing; 4. Transfer box shaft; 5. Tapered roller bearing outer ring; 6. Tapered roller bearing; 7. Bushing of the transfer box shaft;...
Transfer case drive gear bearing replacement Note: Apply transmission fluid to all parts when assembling. 1. Using the special tool, press the tapered roller bearing out of the transfer case drive gear. 1. DRIVE HANDLE, 07749-0010000 2. PRESS 3. DRIVER, 37 x 40...
Replacing the bearing of the driven gear of the transfer case Note: Apply transmission fluid to all parts when assembling. 1. Using the special tool, press the tapered roller bearing off the transfer case driven gear shaft. 1. TRANSFER GEAR DRIVE SHAFT 2. PRESS 3. WASHER 4....
Transfer Case Roller Bearing Replacement Note: Apply transmission fluid to all parts when assembling. 1. Knock out the roller bearing from the transfer case housing. 1. ROLLER BEARING 2. TRANSFER BOX CASE 2. Using the special tool, press in the new roller...
Replacing the outer ring of the bearing cover A of the transfer case Note: Apply transmission fluid to all parts when assembling. 1. Press the tapered roller bearing outer race out of transfer case cover A by heating the cover to almost 100°C with a fan heater. Do not heat the lid above...
Replacing the outer ring of the transfer case housing bearing Note: Apply transmission fluid to all parts when assembling. 1. Knock out the tapered roller bearing outer race from the transfer case housing. 1. TRANSFER BOX CASE 2. BEARING OUTER RING 2. Using the special tool, press...
Transfer case assembly Note: When assembling the transfer case: Check and adjust the shape of the contact patch of the gear teeth of the transfer case. Measure and adjust the clearance in the transfer case gears. Check and adjust the starting...
Assembling the automatic transmission 11 Thoroughly soak the reverse brake discs in the recommended transmission fluid for at least 30 minutes. 12. Install the belleville spring on the reverse brake piston. 13. Starting with the reverse brake plate, install...
Installing an automatic transmission 1. Remove used grease from flywheel hub cap and flywheel splines. 2. Refill the flywheel hub cap and coat the flywheel splines with Super Urea Grease (P/N 08798-9002), as it shown on the picture. 3. Install a new O-ring...
Shift cable — adjustment Warning! Make sure the lifts, jacks and safety stands are properly installed ( see ch. 1 ). 1. Remove the front console (see ch. « Body »). 2. Switch to any position, then remove the lock pin from the regulator. Note:...
Shift cable — replacement Warning! Make sure the lifts, jacks and safety stands are properly installed ( see ch. 1 ). 1. Remove the front console (see ch. « Body »). 2. Shift to N, then remove the lock pin from the adjuster. Note: The...
Selector lever — removal and installation MODEL KG 1. BUTTON 2. SPRING 3. SELECTOR LEVER HANDLE 4. SCREW, 3 Nm (0.3 kgf/m). Apply thread blocking compound 5. GEAR RANGES INDICATOR PANEL 6. LEVER COVER 7. BUSHING. Silicone Grease 8. SELECTOR LEVER ASSEMBLY 9....
Automatic transmission range indicator panel — adjustment 1. Make sure that when the transmission is shifted to the N position, the pointer mark on the selector lever is aligned with the N pointer mark on the gear range indicator panel. 2. If the marks do not line up, remove...
ATF Cooler Hoses — Installation 1. Apply transmission fluid to the joint between the pipe and the ATF cooler hose. 2. Connect the hoses to the ATF cooler pipes and secure with clips as shown. Note: Install the clip tabs so that they do not interfere...