Chariot Service Manual

00109000812

General . . . . . . . . . . . . . . . . . . . . . . . .

00

Engine . . . . . . . . . . . . . . . . . . . . . . . . .

11

Engine Lubrication . . . . . . . . . . . . .

12

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Engine Cooling . . . . . . . . . . . . . . . . .

14

Intake and Exhaust

............

15

FOREWORD

Engine Electrical . . . . . . . . . . . . . . .

16

This Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required.

Engine and Emission Control . . . .

17

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

21

Manual Transmission . . . . . . . . . . .

22

TECHNICAL INFORMATION MANUAL PYDE9802 WORKSHOP MANUAL ENGINE GROUP PWEEjjjj (Looseleaf edition) ELECTRICAL WIRING PHDE9802 BODY REPAIR MANUAL PBDE9802 PARTS CATALOGUE SPACE RUNNER B608V509Aj SPACE WAGON B608W509Aj

Automatic Transmission . . . . . . . .

23

Propeller Shaft . . . . . . . . . . . . . . . . .

25

Front Axle . . . . . . . . . . . . . . . . . . . . . .

26

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

27

Wheel and Tyre . . . . . . . . . . . . . . . . .

31

Power Plant Mount . . . . . . . . . . . . . .

32

Front Suspension . . . . . . . . . . . . . . .

33

Rear Suspension . . . . . . . . . . . . . . .

34

Service Brakes . . . . . . . . . . . . . . . . .

35

Parking Brakes . . . . . . . . . . . . . . . . .

36

Steering . . . . . . . . . . . . . . . . . . . . . . . .

37

Body . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

51

WORKSHOP MANUAL

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Interior and Supplemental Restraint System (SRS) . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . . “GDI” is the trade mark which Mitsubishi Motors Corporation holds. E Mitsubishi Motors Corporation

Aug. 1998

Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . . . .

52 54 55

WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (driver’s side and front passenger’s side), clock spring, side impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more (3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

21-1

CLUTCH CONTENTS

21109000190

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2 Clutch Pedal Inspection and Adjustment . . . . . . . 2 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7

21-2

CLUTCH -

General Information/Service Specifications/Lubricants/On-vehicle Service

GENERAL INFORMATION

21100010093

The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control.

SERVICE SPECIFICATIONS

21100030150

Items

Standard value

Clutch pedal height mm

224 - 227 211 - 214

Clutch pedal clevis pin play mm

1- 3

Clutch pedal free play mm

6 - 13

Distance between the clutch pedal and the toeboard when the clutch is disengaged mm

125 or more

LUBRICANTS

21100040078

Items

Specified lubricants

Quantity

Clutch fluid

Brake fluid DOT3 or DOT4

As required

Push rod assembly

Rubber grease

Boot Release cylinder push rod

Clutch pedal height

MITSUBISHI genuine grease Part No. 0101011

Clutch pedal clevis pin play

ON-VEHICLE SERVICE

21100090158

CLUTCH PEDAL INSPECTION AND ADJUSTMENT A

B

1. Turn up the carpet, etc. under the clutch pedal. 2. Measure the clutch pedal height and the clutch pedal clevis pin play. Standard value (A): 224 - 227 211 - 214 Standard value (B): 1 - 3 mm

CLUTCH - On-vehicle Service

21-3

3. If the clutch pedal height and the clutch pedal clevis pin play are outside the standard value, turn the setting nut to adjust them to the standard value.

Setting nut

Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly. Clutch pedal 12 Nm

4. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the toeboard when the clutch is disengaged are within the standard value ranges.

Clutch pedal free play

C

Distance between the clutch pedal and the toeboard when the clutch is disengaged

Standard value (C): 6 - 13 mm Standard value (D): 125 mm or more 5. If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch. 6. Turn back the carpet, etc.

D

BLEEDING

21100140143

Specified fluid: Brake fluid DOT 3 or DOT 4 Caution Use the specified brake fluid. Avoid using a mixture of the specified fluid and other fluid.

21-4

CLUTCH - Clutch Pedal

CLUTCH PEDAL

21100160224

REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-2)

5

7 12 Nm

2

4

1 10

6

3 12 Nm

8

9

Removal steps 1. Clutch switch 2. Clip 3. Snap pin 4. Bushing 5. Pin assembly

6. 7. 8. 9. 10.

Clutch master cylinder mounting nut Master cylinder member mounting bolt Clutch pedal Stopper Pedal pad

21-5

CLUTCH - Clutch Control

CLUTCH CONTROL

21100190216

REMOVAL AND INSTALLATION Pre-removal Operation Clutch Fluid Draining

Post-installation Operation D Clutch Fluid Supplying D Clutch Line Bleeding (Refer to P.21-3) D Clutch Pedal Adjustment (Refer to P.21-2)

3

1

4

5

9

7

12 Nm

6

2

29 Nm

8 8 12 Nm 19 Nm

Release cylinder push rod

Release fork

15 Nm

7, 8

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Clutch hose 9. Bracket 10. Clutch hose

21-6

CLUTCH - Clutch Control



3 1

4

5

7

12 Nm

2 9

7

6

8 12 Nm 19 Nm

Release cylinder push rod

Release fork

15 Nm

8

Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Reservoir hose 4. Clutch master cylinder

Specified grease: MITSUBISHI genuine grease Part No. 0101011

Clutch release cylinder removal steps 5. Clutch pipe connection 6. Clutch release cylinder Clutch line removal steps 7. Clutch pipe 8. Bracket 9. Clutch hose

21-7

CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLY

21100210172

CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly.

6 12 Nm

5

2

9 3 4

1



6 12 Nm

2

5

9 3 4

1

8

7

44 Nm

2

1

4

2 2

3 Piston repair kit Disassembly steps 1. Piston stopper ring 2. Piston assembly "AA 3. Push rod assembly 4. Boot 5. Spring pin

Clutch fluid: Brake fluid DOT3 or DOT4

Grease: Rubber grease

6. 7. 8. 9.

Nipple Gasket Damper assembly Master cylinder body

21-8

CLUTCH - Clutch Control INSTALLATION SERVICE POINT "AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjustment of clutch pedal easier. 103 mm 121 mm

22-1

MANUAL TRANSMISSION CONTENTS LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . 3 Transfer Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

22109000395

Transfer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Temperature Sensor Check . . . . . . . . . . . . . . . . 4

TRANSMISSION CONTROL* . . . . . . . . . . . . . . . . 5 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . 8 TRANSFER ASSEMBLY . . . . . . . . . . . . . . . . . . 15

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

22-2

MANUAL TRANSMISSION - Lubricant/Special Tools

LUBRICANT

22100040310

Item Transmission oil

2WD 4WD

Transfer oil

Specified lubricant

Quantity L

Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4

2.2

Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4

0.53

2.3

SPECIAL TOOLS Tool

221000600224

Number

Name

Use

MB990635 or MB991113

Steering linkage puller

Ball joint disconnection

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger

MB991721

Sliding hammer

Driving out of the output shaft

MB991193

Plug

To prevent excessive transfer oil loss or system contamination

MANUAL TRANSMISSION - On-vehicle Service

22-3

ON-VEHICLE SERVICE

22100090308

TRANSMISSION OIL CHECK Transmission oil

Filler plug hole

1. Remove the oil filler plug. 2. Oil level should be at the lower portion of the filler plug hole. 3. Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 Nm

TRANSMISSION OIL CHANGE Filler plug

22100100315

1. Remove the drain plug to drain oil. 2. Tighten the drain plug to the specified torque. 3. Remove the filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole. Transmission oil Drain plug

32 Nm

Specified oil: Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Quantity: 2.2 L 2.3 L 4. Tighten the filler plug to the specified torque.

TRANSFER OIL CHECK Filler plug

Drain plug

22100110134

1. Remove the oil filler plug. 2. Oil level should be at the lower portion of the filler plug hole. 3. Check that the transfer oil is not noticeably dirty, and it has a suitable viscosity. 4. Install the oil filler plug, and then tighten it to the specified torque. Tightening torque: 32 Nm

22-4

MANUAL TRANSMISSION - On-vehicle Service

TRANSFER OIL CHANGE

22100120137

1. Remove the oil drain plug to drain oil. 2. Install the oil drain plug, and then tighten it to the specified torque.

Transfer oil

Tightening torque: 32 Nm 3. Remove the oil filler plug, and then fill with specified oil till the level comes to the lower portion of filler plug hole. Transfer oil Specified oil: Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Quantity: 0.53 L 4. Install the oil filler plug, and then tighten it to the specified torque. Specified torque: 32 Nm

OIL TEMPERATURE SENSOR CHECK

22100670038

1. Remove the oil drain plug, and then drain the transmission oil. 2. Remove the oil temperature sensor.

Oil temperature sensor

3. Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector. Standard value:

Transmission oil

Oil temperature _C

Resistance kW

20

2.31 - 2.59

110

0.145 - 0.149

4. If the resistance is not within the standard value, replace the oil temperature sensor. 5. Install the oil temperature sensor, and then tighten it to the specified torque. Tightening torque: 20 - 25 Nm 6. Install the drain plug and tighten it to the specified torque. Supply a transmission oil. (Refer to P.22-3.)

22-5

MANUAL TRANSMISSION - Transmission Control

TRANSMISSION CONTROL

22100380238

REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly. Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation

10 1

14 12 Nm

11

2 3

9 12

6

10

7

4 5 8

13 5 Nm

"BA "BA "BA

AA" "AA "AA "AA

Shift cable and select cable assembly removal steps 1. Shift knob 2. Spring washer 3. Nut D Center console box (Refer to GROUP 52A.) 4. Insulator 5. Snap pin 6. Select cable connection (Shift lever side) 7. Clip 8. Shift cable connection (Shift lever side) 9. Clip 10. Snap pin 11. Select cable connection (Transmission side) 12. Shift cable connection (Transmission side)

13. Shift lever assembly "AA 14. Shift cable and select cable assembly Shift lever assembly removal steps "BA 1. Shift knob "BA 2. Spring washer "BA 3. Nut D Center console box (Refer to GROUP 52A.) 4. Insulator 5. Snap pin 6. Select cable connection (Shift lever side) 7. Clip 8. Shift cable connection (Shift lever side) 12. Shift lever assembly

22-6

MANUAL TRANSMISSION - Transmission Control

REMOVAL SERVICE POINTS

Tabs

AA" CLIP REMOVAL Pry the tabs of the clip with a screwdriver or similar, and then remove the clip.

INSTALLATION SERVICE POINTS Shift lever

"AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/ SHIFT CABLE CONNECTION/SELECT CABLE CONNECTION 1. Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position.

Neutral position

2. For the transmission side, the paint marks on the shift and select cable ends should face the snap pins. 3. Install new clips to the cable bracket at the transmission, and then install shift cable and select cable to the cable bracket. 4. Move the passenger compartment side shift lever to all positions and check that the operation is smooth.

"BA NUT/SPRING WASHER/SHIFT KNOB INSTALLATION 1. Screw in the nut all the way by hand, turn back half a turn, and then insert the spring washer. 2. Screw in the shift knob until it touches the spring washer, and make one more turn. Then turn more to adjust the shift pattern on the shift knob. 3. If the above steps are impossible, you can turn back the shift knob by one turn at most after screwing in all the way to adjust the shift pattern.

22-7

MANUAL TRANSMISSION - Transmission Control

SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY

22100400101

8 9 10 1 4 2

14 Nm

4 7

9 Nm 12 Nm

3 16

5

6 10 Nm

11

13

12 9 Nm

15 14

Disassembly steps 1. Lever assembly 2. Bolt 3. Select lever 4. Bushing 5. Return spring 6. Collar 7. Bolt 8. Cap

9. 10. 11. 12. 13. 14. 15. 16.

Shift lever Shift lever bushing Base bracket Lever mount bracket assembly Insulator Stay Lever mount bracket Base bracket

22-8

MANUAL TRANSMISSION - Transmission Assembly

TRANSMISSION ASSEMBLY

22100270290

REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Radiator and Coolant Reservoir Removal and Installation (Refer to GROUP 14.) D Starter Removal and Installation (Refer to GROUP 16.) D Under Cover Removal and Installation

D D D D D

Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Check the Dust Cover for Crack or Damage by Pushing it with Finger Shift Lever Operation Check Instruments Operation Check Wheel Alignment Check (Refer to GROUP 33A - On-vehicle Service.)

19 Nm

6

2

19 Nm 48 Nm

1 3

10 4

5

9 12 Nm 12 Nm

8 69 Nm

9 12 Nm

9 9 7 24 - 33 Nm

Removal steps 1. Clip (Refer to P.22-5.) 2. Select cable connection (Refer to P.22-5.) 3. Shift cable connection (Refer to P.22-5.) 4. Back-up lamp switch connector 5. Vehicle speed sensor connector

AA" AB"

6. Clutch release cylinder connection 7. Tie rod end connection 8. Steering gear and linkage mounting bolts 9. Oil line mounting bolts 10. Transmission assembly upper coupling bolt

22-9

MANUAL TRANSMISSION - Transmission Assembly

57 Nm*

24

81 Nm*

25

24

48 Nm

23

25 26 14

39 Nm

14

18

17

15

40 Nm

9 Nm

98 - 118 Nm 49 - 64 Nm*

13

19

20 44 Nm 49 - 64 Nm*

196 - 255 Nm

22 Nm

11

21 12

22

78 Nm

177 Nm 78 Nm

11. Stabilizer link connection "CA 12. Lower arm connection 13. Wheel speed sensor connection (Refer to GROUP 35B.) AC" "BA 14. Drive shaft AC" "BA 15. Drive shaft and inner shaft 17. Transmission stay 18. Bell housing cover 19. Front roll stopper connection

177 Nm

20. 21. 22. AE" 23. "AA 24. AF" D AG" AG"

Rear roll stopper connection Stay Front member assembly Transmission mount bracket Transmission mount stopper Engine and transmission assembly supporting 25. Transmission assembly lower part coupling bolts 26. Transmission assembly

22-10

MANUAL TRANSMISSION - Transmission Assembly

REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Transfer Oil Draining and Refilling (Refer to P.22-3.) D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Radiator and Coolant Reservoir Removal and Installation (Refer to GROUP 14.) D Starter Removal and Installation (Refer to GROUP 16.) D Propeller Shaft Removal and Installation (Refer to GROUP 25.)

D D D D D D

Under Cover Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Check the Dust Cover for Crack or Damage by Pushing it with Finger Shift Lever Operation Check Instruments Operation Check Wheel Alignment Check (Refer to GROUP 33A - On-vehicle Service.)

19 Nm 19 Nm

6

2

48 Nm

1 10

3

4 5

9 12 Nm

12 Nm

8 69 Nm

9 12 Nm

9

9 7 24 - 33 Nm

Removal steps 1. Clip (Refer to P.22-5.) 2. Select cable connection (Refer to P.22-5.) 3. Shift cable connection (Refer to P.22-5.) 4. Back-up lamp switch connector 5. Vehicle speed sensor connector

AA" AB"

6. Clutch release cylinder connection 7. Tie rod end connection 8. Steering gear and linkage mounting bolts 9. Oil line mounting bolts 10. Transmission assembly upper coupling bolt

22-11

MANUAL TRANSMISSION - Transmission Assembly 57 Nm* 81 Nm*

24 25

24

48 Nm

23 25 26 39 Nm

14

14 17 16

44 Nm

18 9 Nm

98 - 118 Nm

49 - 64 Nm*

13

19

20 49 - 64 Nm*

22 Nm

196 - 255 Nm

11

12

21 22

78 Nm

177 Nm 78 Nm

11. Stabilizer link connection "CA 12. Lower arm connection 13. Wheel speed sensor connection (Refer to GROUP 35B.) AC" "BA 14. Drive shaft AD" "BA 16. Output shaft D Transfer assembly removal (Refer to P.22-15.) 17. Transmission stay 18. Bell housing cover 19. Front roll stopper connection

177 Nm

20. 21. 22. AE" 23. "AA 24. AF" D AG" AG"

Rear roll stopper connection Stay Front member assembly Transmission mount bracket Transmission mount stopper Engine and transmission assembly supporting 25. Transmission assembly lower part coupling bolts 26. Transmission assembly

22-12

MANUAL TRANSMISSION - Transmission Assembly

REMOVAL SERVICE POINTS

Cord

AA" TIE ROD END DISCONNECTION

Ball joint MB990635 or MB991113

Caution 1. Use the special tool to loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. not to let it come off.

Nut

AB" STEERING GEAR AND LINKAGE MOUNTING BOLT REMOVAL Remove the steering gear and linkage mounting bolts, and then support the steering gear box to the vehicle body with a wire.

Fig. 1

AC" DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY REMOVAL Remove the drive shaft or the drive shaft and inner shaft assembly from the transmission by the following procedure:

Transmission

Drive shaft Prybar

Fig. 2

Transmission

Drive shaft

Center bearing bracket Hammer Transfer

Fig. 3

Hammer

Drive shaft

Projection Prybar

2WD (except SPACE WAGON - M/T - R.H.), 4WD (L.H.)

Fig. 1

2WD (SPACE WAGON - M/T - R.H.)

Fig. 2

4WD (R.H.)

Fig. 3

Insert a pry bar between the drive shaft and the transmission case, and then pry off the drive shaft. Tap the center bearing bracket with a hammer to remove the drive shaft. Place a hammer on the projection at the transfer and insert a pry bar between the drive shaft and the transfer, and then pry off the drive shaft. Caution 1. Above-mentioned procedure must be observed. Pulling the B.J. assembly to remove the drive shaft or drive shaft and inner shaft assembly will damage the T.J. assembly. 2. Take care that the transmission oil seal will not be damaged by the drive shaft spline.

MANUAL TRANSMISSION - Transmission Assembly

22-13

AD" OUTPUT SHAFT REMOVAL 1. Use the special tool to withdraw the output shaft.

MB991721

Caution Be careful not to transmission by the 2. Use a shop towel to to let foreign material

damage the oil seal of the spline of the output shaft. cover the transmission case not get into it.

Output shaft

AE" TRANSMISSION MOUNT BRACKET REMOVAL Carefully lower the transmission assembly with a garage jack, and remove the transmission mount bracket.

AF" ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING Set the special tool to the vehicle to support the engine and transmission assembly.

MZ203827

MB991453

AG" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly with a transmission jack. 2. Remove the transmission assembly lower part coupling bolts, and lower the transmission assembly to remove.

Engine side

INSTALLATION SERVICE POINTS "AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow points as shown in the illustration.

Transmission mount stopper

Transmission mount bracket

NOTE Disregard F and R stamped as a shared part.

22-14

MANUAL TRANSMISSION - Transmission Assembly "BA OUTPUT SHAFT/DRIVE SHAFT INSTALLATION Caution Be careful not to damage the oil seal of the transmission or transfer by the spline of the drive shaft or the output shaft.

"CA LOWER ARM INSTALLATION 1. Install the lower arm assembly to the knuckle.

Knuckle A

Lower arm assembly

Caution The lower arm should not protrude 4 mm or more from the knuckle end (A shown), otherwise grease may pour out from the dust cover. 2. If grease has poured out due to the excessive arm protrusion, the dust cover must be replaced (Refer to GROUP 33A - Lower Arm). 3. There should be not clearance between the knuckle and the dust cover.

22-15

MANUAL TRANSMISSION - Transfer Assembly

TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal and Post-installation Operation D Transmission Oil Draining and Refilling (Refer to P.22-3.) D Transfer Oil Draining and Refilling (Refer to P.22-4.)

D

Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)

69 Nm

Gear oil: Hypoid gear oil SAE 75W - 85W or 75W - 90 conforming to API GL-4

2 1

Removal steps D Drive shaft connection (Refer to P.22-11.) D Output shaft (Refer to P.22-11.)

AA"

1. Front propeller shaft (Refer to GROUP 25.) 2. Transfer assembly

REMOVAL SERVICE POINT AA" TRANSFER ASSEMBLY REMOVAL

Oil seal lip

MB991113

Caution 1. Be careful not to damage the transfer oil seal lip. 2. Use the special tool to plug the transfer case opening to to prevent excessive oil loss or system contamination.

NOTES

23-1

AUTOMATIC TRANSMISSION CONTENTS SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 44 Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 A/T Control Component Location . . . . . . . . . . . . . 50 A/T Control Component Check . . . . . . . . . . . . . . . 51

23109000576

Torque Converter Stall Test . . . . . . . . . . . . . . . . . . 53 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . 55 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Line Pressure Adjustment . . . . . . . . . . . . . . . . . . . . 61 Selector Lever Operation Check . . . . . . . . . . . . . . 61

TRANSMISSION CONTROL* . . . . . . . . . . . . . . 63 SHIFT LOCK AND KEY INTERLOCK MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . 68

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

23-2

AUTOMATIC TRANSMISSION -

Service Specifications/Lubricant/Special Tools

SERVICE SPECIFICATIONS

23100030284

Items

Standard value

Oil temperature sensor kW

at 0_C

16.5 - 20.5

at 100_C

0.57 - 0.69

Resistance of damper clutch control solenoid valve coil (at 20_C) W

2.7 - 3.4

Resistance of Low-Reverse solenoid valve coil (at 20_C) W

2.7 - 3.4

Resistance of second solenoid valve coil (at 20_C) W

2.7 - 3.4

Resistance of underdrive solenoid valve coil (at 20_C) W

2.7 - 3.4

Resistance of overdrive solenoid valve coil (at 20_C) W

2.7 - 3.4

Stall speed r/min

4G93

2,200 - 2,700

4G64

2,300 - 2,800

LUBRICANT

23100040270

Items

Specified lubricant

Quantity L

Transmission fluid

DIA QUEEN ATF SPII, ATF SPII M or equivalent

7.8

SPECIAL TOOLS Tool

23100060351

Number

Name

Use

MB991502

MUT-II sub assembly

Checking of the diagnosis code

MD998330 (including MD998331)

Oil pressure gauge (2,942 kPa)

Measurement of oil pressure

MD998332

Adapter

MD998900

Adapter

AUTOMATIC TRANSMISSION - Special Tools Tool

23-3

Number

Name

Use

MB990635 or MB991113

Steering linkage puller

Ball joint disconnection

MB991610

Oil filter wrench

Removal and installation of automatic transmission oil filter

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger assembly

Supporting the engine assembly during removal and installation of the transmission

23-4

AUTOMATIC TRANSMISSION - Troubleshooting

TROUBLESHOOTING

23100760657

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Gathering information from customer.

NG

Check ATF.

Replace ATF.

OK

Check trouble symptoms. Communication with MUT-II not possible

Read the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) Diagnosis code displayed

Inspection Chart For Trouble Symptoms (Refer to P.23-24.)

No diagnosis code displayed Replace the A/T-ECU.

Erase the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

Check trouble symptoms. NG

Carry out the essential service (Refer to P.23-44.) Abnormality exists (no diagnosis code)

Road test (Refer to P.23-6.) Abnormality exists (diagnosis code present)

No abnormality Recheck diagnosis codes which were read before the road test. Diagnosis code displayed

To INSPECTION CHART DIAGNOSIS CODES (Refer to P.23-12.)

FOR

To INSPECTION CHART TROUBLE SYMPTOMS (Refer to P.23-24.)

