1.

Reverse Clutch Snap Ring

Inspection
Check that the clearance
between the snap ring and
clutch reaction plates is within
the standard value. When
measuring the clearance, press
the clutch reaction plate by
force of 5 kg (50N) evenly. If
not within the standard value,
select a snap ring to adjust

Standard Value:
Result:
Remarks:

2. Overdrive Clutch Snap

Ring Inspection
Check that the clearance
between the snap ring and
clutch reaction plates is within
the standard value. If not within
the standard value, select a
snap ring to adjust.

Standard Value:
Result:
Remarks:

3. Underdrive Clutch Snap Ring

Inspection
Check that the clearance between
the snap ring and clutch reaction
plates is within the standard value.
When measuring the clearance,
press the clutch reaction plate by
force of 5 kg (50N) evenly. If not
within the standard value, select a
snap ring to adjust
Standard Value:
Result:
Remarks:

4. Reaction Plate End Play

Inspection
Replaced the pressure plate of the
low reverse brake with special
tools, and then install the brake
disc and plate.
Move the special tool to measure
the end play and than replace
the snap ring to adjust the end
play to standard value
Standard Value:
Result:
Remarks:

5. Low reverse Brake Pressure

Plate end play Inspection
Replaced the pressure plate of the
second brake with special tools,
and then install the brake disc and
plate as shown in the figure.
Install the return spring, second
brake piston and snap ring
Move the special tool to measure
the end play
Standard Value:
Result:
Remarks:

6. Second Brake Pressure Plate

end play Inspection
Reverse the transmission
Move the special tool to measure
the endplay.

Standard Value:
Result:
Remarks:

7. Output shaft Pre load

Inspection
Move the output shaft to measure
operating amount (A) and then
replace the spacer installed in step
(2) with a new one which thickness
is within the following value
(A /Operating Amount) + (B /
thickness of the old spacer) + 0.07
mm to (A /Operating Amount) +
(B / thickness of the old spacer) +
0.09 mm
Standard Value:
Result:
Remarks:

8. Under Drive Sun Gear End

Play Inspection
Install the used trust race No 8 at
the rear cover
Measure endplay of the underdrive
sun gear. Replace the thrust race to
adjust the play to the standard
value.
Note: Installing the underdrive
clutch hub to makes is easy to
measure
Standard Value:
Result:
Remarks:

9. Input Shaft End Play

Inspection
Measure end play of input shaft.
Replace the thrust washer installed
to adjusted the play to the
standard value.

Standard Value:
Result:
Remarks:

10. Differential End Play

Inspection
Install the 1.25 mm thick spacer.
Place a solder (B) approximately 10
mm in length, 3mm diameter on
the differential
Measure used micrometer the
thickness (T)
(T-0.45mm) to (T-o.165mm)
Standard Value:
Result:
Remarks:

11. Inhibitor Switch Inspection

Inhibitor
Indicato

Continuity Check

Remarks

r
P
R
N

Terminal 3 & 8
Terminal 9 & 10
Terminal 7 & 8
Terminal 4 & 8
Terminal 9 & 10

Terminal 1 & 8

Terminal 5 & 8

Terminal 2 & 8

Terminal 6 & 8

12. Solenoid Valve Inspection

Measure the resistance between terminals 1 and 2 of each solenoid valve.
Name

Resistance

DAMPER clutch
Solenoid Valve
Low Reverse
Solenoid Valve
Second Brake
Solenoid Valve
Underdrive Solenoid
Valve
Overdrive Solenoid
Valve
Hydraulic Pressure Test
(1) Warm up the engine until the automatic
transmission fluid temperature is 80--100C.

(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.

