Ford Everes PDF

WARNING.
fm 1 ページ２００６年７月２４日　月曜日　午前９時５２分
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Ford-trained technicians in mind. This manual may be useful to
non-Ford trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks

not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are

effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Ford Motor Company must
satisfy themselves thoroughly that neither personal safety nor safety of
the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are

the latest available at the time of printing, and Ford Motor Company
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Ford replacement parts or with

parts which match the quality of genuine Ford replacement parts.
Persons using replacement parts of lesser quality than that of genuine
Ford replacement parts must satisfy themselves thoroughly that
neither personal safety nor safety of the vehicle will be jeopardized.
Ford Motor Company is not responsible for any problems which may
arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Ford replacement parts, or not being aware of any revision of
this manual.
F1A9-10-06H(INDEX).fm 1 ページ２００６年８月３日　木曜日　午前１１時２６分
CONTENTS
Section
Title Previous New
GENERAL INFORMATION GI 00
RANGER B
EVEREST C
Repair D
ENGINE E 01
Manual F
Supplement G
FOREWORD
This manual contains on-vehicle service and/
T
(CRUISE CONTROL SYSTEM)
or diagnosis procedures for the RANGER,
EVEREST. SUSPENSION R 02
For proper repair and maintenance,
a thorough familiarization with this manual is L
important, and it should always be kept in a DRIVELINE/AXLE 03
handy place for quick and easy reference. M
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
BRAKES P 04
As modifications affecting repair or H
maintenance occur, relevant information
supplementary to this volume will be made TRANSMISSION/
available at Ford dealers. This manual should TRANSAXLE
J 05
be kept up-to-date.
Ford Motor Company reserves the right to
K
alter the specifications and contents of this
manual without obligation or advance notice. STEERING N 06
All rights reserved. No part of this book may HEATER, VENTILATION &
be reproduced or used in any form or by any
means, electronic or mechanical—including AIR CONDITIONING U 07
photocopying and recording and the use of (HVAC)
any kind of information storage and retrieval
system—without permission in writing. S
(SEAT BELT)
Ford Motor Company RESTRAINTS
T 08
APPLICATION: (AIR BAG SYSTEM)
This manual is applicable to vehicles
beginning with the Vehicle Identification
BODY & S
Numbers (VIN), and related materials shown
on the following page. ACCESSORIES 09
T
Note:
For the EVEREST, the differences from the
RANGER have been described.
ALPHABETICAL INDEX – AI
Information for EVEREST not described in © 2006 Ford Motor Company
this manual is common to RANGER, PRINTED IN THAILAND, AUGUST 2006
therefore, refer to the indicated related- F1A9–10–06H
manuals.
F1A9-10-06H(INDEX).fm 2 ページ２００６年８月３日　木曜日　午前１１時２６分
VEHICLE IDENTIFICATION NUMBERS (VIN)

RANGER
MNB BS✻✻✻✻✻✻
MNB DS✻✻✻✻✻✻
MNB LS✻✻✻✻✻✻
MNB US✻✻✻✻✻✻
EVEREST
MNB LS✻✻✻✻✻✻
MNB US✻✻✻✻✻✻
RELATED MATERIALS
RANGER Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F198–10–05L

RANGER Repair Manual Supplement. . . . . . . . . . . . . . . . . . . .F1A4–10–06D
RANGER Repair Manual Supplement. . . . . . . . . . . . . . . . . . . .F1A5–10–06G
RANGER Overhaul Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .F198–20–05L
RANGER Overhaul Manual Supplement . . . . . . . . . . . . . . . . . F1A5–20–06G
RANGER Overhaul Manual Supplement . . . . . . . . . . . . . . . . . F1A9–20–06H
RANGER Body Measurement Chart Manual . . . . . . . . . . . . . .F340–20–05L
RANGER Body Measurement Chart Manual Supplement . . .F344–10–06H
RANGER Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .F198–30–05L
RANGER Wiring Diagrams Supplement. . . . . . . . . . . . . . . . . .F1A4–20–06D
RANGER Wiring Diagrams Supplement. . . . . . . . . . . . . . . . . .F1A5–30–06G
RANGER Wiring Diagrams Supplement. . . . . . . . . . . . . . . . . .F1A9–30–06H
FEATURES
F340-10-05L(00-00).fm 1 ページ２００６年８月１０日　木曜日　午後５時１分
GENERAL INFORMATION 00SECTION

00
Toc of SCT INFORMATION . . . 00-00
GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
AIM OF DEVELOPMENT [AT (5R55S)] . 00-00–1 VEHICLE IDENTIFICATION NUMBER (VIN)
AIM OF DEVELOPMENT [EVEREST] . . 00-00–5 CODE [EVEREST] . . . . . . . . . . . . . . . . . 00-00–14
VEHICLE IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBERS
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . 00-00–14 (VIN) [EVEREST] . . . . . . . . . . . . . . . . . . 00-00–15
End of Toc
AIM OF DEVELOPMENT [AT (5R55S)]
NG: GENERAL INFORMATION
id0000001001a4
External View
arnffn00000086
Vehicle Outline
Engine
• Mechanical
— A roller has been adopted to the rocker arm to reduce rolling resistance. Due to this, fuel economy has
been improved.
— Valve lift has been increased (high lift), improving intake and exhaust efficiencies. Due to this, engine
torque and power have been improved.
— A timing belt auto tensioner has been adopted to reduce timing belt deterioration.
— A DOHC type valve system has been adopted for improved engine torque and power.
— Due to the bifurcated oil pan bottom, vibration in the oil pan has been reduced for improved engine noise
suppression.
— A hard-plastic oil strainer has been adopted for weight reduction.
— A cover has been installed on the upper part of the engine for improved appearance and engine noise
suppression.
— A balance shaft has been adopted for reduced vibration and noise.
• Intake/exhaust and fuel supply systems
— Superior high-output, noise suppression, and low fuel consumption have been realized due to the adoption
of a direct injection type common rail.
— Smooth driveability has been realized due to the adoption of a variable induction turbocharger which
achieves a balance between the air charging pressure providing responsive rise from low speed and the air
charging pressure at the high speed range.
— A water-cooling type EGR cooler with excellent cooling capability has been adopted for improved intake air
charging efficiency, recirculating more exhaust gas. Due to this, NOx has been reduced for improved
exhaust emission performance.
00-00–1
GENERAL INFORMATION
4x4 control
• Remote Freewheel (RFW)
— A special 4x4 control module has been adopted for the 4x4 control system control, and it operates the
transfer motor according to the signals from the speed sensor, 4x4 switch, and digital TR sensor to perform
shifting between 2H, 4H and 4L.
— The 4x4 CM receives signals from the transfer case sensor and other switches. It then activates one of two
solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and switching the
remote freewheel (RFW) unit to lock or free.
— To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-way
check valve.
— The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front
differential.
— The RFW operation is controlled by 4x4 CM.
FRONT DIFFERENTIAL
OUTPUT SHAFT
SLEEVE
JOINT SHAFT
RFW UNIT
DRIVE PINION GEAR

RFW SWITCH
RFW ACTUATOR
arnffn00000092
00-00–2
GENERAL INFORMATION
Transmission
• Automatic transmission [5R55S]
— Five forward speeds automatic transmission has been adopted. 00
— A water-cooling type and an air-cooling type AT oil cooler has been adopted.
— An adaptive learn strategy system has been adopted.
— An engine-transaxle total control system has been adopted.
TORQUE TSS SENSOR ISS SENSOR LOW/REVERSE

FLUID ONE-WAY CLUTCH
CONVERTER PUMP
COAST DIRECT FORWARD OSS SENSOR
CLUTCH CLUTCH CLUTCH
LOW/REVERSE
OVERDRIVE BRAKE
BRAKE
OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

WAY CLUTCH BRAKE BODY
arnffn00000345
00-00–3
GENERAL INFORMATION
• Transfer [5R55S]
— A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during
4x2 driving.
— Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
CHAIN
TRANSFR
SPEED SENSOR
MOTOR
arnffn00000335
End Of Sie
00-00–4
GENERAL INFORMATION
AIM OF DEVELOPMENT [EVEREST]
id0000001001a3
External View 00
arnffn00000295
Vehicle Outline
Engine
• Mechanical
— A roller has been adopted to the rocker arm to reduce rolling resistance. Due to this, fuel economy has
been improved.
— Valve lift has been increased (high lift), improving intake and exhaust efficiencies. Due to this, engine
torque and power have been improved.
— A timing belt auto tensioner has been adopted to reduce timing belt deterioration.
— A DOHC type valve system has been adopted for improved engine torque and power.
— Due to the bifurcated oil pan bottom, vibration in the oil pan has been reduced for improved engine noise
suppression.
— A hard-plastic oil strainer has been adopted for weight reduction.
— A cover has been installed on the upper part of the engine for improved appearance and engine noise
suppression.
— A balance shaft has been adopted for reduced vibration and noise.
• Intake/exhaust and fuel supply systems
— Superior high-output, noise suppression, and low fuel consumption have been realized due to the adoption
of a direct injection type common rail.
— Smooth driveability has been realized due to the adoption of a variable induction turbocharger which
achieves a balance between the air charging pressure providing responsive rise from low speed and the air
charging pressure at the high speed range.
— A water-cooling type EGR cooler with excellent cooling capability has been adopted for improved intake air
charging efficiency, recirculating more exhaust gas. Due to this, NOx has been reduced for improved
exhaust emission performance.
00-00–5
GENERAL INFORMATION
Suspension and steering
• Front suspension
— The double wishbone suspension, which has A-shape lower arms, is used for the front suspension.
A-shape lower arms have high rigidly and durability.
— The torsion bar springs are used for both 4x2 and 4x4 models.
4x2
SHOCK ABSORBER
UPPER ARM
TORSION BAR SPRING
FRONT STABILIZER
LOWER ARM
arnffn00000088
4x4
SHOCK ABSORBER
TORSION BAR SPRING
UPPER ARM
FRONT STABILIZER
LOWER ARM
arnffn00000089
• Rear suspension
— The rigid axle suspension with leaf spring is used for the rear suspension.
— To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the
right side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias
mount).In order to increase the rigidity in the lateral direction, wide shackle plates are used in the frame
mounting.
— The rear springs are mounted on top of the axle housing to raise the center of gravity. Thus, the shock
absorbers attach directly to brackets welded to the axle housing.
00-00–6
GENERAL INFORMATION
• Power steering
— With the adoption of an engine speed sensing power steering mechanism, handling stability has been
improved. 00
— With the adoption of a steering column with a tilt mechanism, operability has been improved. (Some
models)
— With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.
STEERING WHEEL
RESERVE TANK
STEERING COLUMN AND SHAFT
POWER STEERING
OIL PUMP
STEERING GEAR AND LINKAGE
arnffn00000091
00-00–7
GENERAL INFORMATION
4x4 Control
• Remote Freewheel (RFW)
Manual transmission
— The PCM receives signals from the transfer case switch and other switches. It then activates one of two
solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and switching
the remote freewheel (RFW) unit to lock or free.
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-
way check valve.
differential.
— The RFW operation is controlled by PCM.
Automatic transmission
— A special 4x4 control module has been adopted for the 4x4 control system control, and it operates the
transfer motor according to the signals from the speed sensor, 4x4 switch, and digital TR sensor to
perform shifting between 2H, 4H and 4L.
— The 4x4 CM receives signals from the transfer case sensor and other switches. It then activates one of
two solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and
switching the remote freewheel (RFW) unit to lock or free.
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-
way check valve.
differential.
— The RFW operation is controlled by 4x4 CM.
FRONT DIFFERENTIAL
OUTPUT SHAFT
SLEEVE
JOINT SHAFT
RFW UNIT
DRIVE PINION GEAR

RFW SWITCH
RFW ACTUATOR
arnffn00000092
00-00–8
GENERAL INFORMATION
Brakes
• A tandem-type master cylinder has been adopted, improving braking force.
• A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force. 00
• A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
• A two-piston type front disc brake caliper has been adopted, improving braking force.
• A wide width lining for the rear brake drum has been adopted, improving braking force.
• An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability.
• A vacuum pump has been adopted, improving braking force.
LOAD SENSING
PROPORTIONING VALVE (LSPV)
MASTER CYLINDER
POWER BRAKE UNIT
REAR BRAKE (DRUM)
FRONT BRAKE (DISC)
VACUUM PUMP
arnffn00000235
00-00–9
GENERAL INFORMATION
ABS [4W-ABS]
• The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,
resulting in size and weight reduction.
• Select-low controlled-4-wheel anti-lock brake system with 4-sensor and 3-channel has been adopted, and has
the following features.
— The integrated ABS Hydraulic Unit/Control Module (HU/CM) system is compact, lightweight and highly
reliable.
INSTRUMENT CLUSTER
REAR ABS WHEEL-SPEED

SENSOR
ABS WARNING
LIGHT
ABS HU/CM
G SENSOR
FRONT ABS WHEEL-SPEED

SENSOR
arnffn00000231
00-00–10
GENERAL INFORMATION
Transmission
• Manual transmission [S15M-D, S15MX-D]
— A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears. 00
— A linked, double cone synchronizer mechanism has been adopted for 3rd gear.
— A cam-type reverse lockout mechanism has been adopted.
S15M-D
REVERSE GEAR
3RD GEAR 5TH GEAR

2ND GEAR 1ST GEAR
MAINSHAFT
MAIN DRIVE GEAR

SHAFT
S15MX-D
COUNTER REVERSE GEAR REVERSE IDLER GEAR
arnffn00000097
00-00–11
F340-10-05L(00-00).fm 12 ページ２００６年８月１０日　木曜日　午後５時３８分
GENERAL INFORMATION
• Automatic transmission [5R55S]
— Five forward speeds automatic transmission has been adopted.
— A water-cooling type and an air-cooling type AT oil cooler has been adopted.
— An adaptive learn strategy system has been adopted.
— An engine-transaxle total control system has been adopted.