No diagnosis code displayed FOR

Search for cause. Found Repair

NG Confirmation test (road test)

OK

NG

Not found INTERMITTENT MALFUNCTION (GROUP 00 - Points to Note for Intermittent Malfunctions.) OK Completed

AUTOMATIC TRANSMISSION - Troubleshooting DIAGNOSIS FUNCTION 1. N range lamp The N range lamp flashes at a frequency 1 Hz if there is an abnormality in any of table below which are related to the A/T the diagnosis code output if the N range at a frequency of approximately 1 Hz.

23-5 23100770292

of approximately the items in the system. Check lamp is flashing

N range lamp flashing items Crank angle sensor Input shaft speed sensor Output shaft speed sensor Each solenoid valve Out of phase at each shift point

Caution If the N range lamp is flashing at a frequency of approximately 2 Hz (faster than at 1 Hz), it means that the automatic transmission fluid temperature is too high. Stop the vehicle in a safe place and wait until the N range lamp switches off. 2. Method of reading the diagnosis code Use the MUT-II or the N range lamp to take a reading of the diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

23-6

AUTOMATIC TRANSMISSION - Troubleshooting

ROAD TEST

23100780622

Check by the following procedure. No.

State prior to test and operation

Test and operation

Judgement value

Check item

Diagnosis code No.

Inspection procedure page if there is an abnormality

1

Ignition switch: OFF

Ignition switch (1) ON

Data list No. 54 Battery voltage [V]

Control relay

54

A/T Control relay system (23-23)

2

Ignition switch: ON Engine: Stopped Selector lever position: P

Selector lever position (1) P, (2) R, (3) N, (4) D, (5) 3, (6) 2, (7) L

Data list No. 61 (1) P, (2) R, (3)N, (4) D, (5) 3, (6) 2, (7) L

Inhibitor switch

-

Inhibitor switch system (23-35)

Throttle position sensor Accelerator pedal position sensor

11 12 14

Throttle position sensor system (23-13) Accelerator pedal position sensor system (23-13)

Data list No. 25 (1) OFF (2) ON

Wide open throttle switch

25

Wide open throttle switch system (23-15)

Brake pedal (1) Depressed (2) Released

Data list No. 26 (1) ON (2) OFF

Stop lamp switch

26

Stop lamp switch system (23-16)

Data list No. 11 Accelerator pedal (1) 300 - 1,000 mV (1) Released (2) Half depressed (2) Gradually rises from (1) (3) Depressed (3) 4,500 - 5,500 mV

3

Ignition switch: ST Engine: Stopped

Starting test with lever P or N range

Starting should be possible

Starting possible or impossible

-

Starting impossible (23-27)

4

Warming up

Drive for 15 minutes or more so that the automatic fluid temperature becomes 70 90_C.

Data list No. 15 Gradually rises to 70 - 90_C

Oil temperature sensor

15

Oil temperature sensor system (23-13)

23-7

AUTOMATIC TRANSMISSION - Troubleshooting No.

State prior to test and operation

Test and operation

Judgement value

Check item

Diagnosis code No.

Inspection procedure page if there is an abnormality

5

Engine: Idling Selector lever position: N

Brake pedal (Retest) (1) Depressed (2) Released

Data list No. 26 (1) ON (2) OFF

Stop lamp switch

26

Stop lamp switch system (23-16)

A/C switch (1) ON (2) OFF

Data list No. 65 (1) ON (2) OFF

Dual pressure switch

-

Dual pressure switch system (23-35)

21

Crank angle sensor system (23-14)

Data list No. 21 Crank angle Accelerator pedal (1) 550 - 850 r/min sensor (1) Released (2) Half depressed Gradually rises from (1)

Selector lever position (1) N ® D (2) N ® R

Data list No. 57 (2) Data changes

Communication with engineECU

51

Serial communication system (23-23)

Should be no abnormal shifting shocks Time lag should be within 2 seconds

Malfunction when starting

-

Engine stalling during shifting (23-29)

-

Shocks when changing from N to D and large time lag (23-29)

-

Shocks when changing from N to R and large time lag (23-30)

-

Shocks when changing from N to D,N to R and large time lag (23-31)

-

Does not move forward (23-27)

-

Does not reverse (23-28)

-

Does not move (forward or reverse) (23-28)

Driving impossible

23-8

AUTOMATIC TRANSMISSION - Troubleshooting

No.

State prior to test and operation

Test and operation

Judgement value

Check item

Diagnosis code No.

Inspection procedure page if there is an abnormality

6

Selector lever position: N (Carry out on a flat and straight road.)

Selector lever position and vehicle speed (1) Idling in L range (Vehicle stopped) (2) Driving at constant speed of 10 km/h in L position (3) Driving at constant speed of 30 km/h in 2 position (4) Driving at 50 km/h in 3 position with accelerator fully closed (5) Driving at constant speed of 50 km/h in D position (Each condition should be maintained for 10 seconds or more.)

Data list No. 63 (2) 1st, (4) 3rd, (3) 2nd, (5) 4th

Shift condition

-

-

Data list No. 31 (2) 0 %, (4) 100 %, (3) 100 %, (5) 100 %

Low and reverse 31 solenoid valve

Low and reverse solenoid valve system (23-16)

Data list No. 32 (2) 0 %, (4) 0 %, (3) 0 %, (5) 100 %

Underdrive solenoid valve

32

Underdrive solenoid valve system (23-16)

Data list No. 33 (2)100 %, (4) 100 %, (3) 0 %, (5) 0 %

Second solenoid valve

33

Second solenoid valve system (23-16)

Data list No. 34 (2) 100 %, (4) 0 %,

Overdrive solenoid valve

34

Overdrive solenoid valve system (23-16)

Vehicle speed sensor

-

Vehicle speed sensor system (23-36)

Data list No. 22 Input shaft (4) 1,800 - 2,100 speed sensor r/min

22

Input shaft speed sensor system (23-14)

Data list No. 23 Output shaft (4) 1,800 - 2,100 speed sensor r/min

23

Output shaft speed sensor system (23-15)

Selector lever position and vehicle speed (1) Release the accelerator pedal fully while driving at 50 km/h in 3rd gear. (2) Driving at constant speed of 50 km/h in 3rd gear.

Data list No. 36 Damper clutch control solenoid (1) 0 % (2) Approx. 70 - 90 valve %

36 52

Damper clutch control solenoid valve system (23-17)

7

Selector lever position: 3 (Carry out on a flat and straight road.)

(3) 100 %, (5) 0 % Data list No. 29 (1) 0 km/h (4) 50 km/h

Data list No. 52 (1) Approx. 100 - 300 r/min (2) Approx. 0 - 10 r/min

23-9

AUTOMATIC TRANSMISSION - Troubleshooting No.

State prior to test and operation

Test and operation

Judgement value

Check item

Diagnosis code No.

Inspection procedure page if there is an abnormality

8

Use the MUT-II to stop the INVECSII function. Selector lever position: D (Carry out on a flat and straight road.)

Monitor data list No. 11, 23, and 63 with the MUT-II. (1) Accelerate to 4th gear at a throttle position sensor output of 1.5V (accelerator opening angle of 30 %). (2) Gently decelerate to a standstill. (3) Accelerate to 4th gear at a throttle position sensor output of 2.5 V (accelerator opening angle of 50%). (4) While driving at 60 km/h in 4th gear, shift down to 3 range. (5) While driving at 40 km/h in 3rd gear, shift down to 2 range. (6) While driving at 20 km/h in 2nd gear, shift down to L range.

For (1), (2) and (3), the reading should be the same as the specified output shaft speed and no abnormal shocks should occur. For (4), (5) and (6), downshifting should occur immediately after the shifting operation is made.

Malfunction when shifting

-

Shocks and running up (23-31)

Displaced shifting points

-

All points (23-32)

-

Some points (23-33)

Does not shift

-

No diagnosis code (23-33)

22

Input shaft speed sensor system (23-14)

23

Output shaft speed sensor system (23-15)

31

Low and reverse solenoid valve system (23-16)

33

Second solenoid valve system (23-16)

41

1st gear ratio is not specified (23-18)

42

2nd gear ratio is not specified (23-19)

33

Second solenoid valve system (23-16)

34

Overdrive solenoid valve system (23-16)

42

2nd gear ratio is not specified (23-19)

43

3rd gear ratio is not specified (23-20)

32

Underdrive solenoid valve system (23-16)

33

Second solenoid valve system (23-16)

43

3rd gear ratio is not specified (23-20)

44

4th gear ratio is not specified (23-21)

Does not shift from 1 to 2 or 2 to 1

Does not shift from 2 to 3 or 3 to 2

Does not shift from 3 to 4 or 4 to 3

23-10

AUTOMATIC TRANSMISSION - Troubleshooting

No.

State prior to test and operation

Test and operation

Judgement value

Check item

Diagnosis code No.

Inspection procedure page if there is an abnormality

9

Selector lever position: N (Carry out on a flat and straight road.)

Monitor data list No. 22 and No. 23 with the MUT-II. II (1) Move selector lever to R range, drive at constant speed of 10 km/h.

The ratio between data list No. 22 and No. 23 should be the same as the gear ratio when reversing.

Does not shift

22

Input shaft speed sensor system (23-14)

23

Output shaft speed sensor system (23-15)

46

Reverse gear ratio is not specified (23-22)

SHIFT PATTERN UPSHIFT PATTERN Throttle opening %

Thick line: Standard shift pattern

100

1

2

3

3

2

4

2®3 movement range

50

3®4 movement range 0

2,000

1,000

3,000

4,000

5,000

6,000

7,000

Output shaft speed r/min

DOWNSHIFT PATTERN Throttle opening %

Thick line: Standard shift pattern

100 2 (L)

1

1 50

2

2

3

4 2

2¬3 movement range 0

3

1,000

3 (L,2)

3

4 (L,2,3)

3¬4 movement range 2,000

3,000

4,000

Output shaft speed r/min

5,000

6,000

7,000

23-11

AUTOMATIC TRANSMISSION - Troubleshooting UPSHIFT PATTERN

Thick line: Standard shift pattern

Throttle opening % 100

2 2 2®3 movement range

1 50

3

3

4

3®4 movement range 0

1,000

3,000

2,000

4,000

5,000

7,000

6,000

Output shaft speed r/min

DOWNSHIFT PATTERN Throttle opening %

Thick line: Standard shift pattern

100 2 (L)

1 1

2

2

3

4

3

50

2 2¬3 movement range

0

1,000

3

3 (L,2)

4 (L,2,3)

3¬4 movement range 2,000

3,000

4,000

Output shaft speed r/min

5,000

6,000

7,000

23-12

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODE

23100790588

Code

Diagnosis item

11

Short circuit

23-13

Open circuit

23-13

14

Throttle position sensor system Accelerator pedal position sensor system

Sensor maladjustment

23-13

15

Oil temperature sensor system

Open circuit

23-13

21

Crank angle sensor system

Open circuit

23-14

22

Input shaft speed sensor system

Short circuit/open circuit

23-14

23

Output shaft speed sensor system

Short circuit/open circuit

23-15

25

Wide open throttle switch system

Short circuit

23-15

26

Stop lamp switch system

Short circuit/open circuit

23-16

31

Low and reverse solenoid valve system

Short circuit/open circuit

23-16

32

Underdrive solenoid valve system

Short circuit/open circuit

23-16

33

Second solenoid valve system

Short circuit/open circuit

23-16

34

Overdrive solenoid valve system

Short circuit/open circuit

23-16

36

Damper control clutch solenoid valve system

Short circuit/open circuit

23-17

41

1st gear ratio does not meet the specification

23-18

42

2st gear ratio does not meet the specification

23-19

43

3rd gear ratio does not meet the specification

23-20

44

4th gear ratio does not meet the specification

23-21

46

Reverse gear ratio does not meet the specification

23-22

51

Abnormal communication with engine-ECU

23-23

52

Damper control clutch solenoid valve system

Defective system

23-17

54

A/T Control relay system

Short circuit to earth/ open circuit

23-23

56

N range lamp system

Short circuit to earth

23-24

12

Reference page

AUTOMATIC TRANSMISSION - Troubleshooting

23-13

INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 11, 12, 14 Throttle position sensor system , accelerator pedal position sensor system

Probable cause

If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the output is judged to be too high and diagnosis code No. 11 is output. If the TPS or APS output voltage is 0.2 V or lower at times other than when the engine is idling, the output is judged to be too low and diagnosis code No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if it is 1.2 V or higher when the engine is idling, the TPS or APS adjustment is judged to be incorrect and diagnosis code No. 14 is output.

D D

Throttle position sensor check (Refer to GROUP 13B - On-vehicle Servicelink=13100320030.) Accelerator pedal position sensor check (Refer to GROUP 13A - On-vehicle Servicelink=13600430011.)

NG

D D

Malfunction Malfunction Malfunction Malfunction

of the throttle position sensor of the accelerator pedal position sensor of connector of the A/T-ECU

Replace

OK Check the following connectors: D A-73, B-11 D A-63, A-27, B-11

NG

Repair

OK Harness check D Between throttle position sensor and A/T-ECU D Between accelerator pedal position sensor and A/T-ECU OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

Code No. 15 Oil temperature sensor system

Probable cause

If the oil temperature sensor output voltage is 2.6 V or more even after driving for 10 minutes or more (if the oil temperature does not increase), it is judged that there is an open circuit in the oil temperature sensor and diagnosis code No. 15 is output.

D D D

Oil temperature sensor check (Refer to P.23-51.)

NG

Malfunction of the oil temperature sensor Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: A-88, B-11

NG

Repair

OK Harness check D Between oil temperature sensor and A/T-ECU OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

23-14

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 21 Crank angle sensor system

Probable cause

If no output pulse is detected from the crank angle sensor for 5 seconds or more while driving at 25 km/h or more, it is judged that there is an open circuit in the crank angle sensor and diagnosis code No. 21 is output.

D D D

Check the following connectors: A-71, B-51, B-11

NG

Malfunction of the crank angle sensor Malfunction of connector Malfunction of the A/T-ECU

Repair

OK Harness check D Between crank angle sensor and A/T-ECU

NG

Repair

OK Crank angle sensor system check (Refer to GROUP 13 - Troubleshooting.) OK

NG

Check the trouble symptoms.

Replace the A/T-ECU.

Code No. 22 Input shaft speed sensor system

Probable cause

If no output pulse is detected from the input shaft speed sensor for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis code No. 22 is output. If diagnosis code No. 22 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D

Malfunction Malfunction Malfunction Malfunction

of of of of

the input shaft speed sensor the underdrive clutch retainer connector A/T-ECU

L: Refer to the Transmission Workshop Manual. Measure at the input shaft speed sensor connector A-90. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK approx. 5 V (3) Continuity between 1 and earth OK: Continuity

NG

OK Check the following harness: D Between the input shaft speed sensor and the ignition switch D Between the input shaft speed sensor and A/T-ECU OK Check the trouble symptoms.

OK Measure output waveform of the input shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-43 (Inspection procedure using an oscilloscope). There is no noise in the output waveform. OK Check the trouble symptoms.

Check the following connectors: A-90, B-14, B-93, B-89, B-11

NG

NG

NG

NG

Repair

Repair

Replace the A/T-ECU.

Replace the input shaft speed sensor.

Check the trouble symptoms.

NG

A/T overhaul K D Replace the retainer.

underdrive

clutch

Check the trouble symptoms. NG NG

Replace the A/T-ECU.

Eliminate the cause of the noise.

23-15

AUTOMATIC TRANSMISSION - Troubleshooting Code No. 23 Output shaft speed sensor system

Probable cause

If the output from the output shaft speed sensor is continuously 50% lower than the vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnosis code No. 23 is output. If diagnosis code No. 23 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D

Malfunction Malfunction Malfunction Malfunction

of of of of

the output shaft speed sensor the transfer drive gear or driven gear connector the A/T-ECU

L: Refer to the Transmission Workshop Manual. Measure at the output shaft speed sensor connector A-82. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK: approx. 5 V (3) Continuity between 1 and earth OK: Continuity

NG

OK Check the following harness: D Between the output shaft speed sensor and the ignition switch D Between the output shaft speed sensor and A/T-ECU OK

OK

NG

NG

Repair

Repair

Replace the A/T-ECU.

Replace the output shaft speed sensor. NG

Check the trouble symptoms.

A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

NG

Check the trouble symptoms.

NG

NG

Check the trouble symptoms.

OK Measure output waveform of the output shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-43 (Inspection procedure using an oscilloscope). There is no noise in the output waveform.

Check the following connectors: A-82, B-14, B-93, B- 89, B-11

Replace the A/T-ECU.

Code No. 25 Wide open throttle switch system

Probable cause

If the wide open throttle switch is on for 1 second or more with the throttle valve opening angle at 70% or less, it is judged that there is a short circuit in the wide open throttle switch and diagnosis code No. 25 is output.

D D D

Wide open throttle switch check (Refer to P.23-64.)

NG

Malfunction of the wide open throttle switch Malfunction of connector Malfunction of A/T-ECU

Replace

OK Check the following connectors: B-61, B-10

NG

Repair

OK Harness check D Between the wide open throttle switch and the A/T-ECU. OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

23-16

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 26 Stop lamp switch system

Probable cause

If the stop lamp switch is on for 5 minutes or more while driving, it is judged that there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output.

D D D

Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.)

NG

Malfunction of the stop lamp switch Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: B-28, B-65, B-14, B-10

NG

Repair

OK Harness check D Between stop lamp switch and A/T-ECU OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

Probable cause

Code No. 31 Low and reverse solenoid valve system Code No. 32 Underdrive solenoid valve system Code No. 33 Second solenoid valve system Code No. 34 Overdrive solenoid valve system If the resistance value for a solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

Solenoid valve check (Refer to P.23-52.)

NG

D D D

Malfunction of solenoid valve Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: A-88, A- 12X, B-12, B-10

NG

Repair

OK Harness check D Between solenoid valve and A/T-ECU

NG

Repair

OK Replace the solenoid valve.

Check the trouble symptoms.

NG

Replace the A/T-ECU.

AUTOMATIC TRANSMISSION - Troubleshooting Code No. 36, 52 Damper clutch control solenoid valve system

Probable cause

If the resistance value for the damper clutch control solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the damper clutch control solenoid valve and diagnosis code No. 36 is output. If the drive duty rate for the damper clutch control solenoid valve is 100 % for a continuous period of 4 seconds or more, it is judged that there is an abnormality in the damper clutch control system and diagnosis code No. 52 is output. When diagnosis code No. 36 is output, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D

Damper clutch control solenoid valve check (Refer to P.23-52.)

NG

Malfunction of the damper clutch control solenoid valve Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: A-88, A-12X, B-12

NG

Repair

OK Harness check D Between damper clutch control solenoid valve and A/T-ECU

NG

Repair

OK Replace the damper clutch control solenoid valve. Check the trouble symptoms.

NG

23-17

Replace the A/T-ECU.

23-18

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 41 1st gear ratio does not meet the specification

Probable cause

If the output from the output shaft speed sensor multiplied by the 1st gear ratio is not the same as the output from the input shaft speed sensor after shifting to 1st gear has been completed, diagnosis code No. 41 is output. If diagnosis code No. 41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D D D D

Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated

input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system underdrive clutch system

L: Refer to the Transmission Workshop Manual. MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform.

Yes

Yes

NG

Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms.

OK

NG Eliminate the cause of the noise. Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 42, No. 43, or no diagnosis code is output). D Low and reverse brake system check (No. 46 or no diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

AUTOMATIC TRANSMISSION - Troubleshooting Code No. 42 2nd gear ratio does not meet the specification

Probable cause

If the output from the output shaft speed sensor multiplied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis code No. 42 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D D D D

Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated

23-19

input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system underdrive clutch system

L: Refer to the Transmission Workshop Manual. MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform.

Yes

Yes

NG

Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms.

OK

NG Eliminate the cause of the noise. Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 43, or no diagnosis code is output). D Second brake system check (No. 44 or no diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

23-20

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 43 3rd gear ratio does not meet the specification

Probable cause

If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code No. 43 is output. If diagnosis code No. 43 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D D D D

Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated

input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear underdrive clutch system overdrive clutch system

L: Refer to the Transmission Workshop Manual. MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform.

Yes

Yes

NG

Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms.

OK

NG Eliminate the cause of the noise. Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 42, or no diagnosis code is output). D Overdrive clutch system check (No. 44 or no diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

AUTOMATIC TRANSMISSION - Troubleshooting Code No. 44 4th gear ratio does not meet the specification

Probable cause

If the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from the input shaft speed sensor after shifting to 4th gear has been completed, diagnosis code No. 44 is output. If diagnosis code No. 44 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D D D D D

Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated

23-21

input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system overdrive clutch system

L: Refer to the Transmission Workshop Manual. MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform.

Yes

Yes

NG

Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms.

OK

NG Eliminate the cause of the noise. Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Second brake system check (No. 42 or no diagnosis code is output). D Overdrive clutch system check (No. 43 or no diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

23-22

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 46 Reverse gear ratio specification

does not meet the

If the output from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output from the input shaft speed sensor after shifting to reverse gear has been completed, diagnosis code No. 46 is output. If diagnosis code No. 46 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

Probable cause D D D D D D D

Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated

input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system reverse clutch system

L: Refer to the Transmission Workshop Manual. MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector A-90 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform.

Yes

Yes

NG

Code No. 22 Input shaft speed sensor system check (Refer to P.23-14.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-15.) Replace the input shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms.

OK

NG Eliminate the cause of the noise. Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector A-82 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-43 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 ¨ 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Low and reverse brake system check (No. 41 or no diagnosis code is output). D Reverse clutch system check (No diagnosis code is output).

NG

Replace the output shaft speed sensor.

Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

AUTOMATIC TRANSMISSION - Troubleshooting Code No. 51 Abnormal communication with engine-ECU

Probable cause

If normal communication is not possible for a continuous period of 1 second or more when the ignition switch is at the ON position, the battery voltage is 10 V or more and the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosis code No. 51 is also output if the data being received is abnormal for a continuous period of 4 seconds under the same conditions.

D D D

Check the following connectors: D B-54, B-52, B-10 D B-53, B-52, B-10 OK Harness check D Between engine-ECU and A/T-ECU

NG

NG

Malfunction of connector Malfunction of the engine-ECU Malfunction of the A/T-ECU

Repair

Repair

OK Check the trouble symptoms. NG Replace the engine-ECU. NG

Check the trouble symptoms.

Replace the A/T-ECU.

Code No. 54 A/T control relay system

Probable cause

If the A/T control relay voltage is less than 7 V after the ignition switch has been turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control relay circuit and diagnosis code No. 54 is output. Then the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

D D D

Check the A/T control relay. (Refer to P.23-52.)

NG

Malfunction of the A/T control relay Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: A-12X, A-29, B-12, B-10

NG

Repair

OK Harness check D Between control relay and body earth D Between control relay and fusible link D Between control relay and A/T-ECU OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

23-23

23-24

AUTOMATIC TRANSMISSION - Troubleshooting

Code No. 56 N range lamp system

Probable cause

If the N range signal is off after an N range lamp illumination instruction (ON instruction) has been given, it is judged that there is a short-circuit in the N range lamp earth and diagnosis code No. 56 is output.

D D D

Check the N range lamp bulb (Refer to GROUP 52A - Instrument Panel.)

