AT-1 AUTOMATIC TRANSMISSION

IONAT-4TROUBLESHOOTINGAT-9General NotesAT-9General TroubleshootingAT-10Preliminary CheckAT-12Mechanical System TestsAT-14Automatic Shift ScheduleAT-26Neutral Start SwitchAT-28O/D Solenoid (w/ Cruise Control System)AT-28A/T Fluid Temperature Warning SystemAT-29ON-VEHICLE REPAIRAT-30Valve BodyAT-30Throttle CableAT-33REMOVAL AND INSTALLATIONOF TRANSMISSIONAT-36REMOVAL OF TRANSMISSIONAT-38INSTALLATION OF TRANSMISSIONAT-44

AT-2AUTOMATIC TRANSMISSION - DescriptionDESCRIPTIONGENERALThe A440F and A442F automatic transmissions are the four-speed automatic transmission with a twospeed transfer, developed with the aim of producing an easy-driving 4WD vehicle. A lock-up mechanism isbuilt into the torque converter.AT6021The A440F and A442F transmissions are mainly composed of the torque converter, the overdrive (hereafter called O/D) planetary gear unit, 3-speed planetary gear unit, 2-speed transfer and the hydraulic controlsystem.AT3917

AUTOMATIC TRANSMISSIONGeneral Specifications-DescriptionAT-3

AT-4AUTOMATIC TRANSMISSION - OperationOPERATIONPLANETARY GEAR UNITThe planetary gear unit is composed of three sets of planetary gears, three clutched which transmit powerto the planetary gears, and three brakes and two one-way clutches which immobilize the planetary carrierand planetary sun gear.Power from the engine transmitted the input shaft via the torque converter is than transmitted to the planetary gears by the operation of the clutches. By operation of the brakes and one-way clutches, either theplanetary carrier or the planetary sun gear is immobilized, altering the speed of revolution of the planetarygear unit. Shift change is carried out by altering the combination of clutch and brake operation.Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttleopening angle and vehicle speed, and shift change automatically occurs.OPERATION OF EACH ELEMENT

AUTOMATIC TRANSMISSION - OperationOPERATING CONDITION FOR EACH GEARFUNCTION OF COMPONENTSThe conditions of operation for each gear position are shown on the following illustration:AT-5

AT-6AUTOMATIC TRANSMISSION - OperationFUNCTION OF COMPONENTS (Cont'd)

AUTOMATIC TRANSMISSION - OperationAT-7Hydraulic Control SystemThe hydraulic control system is composed of the oil pump, the valve body, the solenoid valve, the accumulators, the clutches and brakes, as well as the fluid passages which connect all of these components.Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulicpressure acting on the torque converter, clutches and brakes in accordance with the vehicle driving conditions.There is a solenoid valve on the valve body.The solenoid valve accompany with the cruise control system is turned on and off by signals from the CCSECU to operate the 3-4 shift valve, and change the gear shift position.

AT-8AUTOMATIC TRANSMISSION - OperationA.T. FLUID TEMPERATURE WARNING SYSTEMThe ECU detects the A/T fluid temperature by means of a fluid temperature sensor fitted to the union. TheA/T fluid may become extremely hot when the vehicle is under and extreme load, as when driving on sandor climbing uphill. Should the fluid temperature increase above 150 C (302 F), the ECU lights the warning light located in the combination meter. The light goes off when the temperature falls below 120 C(248 F).A.T. Fluid Temp.AT6023A.T.P. (Automatic Transmission Parking) INDICATORThe propeller shaft and wheels are free even when the transmission shift lever is set to "P" as long as thetransfer shift lever is in "neutral" position. The A.T.P. indicator lights up to warn the driver that the propeller shaft and wheels are not locked. If the A.T.P. indicator light goes on, the transfer shift lever should beshifted to out of " N " position.AT6024AT3920