CONVERTER PUMP
LOW/REVERSE
OVERDRIVE BRAKE
BRAKE

arnffn00000345
00-00–12
F340-10-05L(00-00).fm 13 ページ２００６年８月１０日　木曜日　午後５時４３分
GENERAL INFORMATION
• Transfer [5R55S]
— A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during 00
4x2 driving.
— Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
CHAIN
TRANSFR
SPEED SENSOR
MOTOR
arnffn00000335
Safety
• An immobilizer system has been adopted. This anti-theft device prevents the engine from being started unless
the encrypted identification code, transmitted from a special electronic chip embedded in the key, corresponds
with the identification code registered in the vehicle.
• Side air bags that effectively protect the chest area have been adopted for the seats.
• Pre-tensioner and load limiter mechanisms have been adopted for the seat belts.
End Of Sie
00-00–13
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000100200
M N B B S 1 D 1 0 6W 1 2 3 4 5 6
Serial No.
Plant W=A. A. Thailand
6= 2006
Production year 7= 2007
No meaning 0
1= WL-C (2.5 L-DI)

2= WL-3 (2.5 L Diesel-Emission Turbo)
Engine type 9= WE-C (3.0 L-DI)
D= 2268—2721 kg {5001—6000 lbs}

Gross vehicle weight E= 2722—3175 kg {6001—7000 lbs}
A= Regular cab.-without box
B= Regular cab.-with box
E= Double cab.-without box
F= Double cab.-with box
1= Stretch cab.
(with Rear Access System) -without box
2= Stretch cab.
Body style (with Rear Access System) -with box
Product sorce S= Japan (for Thailand)
B= Seatbelt only
D= with Air bag (Driver side)
L= with Air bag (Driver and Passenger)
Air bag U= with Air bag (Driver, Passenger and Side air bag)
World manufacturer identification MNB= FORD (Thailand)

DCF000ZWB001
End Of Sie
VEHICLE IDENTIFICATION NUMBER (VIN) CODE [EVEREST]
id0000001002a3
M N B L S 4 D 1 0 6W 1 2 3 4 5 6
Serial No.
Production year 6= 2006, 7= 2007, 8=2008...
No meaning 0
1= WL-C (2.5 L-DI)

D= 2268—2721 kg {5001—6000 lbs}

Body style 4= New Wagon
Product sorce S= Japan


arnffn00000303
End Of Sie
00-00–14
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GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBERS (VIN) [EVEREST]
id0000006001a3
MNB LS******
MNB US******
00
End Of Sie
00-00–15
F340-10-05L(01-14).fm 1 ページ２００６年８月３日　木曜日　午後２時２７分
ENGINE 01
SECTION
Toc
FUELof SCT
SYSTEM EXHAUST SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-14B [WL-C, WE-C] . . . . . . . . . . . . . 01-15B
EMISSION SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . . 01-16B
Toc of SCT
01-14B FUEL SYSTEM [WL-C, WE-C] 01
FUEL SYSTEM OUTLINE FUEL SYSTEM STRUCTURAL VIEW
[WL-C, WE-C (EVEREST)] . . . . . . . . . . 01-14B–1 [WL-C, WE-C (EVEREST)]. . . . . . . . . . . 01-14B–2
FUEL TANK CONSTRUCTION
[WL-C, WE-C (EVEREST)]. . . . . . . . . . . 01-14B–2
End of Toc
FUEL SYSTEM OUTLINE[WL-C, WE-C (EVEREST)]
NG: FUEL SYSTEM
id011498100100
Features
Improved exhaust gas purification • Common rail injection system adopted
Specification
Item WL-C, WE-C
Supply pump Electronic control
Fuel injector Electromagnetic control
Fuel tank capacity (reference) (L {US gal, lmp gal}) 70.7 {18.6, 15.5}
End Of Sie
01-14B–1
F340-10-05L(01-14).fm 2 ページ２００６年８月３日　木曜日　午前１１時２９分
FUEL SYSTEM [WL-C, WE-C]

FUEL SYSTEM STRUCTURAL VIEW[WL-C, WE-C (EVEREST)]
id011498100200
Engine Room Side
CHECK VALVE
FUEL INJECTOR
COMMON RAIL
FUEL WARMER*
FUEL FILTER
SEDIMENTOR SWITCH
FUEL METERING VALVE

SUPPLY PUMP *: EUROPEAN (L.H.D.) SPECS.
absggn00000193
Fuel Tank Side
ROLLOVER VALVE
FUEL TANK
FROM INJECTION PUMP
NONRETURN VALVE
TO INJECTION PUMP
arnffn00000236
End Of Sie
FUEL TANK CONSTRUCTION[WL-C, WE-C (EVEREST)]
id011498101900
• Capacity is 70.7 L {18.6 US gal, 15.5 lmp gal}.
End Of Sie
01-14B–2
F340-10-05L(01-15).fm 1 ページ２００６年８月３日　木曜日　午前１１時３０分
EXHAUST SYSTEM [WL-C, WE-C]
01-15B EXHAUST SYSTEM [WL-C, WE-C]

EXHAUST SYSTEM STRUCTURAL VIEW EXHAUST SYSTEM STRUCTURAL VIEW
[WL-C, WE-C (RANGER (AT))] . . . . . . . 01-15B–1 [WL-C, WE-C (EVEREST)]. . . . . . . . . . . 01-15B–2
End of Toc
EXHAUST SYSTEM STRUCTURAL VIEW[WL-C, WE-C (RANGER (AT))]
NG: EXHAUST SYSTEM
id011599100100
Type A
01
TAIL PIPE
OXIDATION CATALYTIC CONVERTER
EXHAUST MANIFOLD
JOINT PIPE
MAIN SILENCER
FRONT PIPE
TURBOCHARGER
arnffn00000239
Type B
TAIL PIPE
EXHAUST MANIFOLD
JOINT PIPE MAIN SILENCER
MIDDLE PIPE
FRONT PIPE
TURBOCHARGER
arnffn00000240
End Of Sie
01-15B–1

EXHAUST SYSTEM STRUCTURAL VIEW[WL-C, WE-C (EVEREST)]
id011598100100
MT
EXHAUST MANIFOLD
TAIL PIPE
JOINT PIPE
MAIN SILENCER
FRONT PIPE
TURBOCHARGER
arnffn00000237
AT
TAIL PIPE
EXHAUST MANIFOLD
JOINT PIPE
MAIN SILENCER
FRONT PIPE
TURBOCHARGER
arnffn00000238
End Of Sie
01-15B–2
EMISSION SYSTEM [WL-C, WE-C]
01-16B EMISSION SYSTEM [WL-C, WE-C]

EMISSION SYSTEM STRUCTURAL VIEW
[WL-C, WE-C (EVEREST)] . . . . . . . . . . 01-16B–1
End of Toc
EMISSION SYSTEM STRUCTURAL VIEW[WL-C, WE-C (EVEREST)]
NG: EMISSION SYSTEM
id011698100200
Engine Room Side
01
EGR COOLER
EGR SOLENOID VALVE
AIR FILTER
EGR VALVE
INTAKE SHUTTER VALVE
EGR CONTROL SOLENOID VALVE
INTAKE SHUTTER SOLENOID VALVE (HALF)
INTAKE SHUTTER SOLENOID VALVE (FULL)
arnffn00000079
Fuel Tank Side
ROLLOVER VALVE
arnffn00000332
End Of Sie
01-16B–1
F340-10-05L(02-00).fm 1 ページ２００６年８月３日　木曜日　午前１１時３１分
SUSPENSION 02
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 02-00

OUTLINE FRONT SUSPENSION . . . . . . . 02-13
WHEEL ALIGNMENT . . . . . . . 02-11 REAR SUSPENSION . . . . . . . . 02-14
WHEEL AND TIRES . . . . . . . . 02-12
Toc of SCT
02-00 OUTLINE
SUSPENSION SPECIFICATIONS
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-00–1
End of Toc
SUSPENSION SPECIFICATIONS[EVEREST]
NG: SUSPENSION
id020000100308
SPECIFICATIONS
Suspension
Item 4x2 4x4
Front suspension 02
Suspension Type Double wishbone
Spring type Torsion bar spring
Type Torsion bar
Stabilizer
Diameter (mm {in}) 28 {0.94}
Shock absorber type Cylindrical, double-acting
Maximum Inner 31°30′—35°30′
steering angleOuter 27°00′—32°00′
Front wheel
alignment Total toe-in (mm {in}) 3—9 {0.12—0.35}
(*Unloaded Camber angle (reference value) 0°45′ ±1°
condition) Caster angle (reference value) 2°06′±1°
Steering axis inclination 10°35′
Rear suspension
Suspension Type Leaf spring
Spring type Semi elliptic leaf spring
Shock absorber type Cylindrical, double-acting
Type Torsion bar
Stabilizer
Diameter (mm {in}) 20 {0.79}
* : Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack, and tools in designated
position.
Wheel and tires

Item Specification
Size 16 × 7J
Offset (mm {in}) 10 {0.39}
Wheel
Pitch circle diameter (mm {in}) 139.7 {5.500}
Material Aluminum alloy
Tire Size 245/70R16 111S
End Of Sie
02-00–1
WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT

FRONT WHEEL ALIGNMENT
DESCRIPTION[EVEREST] . . . . . . . . . . 02-11–1
End of Toc
FRONT WHEEL ALIGNMENT DESCRIPTION[EVEREST]
NG: SUSPENSION
id021100100215
CAMBER AND CASTER
THE CAMBER ANGLE DECREASES IF
THE SHIM THICKNESS IS INCREASED
DO NOT USE MORE THAN ONE
THE CASTER ANGLE

DO NOT USE MORE THAN TWO
DECREASES IF THE SHIM
THICKNESS IS INCREASED
FRONT
THE CASTER ANGLE INCREASES IF
THE SHIM THICKNESS IS INCREASED
02
arnffn00000329
• To adjust the camber and caster angles, loosen the bolts of the upper arm shaft and insert or remove the
adjustment shims.
• The amount of change of the camber and caster due to a 1 mm {0.039 in} shim increase or decrease is as
follows:
Camber: 1 mm {0.039 in} shim = 15’

Caster: 1 mm {0.039 in} shim = 30’
Shim
Thickness (mm {in})
1.0 {0.039}
1.6 {0.063}
For camber
2.0 {0.079}
adjustment
3.2 {0.126}
4.0 {0.157}
1.0 {0.039}
1.6 {0.063}
For caster 2.0 {0.079}
adjustment 3.2 {0.126}
4.0 {0.157}
0.6 {0.024}
02-11–1
WHEEL ALIGNMENT
MAXIMUM STEERING ANGLE
• The maximum steering angle can be adjusted by EVEREST
turning the adjusting bolts.
ADJUSTING BOLT
arnffn00000330
TOTAL TOE-IN
• The total toe-in can be adjusted by turning the tie TIE ROD
rods.
• The left and right tie rods are both right
threaded.To increase the toe-in, turn the right tie
rod toward the front of the vehicle, and turn the
left tie rod by the same amount toward the rear.
• One turn of the tie rod (both sides) changes the
toe-in by about 30 mm {1.18 in}.
End Of Sie
arnffn00000331
02-11–2
F340-10-05L(02-12).fm 1 ページ２００６年８月３日　木曜日　午前１１時３２分
WHEEL AND TIRES
02-12 WHEEL AND TIRES

WHEEL AND TIRES STRUCTURAL
VIEW[EVEREST]. . . . . . . . . . . . . . . . . . 02-12–1
End of Toc
WHEEL AND TIRES STRUCTURAL VIEW[EVEREST]
NG: WHEELS AND TIRES
id0212001042b4
16-INCH ALUMINUM ALLOY WHEEL
02
arnffn00000272
End Of Sie
02-12–1
F340-10-05L(02-13).fm 1 ページ２００６年８月３日　木曜日　午前１１時３３分
FRONT SUSPENSION
02-13 FRONT SUSPENSION

FRONT SUSPENSION OUTLINE FRONT SUSPENSION STRUCTURAL
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-13–1 VIEW[EVEREST] . . . . . . . . . . . . . . . . . . 02-13–1
FRONT SUSPENSION DESCRIPTION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 02-13–2
End of Toc
FRONT SUSPENSION OUTLINE[EVEREST]
NG: FRONT SUSPENSION
id0213001001a7
• The double wishbone suspension, which has A-shape lower arms, is used for the front suspension. A-shape
lower arms have high rigidly and durability.
• The torsion bar springs are used for both 4x2 and 4x4 models.
The torsion bar spring is per-coiled in one direction. It therefore gives ample spring performance when installed
correctly, but only half if installed in reverse.
An R (right) or L (left) is marked on the rear end of the bar to distinguish one form the other.
The left and right, and 4x2 and 4x4 torsion bar springs are not interchangeable.
End Of Sie
FRONT SUSPENSION STRUCTURAL VIEW[EVEREST]
id0213001002a7
4x2
SHOCK ABSORBER
02
UPPER ARM
TORSION BAR SPRING
FRONT STABILIZER
LOWER ARM
arnffn00000326
02-13–1
F340-10-05L(02-13).fm 2 ページ２００６年８月３日　木曜日　午前１１時３３分
FRONT SUSPENSION
4x4
SHOCK ABSORBER
TORSION BAR SPRING
UPPER ARM
FRONT STABILIZER
LOWER ARM
arnffn00000327
End Of Sie
FRONT SUSPENSION DESCRIPTION[EVEREST]
id0213001003a7
• The vehicle height can be adjusted by turning the torsion bar spring anchor bolt. When adjustment is required,
adjust the vehicle height as follows:
1. Place the vehicle on level ground.
2. Inspect the front and rear tire pressure and adjust it if necessary.
3. Measure the distance form the center of each front wheel to the fender brim.
Standard vehicle height: 502—542 mm {19.8—21.3 in}
*Difference between left and right: 10 mm {0.39in} max.
4. If the difference between left and right is not within the specification, adjust the vehicle height by turning the
torsion bar spring anchor bolt.
VEHICLE HEIGHT
4x2 4x4
ANCHOR BOLT
ANCHOR BOLT
arnffn00000328
End Of Sie
02-13–2
F340-10-05L(02-14).fm 1 ページ２００６年８月３日　木曜日　午後２時３２分
REAR SUSPENSION
02-14 REAR SUSPENSION

REAR SUSPENSION OUTLINE REAR SUSPENSION STRUCTURAL VIEW
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-14–1 [RANGER [5R55S], EVEREST] . . . . . . . 02-14–1
End of Toc
REAR SUSPENSION OUTLINE[EVEREST]
NG: REAR SUSPENSION
id0214001001a7
• The rigid axle suspension with leaf spring is used for the rear suspension.
• To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the right
side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias mount).In order
to increase the rigidity in the lateral direction, wide shackle plates are used in the frame mounting.
• The rear springs are mounted on top of the axle housing to raise the center of gravity. Thus, the shock
absorbers attach directly to brackets welded to the axle housing.
End Of Sie
REAR SUSPENSION STRUCTURAL VIEW[RANGER [5R55S], EVEREST]
id0214001002a6
RANGER (Hi-Rider, 4x4) 02