Standard Hydraulic Pressure Test

Measurement Condition

Standard Hydraulic Pressure kPa

Selector

Shift

Engine

UD

REV

OD

LRB

2Nd

Lever

Positio

Speed

Clutch

Clutch

Clutch

Pressur

Brake

Position

(RPM)

Pressur

Pressur

Pressur

Pressur

P
R
N

2,500
Revers
e

2,500

2,500

2,500

1 gear

2,500

2 gear

2,500

3 gear

2,500

4 gear

2,500

Service Data Reference Table

Ite

Actual
m
Check Item

Check Requirement

N
o
Accelerator
Pedal

11

Throttle
Position Sensor

Engine:

Release

Stopped

Accelerator

Selector

Pedal Halfly

Lever

depressed

Position P

Accelerator
Pedal
Depressed
Accelerator
Pedal
Release

15

Oil Temperature
sensor

Accelerator
Warming Up

Pedal Halfly
depressed
Accelerator
Pedal
Depressed
Accelerator
Pedal

21

Crank Angle
Sensor

Engine:

Release

Idling

Accelerator

Selector

Pedal Halfly

Lever

depressed

Position P

Accelerator
Pedal
Depressed
Driving at

22

Input Shaft
Speed sensor

Selector

constant

Lever

speed

Position 3

50km/h at
3rd gear

Normal
Value

Value

Ite

Actual
m
Check Item

Check Requirement

N
o
Driving at
23

Output Shaft
Speed sensor

Selector

constant

Lever

speed

Position 3

50km/h at
3rd gear

26

Ignition

Brake pedal:

Stop lamp

switch: ON

Depressed

Switch

Engine:

Brake Pedal

Stopped

Release
Idling with
1st gear
(Vehicle

29

Vehicle Speed
Sensor

Selector

Stooped)

Lever

Driving at

Position 3

constant
speed of 50
km/h in 3rd
gear

Low and

10 km/h 1

31

Reverse

gear

32

Solenoid Duty%
Underdrive
Solenoid Duty%

Select lever

30 km/h 2nd

position L,

gear

33

Second Brake
Solenoid Duty%

2, 3, D

50 km/h 3rd

34

Overdrive
Solenoid Duty%

gear
70 km/h in
4th gear
Driving at

Selector
36

DCCSV

50km/h in

lever

3rd gear with

position 3

acc released

Normal
Value

Value

Ite

Actual
m
Check Item

Check Requirement

N
o
Selector
36

DCCSV

lever
position 3

54

Control Relay
Output Voltage

IG SW:OFF

Driving at
70km/h in
3rd gear with
acc released
IG SW: ON OFF
Lever: P
Lever: R

61

Inhibitor Switch

IG SW: ON

Lever: N

Engine

Lever: D

Stopped

Lever: 3
Lever: 2

Select Lever
63

Shift Position

Position: L.,
2, 3, D

Lever: 1
Driving at
constant
speed
10km/h at
1st gear
Driving at
constant
speed
30km/h at
2nd gear
Driving at
constant
speed
50km/h at
3rd gear
Driving at
constant
speed
70km/h at
4th gear

10

Normal
Value

Value

Remarks:
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WAJA 1.8 DPO TRANSMISSION

1. Adjusting The Leaf Spring Lever

Hold the mulfunction switch lever in the extreme position (1st gear hold)
using a plastic clip and a bolt in the mechanism housing.

Removed the Bolt (c)

Position the leaf spring lever by placing the roller (A) in the hollow of
sector (B) corresponding to 1st gear hold.

By Used Fit tool B.Vi. 1462 instead and in place of bolt (C) screw the tool
in fully whist holding the leaf spring lever.

Tighten bolt (D) to correct torque.

Remove the tool and refit bolt (C).

Remarks:
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________

11

2. Malfunction Switch
Inspection

Placed the gear lever position

in the Neutral position

Place Multimeter to the two

electrical terminals on the
position control tabs

Check the resistance of

malfunction switch (MFS) by
turn the MFS switch

Standard Value:

Resistance at contact Terminal = 0

Result:
Remarks:

3. Anti Start Relay Inspection

Check the continuity between

terminal 1 and 2

By give power supply to

terminal 1, check the
continuity between terminal
3 and 4

Caution:
Wrong give power supply to
terminal will damage the
relay

Continuity between terminal 1&

2
12

Continuity between terminal 3&

4
Remarks:
3. Solenoid Valve Inspection

Check the resistance of the electro valve.

Electrovalve
EVM & EVLUP
EVC

Standard Value

Actual Value

Approx. 1ohm
Approx. 40 ohm

Remarks:
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13