MITSUBISHI MONTERO 2000 Service Repair Manual

AUTOMATIC
TRANSMISSION
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23-1
AUTOMATIC
TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
SPECIAL TOOLS 2..........................
TROUBLESHOOTING
<A/T> 3.....................................
<SS4II
>70................................
<Shift Lock and Key Interlock Mechanisms>
92 ..........................................
ON-VEHICLE SERVICE 94...................
Basic Adjustment Procedures 94.................
Transfer Oil Check 99...........................
Transfer Oil Change 99.........................
Location of Control Components 101..............
Control Component Checks 102..................
Torque Converter Stall Test 105..................
Fluid Pressure Test 106.........................Hydraulic Circuit 110............................
Line Pressure Adjustment 111...................
Selector Lever Operation Check 111..............
Transfer Shift Lever Operation Check 114........
Transmission Control Cable Adjustment 114......
Transfer-ECU Check 115........................
Position Indicator Lamp Check 115...............
TRANSMISSION CONTROL* 116.............
SHIFT LOCK AND KEY INTERLOCK
MECHANISMS* 120..........................
TRANSMISSION ASSEMBLY 122.............
TRANSMISSION OIL COOLER 127...........
A/T-ECU 129................................
TRANSFER-ECU 130........................
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, and interconnecting
wiring. Other SRS-related components (that mayhave to be removed/installed in connectionwith SRS service or maintenance) are
indicated in the table of contents by an asterisk(*).


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S
ER VIC E SPEC IF IC ATIO NS
I te m S
ta ndard va lu e A
/T flu id te m pera tu re se n- A
t0°C 1
6.7 -20.5 s
o r re sis ta nce kW 7
.3 -8.9 A
t40°C 3
.4 -4.2 A
t60°C 1
.9 -2.2 A
t80°C 1
.0 -1.2 A
t100 °C 0
.5 7 -0.6 9 D
am per clu tc h co ntr o l(D CC)so le noid va lv e co il re sis ta nce (a t 20°C )W L
ow &re ve rs e (L R )so le noid va lv e co il re sis ta nce (a t 20°C )W S
eco nd (2 N D)so le noid va lv e co il re sis ta nce (a t 20°C )W U
nderd riv e so le noid va lv e (U D so le noid va lv e ) co il re sis ta nce (a t 20°C )W O
ve rd riv e so le noid va lv e (O D so le noid va lv e ) co il re sis ta nce (a t 20°C )W R
esis ta nce of re ductio n (R ED )so le noid va lv e co il a t (2 0°C )W S
ta ll s p eed r/m in 6
G 7 2
,2 00 -2,7 00 4
M 4 2
,4 00 -2,9 00 L
in e pre ssu re adju stm ent va lu e kP a 1
,0 10 -1,0 50 B
ra nd Q
uantit y L T
ra nsm is sio n flu id D
IA QUEEN AT F SP II M ,A T F SP III or equiv a le nt 9
.3 T
ra nsfe r oil H
yp oid gear oil S AE 75W -9 0 or 75W -8 5W co nfo rm in g to API
G L-4 2
.8 N
o. N
am e A
pplic a tio n M
B991502 M
UT-II S ub
a sse m bly D
ia gnosis co de ch eckin g M
B991529 D
ia gnosis co de
c h eckin g harn ess M
B991658 T
e st harn ess V
olt a ge measu re m ent of APS M
D998478 T
e st harn ess
( 3 P, tr ia ngle ) V
olt a ge measu re m ent of cra nk angle se nso r