EVEREST
RANGER 4x2
(EXCEPT Hi-Rider)
SHOCK ABSORBER
LEAF SPRING
RANGER (Hi-Rider, 4x4)

EVEREST
arnffn00000325
End Of Sie
02-14–1
F340-10-05L(03-00).fm 1 ページ２００６年８月１０日　木曜日　午後５時４分
DRIVELINE/AXLE 03
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 03-00

OUTLINE TRANSFER[5R55S] . . . . . . . . . 03-16
ON-BOARD DIAGNOSTIC. . . . 03-02 4-WHEEL DRIVE
FRONT AXLE. . . . . . . . . . . . . . 03-11 [AT (5R55S)] . . . . . . . . . . . . . . 03-18
Toc of SCT
03-00 OUTLINE
DRIVELINE/AXLE FEATURES DRIVELINE/AXLE SPECIFICATIONS
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-00–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 03-00–4
DRIVELINE/AXLE SPECIFICATIONS
[RANGER (5R55S)]. . . . . . . . . . . . . . . . 03-00–2
End of Toc
DRIVELINE/AXLE FEATURES [AT (5R55S)]
NG: DRIVELINE/AXLE
id030000100113
Improved rigidity, reduced noise • Constant velocity joint type rear drive shaft adopted
and vibration • 2-part, 3-joint type propeller shaft with a center bearing support has been adopted (4×2,
4×4 rear)
• 1-part type propeller shaft has been adapted (4×4 front)
• Double offset-shaped constant velocity joint adopted for differential-side joint of front
drive shaft
• Bell-shaped constant velocity joint adopted for wheel-side joint of front drive shaft
03
Improved durability • Unit-design taper roller bearing has been adopted
• A spring-tensioned clip-type method of fixing the universal joint has been adopted (4×2,
Improved reliability
4×4 rear)
• Electronic 4x4 control system adopted
Improved operability • Electronic control type transfer case adopted
• Remote freewheel (RFW) has been adopted
Improved serviceability • Unit-design taper roller bearing has been adopted
Improved driveability • LSD has been adopted
End Of Sie
03-00–1
OUTLINE
DRIVELINE/AXLE SPECIFICATIONS [RANGER (5R55S)]
id030000100211
Item Specification
Engine WL-C WE-C
Transmission type 5R55S
Vehicle type 4×2 4×2 Hi-Rider 4×4
Front axle
Bearing type Taper roller bearing
Rear axle
Support type Semi-floating
Casing Banjo type
Length (mm {in}) 739 {29.1}
Diameter (mm {in}) 35.0 {1.4}
Rear differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 8.9
Final gear ratio 3.416 3.727
Grade API service GL-5
Viscosity SAE 90
Differential
Type Capacity
oil
(approx. quantity) 2.45 {2.32, 2.04} 2.35 {2.22, 1.96}
(L {US qt, lmp qt})
Front differential
Reduction gear – Hypoid gear
Differential gear – Straight bevel gear
Ring gear size (Inches) – 8.00
Final gear ratio – 3.727
Grade – API service GL-5
Above -18 °C {0 °F}:
SAE90
Viscosity –
Differential Below -18 °C {0 °F}:
Type SAE80
oil
Capacity
(approx. quantity) – 1.9 {1.8, 1.6}
(L {US qt, lmp qt})
Front drive shaft
Wheel side – Bell joint
Joint type
Differential side – Double offset joint
Shaft diameter (mm {in}) – 30.0 {1.18}
Front propeller shaft
L1 – 13.2 {0.52}
Length (front) (mm {in}) L2 – 588.4 {23.17}
L3 – 34.3 {1.35}
Outer diameter
(mm {in}) D – 26.5 {1.04}
(front)
Rear propeller shaft
L1 192.5 {7.579} 41.1 {1.62}
Length (rear) (mm {in}) L2 677.6 {26.68} 691.6 {27.23} 443.6 {17.46}
L3 909.8 {35.82} 890.3 {35.05} 896.3 {35.29}
Outer diameter
(mm {in}) D 63.5 {2.50}
(rear)
Joint type Cross-shaped joint
03-00–2
OUTLINE
Item Specification
Engine WL-C WE-C
Vehicle type 4×2 4×2 Hi-Rider 4×4
5R55S 4x2 D D
L1 L2 L3
5R55S 4x2 (Hi-Rider)

D D
L1 L2 L3
5R55S 4x4 FRONT
L1
L2 L3
03
5R55S 4x4 REAR
D D
L1 L2 L3
Transfer case
Type – Mercon® V
Transfer Oil capacity
case oil (L {US qt,
(approx. – 1.2 {1.3, 1.1}
Imp qt})
quantity)
End Of Sie
03-00–3
OUTLINE
DRIVELINE/AXLE SPECIFICATIONS [EVEREST]
id030000100212
Item Specification
Engine WL-C WE-C WL-C, WE-C WE-C
Transmission type S15M-D S15MX-D 5R55S
Vehicle type 4×2 4×4 4×2 4×4
Front axle
Rear axle
Support type Semi-floating
Casing Banjo type
Length (mm {in}) 739 {29.1}
Diameter (mm {in}) 35.0 {1.4}
Rear differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 8.9
Final gear ratio 3.727
Grade API service GL-5
Viscosity SAE 90
Differential
Type Capacity
oil
(approx. quantity) 2.45 {2.32, 2.04} 2.35 {2.22, 1.96} 2.45 {2.32, 2.04} 2.35 {2.22, 1.96}
(L {US qt, lmp qt})
Front differential
Reduction gear – Hypoid gear – Hypoid gear
Differential gear – Straight bevel gear – Straight bevel gear
Ring gear size (Inches) – 8.00 – 8.00
Final gear ratio – 3.727 – 3.727
Grade – API service GL-5 – API service GL-5
Above -18 °C {0 Above -18 °C {0
°F}: SAE90 °F}: SAE90
Viscosity – –
Differential Below -18 °C {0 Below -18 °C {0
Type °F}: SAE80 °F}: SAE80
oil
Capacity
(approx. quantity) – 1.9 {1.8, 1.6} – 1.9 {1.8, 1.6}
(L {US qt, lmp qt})
Front drive shaft
Wheel side – Bell joint – Bell joint
Joint type
Differential side – Double offset joint – Double offset joint
Shaft diameter (mm {in}) – 30.0 {1.18} – 30.0 {1.18}
Front propeller shaft
L1 – 45.3 {1.78} – 13.2 {0.52}
Length (front) (mm {in}) L2 – 552.1 {21.74} – 588.4 {23.17}
L3 – 45.3 {1.78} – 34.3 {1.35}
Outer diameter
(mm {in}) D – 63.5 {2.50} – 26.5 {1.04}
(front)
L1 163.4 {6.433} 41.1 {1.62} 192.5 {7.579} 41.1 {1.62}
Length (rear) (mm {in}) L2 670.6 {26.40} 443.6 {17.46} 691.6 {27.23} 443.6 {17.46}
L3 754.3 {29.70}
Outer diameter
(mm {in}) D 63.5 {2.50}
(rear)
Joint type Cross-shaped joint
03-00–4
OUTLINE
Item Specification
Engine WL-C WE-C WL-C, WE-C WE-C
Transmission type S15M-D S15MX-D 5R55S
Vehicle type 4×2 4×4 4×2 4×4
S15M-D 4x2 D D
L1 L2 L3
S15MX-D 4x4 FRONT

D
L1 L2 L3
S15MX-D 4x4 REAR

D D
L1 L2 L3
03
5R55S 4x2
D D
L1 L2 L3
5R55S 4x4 FRONT
L1
L2 L3
5R55S 4x4 REAR

D D
L1 L2 L3
Transfer case
Mercon® Multi-
Type – purpose AFT XT-2- – Mercon® V
Transfer QDX
case oil Oil capacity
(L {US qt,
(approx. – 1.85 {1.95, 1.63} – 1.2 {1.3, 1.1}
Imp qt})
quantity)
End Of Sie
03-00–5
F340-10-05L(03-02).fm 1 ページ２００６年８月１０日　木曜日　午後５時５分
ON-BOARD DIAGNOSTIC
03-02 ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC OUTLINE
[4x4 control module] . . . . . . . . . . . . . . 03-02–1
End of Toc
ON-BOARD DIAGNOSTIC OUTLINE [4x4 control module]
NG: ELECTRONIC 4WD CONTROL SYSTEM
id0302a1100100
Special Features
• When a 4x4 control system malfunction is detected, the 4x4 indicator light and 4L indicator light are flashed to
notify the occurrence of the malfunction.
Memory Function
• The memory function records signal systems which have been determined to be abnormal by the malfunction
detection function, and the recorded malfunction information is not cleared even when the engine switch is
turned off (LOCK position) or the malfunction is repaired.
• Refer to the Workshop Manual for the DTC clearing procedure.
Malfunction Indication Function

• The malfunction indication function flashes the 4x4 indicator light and 4L indicator light as a DTC based on the
signal determined to be a malfunction by the malfunction detection function.
DTC Table
DTC stored in
DTC No. Malfunction location
memory
1
2
4x4 control module malfunction
Motor component (shift motor) malfunction
X
X
03
3 Clutch coil malfunction X
4 Speed sensor malfunction X
5 Solenoid valve malfunction X
6 4x4 switch malfunction X
7 Motor component (position sensor) malfunction X
End Of Sie
03-02–1
F340-10-05L(03-11).fm 1 ページ２００６年８月１０日　木曜日　午後５時６分
FRONT AXLE
03-11 FRONT AXLE

FRONT AXLE CROSS-SECTIONAL VIEW
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 03-11–1
End of Toc
FRONT AXLE CROSS-SECTIONAL VIEW [EVEREST]
NG: FRONT AXLE
id0311001002b1
4x2 4x4
ABS ABS
WHEEL-SPEED WHEEL-
SENSOR SPEED
ABS SENSOR
ROTOR
ABS SENSOR
ROTOR
03
TAPER TAPER
ROLLER ROLLER
BEARING BEARING
(UNIT-TYPE) (UNIT-TYPE)
arnffn00000260
End Of Sie
03-11–1
F340-10-05L(03-16).fm 1 ページ２００６年８月１０日　木曜日　午後５時７分
TRANSFER [5R55S]
03-16 TRANSFER [5R55S]

TRANSFER CASE SPEED SENSOR
OUTLINE [5R55S] . . . . . . . . . . . . . . . . . 03-16–1 CONSTRUCTION [5R55S] . . . . . . . . . . . 03-16–9
TRANSFER CASE MOTOR POSITION
STRUCTURAL VIEW [5R55S] . . . . . . . 03-16–1 DETECTION SWITCH
TRANSFER CASE FUNCTION [5R55S] . . . . . . . . . . . . . . . . 03-16–9
POWER FLOW [5R55S] . . . . . . . . . . . . 03-16–4 MOTOR POSITION
TRANSFER CASE DETECTION SWITCH
ELECTRONIC CONTROL SYSTEM CONSTRUCTION/OPERATION
OUTLINE [5R55S] . . . . . . . . . . . . . . . . . 03-16–8 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–10
TRANSFER CASE MOTOR CONSTRUCTION [5R55S] . . . . . 03-16–10
SYSTEM WIRING DIAGRAM CLUTCH COIL
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–8 CONSTRUCTION [5R55S] . . . . . . . . . . . 03-16–11
End of Toc
TRANSFER CASE OUTLINE [5R55S]
NG: TRANSFER
id0316c1137500
• A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during 4x2
driving.
• Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
End Of Sie
TRANSFER CASE STRUCTURAL VIEW [5R55S]

id0316c1100500
03
CHAIN
TRANSFER CASE
SPEED SENSOR
MOTOR
arnffn00000404
03-16–1
TRANSFER [5R55S]
Exploded view
13
18
16
15
14
19
20
17 10
22 23
21 9
11 7
8
5
44
70
76 48 45
46 12
77 47 36
60 59 57 49
58 38
75 5 37
74 73 39
40
80
85 72 41
69
66 3 4 68
84
79
28 27
83 34 35
29
82 25
67 24
81 32 30 26
78
31
86 65 33
64 62
63 71
61 52
53 43 42
50
51
54 4
3 2
1
5 57
6 56 58 59
60
55
b5r5za00000446
1 Center transfer case 6 Center transfer case component

2 Dowel pin 7 Front transfer case
3 Bearing 8 Dowel pin
4 Snap ring 9 Snap ring
5 Oil seal 10 Front transfer case component
03-16–2
TRANSFER [5R55S]
11 Clip 49 Drive sprocket
12 Bolt 50 Drive chain
13 Input shaft component 51 Driven sprocket
14 Input shaft 52 Snap ring
15 Needle bearing 53 Spacer
16 Bushing 54 Lower output shaft
17 Thrust washer 55 Front output flange component
18 Planetary gear component 56 Front output flange
19 Sun gear 57 Deflector
20 Thrust plate 58 Oil seal
21 Snap ring 59 Washer
22 Ball bearing 60 Locknut
23 Snap ring 61 Rear transfer case component
24 Reduction shift fork component 62 Rear transfer case
25 Reduction shift fork 63 Needle bearing
26 Reduction shift fork facing 64 Sleeve
27 Lockup shift fork component 65 Seal
28 Lockup shift fork 66 Snubber
29 Lockup shift fork facing 67 Bolt
30 Spring 68 Clutch coil
31 Spacer 69 Nut
32 Cam 70 Clutch housing
33 Shift shaft 71 Breather pipe
34 Rail shift 72 Speed sensor component
03
35 Return spring 73 Bracket
36 Output shaft and gerotor pump component 74 Bolt
37 Output shaft component 75 Spacer
38 Gerotor pump component 76 Rear companion flange component
39 Reduction hub 77 Rear companion flange
40 Pump hose 78 Oil plug
41 Hose clamp 79 Motor component
42 Oil strainer 80 Bracket
43 Magnet 81 Terminal connector
44 Lockup component 82 Clip
45 Lockup hub 83 Bracket
46 Spring 84 Clip
47 Lockup collar 85 Bolt
48 Snap ring 86 Bolt
End Of Sie
03-16–3
TRANSFER [5R55S]
TRANSFER CASE POWER FLOW [5R55S]
id0316c1100600
Shifting From 4x2 HIGH to 4x4 HIGH
• During 4x2 driving, drive force from the transmission is transmitted from the input shaft to the output shaft
through the reduction hub, and the drive force from the output shaft is transmitted to the rear differential
Shifting between 4x2 and 4x4 is performed using the lockup component operation. During 4x2 driving, drive
force is not transmitted to the chain because the lockup component does not contact the clutch housing,
therefore, the drive force is not transmitted to the front differential.
REAR DIFFERENTIAL TRANSMISSION

SIDE SIDE
LOCKUP CHAIN
COMPONENT
OUTPUT SHAFT
CLUTCH
HOUSING
CLUTCH LOCKUP
HOUSING COMPONENT
arnffn00000336
03-16–4
TRANSFER [5R55S]
• When the 4x4 switch is switched to the 4H position during 4x2 driving, the motor rotates from the 2H to 4H
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates, the lockup shift
fork component slides to the clutch housing side. In conjunction with this operation, the clutch coil is energized
and magnetic force is generated, and the lockup shift fork component is pulled toward the clutch housing. In the
lockup shift fork component operation, the lockup hub contacts the clutch housing first, then the lockup collar
slides to the lockup housing side. At this time, if the lockup hub is not engaged with the clutch housing spline,
the lock up hub is pressed into the lockup collar. If the clutch housing rotates in this condition, such as when the
vehicle is being driven, the lockup hub engages with the clutch housing spline. The lockup shift fork component
is engaged with the drive sprocket and the clutch housing is engaged with the output shaft, therefore, drive
force from the output shaft is transmitted to the lower output shaft via the chain. Due to this, drive force is
transmitted to the front differential.