AUTOMATIC TRANSMISSION - Troubleshooting (General Notes)AT-9TROUBLESHOOTINGGeneral Notes1.2.3.Troubles occuring with the automatic transmission can be caused by either the engine or the transmission itself. These two areas should be distinctly isolated before proceeding with troubleshooting.Troubleshooting should begin with the simplest operation, working up in order of difficulty, but firstdetermine whether the trouble lies within the engine, electrical control or transmission.Proceed with the inspection as follows:PRELIMINARY CHECK (See Page AT-12)(a) Check the tire inflation.(b) Check the idle speed.(c) Check the fluid level and fluid condition.(d) Check the throttle cable mark.(e) Check the shift linkage.(f) Check the neutral start switch.STALL TEST (See page AT-14)Check the engine and torque converter.TIME LAG TEST (See page AT-15)Check the automatic transmission (each clutch, brake and gear) forwear.HYDRAULIC TEST (See page AT-16)Measure the line pressure and make a basic check of fluid circuit.ROAD TEST (See page AT-22)Confirm if trouble lies within automatic transmission.If noisy or vibrating, the possible cause could be with the compressor, engine,propeller shafts, tires, etc.

AT-10AUTOMATIC TRANSMISSION — Troubleshooting (General Troubleshooting)General TroubleshootingProblemFluid discolored orsmells burntVehicle does notmove in any forwardrange or reverseShift lever positionincorrectHarsh engagementinto any driverangeDelayed 1-2, 2-3 or3-0/D up-shift, ordown-shifts from O/D3 or 3-2 and shiftsback to O/D or 3Slips on 1-2, 2-3 or3-O/D up-shift, orslips or shudders onaccelerationDrag, binding or tieup of 1-2, 2-3 or 30/D up-shiftPossible causeRemedyPageFluid contaminatedReplace fluidAT-12Torque converter faultyReplace torque converterAT-37Transmission faultyDisassemble and inspect transmissionManual linkage out of adjustmentAdjust linkageAT-13Valve body or primary regulator faultyInspect valve bodyAT-29Parking lock pawl faultyInspect parking lock pawlTorque converter faultyReplace torque converterAT-37Converter drive plate brokenReplace drive plateAT-37Oil pump intake strainer blockedClean strainerAT-29Transmission faultyDisassemble and inspect transmissionManual linkage out of adjustmentAdjust linkageAT-13Manual valve and lever faultyInspect valve bodyAT-29Transmission faultyDisassemble and inspecttransmissionThrottle cable out of adjustmentAdjust throttle cableAT-13Valve body or primary regulator faultyInspect valve bodyAT-29Accumulator pistons faultyInspect accumulator pistonsTransmission faultyDisassemble and inspecttransmissionThrottle cable out of adjustmentAdjust throttle cableAT-13Throttle cable and cam faultyInspect throttle-cable and camAT-32Governor faultyInspect governorValve body faultyInspect valve bodyAT-29Manual linkage out of adjustmentAdjust linkageAT-13Throttle cable out of adjustmentAdjust throttle cableAT-13Valve body faultyInspect valve bodyAT-29Transmission faultyDisassemble and inspecttransmissionManual linkage out of adjustmentAdjust linkageAT-13Valve body faultyInspect valve bodyAT-29Transmission faultyDisassemble and inspecttransmission

AUTOMATIC TRANSMISSION - Troubleshooting (General Troubleshooting)AT-11General Troubleshooting (Cout'd)ProblemNo lock-upPossible causeRemedyPageValve body faultyInspect valve bodyAT-29Torque converter faultyReplace torque converterAT-44Transmission faultyDisassemble and inspect transmissionThrottle cable out of adjustmentAdjust throttle cableAT-13Throttle cable and cam faultyInspect throttle cable and camAT-32Accumulator pistons faultyInspect accumulator pistonsValve body faultyInspect valve bodyTransmission faultyDisassemble and inspecttransmissionGovernor faultyInspect governorValve body faultyInspect valve bodyAT-29Throttle cable out of adjustmentAdjust throttle cableAT-13Governor faultyInspect governorValve body faultyInspect valve bodyTransmission faultyDisassemble and inspecttransmissionThrottle cable out of adjustmentAdjust throttle cableGovernor faultyInspect governorValve body faultyInspect valve bodyAT-29No engine brakingin 2 or L rangeValve body faultyInspect valve bodyAT-29Transmission faultyDisassemble and inspecttransmissionVehicle does not holdinPManual linkage out of adjustmentAdjust linkageParking lock pawl cam and spring faultyInspect cam and springHarsh down-shiftNo down-shift whencoastingDown-shift occurstoo quickly or toolate while coastingNo O/D-3 , 3-2 or2-1 kick-downAT-29AT-29AT-13AT-13