NG

Malfunction of the N range lamp bulb Malfunction of connector Malfunction of the A/T-ECU

Replace

OK Check the following connectors: B-01, B-14, A-89, B-10

NG

Repair

OK Harness check D Between N range lamp bulb and A/T-ECU OK Check the trouble symptoms.

NG

NG

Repair

Replace the A/T-ECU.

INSPECTION CHART FOR TROUBLE SYMPTOMS

23100800588

Trouble symptom

Inspection procedure No.

Reference page

MUT-II can not communicate with any systems.

1

23-25

MUT-II can not communicate with the A/T-ECU.

2

23-26

Driving impossible

Starting impossible

3

23-27

Does not move forward

4

23-27

Does not reverse

5

23-28

Does not move (forward or reverse)

6

23-28

Engine stalling when shifting

7

23-29

Shocks when changing from N to D and large time lag

8

23-29

Shocks when changing from N to R and large time lag

9

23-30

Shocks when changing from N to D, N to R and large time lag

10

23-31

Shocks and running up

11

23-31

Malfunction when starting

Malfunction when shifting

23-25

AUTOMATIC TRANSMISSION - Troubleshooting Trouble symptom

Inspection procedure No.

Reference page

All points

12

23-32

Some points

13

23-33

Does not shift

No diagnosis codes

14

23-33

Malfunction while driving

Poor acceleration

15

23-34

Vibration

16

23-34

Inhibitor switch system

17

23-35

Dual pressure switch system

18

23-35

Vehicle speed sensor system

19

23-36

Displaced shifting points

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 MUT-II can not communicate with any systems.

Probable cause

It is suspected that this malfunction is caused by a defective power supply and earth circuits of the diagnosis connector.

D D

Measure at diagnosis connector B-25. NG D Voltage between terminal No. 16 and body earth OK: Battery voltage OK Measure at diagnosis connector B-25. D Continuity between terminal Nos. 4, NG 5 and body earth OK: Continuity OK

Check the following connectors: NG B-25, B-91, B-92, B-66

NG Replace the MUT-II.

Repair

OK Check the trouble symptoms.

Check the following connector: B-25

NG

NG

Check the harness wire between the fusible link and the diagnosis connector, and repair if necessary. Repair

OK Check trouble symptoms.

Check trouble symptoms.

Malfunction of diagnosis connector Malfunction of harness or connector

NG

Check the harness wire between the diagnosis connector and the earth, and repair if necessary.

23-26

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 2 MUT-II can not communicate with the A/T-ECU.

Probable cause

It is suspected that this malfunction is caused by an open circuit in A/T-ECU power supply circuit or diagnosis output circuit.

D D

Measure at diagnosis connector B-25 and A/T-ECU connectors B-12, B-10. D Disconnect the connectors, and measure at the harness side. D Continuity between the following terminals: No. 1 (of diagnosis connector) and 23 (of B-12) No. 7 (of diagnosis connector) and 63 (of B-10) OK: Continuity

NG

Malfunction of harness or connector Malfunction of A/T-ECU NG

Check the following connectors: B-12, B-10, B-14, B-102, B-25

Repair

OK Check trouble symptoms.

NG

Check the harness wire between the A/T-ECU and the diagnosis connector, and repair if necessary.

OK Measure at A/T-ECU connector B-12. D Disconnect the connector, and measure at the harness side. D Ignition switch: ON D Voltage between Nos. 11, 24 and body earth OK: Battery voltage

NG

Check the following connectors: B-12, B-14, B-93, B-89

NG

OK Check trouble symptoms.

NG

OK

Measure at A/T-ECU connectors B-12, NG B-10. D Disconnect the connector, and measure at the harness side. D Continuity between terminal Nos. 12, 13, 25, 26, 72 - body earth OK: Continuity

NG Repair

Check the following connectors: B-12, B-10

OK

NG

Check the harness wire between the ignition switch and the A/T-ECU, and repair if necessary.

Repair

OK Check trouble symptoms.

OK

Check the following connectors: B-12, B-10

Repair

Check trouble symptoms.

NG

NG

Check the harness wire between the A/T-ECU and the earth, and repair if necessary. Replace the A/T-ECU.

AUTOMATIC TRANSMISSION - Troubleshooting

23-27

INSPECTION PROCEDURE 3 Starting impossible

Probable cause

Starting is not possible when the selector lever is in P or N range. In such cases, the cause is probably a defective inhibitor switch system, transmission control cable assembly, engine system, torque converter or oil pump.

D D D D D

Check the inhibitor switch system (Refer to P.23-35, INSPECTION PROCEDURE 17).

NG

Malfunction of the inhibitor switch system Malfunction of the transmission control cable assembly Malfunction of the engine system Malfunction of the torque converter Malfunction of the oil pump

L: Refer to the Transmission Workshop Manual. Repair, replace

OK Check the transmission control cable assembly.

NG

Repair, replace

OK Check the engine system. D Control system, ignition system, fuel system, main engine system

NG

Repair, replace

OK NG Torque converter check D Check for incorrect installation (inserted at an angle, etc.) and for damaged splines.

Repair if possible. If the splines are damaged and repairs are not possible, replace the torque converter assembly.

OK Replace the oil pump assembly. L (The oil pump cannot be disassembled.)

INSPECTION PROCEDURE 4 Does not move (forward)

Probable cause

If the vehicle does not move forward when the selector lever is shifted from N to D, 3, 2 or L range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body.

D D D D

Abnormal line Malfunction of Malfunction of Malfunction of

pressure the underdrive solenoid valve the underdrive clutch the valve body

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure test (Refer to P.23-55.) D Measure the hydraulic pressure for each element when in L range. Standard value: Refer to P.23-56.

NG

NG

OK OK Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. NG D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case.

Replace the solenoid valve. L

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

23-28

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 5 Does not reverse

Probable cause

If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse brake or valve body.

D D D D D D

Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure check (Refer to P.23-55.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-56. OK Hydraulic pressure check (Refer to P.23-55.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-56.

NG

Replace the low and reverse solenoid valve. L

NG

NG

OK Reverse clutch system and low and reverse brake system check OK L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained NG when air is blown through the reverse clutch oil hole and the low reverse brake oil hole in the transmission case.

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

Reverse clutch and low and reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

INSPECTION PROCEDURE 6 Does not move (forward or reverse)

Probable cause

If the vehicle does not move forward or reverse when the selector lever is shifted to any position while the engine is idling, the cause is probably abnormal line pressure, or a malfunction of the power train, oil pump or valve body.

D D D D

Abnormal line Malfunction of Malfunction of Malfunction of

pressure power train the oil pump the valve body

L: Refer to the Transmission Workshop Manual. Hydraulic pressure check (Refer to P.23-55.) D Measure the hydraulic pressure for each element when moving forward and back. Standard value: Refer to P.23-56. NG Replace the oil pump assembly. L (The oil pump cannot be disassembled.)

OK

NG

Power train check L D Disassemble the transmission, check the condition of the planetary carrier, output shaft and differential, etc.

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

AUTOMATIC TRANSMISSION - Troubleshooting

23-29

INSPECTION PROCEDURE 7 Engine stalling when shifting

Probable cause

If the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine system, damper clutch solenoid valve, valve body or torque converter (damper clutch malfunction).

D D D D

Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the valve body Malfunction of the torque converter (Malfunction of the damper clutch)

L: Refer to the Transmission Workshop Manual. Engine system check D Check the control system, ignition system, fuel system and main system.

NG

Repair, replace

OK Replace the damper clutch control solenoid valve. Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

NG

Replace the torque converter.

INSPECTION PROCEDURE 8 Shocks when changing from N to D and large time lag

Probable cause

If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve body, TPS or APS .

D D D D D D D

Abnormal underdrive clutch pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Malfunction of the idle position switch Malfunction of the TPS Malfunction of the APS

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK

NG

Replace the underdrive solenoid valve. L

When starting Shocks sometimes occur

When does the shock occur?

No

When shifting Hydraulic pressure test (Refer to P.23-55.) D Measure the underdrive clutch pressure when shifting from N to D. Standard value: Refer to P.23-56.

NG

Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case. NG Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle. OK

OK OK

Yes

NG

Code Nos. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

23-30

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 9 Shocks when changing from N to R and large time lag

Probable cause

If abnormal shocks or a time lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction of the reverse clutch, low and reverse brake, valve body, TPS or APS .

D D D D D D D D D

Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body Malfunction of the idle position switch Malfunction of the TPS Malfunction of the APS

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK

NG

Replace the low and reverse solenoid valve. L

When starting Shocks sometimes occur

When does the shock occur?

No

When shifting Hydraulic pressure test (Refer to P.23-55.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-56.

NG

OK

Hydraulic pressure test (Refer to P.23-55.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-56. OK Reverse clutch system and low reverse brake system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the reverse clutch oil hole and low and reverse brake oil hole in the transmission case. NG Reverse clutch and low reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle. OK

NG

OK

Yes

NG

Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

AUTOMATIC TRANSMISSION - Troubleshooting

23-31

INSPECTION PROCEDURE 10 Shocks when changing from N to D, N to R and large time lag

Probable cause

If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range and from N to R range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the oil pump or valve body.

D D D

Abnormal line pressure Malfunction of the oil pump Malfunction of the valve body

L: Refer to the Transmission Workshop Manual. Hydraulic pressure test (Refer to P.23-55.) D Measure the hydraulic pressure for each element when in D range and R range. Standard value: Refer to P.23-56. OK When does the shock occur?

NG

Adjust the line pressure. (Refer to P.23-61.) NG

When starting

When shifting Replace the oil pump assembly. L (The oil pump cannot be disassembled.)

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

INSPECTION PROCEDURE 11 Shocks and running up

Probable cause

If shocks occur when driving due to upshifting or downshifting and the transmission speed becomes higher than the engine speed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch.

D D D D D

Abnormal line Malfunction of Malfunction of Malfunction of Malfunction of

pressure each solenoid valve the oil pump the valve body each brake or each clutch

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 1 Low and reverse solenoid valve D No. 2 Underdrive solenoid valve D No. 3 Second solenoid valve D No. 4 Overdrive solenoid valve OK: Sound of operation can be heard. OK Adjust the line pressure. (Refer to P.23-61.) OK Clutch and brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

NG

NG

Replace the solenoid valve.

Replace the oil pump assembly. L (The oil pump cannot be disassembled.) NG Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

23-32

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 12 All points (Displaced shifting points)

Probable cause

If all shift points are displaced while driving, the cause is probably a malfunction of the output shaft speed sensor, TPS or of a solenoid valve.

D D D D D D

Malfunction of Malfunction of Malfunction of Abnormal line Malfunction of Malfunction of

the output shaft speed sensor the throttle position sensor each solenoid valve pressure the valve body the A/T-ECU

L: Refer to the Transmission Workshop Manual. MUT-II Data list D No. 23 Output shaft speed sensor OK: Increases in proportion to vehicle speed. OK MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle OK MUT-II Data list D No. 31 Low and reverse solenoid valve duty % D No. 32 Underdrive solenoid valve duty % D No. 33 Second solenoid valve duty % D No. 34 Overdrive solenoid valve duty % OK: Refer to the table below. OK Adjust the line pressure. (Refer to P.23-61.)

NG

Code No. 23 - Output shaft speed sensor system (Refer to P.23-15.)

NG

Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-13.)

NG

Replace the solenoid valve. L NG Replace the A/T-ECU.

NG

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

No. 31

No. 32

No. 33

No. 34

Driving at constant speed in 1st gear

0%

0%

100 %

100 %

Driving at constant speed in 2nd gear

100 %

0%

0%

100 %

Driving at constant speed in 3rd gear

100 %

0%

100 %

0%

Driving at constant speed in 4th gear

100 %

100 %

0%

0%

AUTOMATIC TRANSMISSION - Troubleshooting

23-33

INSPECTION PROCEDURE 13 Some points (Displaced shifting points)

Probable cause

If some of the shift points are displaced while driving, the cause is probably a malfunction of the valve body, or it is related to control and is not an abnormality.

D

Malfunction of the valve body

L: Refer to the Transmission Workshop Manual. INVECS-II CANCEL COMMAND D Use the MUT-II to stop the INVECS-II function. Does standard shifting occur normally?

No

Yes

Does the problem occur only when the automatictransmissionfluidtemperature is - 29_C or lower or 125_C or higher?

No

Yes It is related to control and is not an abnormality.

Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

INSPECTION PROCEDURE 14 No diagnosis codes (Does not shift)

Probable cause

If shifting does not occur while driving and no diagnosis codes are output, the cause is probably a malfunction of the inhibitor switch, or A/T-ECU.

D D

Does the transmission remain in 3rd gear with selector lever in position D ?

No

Yes Is backup power being supplied to the A/T-ECU? No

OK Replace the A/T-ECU.

Yes

Is power being supplied to the A/T-ECU? No Power supply circuit check D Pay particular attention to open circuits in the harnesses, poor connector connections and open circuits in fuses. D If there is a blown fuse, investigate why a short-circuit has occurred and then replace the fuse.

MUT-II Data list D No. 61 Inhibitor switch OK: A/T-ECU input signal and selector lever position should match.

Yes

Malfunction of the inhibitor switch Malfunction of the A/T-ECU NG

Inhibitor switch check D INSPECTION PROCEDURE 17 Inhibitor switch system check. (Refer to P.23-35.)

23-34

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 15 Poor acceleration

Probable cause

If acceleration is poor even if downshifting occurs while driving, the cause is probably a malfunction of the engine system or of a brake or clutch.

D D

Malfunction of the engine system Malfunction of the brake or clutch

L: Refer to the Transmission Workshop Manual. Engine system check D Check the control system, ignition system, fuel system and main system.

NG

Replace, repair

OK Brake or clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

INSPECTION PROCEDURE 16 Vibration

Probable cause

If vibration occurs when driving at constant speed or when accelerating and deceleration in top range, the cause is probably abnormal damper clutch pressure or a malfunction of the engine system, damper clutch control solenoid valve, torque converter or valve body.

D D D D D

Abnormal damper clutch pressure Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the torque converter Malfunction of the valve body

L: Refer to the Transmission Workshop Manual. MUT-II Actuator test D No. 6 Damper clutch control solenoid valve OK: Sound of operation can be heard. OK Does the problem occur even when the oil temperature sensor connector is disconnected?

NG

Yes

No Hydraulic pressure test (Refer to P.23-55.) D Measure the damper clutch pressure. Standard value: Refer to P.23-56. OK Replace the torque converter assembly.

NG

Replace the damper clutch control solenoid valve. L

Engine system check D Check the control system, ignition system, fuel system and main system. Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

23-35

AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURE 17 Inhibitor switch system

Probable cause

The cause is probably a malfunction of the inhibitor switch circuit, ignition switch circuit or a defective A/T-ECU.

D D D D

Inhibitor switch check (Refer to P.23-48.) OK Check the voltage of the inhibitor switch connector A-89. D Disconnect the connector and measure at the harness side. D Voltage between terminal No. 8 and earth OK: Battery voltage OK Check the A-89, B-10

following connectors:

of of of of

the inhibitor switch the ignition switch connector the A/T-ECU

Replace

NG

Check the following connectors: B-14, B-93, B-89 OK

NG

Harness check D Between inhibitor switch and ignition switch NG

NG

Repair

Repair

OK Repair

Check the trouble symptoms. NG

OK Harness check D Between inhibitor A/T-ECU connector

NG

Malfunction Malfunction Malfunction Malfunction

NG switch

and

OK Check the trouble symptoms.

Repair

NG

Ignition switch check (Refer to GROUP54 - Ignition Switch.)

Replace the A/T-ECU.

INSPECTION PROCEDURE 18 Dual pressure switch system

Probable cause

The cause is probably a defective dual pressure switch circuit or a defective A/T-ECU.

D D D D

Dual pressure switch check (Refer to GROUP 55 - On-vehicle service.) OK Check the voltage of the A/T-ECU connector B-12. D Disconnect the connector and check at the harness side. D Ignition switch: ON D A/C switch: ON D Voltage between terminal No. 10 and earth OK: Battery voltage NG Replace the A/T-ECU.

NG

OK

Malfunction Malfunction Malfunction Malfunction

of of of of

the dual pressure switch connector A/C system the A/T-ECU

Replace

Check the following connectors: B-12, A-28

NG

Repair

OK Check the trouble symptoms. NG Check the A/C system. (Refer to GROUP 55 - Troubleshooting.) OK Replace the A/T-ECU.

NG

Repair

23-36

AUTOMATIC TRANSMISSION - Troubleshooting

INSPECTION PROCEDURE 19 Vehicle speed sensor system

Probable cause

The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU.

D D D

Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.)

NG

Malfunction of the vehicle speed sensor Malfunction of connector Malfunction of the A/T-ECU

Replace

OK (1) NG Measure at the vehicle speed sensor connector A-85. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 1 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 3 and earth (Ignition switch: ON) (3) NG OK: 4.8 - 5.2 V (3) Continuity between 2 and earth OK: Continuity OK Check the connector: A-85

following

NG

Repair

OK

Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK

NG

Repair

OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and ignition switch connector. OK

NG

Repair

Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)

Check trouble symptom. NG

Check the following connectors: A-81, B-14, B-91, B-89

NG

Repair

Check the following connectors: A-81, B-14, B-10 OK

NG

Repair

Check trouble symptom. NG

Replace the engine-ECU.

Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK

NG

Repair

Replace the engine-ECU. Check the connectors: A-81

following

NG

Repair

OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary.

23-37

AUTOMATIC TRANSMISSION - Troubleshooting DATA LIST REFERENCE TABLE Item No. Check item

Check requirement

11

Engine: Stopped Selector lever position: P

Throttle position sensor Accelerator pedal position sensor

23100810284

Normal value Accelerator pedal: Released

300 - 1,000 mV

Accelerator pedal: Half depressed

Gradually rises from the above value

Accelerator pedal: Depressed

4,500 - 5,500 mV

15

Oil temperature sensor

Warming up

Drive for 15 minutes or more so that the automatic transmission fluid temperature becomes 70 - 90 _C.

Gradually rises to 70 - 90 _C

21

Crank angle sensor

Engine: Idling Selector lever position: P

Accelerator pedal: Released

550 - 900 r/min

Accelerator pedal: Half depressed

Gradually rises from the above value

22

Input shaft speed sensor

Selector lever position: 3

Driving at constant speed of 50 km/h in 3rd gear

1,800 - 2,100 r/min

23

Output shaft speed sensor

Selector lever position: 3

Driving at constant speed of 50 km/h in 3rd gear

1,800 - 2,100 r/min

25

Wide open throttle switch

Accelerator pedal position

Released

OFF

Depressed

ON

Stop lamp switch

Ignition switch: ON Engine: Stopped

Brake pedal: Depressed

ON

Brake pedal: Released

OFF

Selector lever position: 3

Idling with 1st gear (Vehicle stopped)

0 km/h

Driving at constant speed of 50 km/h in 3rd gear

50 km/h

10 km/h in 1st gear

No. 31: 0 %, No. 32: 0 %, No. 33: 100 %, No. 34: 100%

26

29

Vehicle speed sensor

31

Low and reverse solenoid valve duty %

Selector lever position: L, 2, 3, D

32

Underdrive solenoid valve duty %

30 km/h in 2nd gear

No. 31: 100 %, No. 32: 0 %, No. 33: 0 %, No. 34: 100%

33

Second solenoid valve duty %

50 km/h in 3rd gear

No. 31: 100 %, No. 32: 0 %, No. 33: 100 %, No. 34: 0%

34

Overdrive solenoid valve duty %

70 km/h in 4th gear

No. 31: 100 %, No. 32: 100 %, No. 33: 0 %, No. 34: 0%

23-38

AUTOMATIC TRANSMISSION - Troubleshooting

Item No. Check item

Check requirement

36

Selector lever position: 3

52

Damper clutch control solenoid valve duty %

Amount of damper clutch slippage

Selector lever position: 3

Normal value Driving at 50 km/h in 3rd gear with accelerator released

0%

Driving at constant speed of 70 km/h in 3rd gear

Approx. 70 - 90 %

Driving at 50 km/h in 3rd gear with accelerator fully closed

Approx. 100 - 300 r/min

Driving at constant speed of 70 km/h in 3rd gear

Approx. 0 - 10 r/min

54

Control relay output voltage

Ignition switch : OFF

Ignition switch: ON ® OFF

Battery voltage (V) ®0V

57

Engine volumetric efficiency

Selector lever position: N

N range with accelerator pedal released ® depressed.

Data changes

61

Inhibitor switch

Ignition switch: ON Engine: Stopped

Selector lever position: P

P

Selector lever position: R

R

Selector lever position: N

N

Selector lever position: D

D

Selector lever position: 3

3

Selector lever position: 2

2

Selector lever position: L

L

Driving at constant speed of 10 km/h in 1st gear

1st

Driving at constant speed of 30 km/h in 2nd gear

2nd

Driving at constant speed of 50 km/h in 3rd gear

3rd

Driving at constant speed of 70 km/h in 4th gear

4th

A/C switch: ON

ON

A/C switch: OFF

OFF

63

65

Shift position

Dual pressure switch

Selector lever position: L, 2, 3, D

Engine: Idling Selector lever position: N

AUTOMATIC TRANSMISSION - Troubleshooting ACTUATOR TEST JUDGEMENT VALUE

23-39 23100820157

Item No.

Check item

Test content

Check requirement

Normal value

1

Low reverse solenoid valve

2

Underdrive solenoid valve Second solenoid valve

4

Overdrive solenoid valve

6

Damper clutch control solenoid valve

12

A/T control relay

Ignition switch: ON Selector lever position: P Engine: 0 r/min Vehicle speed: 0 km/h (Vehicle stopped) Throttle (Accelerator) opening voltage: Less than 0 V

The operation sound should be audible when the solenoid valve is driven.

3

Drive the solenoid valve specified by the MUT-II at 50 % duty for 5 seconds. No other solenoid valve should be energized.

Control relay is OFF for 3 seconds.

Data list No. 54 (1) During test: 0 V (2) Normal: Battery voltage [V]

INVECS-II CANCEL COMMAND

23100950122

Item No.

Item

Content

Remarks

14

INVECS-II

Stop the INVECS-II control and change gears according to the standard shift pattern.

Use this function when carrying out procedure 8 in the road tests.

23-40

AUTOMATIC TRANSMISSION - Troubleshooting

CHECK AT A/T-ECU TERMINALS

23100840252

Terminal No.

Check item

Check requirement

Standard value

1

Underdrive solenoid valve

Selector lever position: D (1st gear)

Battery voltage

Selector lever position: P

Approx.7 - 9 V

Ignition switch: OFF

0V

Ignition switch: ON

Battery voltage

Ignition switch: OFF

0V

Ignition switch: ON

Battery voltage

A/C switch: OFF

0V

A/C switch: ON

Battery voltage

Ignition switch: OFF

0V

Ignition switch: ON

Battery voltage

2

3

10

11

Solenoid valve power supply

Solenoid valve power supply

A/C compressor load signal

Power supply

12

Earth

Always

0V

13

Earth

Always

0V

14

Overdrive solenoid valve

Selector lever position: D (3rd gear)

Battery voltage

Selector lever position: P

Approx. 7 - 9 V

Damper clutch control solenoid valve

Selector lever position: L (1st gear)

Battery voltage

Selector lever position: 3 (50 km/h in 3rd gear)

Other than battery voltage

Second solenoid valve

Selector lever position: 2 (2nd gear)

Battery voltage

Selector lever position: P

Approx. 7 - 9 V

15

16

23

Diagnosis control

-

-

24

Power supply

Ignition switch: OFF

0V

Ignition switch: ON

Battery voltage

Always

0V

25

Earth

23-41

AUTOMATIC TRANSMISSION - Troubleshooting Terminal No.