SIDE SIDE
LOCKUP
COMPONENT
CHAIN
CLUTCH
COIL
CLUTCH
HOUSING
LOCKUP SHIFT FORK

COMPONENT 03
SHIFT SHAFT
CAM
LOCKUP LOCKUP
HUB COLLAR LOCKUP
CLUTCH COIL COLLAR
CLUTCH LOCKUP CLUTCH LOCKUP CLUTCH LOCKUP

HOUSING COMPONENT HOUSING HUB HOUSING HUB
arnffn00000337
03-16–5
TRANSFER [5R55S]
Shifting From 4x4 HIGH to 4x2 HIGH
• When the 4x4 switch is switched to the 2H position while in 4x4 HIGH, the motor rotates from the 4H to 2H
position. Due to the motor rotation, the cam rotates via the shift shaft. The lockup shift fork component slides
due to the cam rotation and spring force of the return spring, and separates from the clutch housing. At this
time, the clutch coil is not energized.When the lockup shift fork component separates from the clutch housing,
drive force transmission to the lower output side is interrupted, and drive force is transmitted only to the rear
differential.

SIDE SIDE
LOCKUP CHAIN
COMPONENT
OUTPUT SHAFT
CLUTCH
HOUSING
RETURN
SPRING
SHIFT SHAFT
CAM
LOCKUP
COLLAR
CLUTCH COIL
CLUTCH LOCKUP
HOUSING HUB
arnffn00000338
03-16–6
TRANSFER [5R55S]
Shifting From 4x4 HIGH to 4x4 LOW
• When the 4x4 switch is switched to the 4L position while in 4x4 HIGH, the motor rotates from the 4H to 4L
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the spline
which is inside the carrier of the planetary gear component. If the drive force is transmitted to the input shaft in
this condition, the output speed is reduced due to the planetary gear operation, and the rotational torque
increases.This drive force is transmitted to the front and rear differentials.

SIDE SIDE
REDUCTION HUB
PLANETARY GEAR
COMPONENT
OUTPUT INPUT
SHAFT SHAFT
REDUCTION
SHIFT FORK
COMPONENT
CARRIER
03
REDUCTION HUB
SHIFT SHAFT
CAM
arnffn00000339
Shifting From 4x4 LOW to 4x4 HIGH

• When the 4x4 switch is switched to the 4H position while in 4x4 LOW, the motor rotates from the 4L to 4H
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the input shaft
spline. Due to this, the drive force from the input shaft is transmitted to the output shaft without being input to
the planetary gear, and then it is transmitted to the front and rear differential with the output speed and
rotational torque remaining unchanged.

SIDE SIDE
PLANETARY GEAR
COMPONENT
REDUCTION HUB INPUT
SHAFT
OUTPUT
SHAFT
REDUCTION
SHIFT FORK
COMPONENT
CARRIER
REDUCTION HUB
SHIFT SHAFT
CAM
arnffn00000340
End Of Sie
03-16–7
TRANSFER [5R55S]
TRANSFER CASE ELECTRONIC CONTROL SYSTEM OUTLINE [5R55S]
id0316c1137600
• A 4x4 control module has been adopted which operates the motor according to signals from the speed sensor
and motor position detection switch to control shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW.
End Of Sie
TRANSFER CASE SYSTEM WIRING DIAGRAM [5R55S]

id0316c1137700
4x4
B+ CONTROL
IG1
MODULE
TRANSFER CASE
Y T
U C
Z CLUTCH COIL
BB S 4x4 LO M B SPEED
TCM N A SENSOR
BA R 4x4 HI
MOTOR COMPONENT
DLC Q
G
4x4 SWITCH J E
4x2 HI POSITION 1
A G
4x4 HI I B
D
4x4 LO POSITION 2
C F
L A
F POSITION 3
H D
POSITION 4
DIGITAL TR SENSOR J E
A
B C
B V
LOCK SOLENOID
A
C F
A E D
D
B X
B+
4x4 RELAY W
A B
FREE SOLENOID
arnffw00001937
End Of Sie
03-16–8
TRANSFER [5R55S]
SPEED SENSOR CONSTRUCTION [5R55S]
id0316c1137000
• The speed sensor detects the output shaft rotation speed, and the signal is input to the 4x4 control module.
• Signals from the speed sensor are used by the 4x4 control module to perform each control.
SPEED SENSOR
SPEED SENSOR OUTPUT SHAFT
CLUTCH
HOUSING
03
arnffn00000341
End Of Sie
MOTOR POSITION DETECTION SWITCH FUNCTION [5R55S]

id0316c1137100
• The motor position detection switch detects the motor position and outputs control signals to the 4x4 control
module.
• The 4x4 control module determines the motor position according to the signals from the motor position
detection switch.
End Of Sie
03-16–9
TRANSFER [5R55S]
MOTOR POSITION DETECTION SWITCH CONSTRUCTION/OPERATION [5R55S]
id0316c1137200
• The motor position detection switch is integrated into the motor, and turns on or off according to the motor
position.
• The motor position detection switch detects the motor position using a combination of four switches.
Motor Position Position 1 Position 2 Position 3 Position 4
2H Off On Off On
4H On On Off Off
4L Off Off On On
2H
A
B
C
D
E
4L
4H
MOTOR
: SWITCH ON A: POSITION 4 D: POSITION 1

B: POSITION 3 E: GROUND
: SWITCH OFF C: POSITION 2
arnffn00000342
End Of Sie
MOTOR CONSTRUCTION [5R55S]
id0316c1137300
• The motor switches between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW according to the signals from the 4x4 control
module.
• A switch for motor position detection is integrated in the motor.
MOTOR
arnffn00000343
03-16–10
TRANSFER [5R55S]
End Of Sie
CLUTCH COIL CONSTRUCTION [5R55S]
id0316c1137400
• The clutch coil is integrated in the transfer.
• When a 4x4 shift signal is input to the 4x4 control module, electricity flows from the control module to the clutch
coil and magnetic force is generated. Using the magnetic force, the lockup collar is pulled toward the clutch
housing, shifting from 4x2 to 4x4.
CLUTCH COIL
arnffn00000344
03
End Of Sie
03-16–11
F340-10-05L(03-18).fm 1 ページ２００６年８月１０日　木曜日　午後５時２１分
4-WHEEL DRIVE [AT (5R55S)]
03-18 4-WHEEL DRIVE [AT (5R55S)]

4x4 CONTROL SYSTEM 4x4 CONTROL SYSTEM
OUTLINE [AT (5R55S)] . . . . . . . . . . . . . 03-18–1 SYSTEM DIAGRAM [AT (5R55S)] . . . . . 03-18–3
4x4 CONTROL SYSTEM 4x4 CONTROL SYSTEM
CONSTRUCTION [AT (5R55S)] . . . . . . 03-18–1 SYSTEM WIRING DIAGRAM
4x4 CONTROL SYSTEM [AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . 03-18–4
COMPONENTS AND FUNCTIONS 4x4 CONTROL SYSTEM
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-18–2 OPERATION [AT (5R55S)] . . . . . . . . . . . 03-18–4
End of Toc
4x4 CONTROL SYSTEM OUTLINE [AT (5R55S)]
NG: CENTER DIFFERENTIAL LOCK SWITCH
id0318d2164200
• A special 4x4 control module has been adopted for the 4x4 control system control, and it operates the transfer
motor according to the signals from the speed sensor, 4x4 switch, and digital TR sensor to perform shifting
between 2H, 4H and 4L.
• The 4x4 CM receives signals from the transfer case sensor and other switches. It then activates one of two
solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and switching the
remote freewheel (RFW) unit to lock or free.
• To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum pump,
such as during acceleration or at high altitude operation, the actuation system includes a one-way check valve.
• The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front differential.
• The RFW operation is controlled by 4x4 CM.
End Of Sie
4x4 CONTROL SYSTEM CONSTRUCTION [AT (5R55S)]

id0318d2164100
03
FRONT DIFFERENTIAL
OUTPUT SHAFT
SLEEVE
JOINT SHAFT
RFW UNIT
DRIVE PINION GEAR

RFW ACTUATOR
arnffn00000273
End Of Sie
03-18–1

4x4 CONTROL SYSTEM COMPONENTS AND FUNCTIONS [AT (5R55S)]
id0318d2164000
Electrical component
Part name Function
• Sends ON/OFF signals to lock and free solenoids and indicator lights
4x4 CM
according to signals from various switches
Digital TR sensor • Detects selector lever N position
Input 4x4 switch • Detects 4x4 switch 2H, 4H or 4L position
Speed sensor • Detects output shaft speed
• Switched ON/OFF by electrical signals from 4x4 CM
• Regulates RFW unit “lock“ or “free”
Solenoid
Lock • Switched ON when “locked”
Free • Switched ON when “free”
Output
Motor component (transfer case) • Sets transfer case operation mode (2H, 4H or 4L)
Clutch coil (transfer case) • Operates when 4H or 4L selected
4x4 indicator light • Illuminates when 4H or 4L selected
4L indicator light • Illuminates when 4L selected
Mechanical component
Part name Function
RFW unit • Transmits front propeller shaft rotation to front tires
RFW actuator • “Locks“ or “free” RFW unit
One-way check valve • Prevents leakage of vacuum
Motor component (transfer
• Motor operates to slide each shift fork
case)
Clutch coil (transfer case) • Magnetic force occur in clutch coil during operation to pull the lockup component
Relationship of Component and Function

Part name Input Output
Digital Motor 4x4 4L
4x4 Speed Lock Free Clutch
TR compon indicator indicator
switch sensor solenoid solenoid coil
Function sensor ent light light
Controlled by driver x x
Controlled by 4x4 CM x x x x x x x
End Of Sie
03-18–2

4x4 CONTROL SYSTEM SYSTEM DIAGRAM [AT (5R55S)]
id0318d2163800
FRONT
DIFFERENTIAL
4x4 4L
INDICATOR INDICATOR RFW
LIGHT LIGHT ACTUATOR
TO BATTERY FREE LOCK
DIGITAL TR SENSOR FREE LOCK
EXCEPT
N POSITION
TO BATTERY TRANSMISSION
RFW UNIT
4x4 SWITCH TRANSFER
N POSITION FREE LOCK CLUTCH SPEED SENSOR
4H SOLENOID SOLENOID COIL
MOTOR
2H 4L COMPONENT
ENGINE
SWITCH
N R
TO VACUUM
TCM PUMP
ONE-WAY
BA BB CHECK VALVE
03
4x4 RELAY
BATTERY
Z Y T E G F R S V U M N J I L H A B C D
W
X 4x4 CM
arnffn00000399
End Of Sie
03-18–3

4x4 CONTROL SYSTEM SYSTEM WIRING DIAGRAM [AT (5R55S)]
id0318d2163900
4x4
B+ CONTROL
IG1
MODULE
TRANSFER CASE
Y T
U C
Z CLUTCH COIL
TCM N A SENSOR
BA R 4x4 HI
MOTOR COMPONENT
DLC Q
G
4x4 SWITCH J E
4x2 HI POSITION 1
A G
4x4 HI I B
D
4x4 LO POSITION 2
C F
L A
F POSITION 3
H D
POSITION 4
A
B C
B V
LOCK SOLENOID
A
C F
A E D
D
B X
B+
4x4 RELAY W
A B
FREE SOLENOID
arnffw00001937
End Of Sie
4x4 CONTROL SYSTEM OPERATION [AT (5R55S)]
id0318d2165000
Note
• Shifting from 2H to 4H or 4H to 2H can be performed whether the vehicle is stopped or driving.
2H to 4H Selection
• When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
4H to 2H Selection
• When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
4H to 4L Selection
• Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18–4

4L to 4H Selection
• Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
Remote Freewheel Unit: FREE
FRONT DIFFERENTIAL
OUTPUT SHAFT
SLEEVE
JOINT SHAFT
RING GEAR
DRIVE PINION GEAR

03
RFW UNIT
RFW ACTUATOR
FRONT PROPELLER SHAFT
arnffn00000029
• The RFW actuator pulls the sleeve away from the front differential output shaft, allowing the front differential to
rotate freely.
The rotation of the right front tire is absorbed by the front differential, with the result that the ring gear, drive
pinion gear, and front propeller shaft do not turn.
03-18–5

Remote Freewheel Unit: LOCK
OUTPUT SHAFT
FRONT DIFFERENTIAL
SLEEVE
JOINT SHAFT
RFW UNIT
RFW ACTUATOR
FRONT PROPELLER SHAFT
arnffn00000030
• The RFW actuator pushes the sleeve over the output shaft, and the front differential output shaft and joint shaft
are coupled together.
If the sleeve and the output shaft are not aligned when actuated, the RFW actuator applies pressure to the
sleeve unit it can slide into place.
The rotation of the front propeller shaft is then transferred, via the front differential, to the front tires, and four-
wheel-drive operation is possible.
03-18–6