M
D998330
( in clu din g
M D998331) O
il p re ssu re gauge
( 2 ,9 42 kP a) H
yd ra ulic pre ssu re measu re m ent M
D998332 A
dapte r O
il p re ssu re gauge co nnectio n M
D998900 A
dapte r N
o dia gnosis co de
o utp ut (n o abnorm alit y ) A
sk about tr o uble sym pto m s. C
heck th e A/T flu id . N
G R
epla ce th e A/T flu id .
O K C
heck th e tr o uble sym pto m s. R
eadin g of a dia gnosis co de
( R efe r to P.2 3-4 .) C
om munic a tio n
w it h th e MUT-
II
i s not possib le I
n sp ectio n pro ce dure ch eck by
t r o uble sym pto m
P ro ce dure 1(R efe r to P.2 3-4 8.)
D ia gnosis co de outp ut exis ts N
o dia gnosis co de
o utp ut R
oad te st (R efe r to P.2 3-5 .)
D ia gnosis co de outp ut
e xis ts G
o to Dia gnosis Code Lis t
( R efe r to P.2 3-1 2.) N
o dia gnosis co de
o utp ut (a bnorm alit y
e xis ts ) C
heck fo r th e ca use . N
ot fo und
N G N
G R
epair
O K G
o to Tro uble Sym pto m Lis t
( R efe r to P.2 3-4 7.) V
erif ic a tio n te st (ro ad te st)
F
ound E
N D E
ra se of a dia gnosis co de
( R efe r to P.2 3-4 .) T
ra nsie nt m alf u nctio n (R efe r to
G RO UP 00 -Poin ts to Note fo r
T ra nsie nt M alf u nctio ns.) O
K
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O
utp ut sh aft se nso r syste m S
ole noid va lv e syste m N
on-s yn ch ro niz a tio n at va rio us sh if t ra nges A
/T co ntr o lre la y syste m

AUTOMATIC TRANSMISSION -Troubleshooting <A/T>AUTOMATIC TRANSMISSION -Troubleshooting <A/T>23-5
ROAD TEST
No.Pre-test/opera-
tion conditionsTest/operationJudgment valueCheck itemDiag-
nosis
code
No.Inspection pro-
cedure if there is
an abnormality
1Ignition switch:
OFFIgnition switch
(1) ONData List No. 54
(1) 10 - 12 VA/T control
relay54A/T control relay
system
2Ignition switch:
ON
Engine:Stop
Selector lever
position: PSelector lever posi-
tion
(1) P
(2) R
(3) N
(4) DData List No. 61
(1) P
(2) R
(3) N
(4) DInhibitor
switch-Inhibitor switch
system
Selector lever opera-
tion
(1) D (1st)
(2) Sports mode se-
lected (1st)
(3) Lever moved toData List
No.67 No.68 No.69
(1)OFF OFF OFF
(2)ON OFF OFF
(3)ON ON OFF
(4)ON OFF ON
Select switch
Upshift
switch
Downshift
switch-Sports mode
switch system
upshift position
and held (2nd)
(4) Lever moved to
downshift
position and held
(1st)Shift indicator lamp
(1) D and 1
illuminate
(2) Only 1
illuminates
(3) Only 2
illuminates
(4) Only 1
illuminates
Accelerator pedal
(1) Fully closed
(2) Depressed
(3) Fully openedData List No. 11
(1) 985 - 1,085 mV
(2) Gradually in-
creases from (1)
(3) 4,000 mV or
moreAPS11
12
14APS system
Data list No.25
(1) OFF
(2) ONWide open
throttle
switch25Wide open
throttle switch
system
2Ignition switch:
ON
Engine: StopBrake pedal
(1) Depressed
(2) ReleasedData List No. 26
(1) ON
(2) OFFStop lamp
switch26Stop lamp
switch system
Selector lever
position: PTransfer shift lever
position
(1) Except for 4LLc
(2) 4LLcData List No. 75
(1) OFF
(2) ON4LLc switch-4LLc switch sys-
tem