Check item

Check requirement

Standard value

26

Earth

Always

0V

31

Input shaft speed sensor

Measure between terminal No. 31 and No. 43 by an oscilloscope. Engine: 2,000 r/min Selector lever position: 3

Refer to P.23-43, Oscilloscope inspection procedure.

32

Output shaft speed sensor

Measure between terminal No. 32 and No. 43 by an oscilloscope. Engine: 2,000 r/min Selector lever position: 3

Refer to P.23-43, Oscilloscope inspection procedure.

33

Crank angle sensor

Engine: Idling

2.0 - 2.4 V

38

Back up power supply

Ignition switch: OFF

Battery voltage

43

Sensor earth

Always

0V

44

Oil temperature sensor

ATF temperature: 25 _C

3.8 - 4.0 V

ATF temperature: 80 _C

2.3 - 2.5 V

Throttle position sensor (TPS) Accelerator pedal position sensor (APS)

Accelerator pedal: Released (Engine stopped)

0.5 - 1.0 V

Accelerator pedal: Depressed (Engine stopped)

4.5 - 5.0 V

53

Communication with engine-ECU

Engine: Idling Selector lever position: D

Other than 0 V

54

Communication with engine-ECU

Engine: Idling Selector lever position: D

Other than 0 V

55

Inhibitor switch P

Selector lever position: P

Battery voltage

Selector lever position: Other than above

0V

Selector lever position: N

Battery voltage

Selector lever position: Other than above

0V

Selector lever position: 3

Battery voltage

Selector lever position: Other than above

0V

Selector lever position: L

Battery voltage

Selector lever position: Other than above

0V

Brake pedal: Depressed

Battery voltage

Brake pedal: Released

0V

Selector lever position: D (1st gear)

Battery voltage

Selector lever position: D (2nd gear)

Approx. 7 - 9 V

Normal (No diagnosis code output)

0 ® 5 V flashing

45

56

57

58

59

62

63

Inhibitor switch N

Inhibitor switch 3

Inhibitor switch L

Stop lamp switch

Low and reverse solenoid valve

Diagnosis output

23-42

AUTOMATIC TRANSMISSION - Troubleshooting

Terminal No.

Check item

Check requirement

Standard value

65

Wide open throttle switch

Accelerator pedal: Released

4.5 - 5.5 V

Accelerator pedal: Depressed

Less than 0.4 V

Selector lever position: R

Battery voltage

Selector lever position: Other than above

0V

Selector lever position: D

Battery voltage

Selector lever position: Other than above

0V

Selector lever position: 2

Battery voltage

Selector lever position: Other than above

0V

When stopped

0V

Move forward slowly

0 ® 5 V flashing

Ignition switch: OFF

0V

Ignition switch: ON

Battery voltage

Ignition switch: ON

0V

66

67

68

69

71

72

Inhibitor switch R

Inhibitor switch D

Inhibitor switch 2

Vehicle speed sensor

A/T control relay

Earth

AUTOMATIC TRANSMISSION - Troubleshooting OSCILLOSCOPE INSPECTION PROCEDURE

23-43 23100850132

Check item

Check requirement

Crank angle sensor

Selector lever position: N

Idling (Vehicle stopped)

Waveform A

Input shaft speed sensor

Selector lever position: 3

Driving at constant speed of 50 km/h in 3rd gear (Engine: 1,800 - 2,100 r/min)

Waveform B

Ignition switch: ON Selector lever position: P Engine: 0 r/min Vehicle speed: 0 km/h (Vehicle stopped) Throttle (Accelerator) opening angle: Less than 1 V

Force drive each solenoid valve (Actuator test)

Waveform C

Output shaft speed sensor

Normal condition (Waveform sample)

Vehicle speed sensor Low reverse solenoid valve Underdrive solenoid valve Second solenoid valve Overdrive solenoid valve Damper clutch control solenoid valve

Waveform sample Waveform A

Waveform B

(V)

Waveform C (V) 60

(V) 5

5

40 20 0

0 (ms)

(ms)

0

(ms)

23-44

AUTOMATIC TRANSMISSION - On-vehicle Service

ON-VEHICLE SERVICE

23100090374

ESSENTIAL SERVICE AUTOMATIC TRANSMISSION FLUID CHECK Caution When the transmission has been replaced or overhauled, or driving has been carried out under the severe condition, the transmission fluid cooler line flushing should always be carried out and also, the transmission fluid and oil filters (special filters for transmission only) should always be replaced. 1. Drive the vehicle until the fluid temperature rises to the normal temperature (70 - 80_C). 2. Park the vehicle on a level surface. 3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the N position. 4. After wiping off any dirt around the oil level gauge, remove the oil level gauge and check the condition of the fluid. NOTE If the fluid smells as if it is burning, it means that the fluid has been contaminated by the particles from the bushes and friction materials, a transmission overhaul and flushing the cooler line may be necessary. 5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, pour in more fluid until the level reaches the HOT mark. Automatic transmission fluid: Dia Queen ATF SP II, ATF SP II M or equivalent NOTE If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, in which case it may be mistaken for a leak. 6. Securely insert the oil level gauge.

AUTOMATIC TRANSMISSION - On-vehicle Service

23-45

AUTOMATIC TRANSMISSION FLUID REPLACEMENT 23100100411

Caution When the transmission has been replaced or overhauled, the transmission fluid cooler line flushing should always be carried out before installing the transmission fluid cooler hose. If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluid by the following procedure. 1. Disconnect the hose shown in the illustration which connects the transmission and the oil cooler (inside the radiator). 2. Start the engine and let the fluid drain out. Running conditions: N range with engine idling Caution The engine should be stopped within one minute after it is started. If the fluid has all drained out before then, the engine should be stopped at that point. Discharge volume: Approx. 3.5 L 3. Remove the drain plug from the bottom of the transmission case to drain the fluid. Discharge volume: Approx. 2.0 L 4. Replace the oil filters. (Refer to P.23-47.) 5. Install the drain plug via a new gasket, and tighten it to the specified torque. Tightening torque: 32 Nm 6. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 5.5 L Caution Stop pouring if the full volume of fluid cannot be poured in. 7. Repeat the procedure in step 2. NOTE Drain the fluid from the cooler hose 7 lit. at least. Then drain the fluid a little and check the fluid for dirt. If it has been contaminated, repeat the steps 6 and 7. 8. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 3.5 L

23-46

AUTOMATIC TRANSMISSION - On-vehicle Service 9. Reconnect the hose which was disconnected in step 1 above, and firmly replace the oil level gauge. 10. Start the engine and run it at idle for 1 - 2 minutes. 11. Move the selector lever through all positions, and then move it to the N position.

12. Check that the fluid level is at the COLD mark on the oil level gauge. If the level is lower than this, pour in more fluid. 13. Drive the vehicle until the fluid temperature rises to the normal temperature (70 - 80_C), and then check the fluid level again. The fluid level must be at the HOT mark. NOTE The COLD level is for reference only; the HOT level should be regarded as the standard level. 14. Firmly insert the oil level gauge into the oil filler tube.

AUTOMATIC TRANSMISSION FLUID COOLER LINE 23101300070 FLUSHING Caution When the transmission has been replaced or overhauled, or automatic transmission fluid is contaminated, the transmission fluid cooler line flushing should always be carried out. 1. Disconnect the hose shown in the illustration which connects the transmission and the oil cooler (inside the radiator). 2. Start the engine and let the fluid drain out. Caution The engine should be stopped within one minute after it is started. If the fluid has all drained out before then, the engine should be stopped at that point. Discharge volume: Approx. 3.5 L

AUTOMATIC TRANSMISSION - On-vehicle Service

23-47

3. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 3.5 L Caution Stop pouring if the 3.5 lit. of fluid cannot be poured in. 4. Repeat the procedure in step 2. NOTE Drain the fluid from the cooler hose 7.0 lit. at least i step 2. Then drain the fluid a little and check the fluid for dirt. If it has been contaminated, repeat steps 3 and 4. 5. Follow the automatic transmission fluid replacement procedure from step 3.

23101050111 OIL FILTER REPLACEMENT 1. Use the special tool (MB991610) to remove the automatic transmission oil filter. 2. Clean the filter bracket side mounting surface.

MB991610

Apply ATF to O-ring

3. Apply a small amount of automatic transmission fluid to the O-ring of the new oil filter. 4. Use the special tool (MB991610) to install the automatic transmission oil filter. NOTE Tightening torque: 12 Nm 5. Check the quantity of the automatic transmission fluid. (Refer to P.23-44.)

THROTTLE POSITION SENSOR ADJUSTMENT 23100190210

Refer to GROUP 13B - On-vehicle Service. ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT Refer to GROUP 13A - On-vehicle Service.

23100250062

23-48

AUTOMATIC TRANSMISSION - On-vehicle Service Inhibitor switch

INHIBITOR SWITCH CONTINUITY CHECK Items

23100140475

Terminal No. 1

2

3

4

5

6

7

8

9

10

P R N D 3 2 L P R N D 3 2 L

Transmission control cable

Manual control lever

Adjusting nut

INHIBITOR SWITCH AND CONTROL CABLE 23100150201 ADJUSTMENT 1. Set the selector lever to the “N” position. 2. Loosen the control cable to manual control lever coupling nut to free the cable and lever. 3. Set the manual control lever to the neutral position.

AUTOMATIC TRANSMISSION - On-vehicle Service 10 - 12 Nm Mounting bolts

A

23-49

4. Loosen the inhibitor switch body mounting bolts and the turn the inhibitor switch body so the hole in the end of the manual control lever and the hole (cross section A - A in the figure on the left) in the flange of the inhibitor switch body flange are aligned. 5. Tighten the inhibitor switch body mounting bolts to the specified torque. Be careful at this time that the position of the switch body is not changed.

A Manual control lever Section A - A Hole in end Hole in flange

Manual control lever Inhibitor switch body

Adjusting nut 12 Nm

Manual control lever

6. Gently pull the transmission control cable in the direction of the arrow, and then tighten the adjusting nut. 7. Check that the selector lever is in the “N” position. 8. Check that each range on the transmission side operates and functions correctly for each position of the selector lever.

23-50

AUTOMATIC TRANSMISSION - On-vehicle Service

A/T CONTROL COMPONENT LOCATION

23100860319

Name

Symbol

Name

Symbol

Accelerator position sensor

A

Oil temperature sensor

F

A/T control relay

E

Output shaft speed sensor

H

A/T-ECU

K

Shift indicator lamp

J

Crank angle sensor

B

Solenoid valve

F

Diagnosis connector

N

Stop lamp switch

O

Dual pressure switch

I

Throttle position sensor

C

Engine-ECU

L

Vehicle speed sensor

D

Inhibitor switch

G

Wide open throttle switch

M

Input shaft speed sensor

H spot=GA

A

C

B

H

I

D

E

F

G

J

O

N

M

L

K

AUTOMATIC TRANSMISSION - On-vehicle Service A/T CONTROL COMPONENT CHECK

23-51 23100900134

CRANK ANGLE SENSOR CHECK Refer to GROUP 13 - Troubleshootinglink=13100850034. THROTTLE POSITION SENSOR CHECK 23100390337 Refer to GROUP 13B - On-vehicle Servicelink=13100320030. ACCELERATOR PEDAL POSITION SENSOR CHECK 23100420067 Refer to GROUP 13A - On-vehicle Servicelink=13600430011.

OIL TEMPERATURE SENSOR CHECK 1. Remove the oil temperature sensor.

23100450196

Oil temperature sensor

2. Measure the resistance between terminals No. 1 and No. 2 of the oil temperature sensor connector. Standard value:

ATF

Oil temperature (_C)

Resistance (kW)

0

16.7 - 20.5

100

0.57 - 0.69

INHIBITOR SWITCH CHECK Refer to P.23A-48.

23100140482

STOP LAMP SWITCH CHECK Refer to GROUP 35 - Brake Pedallink=35100890045.

23100910113

23100460229 VEHICLE SPEED SENSOR CHECK Refer to GROUP 54 - On-vehicle Servicelink=54300300019.

23-52

AUTOMATIC TRANSMISSION - On-vehicle Service 23100470185 DUAL PRESSURE SWITCH CHECK Refer to GROUP 55 - On-vehicle Servicelink=55201040068.

WIDE OPEN THROTTLE SWITCH CHECK Refer to P.23-64.

23100890080

A/T CONTROL RELAY CHECK 1. Remove the A/T control relay.

23100930119

A/T control relay

2. Use jumper wires to connect A/T control relay terminal 2 to the battery ( - ) terminal and terminal 4 to the battery (+) terminal. 3. Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are connected to and disconnected from the battery. Jumper wire

Continuity between terminals No. 1 and No. 3

Connected

Continuity

Disconnected

No continuity

4. If there is a problem, replace the A/T control relay.

Overdrive solenoid valve

Underdrive solenoid valve Second solenoid valve

Low and reverse solenoid valve

Damper clutch solenoid valve

23100940105 SOLENOID VALVE CHECK 1. Remove the valve body cover. 2. Disconnect the connectors of each solenoid valve.

23-53

AUTOMATIC TRANSMISSION - On-vehicle Service

3. Measure the resistance between terminals 1 and 2 of each solenoid valve. Standard value: Name

Resistance

Damper clutch solenoid valve

2.7 - 3.4 W (at 20_C)

Low and reverse solenoid valve Second solenoid valve Underdrive solenoid valve Overdrive solenoid valve

4. If the resistance is outside the standard value, replace the solenoid valve.

Reverse clutch

Torque converter Low-reverse Underdrive brake clutch

TORQUE CONVERTER STALL TEST

23100540275

This test measures the maximum engine speed when the selector lever is at the D or R position and the torque converter stalls to test the operation of the torque converter, starter motor and one-way clutch operation and the holding performance of the clutches and brakes in the transmission. Caution Do not let anybody stand in front of or behind the vehicle while this test is being carried out. 1. Check the automatic transmission fluid level and temperature and the engine coolant temperature. D Fluid level: At the HOT mark on the oil level gauge D Fluid temperature: 80 - 100_C D Engine coolant temperature: 80 - 100_C

23-54

AUTOMATIC TRANSMISSION - On-vehicle Service 2. Check both rear wheels (left and right). 3. Pull the parking brake lever on, with the brake pedal fully depressed. 4. Start the engine. 5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the maximum engine speed at this time. Caution 1. The throttle should not be left fully open for any more than eight seconds. 2. If carrying out the stall test two or more times, move the selector lever to the N position and run the engine at 1,000 r/min to let the automatic transmission fluid cool down before carrying out subsequent tests. Standard value Stall speed: 2,200 - 2,700 r/min 2,300 - 2,800 r/min 6. Move the selector lever to the R position and carry out the same test again. Standard value Stall speed: 2,200 - 2,700 r/min 2,300 - 2,800 r/min TORQUE CONVERTER STALL TEST JUDGEMENT RESULTS 1. Stall speed is too high in both D and R ranges D Low line pressure D Low & reverse brake slippage 2. Stall speed is too high in D range only D Underdrive clutch slippage 3. Stall speed is too high in R range only D Reverse clutch slippage 4. Stall speed too low in both D and R ranges D Malfunction of torque converter D Insufficient engine output

AUTOMATIC TRANSMISSION - On-vehicle Service

23-55

HYDRAULIC PRESSURE TEST

23100550285 sub=01

1. Warm up the engine until the automatic transmission fluid temperature is 80 - 100_C. 2. Jack up the vehicle so that the wheels are free to turn. 3. Connect the special tools (2,942 kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900]) to each pressure discharge port. 4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table, and check that the measured values are within the standard value ranges. 5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.

23-56

AUTOMATIC TRANSMISSION - On-vehicle Service

STANDARD HYDRAULIC PRESSURE TESTsub=02 Measurement condition

Standard hydraulic pressure kPa

Selector lever position

Shift position

Engine speed (r/min)

Underdrive clutch pressure

Reverse clutch pressure

Overdrive clutch pressure

Low and reverse brake pressure

Second brake pressure

Torque converter pressure

P

-

2,500

-

-

-

310 - 390

-

500 - 700

R

Reverse

2,500

-

1,320 1,720

-

1,320 1,720

-

500 - 700

N

-

2,500

-

-

-

310 - 390

-

500 - 700

D

1st gear

2,500

1,010 1,050

-

-

1,010 1,050

-

500 - 700

2nd gear

2,500

1,010 1,050

-

-

-

1,010 1,050

500 - 700

3rd gear

2,500

590 - 690

-

590 - 690

-

-

450 - 650

4th gear

2,500

-

-

590 - 690

-

590 - 690

450 - 650

Measurement condition

Standard hydraulic pressure kPa

Selector lever position

Shift position

Engine speed (r/min)

Underdrive clutch pressure

Reverse clutch pressure

Overdrive clutch pressure

Low and reverse brake pressure

Second brake pressure

Torque converter pressure

P

-

2,500

-

-

-

260 - 340

-

500 - 700

R

Reverse

2,500

-

1,320 1,720

-

1,320 1,720

-

500 - 700

N

-

2,500

-

-

-

260 - 340

-

500 - 700

D

1st gear

2,500

1,010 1,050

-

-

1,010 1,050

-

500 - 700

2nd gear

2,500

1,010 1,050

-

-

-

1,010 1,050

500 - 700

3rd gear

2,500

780 - 880

-

780 - 880

-

-

450 - 650

4th gear

2,500

-

-

780 - 880

-

780 - 880

450 - 650

AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC PRESSURE TEST DIAGNOSIS TABLEsub=03 Trouble symptom

Probable cause

All hydraulic pressures are high.

Incorrect transmission control cable adjustment Malfunction of the regulator valve

All hydraulic pressures are low.

Incorrect transmission control cable adjustment Malfunction of the oil pump Clogged internal oil filter Clogged external oil filter Clogged oil cooler Malfunction of the regulator valve Malfunction of the relief valve Incorrect valve body installation

Hydraulic pressure is abnormal in “R” range only.

Malfunction of the regulator valve Clogged orifice Incorrect valve body installation

Hydraulic pressure is abnormal in “3” or “4” range only.

Malfunction of the overdrive solenoid valve Malfunction of the overdrive pressure control valve Malfunction of the regulator valve Malfunction of the switch valve Clogged orifice Incorrect valve body installation

Only underdrive hydraulic pressure is abnormal.

Malfunction of the oil seal K Malfunction of the oil seal L Malfunction of the oil seal M Malfunction of the underdrive solenoid valve Malfunction of the underdrive pressure control valve Malfunction of check ball Clogged orifice Incorrect valve body installation

Only reverse clutch hydraulic pressure is abnormal.

Malfunction of the oil seal A Malfunction of the oil seal B Malfunction of the oil seal C Clogged orifice Incorrect valve body installation

23-57

23-58

AUTOMATIC TRANSMISSION - On-vehicle Service

Trouble symptom

Probable cause

Only overdrive hydraulic pressure is abnormal.

Malfunction of the oil seal D Malfunction of the oil seal E Malfunction of the oil seal F Malfunction of the overdrive solenoid valve Malfunction of the overdrive pressure control valve Malfunction check ball Clogged orifice Incorrect valve body installation

Only low and reverse hydraulic pressure is abnormal.

Malfunction of the oil seal I Malfunction of the oil seal J Malfunction of the low and reverse solenoid valve Malfunction of the low and reverse pressure control valve Malfunction of the switch valve Malfunction of the fail safe valve A Malfunction of check ball Clogged orifice Incorrect valve body installation

Only second hydraulic pressure is abnormal.

Malfunction of the oil seal G Malfunction of the oil seal H Malfunction of the oil seal O Malfunction of the second solenoid valve Malfunction of the second pressure control valve Malfunction of the fail safe valve B Clogged orifice Incorrect valve body installation

Only torque converter pressure is abnormal.

Malfunction of the oil cooler Malfunction of the oil seal N Malfunction of the damper clutch control solenoid valve Malfunction of the damper clutch control valve Malfunction of the torque converter pressure control valve Clogged orifice Incorrect valve body installation

Pressure applied to non operating element.

Incorrect transmission control cable adjustment Malfunction of the manual valve Malfunction of check ball Incorrect valve body installation

AUTOMATIC TRANSMISSION - On-vehicle Service OIL SEAL LAYOUTsub=04

E

F G

H

J

I

D C B A

O

K

L

M

N

23-59

23-60

AUTOMATIC TRANSMISSION - On-vehicle Service

HYDRAULIC CIRCUIT

23100880193

PARKING AND NEUTRAL

1

2

3

6

4

6

6

5 6

7

8

9

10

11 12 13

14

15

19

17 21

16 20

24

18 22

23

25 26 R ND P3 2 L

27 29

28 30

31

32

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Reverse clutch Low-reverse brake Second brake Underdrive clutch Overdrive clutch Accumulator Check ball Damper clutch Fail safe valve A Fail safe valve B Damper clutch control valve Switch valve Automatic transmission fluid cooler Lubrication Low-reverse pressure control valve Second pressure control valve Underdrive pressure control valve

18. Overdrive pressure control valve 19. Damper clutch control solenoid valve 20. Low-reverse solenoid valve 21. Second solenoid valve 22. Underdrive solenoid valve 23. Overdrive solenoid valve 24. Torque converter pressure control valve 25. Regulator valve 26. Manual valve 27. Oil filter 28. Oil pump 29. Oil strainer 30. Oil filter (Built in type) 31. Relief valve 32. Oil pan

AUTOMATIC TRANSMISSION - On-vehicle Service LINE PRESSURE ADJUSTMENT

Adjusting screw

23-61 23100170177

1. Discharge the automatic transmission fluid, and then remove the valve body cover. 2. Turn the adjusting screw shown in the illustration at left to adjust the underdrive pressure to the standard value. The pressure increases when the screw is turned to the left. NOTE When adjusting the underdrive pressure, adjust to the middle of the standard value range. Standard value: 1,010 - 1,050 kPa Change in pressure for each turn of the adjusting screw: 35 kPa 3. Install the valve body cover, and pour in the standard volume of automatic transmission fluid. 4. Carry out a hydraulic pressure test. (Refer to P.23-55.) Readjust the line pressure if necessary.

SELECTOR LEVER OPERATION CHECK 23100130243

Turn the ignition switch to any position other than “LOCK”, and operate the selector lever with the brake pedal depressed and the push button pushed. Operate the selector lever without pushing the push button.

Operate the selector lever with the push button pushed.

1. Shift selector lever to each range and check that lever moves smoothly and is controlled. Check that position indicator is correct. 2. Check the selector lever can be moved to each position (by button operation as shown in the illustration). 3. Start the engine and check if the vehicle moves forward when the selector lever is moved from N or D, and moves backward when moved to R. 4. When the shift lever malfunctions, adjust control cable and selector lever sleeve. Check for worm shift lever assembly sliding parts.