2H to 4H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
ACTUATOR
TO BATTERY LOCK
DIGITAL TR SENSOR LOCK
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY
RFW UNIT TRANSMISSION
4x4 SWITCH
N POSITION FREE LOCK CLUTCH TRANSFER
4H SOLENOID SOLENOID COIL SPEED SENSORS
2H 4L ON
MOTOR
COMPONENT
ENGINE
SWITCH
N R
TO VACUUM
TCM PUMP
ONE-WAY
BA BB CHECK VALVE
4x4 RELAY
03
BATTERY
W
X 4x4 CM
arnffn00000400

RFW
Digital Motor 4x4 4L actuator
TR compon indicato indicato Position
Condition sensor ent r light r light
2H - 2H - OFF ON 2H OFF OFF OFF Free
4H - 4H - ON OFF 4H ON ON OFF Lock
• When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
03-18–7

4H to 2H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
ACTUATOR
TO BATTERY
FREE
DIGITAL TR SENSOR FREE
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY
4x4 SWITCH
4H SOLENOID SOLENOID COIL SPEED SENSOR
2H 4L ON OFF MOTOR
COMPONENT
ENGINE
SWITCH
N R
TO VACUUM
TCM PUMP
ONE-WAY
BA BB CHECK VALVE
4x4 RELAY
BATTERY
W
X 4x4 CM
arnffn00000401

RFW
4H - 4H - ON OFF 4H ON ON OFF Lock
2H - 2H - OFF ON 2H OFF OFF OFF Free
• When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
03-18–8

4H to 4L Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
ACTUATOR
TO BATTERY LOCK
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY
4x4 SWITCH
2H 4L ON
MOTOR
COMPONENT
ENGINE
SWITCH
N R
TO VACUUM
TCM PUMP
ONE-WAY
BA BB CHECK VALVE
4x4 RELAY
03
BATTERY
W
X 4x4 CM
arnffn00000402

RFW
vehicle
4H N 4H ON OFF 4H ON ON OFF Lock
stop
vehicle
4L N 4L ON OFF 4L ON ON ON Lock
stop
• Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18–9

4L to 4H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
ACTUATOR
TO BATTERY LOCK
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY
4x4 SWITCH
2H 4L ON
MOTOR
COMPONENT
ENGINE
SWITCH
N R
TO VACUUM
TCM PUMP
ONE-WAY
BA BB CHECK VALVE
4x4 RELAY
BATTERY
W
X 4x4 CM
arnffn00000403

RFW
vehicle
4L N 4L ON OFF 4L ON ON ON Lock
stop
vehicle
4H N 4H ON OFF 4H ON ON OFF Lock
stop
• Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
End Of Sie
03-18–10
F340-10-05L(04-00).fm 1 ページ２００６年８月３日　木曜日　午前１１時３４分
BRAKES 04
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 04-00

OUTLINE CONVENTIONAL BRAKE
ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . . . . . . . . . 04-11
[4W-ABS]. . . . . . . . . . . . . . . . 04-02B PARKING BRAKE SYSTEM. . . 04-12
ANTILOCK BRAKE SYSTEM
[4W-ABS] . . . . . . . . . . . . . . . . 04-13B
Toc of SCT
04-00 OUTLINE
BRAKE FEATURES[EVEREST] . . . . . . . 04-00–1 BRAKE SPECIFICATIONS[EVEREST] . . 04-00–1
End of Toc
BRAKE FEATURES[EVEREST]
NG: BRAKES
id0400001002d1
Improved safety • 4-wheel antilock brake system (4W-ABS) adopted

Improved braking force • Tandem diaphragm power brake unit adopted
• Load sensing proportioning valve (LSPV) has been adopted
• Large diameter front disc brakes adopted
• Two-piston type front disc brake caliper adopted
• Wide width lining for the rear brake drum adopted
• Vacuum pump adopted
Improved serviceability • Automatic adjustment mechanism rear brake (drum) has been adopted
Size and weight reduction • Integrated construction of the hydraulic unit (HU) and control module (CM) adopted for the ABS
HU/CM 04
End Of Sie
BRAKE SPECIFICATIONS[EVEREST]
id0400001003d1
Item Specification
Type Suspended design
Brake pedal Pedal lever ratio 3.68
Max. stroke (mm {in}) 129 {5.08}
Master Type Tandem (with level sensor)
cylinder Cylinder bore (mm {in}) 25.4 {1.00}
Type Ventilated disc
Cylinder bore (mm {in}) 42.86 {1.687} x 2
Pad dimensions (area x thickness)
Front brake 5,500 {8.525} x 9 {0.35}
(disc) (mm2 x mm {in2 x in})
Disc plate dimensions
(outer diameter x thickness) 289 {11.4} x 28 {1.1}
(mm {in})
Type Leading-trailing
Wheel cylinder bore (mm {in}) 23.81 {0.9374}
Lining dimensions
Rear brake (width x length x thickness) 55 {2.2} x 296 {11.7} x 5.5 {0.22}
(drum)
(mm {in})
Drum inner diameter (mm {in}) 295 {11.6}
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
Power brake Type
Tandem diaphragm
unit
Outer diameter (mm {in}) 188.4 {7.417} + 215.2 {8.472}
Rear wheel
braking force Type Load sensing proportioning valve
control device
04-00–1
F340-10-05L(04-00).fm 2 ページ２００６年８月３日　木曜日　午前１１時３４分
OUTLINE
Item Specification
Type Mechanical two-rear-wheel control
Parking brake
Operation system Stick lever type
Brake fluid Type SAE J1703, FMVSS 116 DOT-3
End Of Sie
04-00–2
F340-10-05L(04-02).fm 1 ページ２００６年８月３日　木曜日　午前１１時３５分
ON-BOARD DIAGNOSTIC [4W-ABS]
04-02B ON-BOARD DIAGNOSTIC [4W-ABS]

ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM
FUNCTION[4W-ABS (EVEREST)] . . . . 04-02B–1 PID/DATA MONITOR FUNCTION
[4W-ABS (EVEREST)] . . . . . . . . . . . . . . 04-02B–2
End of Toc
ON-BOARD DIAGNOSTIC SYSTEM FUNCTION[4W-ABS (EVEREST)]
NG: DYNAMIC STABILITY CONTROL
id0402d5100800
Malfunction Detection Function
• The malfunction detection function detects malfunctions in the input/output signal system of the ABS HU/CM
when the engine switch is at the ON position.
• When the ABS HU/CM are started up, the following malfunction detections are performed.
— The ABS warning light illuminate for approx. 3 s when the engine switch is turned to the ON position. At the
same time, the fail-safe relay is operated, and the input/output signals of each part is monitored for
malfunction diagnosis. After starting to drive, the first time the vehicle speed is approx. 12 km/h {7.5 mph}
or more the pump motor is operated and malfunction diagnosis is performed again.
• When malfunctions are detected, the corresponding lights are illuminated to alert the driver. Using the external
tester communication function, DTCs can be output through the KLN of the DLC-2. At the same time,
malfunction detection results are sent to the memory and fail-safe functions.
Memory Function
• The memory function stores DTCs of malfunctions in input/output signal systems. With this function, once a
DTC is stored it is not cleared after the engine switch has been turned off (LOCK position), even if the
malfunctioning signal system has returned to normal.
• Since the ABS HU/CM has a built-in non-volatile memory, DTCs are not cleared even if the battery is removed.
Therefore, it is necessary to clear the memory after performing repairs. Refer to the Workshop Manual for the
DTC clearing procedure.
Fail-safe Function
• When the malfunction detection function determines a malfunction, each light illuminates to advise the driver. 04
At this time, the fail-safe function controls the ABS as shown in the fail-safe function table.
Fail-safe Function Malfunction Contents
Fail-safe function
Malfunction location DTC number Warning light illumination status Control status
ABS warning light ABS control
B1317
Power supply system Illuminated*1 Control disabled*2
B1318
ABS HU/CM system B1342 Illuminated Control disabled
Brake switch signal system B1484 Not illuminated Control enabled
C1095
Pump motor, motor relay systems Illuminated Control disabled
C1096
C1145
C1155
ABS wheel-speed sensor system Illuminated Control disabled
C1165
C1175
Fail-safe relay system C1186 Illuminated Control disabled
C1194
C1198
C1202
Solenoid valve system Illuminated Control disabled
C1206
C1210
C1214
ABS wheel-speed sensor (slip
C1222 Illuminated Control disabled
monitor) system
C1233
ABS wheel-speed sensor/ABS C1234
Illuminated Control disabled
sensor rotor systems C1235
C1236
Incorrect ABS HU/CM installed C1414 Illuminated Control disabled
04-02B–1

Fail-safe function
Malfunction location DTC number Warning light illumination status Control status
ABS warning light ABS control
C1730
G sensor system C1949 Illuminated Control disabled
C1950
*1
: If the ignition voltage returns to normal, the light goes out.
*2
: If the ignition voltage returns to normal, control is enabled.
End Of Sie
ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION[4W-ABS (EVEREST)]
id0402d5100900
• The PID/data monitor function is used for optionally selecting input/output signal monitor items preset in the
ABS HU/CM and reading them out in real-time.
Unit/Condition
PID/data monitor item Input/output part
(Tester display)
ABS_LAMP ABS warning light On/Off
ABS_VOLT Battery V
ACCLMTR G sensor G
BOO_ABS Brake switch On/Off
CCNTABS Number of continuous DTCs —
PMP_MOTOR Pump motor On/Off
RLY_PMP Pump motor relay On/Off
RLY_VLV Solenoid valve relay On/Off
V_LF_INL LF inlet solenoid valve On/Off
V_LF_OTL LF outlet solenoid valve On/Off
V_RF_INL RF inlet solenoid valve On/Off
V_RF_OTL RF outlet solenoid valve On/Off
V_Rear_INL Rear inlet solenoid valve On/Off
V_Rear_OTL Rear outlet solenoid valve On/Off
WSPD_LF ABS wheel-speed sensor (LF) KPH, MPH
WSPD_LR ABS wheel-speed sensor (LR) KPH, MPH
WSPD_RF ABS wheel-speed sensor (RF) KPH, MPH
WSPD_RR ABS wheel-speed sensor (RR) KPH, MPH
End Of Sie
04-02B–2
CONVENTIONAL BRAKE SYSTEM
04-11 CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC)
OUTLINE[EVEREST] . . . . . . . . . . . . . . 04-11–1 CONSTRUCTION[EVEREST] . . . . . . . . 04-11–1
CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DRUM)
STRUCTURAL VIEW[EVEREST] . . . . . 04-11–1 CONSTRUCTION[EVEREST] . . . . . . . . 04-11–2
End of Toc
CONVENTIONAL BRAKE SYSTEM OUTLINE[EVEREST]
NG: CONVENTIONAL BRAKE SYSTEM
id0411001001d4
• A tandem-type master cylinder has been adopted, improving braking force.
• A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force.
• A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
• A two-piston type front disc brake caliper has been adopted, improving braking force.
• A wide width lining for the rear brake drum has been adopted, improving braking force.
• An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability
• A vacuum pump has been adopted, improving braking force.
End Of Sie
CONVENTIONAL BRAKE SYSTEM STRUCTURAL VIEW[EVEREST]
id0411001002d4
LOAD SENSING
PROPORTIONING VALVE (LSPV)
MASTER CYLINDER
POWER BRAKE UNIT
04
REAR BRAKE (DRUM)
FRONT BRAKE (DISC)
VACUUM PUMP
arnffn00000235
End Of Sie
FRONT BRAKE (DISC) CONSTRUCTION[EVEREST]
id0411001004d4
• Two-piston type front disc brake caliper has been

adopted, improving braking force.
• Large diameter, ventilated disc type front brakes
with a 289 mm {11.4 in} diameter and 28 mm
{1.1 in} thickness have been adopted, improving
braking force and fade resistance.
End Of Sie
arnffn00000216
04-11–1

REAR BRAKE (DRUM) CONSTRUCTION[EVEREST]
id0411008108d4
• A leading/trailing type rear drum brake, with a 295 mm {11.6 in} drum inner diameter and 23.81 mm {0.937 in}
wheel cylinder inner diameter, has been adopted, improving braking force and fade resistance.
• Braking stability is ensured by use of 55 mm {2.16 in} width linings.
• If has an incremental automatic adjustment mechanism of shoe clearance to improve serviceability.
BACKING PLATE
SHOE HOLD PIN
WHEEL CYLINDER
OPERATING LEVER
BRAKE SHOE
BRAKE DRUM
REAR PARKING
BRAKE CABLE
ADJUST STRUT
PAWL LEVER
arnffn00000217
End Of Sie
04-11–2
PARKING BRAKE SYSTEM
04-12 PARKING BRAKE SYSTEM

PARKING BRAKE SYSTEM STRUCTURAL
VIEW[EVEREST]. . . . . . . . . . . . . . . . . . 04-12–1
End of Toc
PARKING BRAKE SYSTEM STRUCTURAL VIEW[EVEREST]
NG: PARKING BRAKE SYSTEM
id0412001002c2
PARKING BRAKE
PARKING BRAKE LEVER
SWITCH
REAR PARKING
FRONT PARKING BRAKE CABLE BRAKE CABLE
arnffn00000230
End Of Sie
04
04-12–1
F340-10-05L(04-13).fm 1 ページ２００６年８月３日　木曜日　午後２時３６分
ANTILOCK BRAKE SYSTEM [4W-ABS]
04-13B ANTILOCK BRAKE SYSTEM [4W-ABS]

ABS STRUCTURAL VIEW ABS WHEEL-SPEED SENSOR AND
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-13B–1 ABS SENSOR ROTOR
ABS SYSTEM WIRING DIAGRAM CONSTRUCTION/OPERATION
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-13B–2 [4W-ABS (EVEREST)] . . . . . . . . . . . . . . 04-13B–4
ABS CONTROL OUTLINE G SENSOR FUNCTION
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-13B–3 [4W-ABS (EVEREST)] . . . . . . . . . . . . . . 04-13B–4
End of Toc
ABS STRUCTURAL VIEW[4W-ABS (EVEREST)]
NG: ANTILOCK BRAKE SYSTEM
id0413c5184900
INSTRUMENT CLUSTER
REAR ABS WHEEL-SPEED