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AUTOMATIC TRANSMISSION -Troubleshooting <A/T>23-6
No.Inspection pro-
cedure if there is
an abnormality Diag-
nosis
code
No. Check item Judgment value Test/operation Pre-test/opera-
tion conditions
3Ignition switch:
START
Engine: StoppedStarting test at P or N
positionStarting should be
possibleStarting pos-
sible/not
possible-Starting not
possible
4Driving after en-
gine has warmed
upDrive for 15 minutes
or more until the A/T
fluid temperature
rises to 70 - 80_
C.Data list No.15
Gradually rises to 70
-80_
CA/T fluid tem-
perature
sensor15A/T fluid temper-
ature sensor sys-
tem
5Engine: Idling
Selector lever
position: NBrake pedal (re-test)
(1) Depressed
(2) ReleasedData List No. 26
(1) ON
(2) OFFStop lamp
switch26Stop lamp switch
system
A/C switch
(1) ON
(2) OFFData List No. 65
(1) ON
(2) OFFDual pres-
sure switch-Dual pressure
switch system
Accelerator pedal
(1) Fully closed
(2) ApplyData List No. 21
(1) The engine
speed displayed
on the tachome-
ter is identical to
the engine
speed displayed
on MUT-II.
(2) Gradually in-
creases from (1)Crank angle
sensor
<6G7>
Engine
speed sen-
sor
<4M4>21Crank angle sen-
sor system
<6G7>
Engine speed
sensor system
<4M4>
Data List
No.73 <6G7>
No.76 <4M4>
(2) Data changes.Communica-
tion with en-
gine-ECU51Serial commu-
nication system
Selector lever posi-
tionNo abnormal shock
during shiftingMalfunction
when start--Engine stalls dur-
ing shifting
(1) N to D
(2) N to RWithin 2 seconds of
time laging off-N-to-D shocks,
large time lag
-N-to-R shocks,
large time lag
-N-to-D, N-to-R
shocks, large
time lag
Driving not
possible-Does not move
forward
-Does not reverse
-Does not move
(forward or re-
verse)


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AUTOMATIC TRANSMISSION -Troubleshooting <A/T>23-7
No.Inspection pro-
cedure if there is
an abnormality Diag-
nosis
code
No. Check item Judgment value Test/operation Pre-test/opera-
tion conditions
6Selector lever
position:
Sports mode
(Must be done on
a level and
straight road.)Selector lever posi-
tion and engine
(1) Idling in 1st
(Vehicle
stopped)
(2) Driving at aData List No. 63
(2) 1st
(3) 2nd
(4) 3rd
(5) 4th
(6) 5thShift condi-
tion--
constant speed
of 10 km/h in 1st
(3) Driving at a
constant speed
of 30 km/h in 2nd
(4) Driving at a
constant speedData List No. 31
(2) 0%
(3) 100%
(4) 100%
(5) 100%
(6) 100%Low & re-
verse sole-
noid valve
(LR solenoid
valve)31LR solenoid
valve system
constant speed
of 50 km/h in 3rd
(5) Driving at a
constant speed
of 50 km/h in 4th
(6) Driving at a
constant speed
Data List No. 32
(2) 0%
(3) 0%
(4) 0%
(5) 0%
(6) 100%Underdrive
solenoid
valve (UD
solenoid
valve)32UD solenoid
valve system
of 70 km/h in 5th
(Each condition
should be main-
tained for 10 seconds
or more)
Data List No. 33
(2) 100%
(3) 0%
(4) 100%
(5) 100%
(6) 0%Second sole-
noid valve
(2ND sole-
noid valve)332nd solenoid
valve system
Data List No. 34
(2) 100% (5) 0%
(3) 100% (6) 0%
(4) 0%Overdrive
solenoid
valve (OD
solenoid
valve)34OD solenoid
valve system
Data List No. 35
(2) 0% (5) 100%
(3) 0% (6) 100%
(4) 0%Reduction
solenoid
valve (RED
solenoid
valve)35RED solenoid
valve system
Data List No. 29
(1) 0 km/h
(5) 50 km/hVehicle
speed sen-
sor-Vehicle speed
sensor system
Data List No. 22
(5) 1,300 - 1,600
r/minInput shaft
speed sen-
sor22Input shaft
speed sensor
system
Data List No. 23
(5) 1,300 - 1,600
r/minOutput shaft
speed sen-
sor23Output shaft
sensor system
Selector lever posi-
tion and engine
(1) Driving at 30
km/h in 2 range,Data List No. 36
(1) 70% - 90% to
0%
(2) 70% - 90%Damper
clutch con-
trol solenoid
valve (DCC36
52DCC solenoid
valve system
then fully close
the accelerator.
(2) Driving at a
constant speed
of 50 km/h in 4thData List No. 52
(1) - 300 - - 100
r/min or 100 -
300 r/min
(2) - 10 - 10 r/minsolenoid
valve)