23-62

AUTOMATIC TRANSMISSION - On-vehicle Service

KEY INTERLOCK AND SHIFT LOCK SYSTEM CHECK 1. Carry out the following inspection: Inspection procedure

Requirements

1

Brake pedal: Depressed

2 3

Brake pedal: Not depressed

4

Normal condition Turn the ignition key to “LOCK”, or remove it.

The selector lever push button can not be pushed, and the selector lever should not be moved from “P” position.

Turn the ignition key to “ACC.”

The selector lever push button can be pushed, and the selector lever can be moved from “P” position.

Selector lever: Other than “P”

The ignition key can not be turned to “LOCK” position.

Selector lever: “P”

The ignition key can be turned to “LOCK.”

Inspection procedure

Requirements

Normal condition

1

Brake pedal: Not depressed

2

Brake pedal: Depressed

The selector lever push button can be pushed, and the selector lever can be moved from “P” position.

3

Brake pedal: Not depressed

The selector lever push button can be pushed, and the selector lever can be moved from “R” position to “P” position.

Turn the ignition key to “ACC.”

The selector lever push button can not be pushed, and the selector lever should not be moved from “P” position.

2. If there is a problem on the inspection above, replace the key interlock and shift lock cable assembly.

23-63

AUTOMATIC TRANSMISSION - Transmission Control

TRANSMISSION CONTROL

23100660247

REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the transmission control cable, the key interlock cable, the selector lever assembly or the A/T-ECU. Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation (Refer to GROUP 15). D Battery and Battery Tray Removal and Installation

D

Operation Check of Instruments

Section A - A

9

1

2 1.5 Nm

2

10 A

3

A

12 Nm

7

5

4

12 Nm

8

5 Nm

6 NOTE : indicate the clip location.

Transmission control cable removal steps 1. Shift knob 2. Indicator panel D Centre console removal and installation (Refer to GROUP 52A.) "AA 3. Nut 4. Adjuster 5. Transmission control cable connection 6. Key interlock and shift lock cable 7. Selector lever assembly 8. Transmission control cable assembly

5 Nm

Selector lever assembly removal steps 1. Shift knob 2. Indicator panel D Centre console removal and installation (Refer to GROUP 52A.) 5. Transmission control cable connection 6. Key interlock and shift lock cable 7. Selector lever assembly A/T-ECU removal 9. A/T-ECU Wide open throttle switch removal 10. Wide open throttle switch

23-64 Manual transmission control cable

AUTOMATIC TRANSMISSION - Transmission Control Adjusting nut

INSTALLATION SERVICE POINT "AA NUT INSTALLATION 1. Put the selector lever in the “N” position and the manual control lever in neutral position. 2. Install the transmission control cable, and tighten the adjusting nut.

Manual control lever

INSPECTION

23100890097

WIDE OPEN THROTTLE SWITCH CHECK OFF ON

Switch position

Terminal No. 1

OFF ON

2

23-65

AUTOMATIC TRANSMISSION - Transmission Control SELECTOR LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY

7

2.5 Nm

4 3

9

1

6 6

2 8

12 Nm

10 9 Nm

13

Disassembly steps 1. Lever assembly 2. Bracket 3. Snap ring 4. Sleeve 5. Lever sub-assembly 6. Bushing 7. Detent spring

9 Nm

11

12

8. 9. 10. 11. 12. 13.

Lock cam Stopper Base bracket Stay Lever mount bracket Base bracket

23-66 AUTOMATIC TRANSMISSION -

Shift Lock and Key Interlock Mechanisms

SHIFT LOCK AND KEY INTERLOCK MECHANISMS

23100660247

REMOVAL AND INSTALLATION Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the key interlock cable or shift lock cable. Pre-removal and Post-installation Operation D Shift Knob, Indicator Panel Removal and Installation (Refer to P.23-63.) D Center Console Removal and Installation (Refer to GROUP 52A.)

12 5 Nm

10

1

8 6

9 11

7

4 5 3

2

Removal steps "BA 1. Key interlock and shift lock cable connection D Lower column cover (Refer to GROUP 37A - Steering Wheel and Shaft.) 2. Cover 3. Key interlock cable connection 4. Snap pin 5. Shift lock cable connection

"AA 6. Key interlock cable 7. Upper case 8. Rod 9. Lever 10. Lower case 11. Shift lock cable ETACS-ECU removal 12. ETACS-ECU

AUTOMATIC TRANSMISSION -

Lock piece

A View A

23-67

INSTALLATION SERVICE POINTS

Key interlock cable

Outer cap

Shift Lock and Key Interlock Mechanisms

Inner cable

"AA KEY INTERLOCK CABLE INSTALLATION 1. After assembling the shift lock cable to the lever, pull up the key interlock cable lock piece to unlock. Then install the interlock cable end to the cam, and then install the outer cap to the lower case. 2. Push in the lock piece to lock while the key interlock inner cable is straightened.

Lock piece

Unlock Lock

Shift lock cable

Mounting bolts Rod

Cam Key interlock cable

"BA KEY INTERLOCK AND SHIFT LOCK CABLE INSTALLATION Engage the rod end into the lever lock cam, and then check that the selector lever is at “P” position. Then tighten the key interlock and shift lock cable with mounting bolts while pulling the rod towards the arrow direction gently.

23-68

AUTOMATIC TRANSMISSION - Transmission Assembly

TRANSMISSION ASSEMBLY

23100570274

REMOVAL AND INSTALLATION Caution The fasteners indicated by * should be tightened to the specified torque after the engine weight is applied to the vehicle body. Pre-removal Operation D Carry out the essential service for the troubleshooting (Refer to P.23-44.) D Transmission Fluid Draining and Refilling (Refer to P.23-45.) D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Radiator and Reservoir Removal and Installation (Refer to GROUP 14.) D Starter Removal and Installation (Refer to GROUP 16.)

D D D D D D

Under Cover Removal and Installation Front exhaust pipe Removal and Installation (Refer to GROUP 15.) Check the Dust Cover for Cracks or Damage by Pushing it with Finger. Selector Lever Operation Check Operation Check of Instruments Wheel Alignment Check and Adjustment (Refer to GROUP 33A - On-vehicle Service.)

5

2

6

1

3 11

4

7 48 Nm

12 Nm

10 10

9 69 Nm

12 Nm

9 69 Nm

8 10 10

24 - 34 Nm

12 Nm

Removal steps 1. Transmission control cable connection 2. Transmission fluid cooler hose connection 3. Bolt 4. Input shaft speed sensor connector 5. Output shaft speed sensor connector 6. A/T control solenoid valve assembly connector

AA" AB"

7. Vehicle speed sensor connector 8. Tie rod end connection 9. Steering gear and linkage mounting bolts 10. Oil line connecting bolt 11. Transmission assembly upper connecting bolt

23-69

AUTOMATIC TRANSMISSION - Transmission Assembly 57 Nm* 81 Nm*

24 48 Nm

26

45 - 52 Nm

26

25

19

27

15 39 Nm 44 Nm

18

9 Nm

16

17

98 - 118 Nm 49 - 64 Nm*

20

21

49 - 64 Nm* 22 Nm

196 - 225 Nm

14 12

23 13 177 Nm

12. Stabilizer link connection "CA 13. Lower arm connection 14. Vehicle speed sensor connection AC" 15. Drive shaft connection AC" 16. Drive shaft connection 17. Transmission stay 18. Bell housing cover 19. Drive plate mounting bolt 20. Front roll stopper connection 21. Rear roll stopper connection

177 Nm

22 78 Nm

22. 23. AD" 24. "BA 25. AE" D

Stay Front member assembly Transmission mount bracket Transmission mount stopper Engine and transmission assembly supporting AF" 26. Transmission assembly lower part coupling bolts AF" "AA 27. Transmission assembly

23-70

AUTOMATIC TRANSMISSION - Transmission Assembly REMOVAL SERVICE POINTS AA" TIE ROD END DISCONNECTION

MB990635 or MB991113 Ball joint

Cord

Nut

Caution 1. Use the special tool to loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. not to let it come off.

AB" STEERING GEAR AND LINKAGE MOUNTING BOLT REMOVAL Remove the steering gear and linkage mounting bolts, and then support the steering gear box to the vehicle body with a wire.

Prybar Projection

Hammer

Drive shaft Transmission case

AC" DRIVE SHAFT DISCONNECTION 1. Position a hammer under the projection, and then use a prybar to pry the drive shaft from the transfer case. Caution (1) Always use a pry bar to withdraw the drive shaft. Pulling out the drive shaft forcibly from the B.J. assembly may damage the T.J. assembly. (2) Be careful not to damage the oil seal of the transmission or transfer by the spline of the drive shaft. 2. Suspend the removed drive shaft with a wire to a nearby part so that there are no sharp bends in any of the joints. 3. Use a shop towel to cover the transmission case not to let foreign material get into it. AD" TRANSMISSION MOUNT BRACKET REMOVAL Carefully lower the transmission assembly with a garage jack, and remove the transmission mount bracket.

MZ203827

MB991453

AE" ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING Set the special tool to the vehicle to support the engine and transmission assembly.

AUTOMATIC TRANSMISSION - Transmission Assembly

23-71

AF" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly with a transmission jack. 2. Push the torque converter into the transmission case until the torque converter does not remain at the engine side. 3. Remove the transmission assembly lower part coupling bolts, and lower the transmission assembly to remove.

INSTALLATION SERVICE POINTS

12.2 mm

"AA TRANSMISSION ASSEMBLY INSTALLATION Push the torque converter into the transmission case as shown, and then install the engine to the transmission assembly.

Weld nut

"BA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow points as shown in the illustration.

Engine side

NOTE Disregard F and R stamped as a shared part.

Transmission mount bracket

Transmission mount stopper

"CA LOWER ARM INSTALLATION 1. Install the lower arm assembly to the knuckle.

Knuckle A

Lower arm assembly

Caution The lower arm should not protrude 4 mm or more from the knuckle end (A shown), otherwise grease may pour out from the dust cover. 2. If grease has poured out due to the excessive arm protrusion, the dust cover must be replaced (Refer to GROUP 33A - Lower Arm). 3. There should be not clearance between the knuckle and the dust cover.

NOTES

25-1

PROPELLER SHAFT CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 4

25-2

PROPELLER SHAFT -

General Information/Service Specifications/Lubricant/Adhesive

GENERAL INFORMATION The propeller shaft is a 3-shaft and 4-joint type with center bearing. Furthermore, a L.J. is used for the No.3 joint.

Center bearing No.2 joint

Center bearing Rear propeller shaft

Center propeller shaft

Front propeller shaft Sleeve yoke

No.4 joint No.3 joint

No.1 joint

SERVICE SPECIFICATIONS Items

Standard value

Limit

Propeller shaft (front, center, rear) runout mm

-

0.6

Clearance of snap ring groove mm

0.01 - 0.03

-

LUBRICANT Items

Specified lubricant

Quantity

Front propeller shaft sleeve yoke

Hypoid gear oil

As required

L.J. assembly

Repair kit grease

45 - 55 g

ADHESIVE Item

Specified adhesive

L.J. assembly rubber packing

3M ATD Part No.8155 or equivalent

PROPELLER SHAFT - Special Tools

25-3

SPECIAL TOOLS Tool

Number

Name

Use

MB990840

Universal joint remover and installer

Disassembly and reassembly of the universal joint

MB991193

Plug

Preventing of entry of foreign objects into the transmission and transfer

MD998801

Bearing remover

Removal of the center bearing assembly

25-4

PROPELLER SHAFT - Propeller Shaft

PROPELLER SHAFT REMOVAL AND INSTALLATION

3

Gear Oil: Hypoid gear oil

2 2

1

1

1

29 - 34 Nm

1 3 40 Nm

Removal steps 1. Insulator 2. Spacer

29 Nm

AA" "AA 3. Propeller shaft assembly

PROPELLER SHAFT - Propeller Shaft REMOVAL SERVICE POINT

Joint boot Cloth

Center propeller shaft

25-5

AA" PROPELLER SHAFT ASSEMBLY REMOVAL 1. Make mating marks on the differential companion flange and on the flange yoke, and then remove the propeller shaft assembly. Caution Straighten front, center and rear shafts when removing the propeller shaft. If not, the joint boot will be pinched by the joint and damaged.

Joint assembly

NOTE Putting a piece of cloth in the joint boot will make the work easier. 2

Cover the transfer with the special tool so that no foreign material gets into the transfer case.

MB991193

INSTALLATION SERVICE POINT "AA PROPELLER SHAFT INSTALLATION Align the mating marks and install the propeller shaft to the companion flange.

Transfer

Oil seal

Caution 1. Take care not to damage the transfer oil seal lip. 2. Eliminate oil and grease from threads of the mounting bolts and nuts before tightening them. If oil or grease is adhered to bolts and nuts, they will be loosened.

INSPECTION PROPELLER SHAFT RUNOUT Measure the runout for each of front, center and rear propeller shafts. Limit: 0.6 mm

25-6

PROPELLER SHAFT - Propeller Shaft

DISASSEMBLY AND REASSEMBLY

15

7

6

5 186 Nm

2

3

1

4

18

19

186 Nm

12 10

9 13

16

14

8

14 10 13

11

34 Nm

17

12 11 12

9 10

13

12

12

9 3

Grease

L.J. repair kit

AA" "GA AB" "FA "FA "EA AC" "EA AD" "EA AE" "DA

Disassembly steps 1. Snap ring 2. Journal bearing 3. Journal 4. Front propeller shaft 5. Self-locking nut 6. Center yoke 7. Center bearing assembly 8. Bolt 9. Snap ring 10. Boot band

Grease

L.J. boot repair kit

AF" "CA 11. 12. AG" "BA 13. 14. 15. "AA 16. AH" "AA 17. "AA 18. 19.

2 1

Universal joint repair kit

L.J. assembly Rubber packing L.J. boot Washer Center propeller shaft Self-locking nut Companion flange Center bearing assembly Rear propeller shaft assembly

PROPELLER SHAFT - Propeller Shaft

25-7

LUBRICATION POINTS Rubber mount

Repair kit grease Quantity: 45 - 55 g

3M ATD Part No.8155 or equivalent

25-8

PROPELLER SHAFT - Propeller Shaft DISASSEMBLY SERVICE POINTS AA" SNAP RING REMOVAL Make mating marks on the yoke and on the propeller shaft, and then remove the snap ring.

Mating marks

AB" JOURNAL BEARING REMOVAL Use the special tool to press-out the journal bearing from the yoke and propeller shaft.

Journal bearing

Collar

Caution Do not tap the journal bearing to remove it. Tapping the journal bearing will upset the balance of the propeller shaft.

MB990840

MB990840

AC" CENTER YOKE REMOVAL Make mating marks on the center yoke and on the center propeller shaft, and then remove the center yoke.

Center bearing assembly

MD998801

AD" CENTER BEARING ASSEMBLY REMOVAL AE" BOLT REMOVAL Make mating marks on the center propeller shaft, L.J. assembly and on the companion flange, and then remove the bolt.

MD998801

AF" L.J. ASSEMBLY REMOVAL 1. Remove the L.J. boot from the L.J. assembly. L.J. assembly

L.J. boot

PROPELLER SHAFT - Propeller Shaft

25-9

2. Make mating marks on the outer race, cage and on the inner race, and then remove the outer race and balls. Outer race

NOTE Note the positions of balls so that they can be reinstalled in their original positions.

Inner race Cage Ball Cage

Inner race

3. Use a puller (commercially available) to remove the inner race with cage from the center propeller shaft assembly. 4. Wipe off the grease and clean the outer race, inner race, cage and balls.

Puller (commercially available)

AG" L.J. BOOT REMOVAL When reusing the L.J. boot, wrap the splined end of the center propeller shaft with adhesive tape before removing the L.J. boot. AH" COMPANION FLANGE REMOVAL Make mating marks on the companion flange and on the rear propeller shaft, and then remove the companion flange.

Companion flange

Self-locking nut

Center bearing assembly

REASSEMBLY SERVICE POINTS "AA CENTER BEARING ASSEMBLY/COMPANION FLANGE/SELF-LOCKING NUT INSTALLATION 1. Face the center bearing assembly as shown in the illustration, and then install it to the rear propeller shaft. 2. Align the mating marks on the companion flange and rear propeller shaft. 3. Tighten the self-locking nut to press-in the center bearing assembly with the companion flange. "BA L.J. BOOT INSTALLATION 1. Install the boot band. 2. Wrap the splined end of the center propeller shaft with adhesive tape, and then install the L.J. boot.

25-10

PROPELLER SHAFT - Propeller Shaft "CA L.J. ASSEMBLY INSTALLATION 1. Apply a thin coat of the specified grease to the ball grooves of the inner and outer races. Specified grease: Repair kit grease

Recessed surface of inner race

2. Assemble the L.J. assembly as follows: (1) Put the cage on the inner race with the mating marks aligned, and then install two balls, one in a groove and the other in the groove opposite to that groove. Both balls should be placed in the grooves where they were before disassembly. (2) Assemble the inner race and cage in the outer race with their mating marks aligned. (3) Confirm that the recessed surface of the inner race, the recessed surface (where packing will be fitted) of the outer race, and the chamfered surface of the cage are all on the same side. Also confirm that the relative positions of the inner and outer races are as shown in the illustration. (4) Install the remaining balls in their original positions. (5) Check that the inner and outer races move smoothly. 3. Apply specified grease uniformly to the L.J. assembly.

Ball

Chamfered surface of cage Recess on outer race for fitting the packing Ball

Specified grease: Repair kit grease Quantity: 45 - 55 g

Rubber packing

L.J. assembly

Socket wrench

4. Apply a small amount of specified adhesive in places shown by arrow in the illustration on the surface where there is a stepped section for packing, and then fit the rubber packing. Specified adhesive: 3M ATD Part No.8155 or equivalent 5. Install the L.J. assembly to the center propeller shaft facing the surface where there is a stepped section for packing toward the L.J. boot.

6. Align the mating marks on the L.J. assembly and the center propeller shaft, and then use a socket wrench and hammer to tap the L.J. assembly in the center propeller shaft.

PROPELLER SHAFT - Propeller Shaft

25-11

7. Align the bolt holes in the L.J. boot and the L.J. assembly using a mounting bolts, and then tighten the mounting bolts to fix the L.J. boot on the L.J. assembly. 8. Fit the rubber packing for the companion flange to the companion flange using the same procedure as in step 4.

Bolt

L.J. boot

"DA BOOT BAND INSTALLATION

Boot band clip position

Caution 1. Position the boot band clip on the side opposite to the bosses which are provided in the boot for ventilation. 2. Be sure to eliminate grease from around the bosses. Grease obstructs the ventilation air passage.

Bosses Boot

Center yoke Selflocking nut

Dust seal

Rubber mount

"EA CENTER BEARING ASSEMBLY/CENTER YOKE/SELF-LOCKING NUT INSTALLATION 1. Face the center bearing assembly as shown in the illustration, and then install it to the center propeller shaft. 2. Align the mating marks on the center yoke and center propeller shaft. 3. Tighten the self-locking nut to press-in the center bearing assembly with the center yoke.

"FA JOURNAL/JOURNAL BEARING INSTALLATION 1. Apply multi-purpose grease to the following points of the universal joint. (1) Shaft and journal (2) Dust seal lip (3) Needle roller bearing Caution Do not apply too much grease. If applying too much grease, improper installation of bearing cap and incorrect selection of snap ring will result.

25-12

PROPELLER SHAFT - Propeller Shaft 2. Press-in the journal bearing by the following procedure: (1) Align the mating marks on the yoke and propeller shaft. (2) Set the base on the special tool. (3) Use the special tool to press-in the yoke and bearing.

MB990840

NOTE Bearing will be stopped at the specified position by the base.

Base

MB990840

Mating marks

"GA SNAP RING INSTALLATION 1. Install a snap ring to one side of the snap ring grooves on the flange yoke and propeller shaft yoke, and then use a brass bar to press-in the journal bearing toward the snap ring.

Snap ring A

2. Install another snap ring to the opposite snap ring groove, and use a thickness gauge to measure the clearance in the snap ring groove. Standard value (A): 0.01 - 0.03 mm Caution Always use snap rings of same thickness on both sides.

26-1

FRONT AXLE CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

26109000201

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 6 Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 6

FRONT HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . 7 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

26-2

FRONT AXLE - General Information/Service Specifications

GENERAL INFORMATION

26100010234

The front axle consists of a knuckle, front hub, unit bearing and drive shaft. The unit bearing is press-fitted to the front hub and bolted to the knuckle. Also, the unit bearing utilizes a double

row angular contact ball bearing. The drive shaft has a Tripod joint (T.J.) on the transmission side and a Birfield joint (B.J.) on the wheel side.

T.J.

Dynamic damper

Knuckle

Front hub Inner shaft

B.J. Unit bearing

T.J.

Center bearing

Output shaft

T.J.

SERVICE SPECIFICATIONS

26100030254

Items

Standard value

Limit

Wheel bearing axial play mm

-

0.05

Wheel bearing rotation starting torque Nm

-

1.0 or less

Setting of T.J. boot length mm

SPACE RUNNER

82

-

SPACE WAGON - 2WD

81

-

SPACE WAGON - 4WD

90

-

When the B.J. boot band (small) is crimped

2.9

-

When the B.J. boot band (large) is crimped

3.2

-

Crimped width of the B.J. boot band mm

2.4 - 2.8

-

Clearance between the B.J. boot (large diameter side) and the stepped phase of the B.J. housing mm

0.1 - 1.5

-

Opening dimension of the special tool (MB991561) mm

26-3

FRONT AXLE - Lubricants/Special Tools

LUBRICANTS

26100040271

Items

Specified lubricant

Quantity g

SPACE RUNNER

Repair kit grease

110

SPACE WAGON - 2WD

Repair kit grease

140

SPACE WAGON - 4WD

Repair kit grease

105

Dust seal inner

Multipurpose grease

14 - 20

Dust seal outer

Multipurpose grease

8 - 12

2WD

Repair kit grease

125

4WD

Repair kit grease

95

T.J.

B.J.

SPECIAL TOOLS Tool

B

26100060246

Number

Name

Use

MB990767

End yoke holder

Hub fixing

MB991618

Hub bolt remover

Hub bolt removal

MB991406, MB990635 or MB991113

Steering linkage puller

Ball joint disconnection

MB990241 A: MB990242 B: MB990244

Axle shaft puller A: Puller shaft B: Puller bar

D D

MB991354

Puller body

A: MB991017 B: MB990998 C: MB991000

A, B: Front hub remover and installer C: Spacer

Front hub assembly removal Drive shaft removal

A

A

B C

Wheel bearing provisional holding MB991000, which belongs to MB990998, should be used as a spacer.

26-4 Tool

FRONT AXLE - Special Tools Number

Name

Use

MB990326

Preload socket

Wheel bearing rotation starting torque measurement

MB990925

Bearing and oil seal installer set

D D D

MB990197

Puller body

Inner shaft press-out

MB990302

Hook

MB991172

Inner shaft installer base

Inner shaft press-fitting

MB991248

Inner shaft remover

Inner shaft press-out

MB991721

Slide hammer

Output shaft removal

MB991561

Boot band clipping tool

Resin boot band installation

Center bearing press-out Center bearing press-fitting Dust seal press-fitting

26-5

FRONT AXLE - Special Tools MB990925 C

Tool box

Brass bar

B Bar (snap-in type)

A Installer adapter

Type

Tool number

O.D. mm

Type

Tool number

O.D. mm

A

MB990926

39

A

MB990933

63.5

MB990927

45

MB990934

67.5

MB990928

49.5

MB990935

71.5

MB990929

51

MB990936

75.5

MB990930

54

MB990937

79

MB990931

57

B

MB990938

-

MB990932

61

C

MB990939

-

26-6

FRONT AXLE - On-vehicle Service

ON-VEHICLE SERVICE

26100090115

WHEEL BEARING AXIAL PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction. Limit: 0.05 mm 4. If axial play exceeds the limit, replace the front hub assembly.