SENSOR
ABS WARNING
LIGHT
ABS HU/CM
G SENSOR
FRONT ABS WHEEL-SPEED 04

SENSOR
arnffn00000231
End Of Sie
04-13B–1
F340-10-05L(04-13).fm 2 ページ２００６年８月３日　木曜日　午前１１時３７分

ABS SYSTEM WIRING DIAGRAM[4W-ABS (EVEREST)]
id0413c5185000
ABS/SOL 20A
C
V
P G SENSOR
ABS 40A W
B
A
ENGINE SW ENGINE 15A
J
BRAKE SWITCH
BATTERY N
BRAKE
LIGHT
ABS WARNING
LIGHT
ABS HU/CM
S Q DLC-2
INSTRUMENT CLUSTER
O
RF
M
E
LF
ABS WHEEL- F
SPEED SENSOR L
RR
K D
I
LR
G
arnffn00000232
End Of Sie
04-13B–2

ABS CONTROL OUTLINE[4W-ABS (EVEREST)]
id0413c5184200
• ABS control occurs when wheel slip is determined by the ABS CM (based on the four ABS wheel-speed
sensors). Then, the ABS HU inlet and outlet solenoid valves are operated and brake fluid pressure is controlled
accordingly to prevent wheel lock-up.
• Use of ABS control during emergency braking or on slippery road surfaces allows directional stability to be
maintained, steerability ensured and stopping distance to be reduced.
• The ABS control system has independent front wheel control and unified control (select low) for the rear
wheels.
Note
• Select low control: A control system in which the left and right vehicle wheel speeds are compared and
brake fluid pressure is controlled according to the wheel most likely to lock-up.
Block Diagram
ABS HU/CM
CM HU
LF ABS WHEEL-SPEED
SENSOR LF CALIPER PISTON
SOLENOID
VALVE
RF ABS WHEEL-SPEED
SENSOR RF CALIPER PISTON
CPU
LR ABS WHEEL-SPEED
SENSOR
PUMP
MOTOR
LR WHEEL CYLINDER
RR ABS WHEEL-SPEED
SENSOR
04
RR WHEEL CYLINDER
G SENSOR
arnffn00000233
End Of Sie
04-13B–3

ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR CONSTRUCTION/OPERATION[4W-ABS
(EVEREST)]
id0413c5185100
Construction
• The front ABS wheel-speed sensor is installed on the steering knuckle and the front ABS sensor rotor is
integrated with the front wheel hub (4x2) or drive shaft (4x4).
• The rear ABS wheel-speed sensor is installed on the hub spindle and the rear ABS sensor rotor is integrated
with the rear axle shaft.
ABS WHEEL-SPEED SENSOR
PERMANENT MAGNET
COIL
ABS SENSOR ROTOR
POLE PIECE
arnffn00000218
Operation
• As the ABS sensor rotor rotates, magnetic flux OUTPUT VOLTAGE WAVEFORM
formed from the permanent magnet varies and +
alternating current is formed with an HIGH SPEED
electromagnetic conductor. Using this alternating
current, rotation speed is expressed as a varying
proportional cycle and from detection of this cycle
V
the CM part of the ABS HU/CM can then detect
the wheel rotation speed. While the structures of
the front and rear ABS wheel-speed sensor differ, LOW SPEED
the operation is the same.
End Of Sie —
arnffn00000219
G SENSOR FUNCTION[4W-ABS (EVEREST)]

id0413c5186200
Note
• Because the 4x2 vehicle is based on the 4x4 vehicle, the 4x4 vehicle ABS system has been adopted.
Therefore, the G-sensor, which is generally installed to 4x4 vehicles only, is installed to the 4x2 vehicle.
• Because the 4x4 vehicle ABS system has been adopted on the 4x2 vehicle, the ABS is controlled in the
same way as the 4x4 vehicle.
• In the 4x2 vehicle and 4x4 vehicle, the G sensor detects and calculates the vehicle G force (acceleration and
deceleration G force), and outputs the change in voltage to the ABS HU/CM.
End Of Sie
04-13B–4
F340-10-05L(05-00).fm 1 ページ２００６年８月１０日　木曜日　午後５時８分
TRANSMISSION/TRANSAXLE 05
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 05-00

OUTLINE AUTOMATIC TRANSMISSION
ON-BOARD [5R55S] . . . . . . . . . . . . . . . . . . 05-13
DIAGNOSTIC[5R55S] . . . . . . 05-02 AUTOMATIC TRANSMISSION
SHIFT MECHANISM. . . . . . . . 05-14
Toc of SCT
05-00 OUTLINE
TRANSMISSION/TRANSAXLE TRANSMISSION/TRANSAXLE
FEATURES [5R55S] . . . . . . . . . . . . . . . 05-00–1 SPECIFICATIONS [5R55S] . . . . . . . . . . 05-00–1
End of Toc
TRANSMISSION/TRANSAXLE FEATURES [5R55S]
NG: TRANSMISSION/TRANSAXLE
id0500001002f1
• Five-speed 5R55S automatic transmission has been adopted.

Improved marketability
• A water-cooling type and an air-cooling type AT oil cooler has been adopted
• Adaptive learn strategy system has been adopted
Superior shift quality
• Engine-transaxle total control system has been adopted
End Of Sie
TRANSMISSION/TRANSAXLE SPECIFICATIONS [5R55S]
id0500001006f1
Item Specification
Transmission control Floor-shift
1GR 3.22
2GR 2.29
3GR 1.55
Gear ratio
4GR 1.00
05
5GR 0.71
Reverse 3.07
Type Mercon® V
ATF Capacity
(L {US qt, lmp qt}) 9.93 {10.49, 8.74}
(approx. quantity)
Hydraulic Forward clutch 5/5
system(Number of Coast clutch 2/2
drive/driven gear
plates) Direct clutch 5/5
End Of Sie
05-00–1
F340-10-05L(05-02).fm 1 ページ２００６年８月１０日　木曜日　午後５時１０分
ON-BOARD DIAGNOSTIC [5R55S]
05-02 ON-BOARD DIAGNOSTIC [5R55S]

ON-BOARD DIAGNOSTIC (OBD) MALFUNCTION INDICATION
SYSTEM OUTLINE [5R55S] . . . . . . . . . 05-02–1 FUNCTION [5R55S] . . . . . . . . . . . . . . . . 05-02–3
ON-BOARD DIAGNOSTIC (OBD) FAIL-SAFE FUNCTION [5R55S] . . . . . . . 05-02–3
SYSTEM BLOCK DIAGRAM PARAMETER IDENTIFICATION (PID)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–1 DATA MONITORING FUNCTION
MALFUNCTION DETECTION [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–4
FUNCTION [5R55S] . . . . . . . . . . . . . . . 05-02–2 SIMULATION FUNCTION [5R55S] . . . . . 05-02–4
MEMORY FUNCTION [5R55S] . . . . . . . . 05-02–3 DLC-2 OUTLINE [5R55S]. . . . . . . . . . . . . 05-02–5
End of Toc
ON-BOARD DIAGNOSTIC (OBD) SYSTEM OUTLINE [5R55S]
NG: AUTOMATIC TRANSAXLE
id0502c1100100
• The OBD system has the following functions:
— Malfunction detection function: Detects malfunctions of the input/output devices and system components of
the AT.
— Fail-safe function: Fixes the output device function and input value of the sensors/switches to ensure
minimum vehicle driveability when a malfunction is detected.
— Memory function: Stores the DTC when a malfunction is detected.
— PID data monitored function: Monitors the input/output signal and calculated value of the TCM, and sends
the monitoring data to the IDS/PDS.
— Simulation function: Allows override operation of simulation items for input/output system parts preset in the
TCM.
End Of Sie
ON-BOARD DIAGNOSTIC (OBD) SYSTEM BLOCK DIAGRAM [5R55S]
id0502c1100200
TCM
OBD SYSTEM INSTRUMENT CLUSTER
O/D OFF
INDICATOR LIGHT
MALFUNCTION
INDICATION FUNCTION CAN CAN
MIL
MEMORY
PCM
05
FUNCTION
CAN
SERIAL COMMUNICATION DLC-2
CAN
IDS/PDS
MALFUNCTION PID DATA
SIMULATION
DETECTION MONITORING
FUNCTION
FUNCTION FUNCTION
FAIL-SAFE
FUNCTION
PCM CAN
OUTPUT
TRANSMISSION CONTROL SYSTEM PARTS
INPUT
PARTS
arnffn00000333
End Of Sie
05-02–1

MALFUNCTION DETECTION FUNCTION [5R55S]
id0502c1100300
Malfunction Detection Function
• In the malfunction detection function, the TCM detects malfunctions in the automatic transmission while driving.
• When vehicle driving conditions correspond with a preset malfunction detection condition, the TCM determines
that the automatic transmission has a malfunction and stores the corresponding DTC.
• When a malfunction is detected, stored DTCs can be retrieved using the IDS/PDS connected to the DLC-2.
DTC Table
DTC No. Condition
P0657 Solenoid valve power supply circuit open
P0658 Solenoid valve power supply circuit voltage low
P0705 Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
P0708 Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
P0711 Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
P0712 Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
P0713 Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
P0715 Turbine shaft speed (TSS) sensor malfunction
P0717 Turbine shaft speed (TSS) sensor signal is not input
P0718 Turbine shaft speed (TSS) sensor signal noise
P0720 Output shaft speed (OSS) sensor malfunction
P0721 Output shaft speed (OSS) sensor signal noise
P0722 Output shaft speed (OSS) sensor signal is not input
P0731 Gear 1 incorrect
P0740 Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
P0741 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
P0742 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
P0743 Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
P0744 Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
P0745 Pressure control solenoid A malfunction (low pressure)
P0748 Pressure control solenoid A circuit malfunction (non-operation)
P0750 Shift solenoid A circuit malfunction (open or short circuit)
P0753 Shift solenoid A circuit malfunction (open or short circuit)
P0755 Shift solenoid B circuit malfunction (open or short circuit)
P0757 Shift solenoid B malfunction (stuck on)
P0758 Shift solenoid B circuit malfunction (open or short circuit)
P0760 Shift solenoid C circuit malfunction (open or short circuit)
P0762 Shift solenoid C malfunction (stuck on)
P0763 Shift solenoid C circuit malfunction (open or short circuit)
P0765 Shift solenoid D circuit malfunction (open or short circuit)
P0768 Shift solenoid D circuit malfunction (open or short circuit)
P0775 Pressure control solenoid B malfunction (low pressure)
P0778 Pressure control solenoid B circuit malfunction (non-operation)
P0791 Intermediate shaft speed (ISS) sensor malfunction
P0794 Intermediate shaft speed (ISS) sensor signal noise
P0795 Pressure control solenoid C malfunction (low pressure)
P0798 Pressure control solenoid C circuit malfunction (non-operation)
P0960 Pressure control solenoid A circuit malfunction (open circuit)
P0962 Pressure control solenoid A circuit malfunction (short to ground)
P0963 Pressure control solenoid A circuit malfunction (short to power supply)
P0964 Pressure control solenoid B circuit malfunction (open circuit)
P0966 Pressure control solenoid B circuit malfunction (short to ground)
P0967 Pressure control solenoid B circuit malfunction (short to power supply)
05-02–2

DTC No. Condition
P0968 Pressure control solenoid C circuit malfunction (open circuit)
P0970 Pressure control solenoid C circuit malfunction (short to ground)
P0971 Pressure control solenoid C circuit malfunction (short to power supply)
P1635 Tire/axle ratio out of acceptable range
P1700 Transmission indeterminate malfunction
P1702 Digital transmission range (TR) sensor circuit intermittent
P1704 Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
P1705 Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
P1711 ATF temperature out of on-board diagnostic range
P1780 O/D OFF switch circuit malfunction (open or short circuit)
P1783 ATF overheating
U0100 Communication error to PCM
U0294 Communication error to PCM
End Of Sie
MEMORY FUNCTION [5R55S]

id0502c1100400
• The memory function stores malfunction information detected in the malfunction detection function. Once
malfunction information is stored, the memory will not be cleared even when the engine switch is turned off
(LOCK position) or the malfunction is repaired.
• The stored memory (malfunction information) can be cleared using the IDS/PDS, or by disconnecting the
negative battery cable.
End Of Sie
MALFUNCTION INDICATION FUNCTION [5R55S]

id0502c1100500
• The malfunction indication function illuminates the MIL or flashing the O/D OFF indicator light when the
malfunction detection function determines that there is a malfunction.
End Of Sie
05
FAIL-SAFE FUNCTION [5R55S]
id0502c1100600
• In the fail-safe function, minimum vehicle driveability is obtained by changing the signals that are determined to
be irregular by the malfunction detection function to the preset values, and limiting TCM control.
End Of Sie
05-02–3

PARAMETER IDENTIFICATION (PID) DATA MONITORING FUNCTION [5R55S]
id0502c1100700
• The PID mode allows access to certain data values, analog and digital input and output, calculations and
system state information.
PID/DATA MONITOR AND RECORD function table
Unit/
Monitor item Definition TCM terminal
Condition
BPP Brake switch on/off N/A
FIRM_ST Firm shaft control (FSC) status requested 0/1 N/A
GEAR Calculated gear range in TCM 1/2/3/4/5 N/A
GEAR_OSC PID used to command gear changes during Simulation Function 1/2/3/4/5 N/A
ISS ISS sensor rpm AM, AS
OSS OSS sensor rpm AD, AG
PCA Pressure control solenoid A pis I, CK
PCB Pressure control solenoid B pis J, CK
PCC Pressure control solenoid C pis M, CK
RPM Engine speed rpm N/A
SSA Shift solenoid A on/off B, CK
SSB Shift solenoid B on/off C, CK
SSC Shift solenoid C on/off F, CK
SSD Shift solenoid D on/off D, CK
TCC TCC control solenoid % A, CK
TCCRAT Torque converter speed ratio ratio N/A
TFT ATF temperature °C, °F AY, BH
TR_D Digital TR sensor signal AX, BU, BY, CA
TR_V Digital TR sensor signal voltage V AX, BU, BY, CA
TR1 TR1 switch 0/1 BY
TR2 TR2 switch 0/1 BU
TR3A TR3 switch 0/1 AX
TR4 TR4 switch 0/1 CA
TSS TSS sensor rpm AH, AP
VSS Vehicle speed mph AD, AG
End Of Sie
SIMULATION FUNCTION [5R55S]

id0502c1100800
• By using the IDS/PDS, simulation items for input/output parts preset in the TCM can be optionally selected and
operated regardless of TCM control conditions.
Simulation item table
Simulation item Applicable component Unit TCM terminal
End Of Sie
05-02–4