AT-12AUTOMATIC TRANSMISSION - Troubleshooting (Preliminary Check)Preliminary Check1.CHECK FLUID LEVELHINT: The vehicle must have driven so that the engine andtransmission are at normal operating temperature.(Fluid temperature:70 - 80 C or 1 58 - 176 F) Only use the COOL range on the dipstick as a roughreference when the fluid is replaced or the engine doesnot run.(a)Park the vehicle on a level surface, set the parkingbrake.(b)With the engine idling, shift the shift lever into allpositions from P to L position and return to P position.(c)Pull out the transmission dipstick and wipe it clean.(d)Push it back fully into the tube.(e)Pull it out and check that the fluid level is on theHOT range.If the level is at the low side, add fluid.Fluid type:ATFDEXRON IINOTICE: Do not overfill.2.CHECK FLUID CONDITIONIf the fluid smells burnt or is black, replace it in the following procedure.(a)Remove the drain plug and drain the fluid.(b)Reinstall the drain plug securely.Torque:(c)280 kg-cm (20 ft-lb, 27 N-m)With the engine OFF, add new fluid through the oilfiller tube.Fluid type:ATF DEXRON IICapacity:Totalw/o Oil cooler15.0 litters (15.9 US qts, 13.2 Imp. qts)w/ Oil cooler15.4 litters (16.3 US qts, 13.6 Imp. qts)Drain and refill6.0 litters (6.3 US qts, 5.3 Imp. qts)(d)Start the engine and shift the shift lever into all positions from P to L position and then shift into P position.(e)With the engine idling, check the fluid level. Addfluid up to the COOL level on the dipstick.(f)Check the fluid level with the normal operating temperature (70 — 80 C or 158 - 176 F) and add asnecessary.NOTICE: Do not overfill.

AUTOMATIC TRANSMISSION - Troubleshooting (Preliminary Check)AT-133.INSPECT THROTTLE CABLE(a) Cheek that the throttle cable is installed correctlyand not bent.(b) With the throttle valve fully closed, measure the distance between the end of the boot and stopper onthe cable.Standard distance:Fully closed 0.5 — 1.5 mm(0.020 - 0.059 in.)Fully opened 32 — 34 mm(1.260 - 1.339 in.)If the distance is not standard, adjust the cable by the adjusting nuts.4.INSPECT TRANSMISSION SHIFT LEVER POSITIONWhen shifting the shift lever from the N position to otherpositions, check that the lever can be shifted smoothlyand accurately to each position and that the position indicator correctly indicates the position.If the indicator is not aligned with the correct position,carry out the following adjustment procedures.(a) Loosen the nut on the control rod.(b) Push the control shaft lever fully toward the rear ofthe vehicle.(c) Return the control shaft lever two notches to N position.(d) Set the shift lever to N position.(e) While holding the shift lever lightly toward the R position side, tighten the control rod nut.(f) Start the engine and make sure that the vehiclemoves forward when shifting the lever from the N toD position and reverse when shifting it to the R position.5.INSPECT NEUTRAL START SWITCHCheck that the engine can be started with the shift leveronly in the N or P position, but not in other positions.If not as started above, carry out the following adjustment procedures.(a) Loosen the neutral start switch bolts and set theshift lever to the N position.(b) Align the groove and neutral basic line.(c) Hold in position and tighten the bolts.Torque: 130 kg-cm (9 ft-lb, 13 N-m)6.INSPECT IDLE SPEED (N RANGE)Connect tachometer test probe to the check connectorterminal IG Q , inspect the idle speed.Idle speed: 650 rpm