HUB BOLT REPLACEMENT MB991618

MB990767

MB990767

Plain washer

26100100115

1. Remove the caliper assembly and secure it with wire so that it does not fall. 2. Remove the brake disc. 3. Use the special tools to remove the hub bolts.

4. Install the plain washer to the new hub bolt, and install the bolt with a nut.

26-7

FRONT AXLE - Front Hub Assembly

FRONT HUB ASSEMBLY

26100170222

REMOVAL AND INSTALLATION Caution The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play. Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.

5 6 39 Nm

24 - 33 Nm

1 8 3

88 Nm

4

127 Nm

7

196 - 255 Nm 98 - 118 Nm

AA"

Removal steps 1. Front wheel speed sensor (Refer to GROUP 35B.) 2. Caliper assembly 3. Brake disc

2

AB" "AA 4. Drive shaft nut AC" 5. Tie rod end connection 6. Stabilizer link connection 7. Lower arm assembly connection AD" 8. Front hub assembly

26-8

FRONT AXLE - Front Hub Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall.

AB" DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, or the ball bearing will be damaged.

MB990767

MB991406, MB990635 or MB991113 Ball joint Cord

AC" TIE ROD END DISCONNECTION Caution 1. Loosen the nut of the special tool, but do not remove it. If it is removed, the ball joint thread may be damaged. 2. Tie the special tool with a cord not to let it fall off.

Nut

AD" FRONT HUB ASSEMBLY REMOVAL 1. Use the special tool to push out the drive shafts from the hub. MB990767 MB990244 (three) MB991354 MB990242

2. Withdraw the drive shaft from the hub by pulling the bottom of the brake disc towards you, and then remove the hub retaining bolts.

FRONT AXLE - Front Hub Assembly

26-9

INSTALLATION SERVICE POINT

196 - 255 Nm

"AA DRIVE SHAFT NUT INSTALLATION 1. Install the drive shaft washer in the specified direction. 2. Using the special tool, tighten the drive shaft nut.

MB990767 Washer

Caution Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. 3. If the position of the split pin holes does not match, tighten the nut up to 255 Nm in maximum. 4. Install the split pin in the first matching holes and bend it securely.

MB991000 (MB990998)

196 - 255 Nm

INSPECTION MB991017

MB990326

Wood block

26100180140

WHEEL BEARING ROTATION STARTING TORQUE CHECK 1. Install the special tool to the front hub assembly and tighten the nut to the specified torque. 2. Use the special tool to measure the wheel bearing starting torque. Limit: 1.0 Nm or less 3. The wheel bearing starting torque should be within the limit value range, and there should be no engagement or feeling of roughness.

Wood block

26100110125 WHEEL BEARING AXIAL PLAY CHECK 1. Install the special tool to the front hub assembly and tighten the nut to the specified torque 196 - 255 Nm. 2. Measure the play in the hub axial direction.

Limit: 0.05 mm 3. If the limit value of hub axial play cannot be obtained, replace the front hub assembly. Wood block

MB991017

26-10

FRONT AXLE - Knuckle

KNUCKLE

26100240183

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Hub Assembly Removal and Installation (Refer to P.26-7.)

106 Nm

2

9 Nm

1

Removal steps 1. Dust shield 2. Knuckle

26-11

FRONT AXLE - Drive Shaft

DRIVE SHAFT

26100350305

REMOVAL AND INSTALLATION Caution On the vehicles with ABS, when the drive shaft is removed or installed, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage. Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.



8

6

7

6

6

Output shaft repair kit

4

40 Nm

6

39 Nm



8

3 2

1

196 - 255 Nm

96 - 118 Nm 24 - 33 Nm

5 Removal steps 1. Front wheel speed sensor (Refer to GROUP 35B.) AA" "BA 2. Drive shaft nut AB" 3. Tie rod end connection 4. Stabilizer link connection 5. Lower arm assembly connection

AC" "AA 6. Drive shaft AC" "AA 7. Drive shaft and inner shaft assembly AD" "AA 8. Output shaft

26-12

FRONT AXLE - Drive Shaft REMOVAL SERVICE POINTS AA" DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, or the ball bearing will be damaged.

MB990767

AB" TIE ROD END DISCONNECTION Caution 1. Loosen the nut of the special tool, but do not remove it. If it is removed, the ball joint thread will be damaged. 2. Tie the special tool with a cord not to let it fall off.

MB991406, MB990635 or MB991113 Ball joint Cord

Nut

AC" DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY REMOVAL 1. Use the special tool to push out the drive shafts from the hub.

MB990767

MB990244 (three) MB990242

MB991354

2. Withdraw the drive shaft from the hub by pulling the bottom of the brake disc towards you.

26-13

FRONT AXLE - Drive Shaft Fig. 1

3. Remove the drive shaft or the drive shaft and inner shaft assembly from the transmission by the following procedure:

Transmission

Drive shaft Prybar

Fig. 2

Transmission

Drive shaft

Center bearing bracket Hammer Transfer

Fig. 3

Drive shaft

Hammer

2WD (except SPACE WAGON - M/T - R.H.), 4WD (L.H.)

Fig. 1

2WD (SPACE WAGON - M/T - R.H.)

Fig. 2

4WD (R.H.)

Fig. 3

Insert a pry bar between the drive shaft and the transmission case, and then pry off the drive shaft. Tap the center bearing bracket with a hammer to remove the drive shaft. Place a hammer on the projection at the transfer and insert a pry bar between the drive shaft and the transfer, and then pry off the drive shaft. Caution (1) Above-mentioned procedure must be observed. Pulling the B.J. assembly to remove the drive shaft or drive shaft and inner shaft assembly will damage the T.J. assembly. (2) Take care that the transmission oil seal will not be damaged by the drive shaft spline.

Projection Prybar

MB991000 (MB990998) MB991017

(3) Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, as the wheel bearing will be damaged. If, however, the vehicle weight must be applied to the bearing (because of moving the vehicle), temporarily secure the wheel bearing by using the special tools.

AD" OUTPUT SHAFT REMOVAL Use the special tool to withdraw the output shaft.

MB991721

Caution Be careful not to damage the oil seal of the transmission by the spline of the output shaft. Output shaft

26-14

FRONT AXLE - Drive Shaft INSTALLATION SERVICE POINTS "AA OUTPUT SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY/DRIVE SHAFT INSTALLATION Caution Be careful not to damage the oil seal of the transmission or transfer by the spline of the shaft.

"BA DRIVE SHAFT NUT INSTALLATION 1. Install the drive shaft washer in the specified direction. 2. Using the special tool, tighten the drive shaft nut.

196 - 255 Nm

Caution Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise, the wheel bearing will be damaged.

MB990767

Washer

3. If the position of the split pin holes does not match, tighten the nut up to 255 Nm in maximum. 4. Install the split pin in the first matching holes and bend it securely.

26-15

FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY

26100370325

Caution On the vehicles with ABS, when the drive shaft is disassembled or reassembled, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage.

13

7 6

4



5 7 10

11

12

8

3



9

13

14

4

15

16 1

4 2 17

18

19 20

13

22 10 11

21 12 9

23 24

Bracket assembly repair kit

13 4

5 14

13 14 15 16

13 16

1

"GA "GA "FA AA" "BA AB" "EA "DA "DA AC" "CA

14

1 2 17 19 22 21

23

2

2 T.J. repair kit

1

T.J. boot repair kit

Disassembly steps 1. T.J. boot band (large) 2. T.J. boot band (small) 3. T.J. case and inner shaft assembly 4. T.J. case 5. Seal plate 6. Inner shaft 7. Dust cover 8. Bracket assembly 9. Dust seal outer 10. Dust seal inner 11. Center bearing 12. Center bearing bracket 13. Circlip

B.J. boot repair kit 14. AA" "BA 15. AD" "AA 16. "AA 17. "AA 18. "AA 19. "AA 20. 21.

Snap ring Spider assembly T.J. boot Damper band Dynamic damper Damper band Dynamic damper B.J. boot band (large) (Refer to P.26-20.) 22. B.J. boot band (small) (Refer to P.26-20.) 23. B.J. boot (Refer to P.26-20.) 24. B.J. assembly (Refer to P.26-20.)

26-16

FRONT AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL 1. Wipe off grease from the spider assembly and the inside of the T.J. case. 2. Always clean the spider assembly when the grease contains water or foreign material. Caution Do not disassemble the spider assembly.

T.J. case

Bar Seal plate

Bar

AB" INNER SHAFT REMOVAL 1. Use the special tool to remove the inner shaft assembly, together with the seal plate, from the T.J. case.

MB991248 MB991248

2. Use the special tools to remove the inner shaft from the bracket.

MB990197

MB990302

AC" CENTER BEARING REMOVAL MB990938 MB990932

AD" T.J. BOOT REMOVAL 1. Wipe off grease from the shaft spline. 2. When reusing the T.J. boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

26-17

FRONT AXLE - Drive Shaft REASSEMBLY SERVICE POINTS B A

"AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT INSTALLATION 1. Install the dynamic damper in the position shown in the illustration. Items SPACE RUNNER SPACE WAGON

A (large)

B (small)

L.H.

-

215 mm

R.H.

395 mm

-

L.H.

-

215 mm

R.H.

405 mm

585 mm

2. Secure the damper bands. Caution There should be no grease adhered to the rubber part of the dynamic damper. 3. Wrap plastic tape around the shaft spline, and then install the T.J. boot band (small) and T.J. boot.

Bevelled section

"BA SPIDER ASSEMBLY/T.J. CASE INSTALLATION 1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller. Specified grease: Repair kit grease Caution (1) The drive shaft joint uses special grease. Do not mix old and new or different types of grease. (2) If the spider assembly has been cleaned, take special care to apply the specified grease. 2. Install the spider assembly to the shaft from the direction of the spline bevelled section. 3. After applying the specified grease to the T.J. case, insert the drive shaft and apply grease one more time. Specified grease: Repair kit grease Amount to use: 110 g 140 g 105 g NOTE The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

26-18

FRONT AXLE - Drive Shaft "CA CENTER BEARING INSTALLATION MB990938 MB990933

Bearing

INNER DUST SEAL MB990938 MB990933

"DA DUST SEAL INNER/DUST SEAL OUTER INSTALLATION 1. Apply multi-purpose grease to the rear surfaces of all dust seals. Amount to use: Dust seal inner 14 - 20 g Dust seal outer 8 - 12 g 2. Use the special tools to install the dust seal so that its surface runs even with that of the center bearing bracket. 3. Apply multi-purpose grease to the lip of each dust seal.

OUTER DUST SEAL MB990938 MB990931

NOTE When applying grease, make sure that it does not adhere to anything outside the lip.

"EA INNER SHAFT INSTALLATION Inner shaft

MB991172

Inner shaft assembly

T.J. case

"FA T.J. CASE AND INNER SHAFT ASSEMBLY INSTALLATION 1. Apply multi-purpose grease to the inner shaft spline, then press fit into the T.J. case.

FRONT AXLE - Drive Shaft T.J. case

Pipe

26-19

2. Use the special tools to support the T.J. case. 3. Use a pipe [Ø 30 mm] to press the seal plate into the T.J. case.

Seal plate

MB991248

"CA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely.

A

Standard value (A): 82 mm 81 mm 90 mm

INSPECTION D D D D D D D D D D

26100380083

Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the inner shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside T.J. case for wear or corrosion. Check the dynamic damper for damage or cracking. Check the boots for deterioration, damage or cracking. Check the center bearing for seizure, discoloration or roughness of rolling surface. Check the dust cover for damage or deterioration.

26-20

FRONT AXLE - Drive Shaft B.J. BOOT (RESIN BOOT) REPLACEMENT 26100520157

1. Remove the B.J. boot bands (large and small). NOTE The B.J. boot bands cannot be re-used. 2. Remove the B.J. boot. 3. Wrap a plastic tape around the shaft spline, and assemble the B.J. boot band and B.J. boot.

4. Install the B.J. boot with the part with the smallest diameter in a position such that the shaft groove can be seen.

Groove

MB991561 Stopper

5. Engage the small diameter side of the plastic boot into the shaft groove .

6. Turn the adjusting bolt on the special tool so that the size of the opening (W) is at the standard value. Standard value (W): 2.9 mm Tighten the adjusting bolt. Loosen the adjusting bolt.

W Adjusting bolt

NOTE (1) The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt. (2) The adjusting bolt should not be turned more than once.

FRONT AXLE - Drive Shaft

26-21

7. Place the B.J. boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.

B.J. boot A

B.J. boot band (small)

Projection

8. Use the special tool to crimp the B.J. boot band (small). Caution (1) Secure the drive shaft in an upright position and clamp the part of the B.J. boot band to be crimped securely in the jaws of the special tool. (2) Crimp the B.J. boot band until the special tool touches the stopper. 9. Check that the crimping amount (B) of the B.J. boot band is at the standard value.

MB991561

B

Standard value (B): 2.4 - 2.8 mm Readjust the value of (W) in step 6 according to the following formula, and then repeat the operation in step 8. W = 5.5 mm - B Example: If B = 2.9 mm, then W = 2.6 mm. Remove the B.J. boot band, readjust the value of (W) in step 6 according to the following formula, and then repeat the operations in steps 7 and 8 using a new B.J. boot band. W = 5.5 mm - B Example: If B = 2.3 mm, then W = 3.2 mm. 10. Check that the B.J. boot band is not sticking out past the place where it has been installed. If the B.J. boot band is sticking out, remove it and then repeat the operations in steps 7 to 9 using a new B.J. boot band.

11. Fill the inside of the B.J. boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: 125 g, 95 g Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

26-22

FRONT AXLE - Drive Shaft 12. Engage the large diameter side of the B.J. boot into the B.J. housing groove.

Groove

C

13. Install the B.J. boot band (large) so that there is the clearance (C) between it and the B.J. housing is at the standard value. Standard value (C): 0.1 - 1.5 mm 14. Follow the same procedure as in step 6 to adjust the size of the opening (W) on the special tool so that it is at the standard value. Standard value (W): 3.2 mm

Projection

B.J. boot

B.J. boot band (large)

15. Place the B.J. boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration. 16. Use the special tool to crimp the B.J. boot band (large) in the same way as in step 8.

D

17. Check that the crimping amount (E) of the B.J. boot band is at the standard value. Standard value (e): 2.4 - 2.8 mm Readjust the value of (W) in step 13 according to the following formula, and then repeat the operation in step 15. W = 5.8 mm - E Example: If E = 2.9 mm, then W = 2.9 mm. E

Remove the B.J. boot band, readjust the value of (W) in step 13 according to the following formula, and then repeat the operations in steps 14 and 15 using a new B.J. boot band. W = 5.8 mm - E Example: If E = 2.3 mm, then W = 3.5 mm. 18. Check that the B.J. boot band is not sticking out past the place where it has been installed. If the B.J. boot band is sticking out, remove it and then repeat the operations in steps 14 to 16 using a new B.J. boot band.

27A-1

REAR AXLE CONTENTS REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27B

27109000246

27A-2

REAR AXLE CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

27109000253

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4 Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 4 Wheel Bearing Rotary-Sliding Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REAR HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . 5

REAR AXLE -

General Information/Service Specifications/Special Tools

GENERAL INFORMATION

27A-3 27100010224

A unit bearing (double-row angular contact ball bearing) is used as the wheel bearing.

For the vehicles with ABS, the hub has a ABS rotor for detecting the wheel rotation speed.

Rear hub assembly

Lower arm assembly

Unit bearing

ABS rotor

SERVICE SPECIFICATIONS

27100030336

Items

Limit

Wheel bearing axial play mm

0.05

Wheel bearing rotary-sliding resistance N

18 or less

SPECIAL TOOLS Tool

B

27100060274

Number

Name

Use

MB990767

End yoke holder

Hub fixing

MB990241 A: MB990242 B: MB990244

Axle shaft puller A: Puller shaft B: Puller bar

Rear hub assembly removal

MB991354

Puller body

A

27A-4

REAR AXLE - On-vehicle Service

ON-VEHICLE SERVICE

27100090174

WHEEL BEARING AXIAL PLAY CHECK 1. Remove the caliper assembly and secure it with wire so that it does not fall, and then remove the brake disc. 2. Remove the hub cap. 3. Check the bearing’s axial play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is axial play. Limit: 0.05 mm 4. If the axial play exceeds the limit, the flange nut should be tightened to the specified torque 255 Nm and check the axial play again. 5. Replace the rear hub assembly if an adjustment cannot be made to within the limit.

WHEEL BEARING ROTARY-SLIDING RESISTANCE CHECK

27100110184

1. Remove the caliper assembly and secure it with wire so that it does not fall, and then remove the brake disc. 2. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90_ angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit: 18 N or less 3. If the limit value is exceeded, loosen the flange nut and then tighten it to the specified torque 196 - 255 Nm and check the rear hub rotary sliding resistance again. 4. Replace the rear hub assembly if an adjustment cannot be made to within the limit.

27A-5

REAR AXLE - Rear Hub Assembly

REAR HUB ASSEMBLY

27100200294

REMOVAL AND INSTALLATION Caution 1. For the vehicles with ABS, care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it will not be able to accurately detect the wheel rotation speed, and the system will not function normally. 2. The rear hub assembly should not be dismantled. When removing the rear hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.

55 - 65 Nm

1

4 6

3 5 2

AA"

Removal steps 1. Caliper assembly 2. Brake disc 3. Hub cap

172 Nm

AB" "AA 4. Flange nut AC" 5. Rear hub assembly 6. Hub bolt

27A-6

REAR AXLE - Rear Hub Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall.

AB" FLANGE NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the flange nut, or the wheel bearing will be damaged.

MB990767

MB991354 MB990244 (three)

MB990242

AC" REAR HUB ASSEMBLY REMOVAL Use the special tools to remove the hub from the lower arm assembly.

MB990767

INSTALLATION SERVICE POINT 226 Nm

MB990767

"AA FLANGE NUT INSTALLATION 1. Using the special tool, tighten the flange nut. Caution Before securely tightening the flange nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. 2. After tightening the flange nut, crimp the nut to meet the concave portion of the spindle.

INSPECTION D D D

27100210167

Check the oil seal for crack or damage. Check the rear hub unit bearing for wear or damage. Check the rear ABS rotor for chipped teeth.

27B-1

REAR AXLE CONTENTS

27109000260

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

Limited Slip Differential Condition Check (VCU Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

Differential Carrier Oil Seal Replacement . . . . . . . 8

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REAR HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . 9

SEALANTS AND ADHESIVES . . . . . . . . . . . . . . 3

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIFFERENTIAL MOUNT . . . . . . . . . . . . . . . . . . 16

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6

DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . 20

Rear Axle Total Backlash Check . . . . . . . . . . . . . . 6 Gear Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . 7 Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 7

LSD CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . 37

27B-2

REAR AXLE - General Information/Service Specifications

GENERAL INFORMATION

27100010231

The drive shaft has two joints (D.O.J. and B.J.) at each side. The D.O.J. joint at the differential side can slide smoothly in the axial direction. The B.J. type constant velocity joint is used at the hub side.

In addition, for vehicles with ABS, an ABS rotor for detecting vehicle wheel speed is mounted in the drive shaft. The wheel bearing used is an angular ball bearing, which is resistant against lateral load. ABS rotor

Differential carrier

Drive shaft B.J.

Rear hub Wheel bearing D.O.J. Drive shaft

SERVICE SPECIFICATIONS

27100030343

Items

Standard value

Limit

Rear axle total backlash mm

-

5

Wheel bearing axial play mm

-

0.05

Setting of D.O.J. boot length mm

80

-

Drive gear backlash mm

0.11 - 0.16

-

Drive gear runout mm

-

0.05

Differential gear backlash mm

0 - 0.076

0.2

When replacing with a new bearing (with rust-prevention oil)

0.9 - 1.2

-

When using a new bearing or when reusing (gear oil application)

0.4 - 0.5

-

When replacing with a new bearing (with rust-prevention oil)

1.0 - 1.3

-

When using a new bearing or when reusing (gear oil application)

0.5 - 0.6

-

Drive pinion turning torque Nm

Without oil seal

With oil seal

REAR AXLE - Lubricants/Sealants and Adhesives/Special Tools

LUBRICANTS

27100040131

Items

Specified lubricant

Quantity

Gear oil

Hypoid gear oil API classification GL-5 or higher SAE viscosity No. 90, 80W

0.55 L

Vehicles without ABS

Repair kit grease

75 g

Vehicles with ABS

Repair kit grease

145 g

Repair kit grease

100 g

B.J.

27B-3

D.O.J.

SEALANTS AND ADHESIVES

27100050103

Items

Specified sealants and adhesives

Vent plug

Semi-drying sealant : 3M ATD Part No. 8661 or equivalent

Differential cover installation surface Drive gear threaded holes

Anaerobic sealant : 3M Stud Locking 4170 or equivalent

SPECIAL TOOLS Tool

27100060281

Number

Name

Use

MB991354

Puller body

D D D

MB990211

Slide hammer

Companion shaft removal

MB990925

Bearing and oil seal installer set

D D D

MB991115

Oil seal installer

Oil seal press-fitting (Use in conjuction with MB990938)

MB990767

End yoke holder

Hub fixing

Companion shaft removal Drive shaft removal Rear hub assembly removal

Oil seal press-fitting Bearing outer race press-fitting Tooth contact of drive gear measurement (Refer to GROUP 26 - Special Tools.)

27B-4

REAR AXLE - Special Tools

Tool

B

Number

Name

Use

MB990241 A: MB990242 B: MB990244

Axle shaft puller A: Puller shaft B: Puller bar

D D

A: MB991017 B: MB990998 C: MB991000

A, B: Front hub remover and installer C: Spacer

Wheel bearing provisional holding MB991000, which belongs to MB990998, should be used as a spacer.

MB991407

Differential support arbor

Driving out and press-fitting of differential support member bushing

MB991318

Lower arm bushing arbor

MB990651

Bar

MB990884

Rear suspension bushing ring

MB990890

Rear suspension bushing base

MB990909

Working base

MB991116

Working base adapter

Drive shaft removal Rear hub assembly removal

A A

B C

Differential carrier assembly disassembly and reassembly

REAR AXLE - Special Tools Tool

A

Number

Name

Use

MB990810

Bearing puller

D D

MB990850

End yoke holder

Companion flange removal and installation

MB990339

Bearing puller

Drive pinion rear bearing inner race removal

MB990374

Pinion bearing remover

MB990835 A: MB990836 B: MB990392

Drive pinion setting Drive pinion height measurement gauge set A: Drive pinion gauge assembly B: Cylinder gauge

MB990326

Preload socket

Breakaway torque of the drive pinion measurement

MB990728

Bearing installer

D

B

D

A

27B-5

Side bearing inner race removal Companion flange removal

Drive pinion rear bearing inner race press-fitting Side bearing inner race press-fitting

MB990031 or MB990699

Oil seal installer

Drive pinion oil seal press-fitting

MB990988 A: MB990989

Side gear holding tool set A: Base

Differential case installation

27B-6 Tool

REAR AXLE - Special Tools/On-vehicle Service Number

Name

Use

MB991357

Side gear holding tool

Limited slip differential gear backlash inspection

ON-VEHICLE SERVICE

27100120156

REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system, measure the rear axle total backlash by the following procedures to see if the differential carrier assembly requires removal. 1. Place the gearshift lever in the neutral position, apply the parking brake and jack up the vehicle.