DLC-2 OUTLINE [5R55S]
id0502c1100900
• A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been
adopted.
• The shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has
been adopted for this connector. The connector has a 16-pin construction that includes the B+, CAN_H,
CAN_L, GND1, GND2 and KLN terminals.
DLC-2
B+ CAN_L
KLN CAN_H GND2 GND1
atraan00000380
Terminal Function
B+ Battery power supply terminal
CAN_L Serial communication terminal (Lo)
CAN_H Serial communication terminal (Hi)
GND1 Body ground terminal
GND2 Serial communication ground terminal
KLN Serial communication terminal (Malfunction diagnosis use)
End Of Sie
05
05-02–5
F340-10-05L(05-13).fm 1 ページ２００６年８月１０日　木曜日　午後５時１１分
AUTOMATIC TRANSMISSION [5R55S]
05-13 AUTOMATIC TRANSMISSION [5R55S]

AUTOMATIC TRANSMISSION FLUID FILTER
OUTLINE [5R55S] . . . . . . . . . . . . . . . . . 05-13–1 CONSTRUCTION [5R55S] . . . . . . . . . . . 05-13–28
AUTOMATIC TRANSMISSION CONTROL VALVE BODY
CROSS-SECTIONAL VIEW OUTLINE [5R55S] . . . . . . . . . . . . . . . . . 05-13–29
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–2 PRESSURE CONTROL
AUTOMATIC TRANSMISSION HYDRAULIC CIRCUITS
CONTROL SYSTEM CONSTRUCTION [5R55S] . . . . . . . . . . . 05-13–32
WIRING DIAGRAM [5R55S] . . . . . . . . . 05-13–3 SHIFT SOLENOID
EC-AT OPERATION CHART HYDRAULIC CIRCUITS
IDENTIFICATION TAG OUTLINE TORQUE CONVERTER/LUBE
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–5 HYDRAULIC CIRCUITS
RANGE SELECTION [5R55S] . . . . . . . . 05-13–6 CONSTRUCTION [5R55S] . . . . . . . . . . . 05-13–42
SHIFT PATTERNS [5R55S]. . . . . . . . . . . 05-13–7 APPLY COMPONENT
POWERFLOW OPERATION HYDRAULIC CIRCUITS
TORQUE CONVERTER OUTLINE ELECTRONIC CONTROL
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–16 SYSTEM OUTLINE [5R55S] . . . . . . . . . 05-13–55
PLANETARY GEARSETS ELECTRONIC CONTROL
CONSTRUCTION [5R55S] . . . . . . . . . . 05-13–17 SYSTEM BLOCK DIAGRAM
APPLY COMPONENTS [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–55
CONSTRUCTION [5R55S] . . . . . . . . . . 05-13–18 ELECTRONIC CONTROL
PARKING LOCK SYSTEM STRUCTURE [5R55S] . . . . . . 05-13–56
CONSTRUCTION [5R55S] . . . . . . . . . . 05-13–25 OIL COOLER CONSTRUCTION
LUBRICATION [5R55S] . . . . . . . . . . . . . 05-13–26 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–58
FLUID PUMP
CONSTRUCTION [5R55S] . . . . . . . . . . 05-13–27
End of Toc
AUTOMATIC TRANSMISSION OUTLINE [5R55S]
NG: AUTOMATIC TRANSMISSION
id0513c1250100
• This transmission has the following features:
— Five forward speeds
— Electronic shift, pressure and torque 05
converter clutch controls
— Three compound planetary gearsets
— Three bands (overdrive, intermediate, low/
reverse)
— Three multi-plate clutches (coast, direct,
forward)
— Two one-way clutches (Overdrive, low/
reverse)
• All hydraulic functions are directed by electronic
arnffv00000559
solenoids. The solenoids control:
— Static engagement feel.
— Shift feel.
— Shift scheduling.
— Modulated torque converter clutch (TCC) applications.
— Engine braking utilizing the coast clutch and band.
— Manual 1st and 2nd timing.
— Reverse inhibit timing.
End Of Sie
05-13–1

AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW [5R55S]
id0513c1250400

CONVERTER PUMP
LOW/REVERSE
OVERDRIVE BRAKE
BRAKE

arnffn00000345
End Of Sie
05-13–2

AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [5R55S]
id0513c1250900
IG1 B+ B+
TCM
AT RELAY
BT
CM
CP
CK
TCC CONTROL SOLENOID
OTHER CB CAN_H A
MODULE
SHIFT SOLENOID A
CF CAN_L
B
SHIFT SOLENOID B
C
4x4 BA 4x4 HI
CONTROL SHIFT SOLENOID C
F
MODULE
BB 4x4 LO
SHIFT SOLENOID D
IG1 D
4x4 HI PRESSURE CONTROL SOLENOID A
N I
PRESSURE CONTROL SOLENOID B
4x4 LO J
R PRESSURE CONTROL SOLENOID C
M
O/D OFF TFT SENSOR
E AY
BH
K
DIGITAL TR SENSOR
Q
INSTRUMENT
CLUSTER TR3A AX 05
G
TR1 BY
U
IG1 TR2 BU
O/D OFF SWITCH
TR4 CA
BM
AG
OSS SENSOR CL
AD
CO
AS
ISS SENSOR AO
AM
AK
AP
TSS SENSOR BS
AH
arnffn00000405
End Of Sie
05-13–3

EC-AT OPERATION CHART [5R55S]
id0513c1251000
Solenoid Operation Chart
Pressure Pressure Pressure
Gear Shift Shift Shift Shift
Selector position control control control
position solenoid A solenoid B solenoid C solenoid D
solenoid A solenoid B solenoid C
P — — On Off Off On Low High/Low Low
R — Reverse On Off Off On Low/High Low High
N — — On Off Off On Low High/Low Low
1GR On Off Off On High High/Low Low
2GR On Off On On Low/High High Low
Normal 3GR On On Off On High Low/High Low
4GR Off Off Off On High Low/High High
D 5GR Off Off On On High High/Low High
1GR On Off Off On High High/Low Low
2GR On Off On On Low/High High Low
O/D OFF
3GR On On Off On High Low/High Low
4GR Off Off Off Off Low/High High High
3 — 3GR On On Off Off High Low High/Low
2 — 2GR On Off On Off High Low High/Low
1 — 1GR On Off Off Off High Low High/Low
Band and Clutch Application Chart A

Gear Overdrive Intermediate Low/reverse Forward
Selector position Direct clutch Coast clutch
position band band band clutch
P — — — — — — — —
R — Reverse — — A — A Ac
N — — — — — — — —
1GR — — — A — —
2GR A — — A — —
Normal 3GR — A — A — —
4GR — — — A A —
D 5GR A — — A A —
1GR — — — A — —
2GR A — — A — —
O/D OFF
3GR — — — A — —
4GR — — — A A Ac
3 — 3GR Ac — A — Ac
2 — 2GR A — Ac A — —
1 — 1GR — — Ac A — Ac
A : Applied
Ac : Applied to carry coast torque.
— : N/A
05-13–4

Band and Clutch Application Chart B
Gear Direct one-way clutch Low/reverse one-way clutch
Selector position Engine braking
position Drive Coast Drive Coast
P — — — — — — —
R — Reverse H NE NE NE No
N — — — — — — —
1GR H NE H NE No
2GR OR OR H NE No
Normal 3GR H NE OR OR No
4GR H NE OR OR No
D 5GR OR OR OR OR Yes
1GR H NE H NE Yes
2GR OR OR H NE Yes
O/D OFF
3GR H NE OR OR Yes
4GR H NE OR OR Yes
3 — 3GR H NE OR OR Yes
2 — 2GR OR OR H NE Yes
1 — 1GR H NE H NE Yes
H : Hold
NE: No effect
OR: Overrunning
— : N/A
End Of Sie
IDENTIFICATION TAG OUTLINE [5R55S]

id0513c1323600
• All vehicles are equipped with a vehicle
certification label, located on the driver side door
lock post. Refer to the code in the space marked TRANSMISSION BAR CODE 1 ITEM TRANSMISSION
TR. For model, service ID level or build date PART NUMBER DESCRIPTION PLANT MODEL CODE
information, refer to the transmission service ID
PART 1 05
tag located on the transmission case.
End Of Sie 6M3P 7000 AB
TRANSMISSION
BL2 PLANT MODEL
404 CODE PART 2
BAR CODE 2
A6G12 020204 040508
ASSEMBLY PLANT TRANSMISSION BUILD TRANSMISSION

LINE SHIFT DATE (DD MM YY) SERIAL NUMBER
arnffn00000347
05-13–5

RANGE SELECTION [5R55S]
id0513c1323700
• The transmission has 7 range positions: P, R, N,
D, 3, 2 and 1.
SELECTOR
LEVER
arnffn00000349
Park (P Position)
• In the P position:
— There is no power flow through the transmission.
— The parking pawl locks the output shaft to the case.
— The engine may be started.
— The ignition key may be removed.
Reverse (R Position)
• In the R position:
— The vehicle may be operated in a rearward direction, at a reduced gear ratio.
Neutral (N Position)
• In the N position:
— There is no power flow through the transmission.
— The output shaft is not held and is free to turn.
— The engine may be started.
Drive—Overdrive Enabled (D range)
• D range (overdrive enabled) is the normal position for most forward driving.
• The D range provides:
— Automatic shifts 1—5 and 5—1.
— Apply and release of the torque converter clutch.
— Maximum fuel economy during normal operation.
— Engine braking in 5GR
Drive—Overdrive Canceled (D range, O/D OFF mode)
• The D range provides:
— Automatic shifts 1—4 and 4—1.
— Apply and release of the torque converter clutch.
— Maximum fuel economy during normal operation.
— Engine braking in 4GR
Manual 3 (3 range)
• The 3 range provides:
— 3GR start and hold.
— Torque converter clutch apply and release.
— Improved traction on slippery roads.
— Engine braking.
Manual 2 (2 range)
• If this position is selected at normal road speeds, the transmission will downshift into the next lower gear and
continue downshifting until the vehicle reaches 2GR.
• The 2 range provides:
— 2GR start and hold.
— Torque converter clutch apply and release.
— Improved traction on slippery roads.
— Engine braking.
Manual 1 (1 range)
• If this position is selected at normal road speeds, the transmission will downshift into the next lower gear and
continue downshifting until the vehicle reaches 1GR.
• This position provides:
— 1GR operation only.
— Engine braking for descending steep grades.
05-13–6

End OfPATTERNS
SHIFT Sie [5R55S]
id0513c1323800
Upshifts
• Transmission upshifting is controlled by the TCM. The TCM receives inputs from various engine or vehicle
sensors and driver demands to control shift scheduling, shift feel and torque converter clutch (TCC) operation.
• The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel.
• Even if the battery is disconnected or a new battery installed, transmission operating parameters are kept. The
TCM must relearn these parameters.
Downshifts
• Under certain conditions the transmission will downshift automatically to a lower gear range (without moving
the range selector lever).
• There are 3 categories of automatic downshifts: coastdown, torque demand and forced or kickdown shifts.
Coastdown
• The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
• The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio.
• If applied, the transmission will disengage the TCC to provide added acceleration.
Kickdown
• For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor.
• A forced downshift into a lower gear is possible below calibrated speeds.
• Specifications for downshift speeds are subject to variations due to tire size and engine and transmission
calibration requirements.
End Of Sie
05
05-13–7

POWERFLOW OPERATION [5R55S]
id0513c1320600
P or N Position
Apply component operation
• Overdrive one-way clutch holding
• Output shaft stationary with the parking pawl holding the parking gear (transmission shifter in P position)
Planetary gearset operation
• Overdrive gearset indirect
• Forward/Reverse gearset driving member:
— None
• Forward/Reverse gearset driven member:
— None
• Forward/Reverse gearset held member:
— None
• Forward/Reverse gearset member also rotating:
— None
P OR N POSITION
OVERDRIVE ONE-WAY
CLUTCH HOLDING
arnffn00000387
R Position
• Overdrive one-way clutch holding (drive)
• Direct clutch applied
• Low/reverse band applied
— Forward/reverse sun gear
— Forward planetary carrier component and reverse ring gear
— Reverse planetary carrier component
— Forward ring gear
05-13–8
R POSITION
OVERDRIVE ONE-WAY CLUTCH

HOLDING (DRIVE ONLY) DIRECT CLUTCH
APPLIED
LOW/REVERSE
BAND APPLIED
arnffn00000388
D Range 1GR
• Forward clutch applied
• Low/reverse one-way clutch holding (drive)
• Forward/Reverse gearset member also rotating: 05
D RANGE 1GR
OVERDRIVE ONE-WAY CLUTCH

HOLDING (DRIVE ONLY) FORWARD CLUTCH
APPLIED
LOW/REVERSE ONE-WAY
CLUTCH (DRIVE ONLY)
arnffn00000389
05-13–9

D Range 2GR
• Overdrive band applied
• Overdrive gearset in overdrive
D RANGE 2GR
OVERDRIVE BAND
APPLIED FORWARD CLUTCH
APPLIED
LOW/REVERSE ONE-WAY CLUTCH
HOLDING (DRIVE ONLY)
arnffn00000390
D Range 3GR
• Intermediate band applied
05-13–10
D RANGE 3GR
INTERMEDIATE BAND
APPLIED
FORWARD CLUTCH
OVERDRIVE ONE-WAY APPLIED
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000391
D Range 4GR
— Forward planetary carrier component and reverse ring gear 05
— None
D RANGE 4GR
DIRECT CLUTCH
APPLIED
FORWARD CLUTCH
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000392
05-13–11

D Range 5GR
— None
D RANGE 5GR
DIRECT CLUTCH
APPLIED
OVERDRIVE BAND
APPLIED FORWARD CLUTCH
APPLIED
arnffn00000393
D Range 4GR, O/D OFF Mode (Manual 4GR)

• Coast clutch applied
— None
05-13–12
D RANGE 4GR, O/D OFF MODE (MANUAL 4GR)
DIRECT CLUTCH
APPLIED
COAST CLUTCH
APPLIED
FORWARD CLUTCH
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000394
3 Range (Manual 3GR)