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AUTOMATIC TRANSMISSION -Troubleshooting <A/T>23-8
No.Inspection pro-
cedure if there is
an abnormality Diag-
nosis
code
No. Check item Judgment value Test/operation Pre-test/opera-
tion conditions
7Suspends the
INVECS-IIfunc-Use the MUT-IIto
monitor data list Nos.For (1), (2) and (3),
the output shaftProblem dur-
ing shifting-Shocks, engine
racing
tion using MUT-II11, 23 and 63.speed (vehicleIncorrect-All pointsSelector level
position:D(1) Accelerate to 5th
gear at an APSspeed) should be
identical, and thereshift points-Some points
(Must be done on
a level andgear at an APS
output of 1.5 V
(opening angleshould be no abnor-
mal shocks. For (4),No shifting-No diagnosis
codes
straight road.)30%).
(2) Slowly deceler-
ate and stop.(5) and (6), down-
shifting should occur
immediately after
22Input shaft speed
sensor system
ate and stop.
(3) Accelerate to 5th
gear at an APSthe operation is car-
ried out.23Output shaft sen-
sor system
output of 2.5 V
(opening angle
50%).No shifting
from 1st to31LR solenoid
valve system
50%).
(4) At 60 km/h in 5th,
select Sports2nd, or no
shifting from332nd solenoid
valve system
mode and shift
down to 4th.
(5) At 40 km/h in 4th,
select Sports2nd to 1st411st without
completion of
shifting
select Sports
mode and shift
down to 3rd.
(6) At 20 km/h in 3rd,
422nd without
completion of
shifting
shift down to 2nd.
(7) At 20 km/h in
2nd, shift downNo shifting
from 2nd to332nd solenoid
valve system
2nd, shift down
to 1st.3rd, or no
shifting from34OD solenoid
valve system
3rd to 2nd422nd without
completion of
shifting
433rd without
completion of
shifting
No shifting
from 3rd to31LR solenoid
valve system
4th, or no
shifting from35RED solenoid
valve system
4th to 3rd433rd without
completion of
shifting
444th without
completion of
shifting
No shifting
from 4th to32UD solenoid
valve system
5th, or no
shifting from332nd solenoid
valve system
5th to 4th444th without
completion of
shifting
455th without
completion of
shifting


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8 S
ele cto r le ve r
p osit io n: N U
se th e MUT-II to
m onit o rd ata lis tN os. T
he ra tio n ofd ata lis t
N o. 22 and No. 23 N
o sh if tin g 2
2 I
n puts h aft s p eed
s e nso r syste m 2
2 and 23.
( 1 ) Sele ct R and s
h ould be th e sa m e
a s th e tr a nsm is sio n 2
3 O
utp uts h aft s e n-
s o r syste m d
riv e at 10 km /h . r
a tio when re ve rs -
i n g. 4
6 R
eve rs e wit h out
c o m ple tio n of
s h if tin g 2
® 3
m ove -
m ent
r a nge 3
® 4
m ove -
m ent
r a nge
Vehic le sp eed km /h 4
® 5
m ove -
m ent
r a nge
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