Mating marks

2. Manually turn the propeller shaft clockwise as far as it will go and make mating marks on the companion flange dust cover and the differential carrier.

3. Manually turn the propeller shaft anti-clockwise as far as it will go and measure the movement of the mating marks. Limit: 5 mm 4. If the backlash exceeds the limit, remove the differential carrier assembly (Refer to P.27B-20.) and adjust the backlash (Refer to P.27B-23.).

REAR AXLE - On-vehicle Service GEAR OIL LEVEL CHECK Gear oil

Upper limit Lower limit

8 mm

27B-7 27200120135

1. Remove the filler plug. 2. Check that the gear oil level is between the upper limit (the bottom of a filler plug) and the lower limit. 3. If the gear oil level is not between the upper limit and the lower limit, add the specified gear oil unitl the gear oil level reaches the bottom of the filler plug. Specified gear oil: Hypoid gear oil API classification GL-5 or higher SAE viscosity No. 90, 80W NOTE When outside air temperature is 10°C or more: SAE90 When outside air temperature is 10°C or less: SAE80W 4. Install the filler plug, and then tighten it to 49 Nm.

WHEEL BEARING AXIAL PLAY CHECK

27100090181

1. Remove the caliper assembly and secure it with wire so that it does not fall, and then remove the brake disc. 2. Check the bearing’s axial play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is axial play. Limit: 0.05 mm 3. If the axial play exceeds the limit, replace the wheel bearing. (Refer to GROUP 34 - Lower Arm Assembly.)

27B-8

REAR AXLE - On-vehicle Service LIMITED SLIP DIFFERENTIAL CONDITION 27300100033 CHECK (VCU TYPE) 1. Place the shift lever in the neutral position and block the front wheels with chocks. 2. Release the parking brake lever fully. 3. Jack up the rear wheels and apply rigid racks to the specified positions of the side sills. 4. Disconnect the propeller shaft from the differential.

Incorrect

Correct

MB990211

MB991354

MB990938

MB991115

5. While turning one wheel slowly and make sure that the opposite wheel turns in the same direction. 6. If the opposite wheel turns in reverse, disassemble the limited slip differential with VCU and replace the VCU.

DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT

27200130077

1. Disconnect the drive shaft from the companion flange, and then support it to a nearby part with a wire. 2. Use the special tool to withdraw the companion flange from the differential carrier. Caution Be careful not to damage the differential carrier oil seal by the companion flange spline. 3. Remove the oil seal of the differential carrier. 4. Use the special tool to set a new oil seal in position. 5. Apply multipurpose grease to the lip section of the oil seal and to the oil seal contact surface of the drive shaft. 6. Replace the circlip on the companion shaft with a new one, and then install the companion shaft onto the differential carrier. Caution Be careful not to damage the differential carrier oil seal by the companion flange spline. 7. Install the drive shaft to the companion flange, and then tighten the retaining nuts to 54 - 64 Nm.

REAR AXLE - Rear Hub Assembly

REAR HUB ASSEMBLY

27B-9 27100200300

REMOVAL AND INSTALLATION

2 1 Removal steps 1. Rear hub assembly (Refer to GROUP 34 - Lower Arm Assembly.) 2. Hub bolt

27B-10

REAR AXLE - Drive Shaft

DRIVE SHAFT

27100330085

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Main Muffler Assembly Removal and Installation (Refer to GROUP 15.)

54 - 64 Nm

2

1 196 - 255 Nm

3

4

Removal steps 1. Cover 2. Bolt

AA" "BA 3. Drive shaft nut AB" "AA 4. Drive shaft

AA" DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut, or the wheel bearing will be damaged.

MB990767

MB990244(three) MB990242 MB990767

MB991354

AB" DRIVE SHAFT REMOVAL Use the special tools to push out the drive shafts from the hub.

27B-11

REAR AXLE - Drive Shaft

196 - 255 Nm

MB991017 MB991000 (MB990998)

Caution Do not apply the vehicle weight to the wheel bearing as possible while loosening the drive shaft nut. Otherwise the wheel bearing may be damaged. If, however, the vehicle weight must be applied to the bearing (because of moving the vehicle), temporarily secure the wheel bearing by using the special tool.

Wheel bearing

INSTALLATION SERVICE POINTS D.O.J. boot band (large)

"AA DRIVE SHAFT INSTALLATION NOTE The left and right drive shafts can also be distinguished from each other by the identification colour of D.O.J. boot band (large). Identification colours of D.O.J. boot band (large) Item

Vehicles without ABS

Vehicles with ABS

Left drive shaft

Yellow

Violet

Right drive shaft

Blue

Brown

"BA DRIVE SHAFT NUT INSTALLATION 1. Install the washer and drive shaft nut in specified direction. 2. Using the special tool, tighten the drive shaft nut.

196 - 255 Nm

Caution Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise, the wheel bearing will be damaged.

MB990767 Washer

3. If the position of the split pin holes does not match, tighten the nut up to 255 Nm in maximum. 4. Install the split pin in the first matching holes and bend it securely.

INSPECTION D D D

27100340040

Check the drive shaft boots for damage or deterioration. Check the ball joints (B.J. and D.O.J.) for excessive play or check operation. Check the drive shaft spline for wear or damage.

27B-12

REAR AXLE - Drive Shaft

DISASSEMBLY AND REASSEMBLY

27100350067

4 3 6 7

8

5

9 1 2

11 10 12 13 14 1 2 11 10 3 6

12

4 3 6 7 8 13

5

9

1

14

B.J. repair kit

2

D.O.J. repair kit

3

6 1

3 6 2 11 10

9 1

12

2

B.J. boot repair kit

"DA "DA AA" "CA AB" "CA AB" AB" "BA

Disassembly steps 1. D.O.J. boot band (large) 2. D.O.J. boot band (small) 3. Circlip 4. D.O.J. outer race 5. Ball 6. Snap ring 7. D.O.J. inner race

D.O.J. boot repair kit

AB" "BA 8. AC" "AA 9. 10. 11. AC" "AA 12. 13. 14.

D.O.J. cage D.O.J. boot B.J. boot band (large) B.J. boot band (small) B.J. boot B.J. assembly Dust cover

REAR AXLE - Drive Shaft

27B-13

DISASSEMBLY SERVICE POINTS AA" D.O.J. OUTER RACE REMOVAL Withdraw the D.O.J. outer race from the B.J. assembly, and then clean wipe grease from the D.O.J. outer race.

AB" BALL/SNAP RING/D.O.J. INNER RACE/D.O.J. CAGE REMOVAL 1. Matchmark the drive shaft, D.O.J. inner race and D.O.J. cage. 2. Remove the balls from the D.O.J. cage.

Mating marks

Caution Do not use a flat-tipped screwdriver, as it will damage the balls.

Snap ring

MB990939

3. Slide the D.O.J. cage from the D.O.J. inner race to the B.J. side, and then remove the snap ring.

4. Use the special tool to tap the D.O.J. inner race evenly and gently, and then remove it from the shaft.

AC" D.O.J. BOOT/B.J. BOOT REMOVAL 1. Wipe off grease from the shaft spline. 2. If the D.O.J. boot / B.J. boot is reused, wrap a plastic tape around the spline of the drive shaft to prevent damage during removal.

27B-14

REAR AXLE - Drive Shaft REASSEMBLY SERVICE POINTS "AA B.J. BOOT/D.O.J. BOOT INSTALLATION 1. Wrap a plastic tape around the spline of the drive shaft, and then remove the B.J. boot and D.O.J. boot in that order. 2. Fill the specified grease inside the B.J. and B.J. boot. Specified grease: Repair kit grease Amount to use: 75 g 145 g NOTE The grease in the repair kit should be used once at a time. One-half of the grease should be filled in the joint, the remaining one-half filled inside the boot. Caution The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease. 3. Tighten the boot band.

Lever

Caution (1) In order to maintain air inside the B.J. boot properly, the drive shaft should be maintained at 0 degree joint angle while the band is tightened. (2) Before tightening the B.J. boot band or D.O.J. boot band, make sure that the boot band is correct by identification number stamped on the lever. Identification numbers of the boot bands Item B.J. boot band D.O.J. boot band

Mating marks

MB990939

Vehicles without ABS

Vehicles with ABS

large

20- 110#BJ87

20- 75#BJ95

small

20- 83#BJ82

20- 111#BJ87

large

20- 82#BJ82

20- 82#BJ82

small

20- 83#BJ82

20- 83#BJ82

"BA D.O.J. CAGE/D.O.J. INNER RACE INSTALLATION 1. Assemble the D.O.J. cage in the drive shaft, and slide it to the B.J. assembly side. 2. Align the mating marks on the D.O.J. inner race and the shaft. 3. Use the special tool to press in the inner race to the shaft projection evenly and gently.

REAR AXLE - Drive Shaft

27B-15

"CA BALL/D.O.J. OUTER RACE INSTALLATION 1. Apply the specified grease to the balls, D.O.J cage and D.O.J. inner race, and then align the mating marks on the D.O.J. cage and D.O.J. inner race to assemble the balls. Specified grease: Repair kit grease Caution The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease. 2. Fill the specified grease in the D.O.J. outer race, and then insert the drive shaft. Finally, fill the grease again. Specified grease: Repair kit grease Amount to use: 100 g NOTE The grease in the repair kit should be used once at a time. One-half of the grease should be filled in the joint, the remaining one-half filled inside the boot. Caution The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease.

"DA D.O.J. BOOT BAND (SMALL)/D.O.J. BOOT BAND (LARGE) INSTALLATION Set the D.O.J. boot bands at the specified distance in order to adjust the amount of air inside the D.O.J. boot, and then tighten the D.O.J. boot bands securely. Standard value (A): 80 mm A

INSPECTION D D D D D

Check the Check the rust. Check the rust, wear Check the Check the

27100360046

drive shaft for bending or wear. B.J. for entry of water, foreign materials or D.O.J. cage, D.O.J. inner race and balls for or damage. circlip for damage or deformation. D.O.J. outer race for wear or damage.

27B-16

REAR AXLE - Differential Mount

DIFFERENTIAL MOUNT

27200650016

REMOVAL AND INSTALLATION 3

98 - 118 Nm

103 Nm 54 - 64 Nm

6 1

4 5 108 - 127 Nm

29 - 34 Nm

2

Bracket assembly removal steps AA" 1. Disconnection of right drive shaft AB" 2. Propeller shaft connection AC" "CA 3. Bracket assembly

Differential support member removal steps D Main muffler assembly (Refer to GROUP 15.) AD" "BA 4. Differential support member "AA 5. Lower stopper "AA 6. Upper stopper

REMOVAL SERVICE POINTS AA" DISCONNECTION OF RIGHT DRIVE SHAFT Disconnect the drive shaft from the companion flange, and then support it to a nearby part with a wire.

AB" PROPELLER SHAFT DISCONNECTION 1. Make mating marks on the differential companion flange and flange yoke, and then separate the differential carrier assembly and the propeller shaft. 2. Suspend the propeller shaft from the body with wire, etc, so that there are no sharp bends. Mating marks

REAR AXLE - Differential Mount

27B-17

AC" BRACKET ASSEMBLY REMOVAL 1. Support the bottom of the differential carrier with a transmission jack, and then remove the bracket assembly retaining bolts. 2. Lower the front of the differential carrier, and then remove the bracket assembly.

Transmission jack

AD" DIFFERENTIAL SUPPORT MEMBER REMOVAL Support the bottom of the differential carrier with a transmission jack, and then remove the bolts securing the differential carrier to the differential support member.

INSTALLATION SERVICE POINTS

Upper stopper

"AA UPPER STOPPER/LOWER STOPPER INSTALLATION Install the upper and lower stoppers as shown in the illustration.

Lower stopper

"BA DIFFERENTIAL SUPPORT MEMBER INSTALLATION Install the differential support member so that a longer projection of its bushing faces towards the front of the vehicle.

Front of the vehicle View A View A

Bushing

Differential support member

"CA BRACKET ASSEMBLY INSTALLATION Insert a bar into the bushing inner pipe, and then push up the inner pipe until it is parallel to the suspension crossmember bolt. While the inner pipe is maintained at this position, install the bracket assembly. Suspension crossmember

Bar

27B-18

REAR AXLE - Differential Mount INSPECTION D D D

2720660019

Check the bracket assembly for cracks or deformation. Check the differential support member for cracks or deformation. Check the bushings for cracks or deterioration.

BUSHING REPLACEMENT

27200670012

Bushing A

Bushing B

Differential support member

MB991318

BUSHING A 1. Use the special tool to press out the bushing.

MB991407 MB990884 MB990890

MB991318 Outer pipe Differential support member

MB991407 Bushing

MB990884 MB990890

Differential support member

Concave part

2. Use the special tool to press in the bushing. 3. Align the concave part of the bushing as shown. 4. Press in the bushing until its outer pipe end is aligned with the differential support member.

REAR AXLE - Differential Mount MB990651

Differential support member

MB991407

27B-19

BUSHING B 1. Position special tool MB991407 on the shorter projection of the bushing inner pipe, and then press out the bushing.

MB990884 MB990890 Inner pipe

Differential carrier side

2. Press in the bushing so that the longer projection of the bushing inner pipe is at the differential carrier side.

View A View A

Bushing

Differential support member

MB990651

Outer pipe

MB991407 Bushing

MB990884 Differential support member

MB990890

3. Set the special tools as described in step 1, and press in the bushing. 4. Press in the bushing unitl its outer pipe end is aligned with the differential support member.

27B-20

REAR AXLE - Differential Carrier

DIFFERENTIAL CARRIER

27200200174

REMOVAL AND INSTALLATION

98 - 118 Nm 103 Nm

29 - 34 Nm

1 49 Nm

3

4

59 - 69 Nm

7 2

Removal steps "CA 1. Filler plug 2. Drain plug AA" 3. Drive shaft connection AB" "BA 4. Propeller shaft connection

6 54 - 64 Nm

5

AC" 5. Differential carrier assembly AD" "AA 6. Companion shaft 7. Differential carrier

REMOVAL SERVICE POINTS AA" DRIVE SHAFT DISCONNECTION Disconnect the drive shaft from the companion flange, and then support it to a nearby part with a wire.

AB" PROPELLER SHAFT DISCONNECTION 1. Make mating marks on the differential companion flange and flange yoke, and then separate the differential carrier assembly and the propeller shaft. 2. Suspend the propeller shaft from the body with wire, etc, so that there are no sharp bends. Mating marks

REAR AXLE - Differential Carrier

27B-21

AC" DIFFERENTIAL CARRIER ASSEMBLY REMOVAL Support the bottom of the differential carrier with a transmission jack, and then remove the differential support member bolts and the bracket assembly retaining bolts.

Transmission jack

MB991354 MB990211

AD" COMPANION SHAFT REMOVAL Secure the differential carrier in a vise, and then use the special tool to withdraw the companion shaft. Caution Be careful not to damage the differential carrier oil seal by the companion shaft spline.

INSTALLATION SERVICE POINTS "AA COMPANION SHAFT INSTALLATION Caution Be careful not to damage the differential carrier oil seal by the companion shaft spline. "BA PROPELLER SHAFT CONNECTION Connect the propeller shaft so that the mating marks on the differential companion flange and the flange yoke are aligned. "CA FILLER PLUG INSTALLATION Fill the specified gear oil until the oil level reaches the bottom of the filler plug. Gear oil

Specified gear oil: Hypoid gear oil API classification GL-5 or higher SAE viscosity No. 90, 80W Amount to use: 0.55 L NOTE When outside air temperature is 10_C or more: SAE90 When outside air temperature is 10_C or less: SAE80W

27B-22

REAR AXLE - Differential Carrier

DISASSEMBLY

27200220170



5 6 4 7 14 13 12 1110 13

17 18 20

28 26 27

3 31

30

21 22

2 1 11 12

9 14

25 29 23 24

8 15

7 6 5

19

5 6

4

7 8

16

7 6 5

AA"

AB" AC" AD" AE"

Disassembly steps D Inspection before disassembly 1. Differential cover assembly 2. Vent plug 3. Bearing cap 4. Differential case assembly 5. Side bearing spacer 6. Side bearing outer race 7. Side bearing inner race 8. Drive gear 9. Lock pin 10. Pinion shaft 11. Pinion gear 12. Pinion washer 13. Side gear 14. Side gear spacer 15. Differential case

AF" AG"

AH"

AI" AI" AI" AI"

16. Limited slip differential case assembly (Refer to P.27-37.) 17. Self-locking nut 18. Washer 19. Drive pinion assembly 20. Companion flange 21. Drive pinion front shim (for preload adjustment) 22. Drive pinion spacer 23. Drive pinion rear bearing inner race 24. Drive pinion rear shim (for pinion height adjustment) 25. Drive pinion 26. Oil seal 27. Drive pinion front bearing inner race 28. Drive pinion front bearing outer race 29. Drive pinion rear bearing outer race 30. Oil seal 31. Gear carrier

REAR AXLE - Differential Carrier MB991116 and MB990909

27B-23

DISASSEMBLY SERVICE POINTS AA" INSPECTION BEFORE DISASSEMBLY Hold the special tool in a vice, and attach the differential carrier to the special tool.

DRIVE GEAR BACKLASH CHECK Check the drive gear backlash by the following procedure: 1. Place a dial gauge on the drive gear teeth. With the drive pinion locked in place, check if the backlash is within the standard value range at four points or more by turning the drive gear. Standard value: 0.11 - 0.16 mm 2. If the backlash is outside the standard value, adjust using the side bearing spacer. 3. After adjustment, inspect the contact of the drive gear. DRIVE GEAR RUNOUT CHECK Check the drive gear runout by the following procedure: 1. Place a dial gauge on the back of the drive gear, and check if the runout does not exceed the limit by turning the drive gear. Limit: 0.05 mm 2. If the runout exceeds the limit value, check that there is no foreign material between the reverse side of the drive gear and the differential case, or that there is no looseness in the drive gear mounting bolt. 3. If step (2) is normal, change the assembly position of the drive gear and differential case, and then take another measurement. If adjustment is impossible, replace the differential case or the drive gear and drive pinion as a set.

27B-24 Wedge

REAR AXLE - Differential Carrier Attachment

Pinion shaft

Side gear spacer

DIFFERENTIAL GEAR BACKLASH CHECK Check the differential gear backlash by the following procedure: 1. Lock a piece of wood between the side gear and the pinion shaft to hold one of the side gears in place. Then place a dial gauge (through a suitable extension) on one of the pinion gears, and check if the backlash is within the standard value range. Repeat this check for the other pinion gear. Standard value: 0 - 0.076 mm Limit: 0.2 mm 2. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear spacers. If adjustment is impossible, replase the side gear and pinion gear as a set.

DRIVE GEAR TOOTH CONTACT CHECK Check the drive gear tooth contact by the following procedure: 1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth. 2. Insert a special tool between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5 - 3.0 Nm] is applied to the drive pinion.

MB990939 (MB990925)

Caution If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check. 3. Check the tooth contact condition of the drive gear and drive pinion.

27B-25

REAR AXLE - Differential Carrier Standard tooth contact pattern

Problem

1 2

Tooth contact pattern resulting from excessive pinion height

3 4

Narrow tooth side Drive-side tooth surface (the side applying power during forward movement) Wide tooth side Coast-side tooth surface (the side applying power during reverse movement)

2

1

Solution

2

1

4

2

1

4

3

3

The drive pinion is positioned too far from the center of the drive gear.

Increase the thickness of the drive pinion rear shim, and position the drive pinion closer to the center of the drive gear. Also, for backlash adjustment, position the drive gear farther from the drive pinion.

4 Tooth contact pattern resulting from insufficient pinion height.

3

2

1

4

2

1

4

3

3

The drive pinion is positioned too close to the center of the drive gear.

Decrease the thickness of the drive pinion rear shim, and position the drive pinion farther from the center of the drive gear. Also, for backlash adjustment, position the drive gear closer to the drive pinion.

NOTE Confirm that the pinion height and backlash adjustments have been done properly by inspecting the tooth contact pattern. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern.

After adjustments, if the correct tooth contact pattern cannot be obtained, the drive gear and the drive pinion are worn beyond the allowable limit. Replace the gear set.

27B-26

REAR AXLE - Differential Carrier AB" DIFFERENTIAL CASE ASSEMBLY REMOVAL Caution Remove the differential case assembly, slowly and carefully so that the side bearing outer race is not dropped. NOTE Be sure to keep the side bearing spacers and outer races in order so that they may be reinstalled in their original positions.

Nut

MB990810

AC" SIDE BEARING INNER RACE REMOVAL Engage the two jaws of the special tool under the bottom of the side bearing inner race by using the differential case notches, and then remove the side bearing inner race.

AD" DRIVE GEAR REMOVAL 1. Make the mating marks to the differential case and the drive gear. 2. Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear. Mating marks

AE" LOCK PIN REMOVAL

AF" SELF-LOCKING NUT REMOVAL

MB990850

REAR AXLE - Differential Carrier

27B-27

AG" DRIVE PINION ASSEMBLY REMOVAL 1. Make mating marks on the drive pinion and the companion flange for reassembly purpose.

MB990810

Caution Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. Companion flange

2. Use the special tool to withdraw the companion flange.

AH" DRIVE PINION REAR BEARING INNER RACE REMOVAL

MB990339

MB990374

FRONT BEARING/ REAR BEARING OIL SEAL MB990939 MB990939

AI" OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE/DRIVE PINION REAR BEARING OUTER RACE REMOVAL

INSPECTION D D D D D D

27200250087

Check the companion flange for wear or damage. Check the bearings for wear or discoloration. Check the gear carrier for cracks. Check the drive pinion and drive gear for wear or cracks. Check the side gears, pinion gears and pinion shaft for wear or damage. Check the side gear spline for wear or damage.

27B-28

REAR AXLE - Differential Carrier

REASSEMBLY

27200230159



2726 25

1819 20

34 - 39 Nm*

28 2122 19 21

30 31 20 23 18 24

16 35 Nm

186 Nm

29

11 4 15 14 13 12 18

19

19

1

Differential gear set

25 26 27

24

21 18

21

2

78 - 88 Nm*

7 6 5 9 8 3 10

15

5

27 26

28

25 24

Final drive gear set

25

"AA "BA "BA "CA

"DA

17

Reassembly steps 1. Gear carrier 2. Oil seal 3. Drive pinion rear bearing outer race 4. Drive pinion front bearing outer race D Drive pinion height adjustment 5. Drive pinion 6. Drive pinion rear shim (for pinion height adjustment) 7. Drive pinion rear bearing inner race 8. Drive pinion spacer D Drive pinion preload adjustment 9. Drive pinion front shim (for turning torque adjustment) 10. Drive pinion assembly 11. Drive pinion front bearing inner race 12. Oil seal 13. Companion flange 14. Washer 15. Self-locking nut 16. Differential case 17. Limited slip differential case assembly (Refer to P.27-37.)

78 - 88 Nm*

26 27

"EA D Differential gear backlash adjustment 18. Side gear spacer 19. Side gear 20. Pinion washer 21. Pinion gear 22. Pinion shaft "FA 23. Lock pin "GA 24. Drive gear "HA 25. Side bearing inner race 26. Side bearing outer race "IA D Drive gear backlash adjustment 27. Side bearing spacer 28. Differential case assembly 29. Bearing cap 30. Vent plug 31. Differential cover assembly NOTE *: Tightening torque with gear oil applied

27B-29

REAR AXLE - Differential Carrier LUBRICATION, SEALING AND ADHESIVE POINTS

3.0 mm

Sealant: 3M ATD Part No. 8663 or equivalent



Adhesive: 3M Stud Locking Part No. 4170 or equivalent

27B-30

REAR AXLE - Differential Carrier REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 1. Use the special tool to press in the new oil seal fully. 2. Lightly apply multipurpose grease to the oil seal lip.

MB990938

MB991115

FRONT BEARING

REAR BEARING MB990938

MB990938 MB990932

MB990935

MB990836 (MB990835)

"BA DRIVE PINION REAR BEARING OUTER RACE/DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION Caution Be careful to press in the outer race straight, otherwise the outer race will be damaged.

"CA DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: 1. Apply a thin coat of the multipurpose grease to the mating face of the washer of the special tool. 2. Install special tools and drive pinion front and rear bearing inner races on the gear carrier in the sequence shown in the illustration.

Washer

3. Gradually tighten the nut of the special tool while checking to drive pinion turning torque until the standard value of drive pinion turning torque is obtained.

MB990836

Standard value:

MB990326

Bearing division

Bearing lubrication

Turning torque Nm

New

None (with anti-rust agent)

0.9 - 1.2 Nm

New or reusing

Gear oil applied

0.4 - 0.5 Nm

NOTE Because the special tool cannot be turned one turn, turn it several times within the range that it can be turned; then, after fitting to the bearing, measure the rotation torque.

REAR AXLE - Differential Carrier MB990392 (MB990835)

Cutout section

27B-31

4. Clean the side bearing seat thoroughly. 5. Set the special tools in place of the side bearings, and align the cutout section as shown. Then make sure that the special tools are secured. 6. Use a thickness gauge to measure the clearance (A) between the special tools.

MB990836 (MB990835)

Thickness gauge

C

MB990392

7. Remove the special tools (MB990392 and MB990836). 8. Use a micrometer to measure the dimensions (B) and (C) of the special tools.

MB990836 B

Cylinder gauge

MB990728 Drive pinion rear shim

9. Install the bearing cap, and then use a cylinder gauge and the micrometer to measure the inside diameter D of the bearing cap as shown in the illustration. 10. Calculate the thickness (E) of the drive pinion rear shim from the following equation, and select the shim that is closest in thickness to this value. E = A + B + C - 1/2 D - 86.00 mm

11. Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner race by using the special tool.

MB990728

"DA DRIVE PINION TURNING TORQUE ADJUSTMENT Adjust the drive pinion turning torque by using the following procedure: 1. Insert the drive pinion into the gear carrier, and then install the drive pinion spacer, the drive pinion front shim, the drive pinion front bearing inner race, and the companion flange in that order. NOTE Do not install the oil seal.

27B-32

REAR AXLE - Differential Carrier 2. Tighten the companion flange to the specified torque by using special tools. 186 Nm

MB990850

MB990326

3. Measure the drive pinion turning torque (without the oil seal) by using the special tools. Standard value: Bearing division

Bearing lubrication

Turning torque Nm

New

None (with anti-rust agent)

0.9 - 1.2 Nm

New or reusing

Gear oil applied

0.4 - 0.5 Nm

4. If the drive pinion turning torque is not within the range of the standard value, adjust the turning torque by replacing the drive pinion front shim(s) or the drive pinion spacer. NOTE When selecting the drive pinion front shims, if the number of shims is large, reduce the number of shims to a minimum by selecting the drive pinion spacers.

MB990031 or MB990699

186 Nm

MB990850

5. Remove the companion flange and drive pinion once again. Drive the oil seal into the gear carrier front lip by using the special tool. 6. Apply a thin coat of multipurpose grease to the companion flange contacting surface of the washer and oil seal contacting surface before installing drive pinion assembly.

7. Install the drive pinion assembly and companion flange with mating marks properly aligned, and tighten the companion flange self-locking nut to the specified torque by using special tools.

REAR AXLE - Differential Carrier MB990326

27B-33

8. Measure the drive pinion turning torque (with the oil seal) by using the special tools to verify that the drive pinion turning torque complies with the standard value. Standard value: Bearing division

Bearing lubrication

Turning torque Nm

New

None (with anti-rust agent)

1.0 - 1.3 Nm

New or reusing

Gear oil applied

0.5 - 0.6 Nm

9. If the drive pinion turning torque is not within the standard value, check the tightening torque of the companion flange self-locking nut and the oil seal.

"EA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedures: 1. Assemble the side gears, side gear spacers, pinion gears and pinion washers into the differential case. 2. Temporarily install the pinion shaft. NOTE Do not drive in the lock pin yet.

Wedge

3. Insert a wedge between the side gear and the pinion shaft to lock the side gear. 4. Measure the differential gear backlash with a dial indicator on the pinion gear.

Attachment

Pinion shaft

Side gear spacer

NOTE (1) The measurement should be made for both pinion gears individually. (2) Refer to P.27-37 for measurement of the limited slip differential gear backlash. Standard value: 0 - 0.076 mm Limit: 0.2 mm 5. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear spacers. If adjustment is not possible, replace the side gears and pinion gears as a set. 6. After adjustment, check that the backlash does not exceed the limit value and the differential gear turns smoothly.

27B-34

REAR AXLE - Differential Carrier "FA LOCK PIN INSTALLATION 1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin. 2. Stake the lock pin with a punch at two points.

"GA DRIVE GEAR INSTALLATION 1. Clean the drive gear attaching bolts. 2. Remove the adhesive adhered to the threaded holes of the drive gear by turning the special tool (tap M10 x 1.25), and then clean the threaded holes by applying compressed air.

Tap

3. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive: 3M Stud Locking Part No. 4170 or equivalent 4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence. Tightening torque: 78 - 88 Nm

Contact plate

MB990728

Contact plate

"HA SIDE BEARING INNER RACE INSTALLATION

MB990728

"IA DRIVE GEAR BACKLASH ADJUSTMENT Adjust the drive gear backlash by the following procedures: 1. Install the side bearing spacers, which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier. NOTE Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side.

REAR AXLE - Differential Carrier

27B-35

2. Push the differential case to one side, and measure the clearance between the gear carrier and the side bearing adjusting spacer with a thickness gauge.

3. Measure the thickness of the side bearing spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm, and then install one pair each to the drive pinion side and the drive gear side.

Clearance/2 + 0.05 mm = Thickness of the spacer on one side

4. Install the side bearing spacers and differential case assembly, as shown in the illustration, to the gear carrier.

5. Tap the side bearing adjusting spacers with special tool to fit them to the side bearing outer race.

MB990939

6. Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.

27B-36

REAR AXLE - Differential Carrier 7. With the drive pinion locked in place, measure the drive gear backlash with a dial indicator on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: 0.11 - 0.16 mm

If backlash is too small Thinner spacer

Thicker spacer

8. Change the side bearing spacers as illustrated, and then adjust the drive gear backlash between the drive gear and the drive pinion. NOTE When increasing the number of side bearing spacers, use the same number for each, and as few as possible.

Thicker spacer

Thinner spacer

9. Check the drive gear and drive pinion for tooth contact. If poor contact is evident, make adjustment. (Refer to P.27-24.)

If backlash is too large

10. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm 11. If the drive gear runout exceeds the limit, reinstall by changing the phase of the drive gear and differential case, and remeasure. 12. If adjustment is not possible, replace the differential case or replace the drive gear and drive pinion as a set.

27B-37

REAR AXLE - LSD Case Assembly

LSD CASE ASSEMBLY

27300140066

DISASSEMBLY AND REASSEMBLY 1 10 9 8

5 6 5 4 3 2

5

7 6 5

Disassembly steps D Inspection before disassembly 1. Screw "AA 2. Differential case (A) AB" "CA 3. Thrust washer (L.H.) 4. Viscous coupling (with differential side gear: L.H.)

AA"

"BA 5. Pinion mate washer "BA 6. Differential pinion mate 7. Differential pinion shaft 8. Differential side gear (R.H.) AB" 9. Thrust washer (R.H.) "AA 10. Differential case (B)

DISASSEMBLY SERVICE POINTS Thickness gauges

AA" INSPECTION BEFORE DISASSEMBLY DIFFERENTIAL GEAR BACKLASH CHECK 1. Hold the limited slip differential case assembly in a vice with the differential side gear (R.H.) up. Caution Be careful not to tighten the vice too strongly to avoid damage to the limited slip differential case assembly.

Thickness gauges

Differential side gear (R.H.)

Thrust washer (R.H.)

2. Install two 0.03 mm thickness gauge blades diagonally between the differential case (B) and the thrust washer (R.H.). Caution Do not insert the thickness gauge in the oil groove provided in the differential case (B).

27B-38

REAR AXLE - LSD Case Assembly

Thickness gauges Thickness gauges

Thickness gauges

MB991357

Thickness gauges

3. Insert the special tool in the splined portion of the differential side gear (R.H.) and make sure that the side gear (R.H.) turns. 4. Replace the thickness gauges with 0.09 mm thickness gauges. 5. Insert the special tool in the splined portion of the differential side gear (R.H.) and make sure that the side gear (R.H.) does not turn. Standard value: Differential gear backlash 0.03 - 0.09 mm NOTE The differential gear backlash is normal if the side gear clearance in the direction of thrust is within the standard value. 6. If the side gear clearance in the direction of thrust is not within the standard value, remove the differential case (A) and adjust by means of thrust washer (L.H.). Thrust washer

Part No.

Thickness mm

L.H.

MB569243

0.8, 0.9, 1.0, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.5

R.H. [Reference]

MB569528

0.8

NOTE The thrust washers (L.H.) are available in a kit. Select one appropriate thrust washer from among 11 washers.

AB" THRUST WASHER (L.H.)/THRUST WASHER (R.H.) REMOVAL The thrust washer (L.H.) differs from the thrust washer (R.H.) in thickness. Keep them separately from each other for reference in assembly.

REAR AXLE - LSD Case Assembly

27B-39

REASSEMBLY SERVICE POINTS Differential case (B) Mating marks

Differential case (A)

"AA DIFFERENTIAL CASE (B)/DIFFERENTIAL CASE (A) INSTALLATION Install the differential cases (A) and (B) with their mating marks in alignment.

MB990989

Pinion mate washer

"BA DIFFERENTIAL PINION MATE/PINION MATE WASHER INSTALLATION Attach the differential pinion mate to the pinion shaft with the pinion washers directed as shown, then assemble them into the differential case (B).

Differential pinion mate

"CATHRUST WASHER (L.H.) SELECTION When the differential side gear and pinion mate gear have been replaced, select the thrust washer (L.H.) by the following procedure. 1. Wash the differential side gear and pinion mate gear with unleaded gasoline and degrease. 2. Assemble the thrust washers so far used, without confusing the R.H. part with the L.H. part and together with each gear, VCU, pinion mate washer and pinion shaft, to the differential cases (A) and (B), and loosely tighten the screws. 3. Check the differential backlash, and select a thrust washer (L.H.) to obtain its standard value. (Refer to P.27-38.)

27B-40

REAR AXLE - LSD Case Assembly INSPECTION

Differential side gear (R.H.)

Differential pinion mate

27300150038

1. Check each gear and the differential pinion shaft for wear and damage. 2. Check the splined portion of the differential side gear (R.H.) for damage and shoulder.

Differential pinion shaft

Differential pinion mate

Thrust washer

Pinion mate washers

Pinion mate washers

3. Check the sliding surfaces of the thrust washer and pinion mate washer for wear, seizure and damage.

Thrust washer

Differential case (B)

D B

Differential case (A) C

4. Check the sliding surfaces of the differential cases (A) and (B) for wear, seizure and damage. A. Surface in sliding contact with VCU B. Surface in sliding contact with pinion mate washer C. Surface in sliding contact with thrust washer D. Surface in sliding contact with thrust washer

A

Surfaces in sliding contact with differential case (B) Side gear (L.H.) of VCU

Splined portion

5. Check the spline of VCU for damage and shoulder and check the surface in sliding contact with the differential case (B). 6. Check the side gear (L.H.) of VCU for wear and damage.

31-1

WHEEL AND TYRE CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3

31109000182

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4 Tyre Inflation Pressure Check . . . . . . . . . . . . . . . . . 4 Tyre Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . . . . 4

31-2

WHEEL AND TYRE - General Information/Service Specifications

GENERAL INFORMATION

31100010276

The wheels and tyres of the following specifications have been established.

SPECIFICATIONS

31100030135

Items Wheel

Specification Type

Steel Aluminium*

Size

15 ¢ 6JJ

Amount of wheel offset mm

46

Pitch circle diameter (P.C.D.) mm

114.3

Tyre

Size

205/65R15 94H

Spare wheel

Type

Steel

Size

15 x 4.0T, 15 x 6JJ*

Amount of wheel offset mm

46

Pitch circle diameter (P.C.D) mm

114.3

Size

T135/90D15 (High pressure) 205/65R15 94H*

Spare tyre

NOTE *: Optional items

SERVICE SPECIFICATIONS

31100030135

Items

Limit

Tread depth of tyre mm

1.6

Wheel runout (Radial runout) mm

Wheel runout (Lateral runout) mm

Steel wheel

1.2 or less

Aluminium wheel

1.0 or less

Steel wheel

1.2 or less

Aluminium wheel

1.0 or less

31-3

WHEEL AND TYRE - Troubleshooting

TROUBLESHOOTING

31100070205

Symptom

Probable cause

Remedy

Reference page

Rapid wear at shoulders

Under-inflation or lack of rotation

Adjust the tyre pressure.

31-4.

Rapid wear at centre

Over-inflation or lack of rotation

Cracked treads

Under-inflation

Adjust the tyre pressure.

31-4.

Wear side

Excessive camber

Inspect the camber.

Refer to GROUP 33A - On-vehicle Service.

Feathered edge

Incorrect toe-in

Adjust the toe-in.

Bald spots

Unbalanced wheel

Adjust the imbalanced wheels.

-

Scalloped wear

Lack of rotation of tyres or worn or out-of-alignment suspension

Rotate the tyres and check the front suspension alignment.

Refer to GROUP 33A - On-vehicle Service.

on

one

31-4

WHEEL AND TYRE - On-vehicle Service/Wheel and Tyre

ON-VEHICLE SERVICE

31100090164

TYRE INFLATION PRESSURE CHECK NOTE For information on tyre inflation pressure, refer to the label attached to the driver’s side front door.

TYRE WEAR CHECK

31100100034

Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre. NOTE When the tread depth of tyres is reduced to 1.6 mm or less, wear indicators will appear.

WHEEL RUNOUT CHECK Radial

31100110037

Jack up the vehicle so that the wheels are clear of the floor. While slowly turning the wheel, measure wheel runout with a dial indicator. Limit:

Lateral

Item

Steel wheel

Aluminium wheel

Radial runout mm

1.2

1.0

Lateral runout mm

1.2

1.0

If wheel runout exceeds the limit, replace the wheel.

WHEEL AND TYRE INSTALLATION SERVICE POINT Tighten the wheel nut to the specified torque. Tightening torque: 98 Nm

31100130071

32-1

POWER PLANT MOUNT CONTENTS

32109000165

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

FRONTMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 3

ROLL STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . 4

32-2

POWER PLANT MOUNT - General Information

GENERAL INFORMATION

32100010150

The engine-transmission mount is of an inertial axis supporting type whose excellent features have already been proven in many Mitsubishi vehicles. The inertial axis supporting type mount supports

the front upper part of the engine at the front and the rear upper part of the transmission at the rear. This arrangement effectively suppresses the engine vibration.

Dynamic damper Engine mount

Frontmember Front Rear roll stopper Front roll stopper

Transmission mount Dynamic damper Engine mount Transmission mount

Front

Front roll stopper

Frontmember

Rear roll stopper

POWER PLANT MOUNT - Engine Mounting

ENGINE MOUNTING

32-3 32100110263

REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation D Engine Cover Removal and Installation D Jack Up the Engine and Transmission Assembly until Weight is off the Insulator.

67 Nm 5 Nm

5

57 Nm

4

3 12 Nm

1 2

88 - 108 Nm*

Removal steps 1. Oil reserver 2. Engine mount insulator mounting bolt

Engine side Arrow

Engine mount stopper Engine mount bracket

3. Engine mount bracket "AA 4. Engine mount stopper 5. Dynamic damper

INSTALLATION SERVICE POINT "AA ENGINE MOUNT STOPPER INSTALLATION Install the engine mount stopper so that the arrow faces the direction shown.

32-4

POWER PLANT MOUNT - Transmission Mounting

TRANSMISSION MOUNTING

32100140170

REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation (Refer to GROUP 15) D Frontmember Removal and Installation (Refer to P.32-5.)

81 Nm*

57 Nm

2 1 2

AA"

Removal steps 1. Transmission mount bracket "AA 2. Transmission mount stoppers

REMOVAL SERVICE POINT AA" TRANSMISSION MOUNT BRACKET REMOVAL 1. Support the engine and transmission assembly with a garage jack. 2. Remove the transmission mount bracket mounting bolts and nuts. 3. After lowering the engine and transmission assembly, remove the transmission mount bracket.

POWER PLANT MOUNT - Transmission Mounting/Frontmember

32-5

INSTALLATION SERVICE POINT

Engine side

"AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow faces the direction shown. Transmission mount bracket

Transmission mount stopper

NOTE Disregard F and R stamped as a shared part.

FRONTMEMBER REMOVAL AND INSTALLATION Caution 1. Before removing the steering gear box, refer to GROUP 52B – SRS Air Bag. Set the front wheels straightforward, and then remove the ignition key; otherwise the SRS clock spring will be damaged. This makes the SRS air bag inoperative and will invite serious driver injury. 2. Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operations D Under Cover Removal and Installation D Side Cover Mounting Clip on Frontmember Side Removal and Installation D Push Dust Cover to Check that Cracks or Damage are not present (After Installation Only)

D D

Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Transfer Assembly Removal and Installation (Refer to GROUP 22 or 23 .)

32-6

POWER PLANT MOUNT - Frontmember

39 Nm

3 2

12 Nm

39 Nm

69 Nm

1

12 44 Nm*

98 - 118 Nm 13 Nm

57 Nm*

98 - 118 Nm*

6

11

10

10

14

88 - 108 Nm

13 16 5

9

4

177 Nm

8 88 - 108 Nm* 57 Nm*

7

78 Nm 177 Nm

15 Frontmember removal steps 1. Steering gear and linkage mounting bolt 2. Oil line mounting bolt 3. Stabilizer link connection 4. Stay "BA 5. Lower arm assembly connection 6. Front roll stopper connecting bolt 7. Rear roll stopper connecting bolt AB" 8. Frontmember mounting bolt

AA"

9. 10. 11. "AA 12. 13. 14. 15. 16.

Lower stopper Upper stopper Front hanger Stabilizer bar Lower arm assembly Front roll stopper Rear roll stopper Frontmember

POWER PLANT MOUNT - Frontmember

32-7

REMOVAL SERVICE POINT AA" STEERING GEAR AND LINKAGE MOUNTING BOLT REMOVAL Use a wire to fix the steering gear box on the vehicle before removing the steering gear and linkage mounting bolts.

AB" FRONTMEMBER MOUNTING BOLT REMOVAL 1. Use a wire to fix the radiator on the vehicle before removing the frontmember. 2. Support the frontmember with a garage jack and a wooden board, and remove the frontmember mounting bolts.

Wooden board

Transmission jack

INSTALLATION SERVICE POINT

Front of vehicle

"AA STABILIZER BAR INSTALLATION 1. Install the bushing so that its cutting faces the direction shown. 2. Place the stabilizer bar identification mark at the left of the vehicle and position it as shown in the illustration. Tighten the stabilizer bar bracket mounting bolts.

Approx. 20 mm

Bushing

"BA LOWER ARM ASSEMBLY INSTALLATION 1. Install the lower arm assembly to the knuckle.

Knuckle

A Lower arm assembly

Caution Be careful that the ball joint stud does not project more than 4 mm from the knuckle (A shown). 2. Replace the dust cover if grease spouted out due to the knuckle too much pressed in. 3. Check that no clearance is present between the knuckle and dust cover.

32-8

POWER PLANT MOUNT - Roll Stopper

ROLL STOPPER

32100140170

Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body.

44 Nm*

57 Nm*

4 57 Nm*

3 2

Front roll stopper removal steps D Radiator (Refer to GROUP 14) 1. Front roll stopper connecting bolt 2. Front roll stopper

1

98 - 118 Nm*

Rear roll stopper removal steps 3. Rear roll stopper connecting bolt 4. Rear roll stopper

33A-1

FRONT SUSPENSION CONTENTS

33109000094

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

LOWER ARM ASSEMBLY . . . . . . . . . . . . . . . . 10

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 14

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4 Wheel Alignment Check and Adjustment . . . . . . . 4 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 5

33A-2 FRONT SUSPENSION -

General Information/Service Specifications

GENERAL INFORMATION

33100010089

The front suspension is a McPherson strut with coil spring. The shock absorber is hydraulic double-acting type.

COIL SPRING Items

SPACE RUNNER

SPACE WAGON - 2WD

SPACE WAGON - 4WD

Wire diameter ´ average diameter ´ free length mm

13.6 ´ 160 ´ 368

14.0 ´ 160 ´ 371

14.1 ´ 160 ´ 381

CONSTRUCTION DIAGRAM Coil spring

Strut assembly Stabilizer link

Stabilizer bar

Lower arm assembly

SERVICE SPECIFICATIONS Items

33100030115

SPACE RUNNER

SPACE WAGON

At the centre of tyre tread mm

0±3

0±3

Toe-angle (per wheel)

0_ 00’ ± 08’

0_ 00’ ± 08’

Toe-out angle on turns (inner wheel when outer wheel at 20_)

22_ 10’

21_ 50’

Camber

0_ 00’ ± 30’ *

- 0_ 10’ ± 30’ *

Caster

2_ 45’ ± 30’ *

2_ 50’ ± 30’ *

Kingpin inclination

11_ 27’

12_ 49’

Lower arm ball joint rotation starting torque Nm

2.0 - 8.8

2.0 - 8.8

Stabilizer link ball joint turning torque Nm

1.7 - 3.1

1.7 - 3.1

Toe-in

NOTE *: difference between right and left wheel: less than 30’

FRONT SUSPENSION - Special Tools

SPECIAL TOOLS Tools

33A-3 33100060077

Number

Name

Use

MB991004

Wheel alignment gauge attachment

Wheel alignment measurement