• Intermediate band applied
05
3 RANGE (MANUAL 3GR)
INTERMEDIATE
BAND APPLIED
COAST CLUTCH FORWARD CLUTCH
APPLIED APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000395
05-13–13

FORWARD CLUTCH
APPLIED
LOW/REVERSE BAND
APPLIED
OVERDRIVE BAND
APPLIED LOW/REVERSE ONE-WAY
CLUTCH HOLDING (DRIVE
ONLY)
arnffn00000396
05-13–14

FORWARD CLUTCH
APPLIED
COAST CLUTCH LOW/REVERSE BAND
APPLIED OVERDRIVE ONE-WAY APPLIED
ONLY) LOW/REVERSE ONE-WAY
ONLY)
05
arnffn00000397
End Of Sie
05-13–15

TORQUE CONVERTER OUTLINE [5R55S]
id0513c1321000
• The torque converter of the 5R55S transmission is a four-element component. It contains an impeller, a turbine
and a reactor, plus TCC (torque converter clutch) for increased fuel economy.
• The impeller and cover assembly drives the impeller blades and fluid pump. It contains hydraulic fluid and
provides a mating surface for the TCC damper assembly.
• The turbine is driven by fluid from the impeller and transmits power to the turbine shaft and planetary gearsets.
• The reactor redirects fluid flow returned from the turbine to the impeller so that it rotates in the same direction
as the impeller. This action assists in torque multiplication.
• The reactor has a one-way clutch to hold it stationary during torque multiplication (at lower vehicle speeds) and
allow it to rotate (at higher vehicle speeds).
• TCC has the following features:
— A piston with damper assembly that connects to the turbine and transmission input shaft
— A friction paper surface on the piston (or on a ring connected to the piston) that makes contact with the
torque converter cover when TCC is applied
— Fluid that flows through the torque converter and pushes the TCC piston away from the torque converter
cover during TCC release
— Fluid that flows through the torque converter and pushes the TCC piston into contact with the torque
converter cover during TCC apply
• TCC operates in three stages:
— Full release
— Controlled modulation
— Full apply
• The TCM controls TCC operation, using the TCC control solenoid.
• TCC control solenoid operation provides the modulation of hydraulic pressure to change the position of the
control valves. The control valves change the pressure and direction of fluid flow in the torque converter.
• TCC may be applied in 2nd gear, 3rd gear, 4th gear and 5th gear.
FULL TCC RELEASE FULL TCC APPLY
TURBINE REACTOR
FROM
CONVERTER
CONTROL VALVE
FROM
IMPELLER CONVERTER
CONTROL VALVE
TCC TO
CONVERTER
CONTROL
VALVE AND
LUBE
arnffn00000346
End Of Sie
05-13–16

PLANETARY GEARSETS CONSTRUCTION [5R55S]
id0513c1321100
• The 5R55S transmission has three planetary gearsets to provide operation in reverse and in five forward
speeds.
• The overdrive planetary gearset has the following parts:
— Overdrive sun gear
— Overdrive planetary carrier component
— Overdrive ring gear
• The input shaft rotates the overdrive planetary carrier component as a driving member. The input shaft may
also drive the overdrive ring gear directly with a 1.00 to 1 ratio.
• When the transmission case holds the overdrive sun gear stationary, the overdrive planetary carrier drives the
overdrive ring gear with an overdrive ring gear with an overdrive ratio of either 0.71 to 1.
• The forward and reverse planetary gearsets have the following parts:
— Forward planetary carrier component
— Output ring gear
• The forward/reverse sun gear is a driving member in reverse. The forward ring gear is a driving member in each
forward gear.
• The forward/reverse sun gear and forward ring gear are driving members for a 1.00 to 1 ratio in 4GR and 5GR.
• The forward planetary carrier component and output ring gear are both connected to the output shaft and are
driven members in reverse and in all forward speeds.
• The transmission case holds the reverse planetary carrier component stationary in 1GR and 2GR.
• The reverse planetary carrier component is a member that rotates at a different speed that the driving and
driven members in 3GR.
• The reverse planetary carrier component rotates at the same speed as the forward/reverse sun gear and
forward ring gear as part of the 1.00 to 1 ratio in 4GR and 5GR.
OUTPUT SHAFT
OUTPUT RING GEAR

05
REVERSE PLANETARY
CARRIER
FORWARD/REVERSE
SUN GEAR AND INPUT
SHELL
FORWARD
PLANETARY
CARRIER
FORWARD
RING GEAR
OVERDRIVE RING
GEAR AND CENTER
SHAFT
OVERDRIVE
PLANETARY
OVERDRIVE CARRIER
SUN GEAR
INPUT SHAFT
arnffn00000348
End Of Sie
05-13–17

APPLY COMPONENTS CONSTRUCTION [5R55S]
id0513c1321200
Clutch/Band Operation
• The apply components of the 5R55S transmission work together to provide a flow of power.
• The coast clutch is applied to provide coast braking in manual 1GR, manual 3GR and manual 4GR. Coast
braking occurs without the use of the coast clutch in manual 2GR and in 5GR.
D
Position/Range R D (O/D 3 2 1
OFF) Planetary
component
Manual Manual Manual Manual
Gear position Reverse 1GR 2GR 3GR 4GR 5GR
4GR 3GR 2GR 1GR
Overdrive band A A A OS
Intermediate band A A FRS
Low/reverse band A A A RP
Coast clutch A A A OS
Direct clutch A A A A FRS
Forward clutch A A A A A A A A A FR
Overdrive Drive H H OR H H OR H H OR H
one-way OS
clutch Coast OR OR OR OR OR OR OR OR OR OR
Low/ Drive H H OR OR OR OR OR H H
reverse
RP
one-way Coast OR OR OR OR OR OR OR OR OR
clutch
A : Applied
H : Holding
OR: Overrunning
OS: Overdrive sun gear
RP: Reverse planetary carrier component
FRS:Forward/reverse sun gear
FR: Forward ring gear
05-13–18

Overdrive Band
• The overdrive band connects the overdrive sun gear to the transmission case.
• The overdrive band is applied in 2GR and 5GR, as well as in manual 2GR.
• During 2GR and 5GR operation, hydraulic pressure is applied to the overdrive servo.
— This pressure causes the piston to move and apply force to the band.
— This action causes the overdrive band to hold the overdrive drum.
— This causes the overdrive sun gear to be held stationary through the adapter plate and the overdrive drum.
SERVO PISTON AND

RETURN SPRING
OVERDRIVE
BAND
SERVO COVER, SEALS
AND RETAINING RING
OVERDRIVE SUN
GEAR AND
ADAPTER
APPLY STRUT
COAST CLUTCH
DRUM
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
arnffn00000350
05
05-13–19

Overdrive One-Way Clutch
• The overdrive one-way clutch connects the input shaft to the center shaft during drive operation.
• The overdrive one-way clutch transmits torque in Reverse, 1GR, 3GR and 4GR, as well as in manual 3GR.
• The direct one-way clutch is a sprag-type one-way clutch that is pressed into the center shaft.
— The overdrive one-way clutch is driven by the ring gear of the overdrive planetary carrier.
— The overdrive one-way clutch holds and drives the outer splines of the center shaft in 1GR, 3GR, 4GR and
Reverse gears.
— The overdrive one-way clutch overruns during all coast operations and at all times in 2GR and 5GR.
OVERDRIVE ONE-WAY CLUTCH SPRAG

ASSEMBLY AND OUTER RACE (PART OF
OVERDRIVE RING GEAR/CENTER SHAFT)
OVERDRIVE ONE-WAY CLUTCH INNER RACE

(PART OF OVERDRIVE PLANETARY CARRIER)
INPUT SHAFT
arnffn00000351
Coast Clutch
• The coast clutch connects the overdrive planetary carrier component to the overdrive sun gear.
• The coast clutch is applied in manual 1GR, manual 3GR, manual 4GR (D range O/D OFF mode) and Reverse
positions.
• The coast clutch is a multi-disc clutch made up of steel and friction plates.
— The coast clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
the hydraulic pressure.
— The coast clutch is housed in the overdrive drum.
— When applied, the coast clutch locks the overdrive sun gear to the overdrive planetary carrier, thus
preventing the one-way clutch from overrunning when the vehicle is coasting.
— This allows the use of engine compression to help slow the vehicle and provide engine braking.
OVERDRIVE
PLANETARY
CARRIER
PRESSURE OVERDRIVE SUN
PLATES GEAR AND
ADAPTER
STEEL
PLATES
PISTON AND
SEALS
COAST
CLUTCH
DRUM RETAINING RING
(SELECT FIT)
FRICTION PLATES
RETURN SPRINGS,
RETAINER AND
RETAINING RING
arnffn00000352
05-13–20

Intermediate Band
• The intermediate band connects the forward/reverse sun gear to the transmission case.
• The intermediate band is applied in 3GR, as well as in manual 3GR.
• During 3GR operation, hydraulic pressure is applied to the intermediate servo.
— This pressure causes the servo to move and apply force to the intermediate band.
— This action causes the direct clutch drum to be held.
— The intermediate band holds the intermediate brake and direct clutch drum to the case in 3GR.
— This causes the input shell and forward sun gear to be held stationary.
SERVO COVER,
SEALS AND
RETAINING RING
INTERMEDIATE
BAND
FORWARD/REVERSE SUN
SERVO PISTON GEAR AND INPUT SHELL
AND SPRING
DIRECT CLUTCH
APPLY STRUT
DRUM
05
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
arnffn00000353
05-13–21

Direct Clutch
• The direct clutch connects the center shaft to the forward/reverse sun gear.
• The direct clutch is applied in Reverse, 4GR and 5GR, as well as in manual 4GR (D range O/D OFF mode).
• The direct clutch is a multi-disc clutch made up of steel and friction plates.
— The direct clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
— It is housed in the direct clutch drum.
— During 4GR, 5GR and Reverse gear application, the direct clutch is applied transferring torque from the
forward clutch cylinder to the direct clutch drum.
— This action causes the forward sun gear to drive the pinions of the low/reverse planetary carrier.
FORWARD/REVERSE SUN
GEAR AND INPUT SHELL
FORWARD CLUTCH
CYLINDER
PRESSURE
PLATES
FRICTION
PLATES
RETURN SPRINGS,
RETAINER AND
RETAINING RING
DIRECT CLUTCH RETAINING RING

DRUM (SELECT FIT)
CENTER SHAFT STEEL

PLATES
PISTON AND
SEALS
arnffn00000354
Forward Clutch
• The forward clutch connects the center shaft to the forward ring gear.
• The forward clutch is applied in all forward gears.
• The forward clutch is a multi-disc clutch made up of steel and friction plates.
— The forward clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
— When applied, the forward clutch provides a direct mechanical coupling between the center shaft and the
forward ring gear and hub.
RETAINING RING FORWARD RING

(SELECT FIT) GEAR
STEEL
PLATES
PISTON, RETURN SPRINGS
AND RETAINING RING
FORWARD
CLUTCH
CYLINDER
PRESSURE
CENTER SHAFT PLATE
FRICTION
PLATES
arnffn00000355
05-13–22

Low/Reverse Band
• The low/reverse band connects the reverse planetary carrier to the transmission case.
• The low/reverse band is applied in Reverse, as well as in manual 1GR and manual 2GR.
• During 2GR operation, 1GR operation and Reverse, hydraulic pressure is applied to the low/reverse servo.
— This pressure causes the servo to move and apply force to the low/reverse band.
— This action causes the low/reverse brake drum to be held.
— This action causes the low/reverse planetary assembly to be held stationary.
LOW/REVERSE
BAND
BAND
REVERSE PLANETARY ACTUATING
CARRIER AND RETAINING
LEVER AND
RING
SHAFT
LOW/REVERSE
DRUM
SERVO PISTON
ASSEMBLY
05
arnffn00000356
05-13–23

Low/Reverse One-Way Clutch
• The low/reverse one-way clutch connects the reverse planetary carrier to the transmission case during drive
operation.
• The low/reverse one-way clutch transmits torque in 1GR and 2GR, as well as in manual 1GR and manual 2GR.
• The low/reverse one-way clutch is a sprag-type one-way clutch.
— The low/reverse one-way clutch holds the low/reverse drum and low/reverse planetary assembly to the
case in 1GR and 2GR.
— In all other gears the low/reverse one-way clutch overruns.
REVERSE PLANETARY
CARRIER AND
RETAINING RING
LOW/REVERSE ONE-WAY CLUTCH INNER

LOW/REVERSE ONE-WAY CLUTCH RACE (PART OF TRANSMISSION CASE)
ASSEMBLY AND OUTER RACE (PART
OF LOW/REVERSE DRUM)
arnffn00000357
End Of Sie
05-13–24

PARKING LOCK CONSTRUCTION [5R55S]
id0513c1321300
• The parking gear is connected to the output shaft. The parking gear has lugs on its outer surface to allow the
operation of the parking lock.
• The parking lock prevents the vehicle wheels from rotating by allowing the transmission case to hold the output
shaft stationary through the parking gear. When the parking pawl engages the parking gear, it holds the gear
stationary.
• When the manual control lever is rotated to the P position, the parking lock works as follows:
— The inner manual control valve detent lever (connected to the manual control shaft) rotates, pushing a
spring-loaded actuator rod.
— The actuator rod pivots the parking pawl into alignment between the lugs of the parking gear.
— The parking pawl (connected to the transmission case) holds the parking gear.
OUTPUT SHAFT AND

PARKING GEAR
PARKING PAWL, SHAFT

ACTUATOR ROD
AND SPRING
MANUAL SHAFT
05
INNER MANUAL
VALVE DETENT
DETENT SPRING LEVER
DIGITAL TR
SENSOR MANUAL SHAFT
LEVER
arnffn00000358
End Of Sie
05-13–25

LUBRICATION [5R55S]
id0513c1321500
• The 5R55S transmission provides lubrication for rotating mechanical components through three hydraulic
circuits to the front, center and rear areas. Fluid in the torque converter hydraulic circuit provides fluid to
lubricate the impeller hub bushing.
• Fluid in this circuit also flows from the transmission case, through a tube, to a cooler located at the front of the
vehicle. Fluid from the cooler returns through another tube into the transmission and then through the three
lube circuits.
• When the temperature of fluid that exits the torque converter contains less heat, the action of a thermostatically
controlled valve in the main control causes the cooler to be bypassed. Fluid flows directly from the torque
converter into the lube circuits.
• As transmission fluid temperature increases, the thermostatically controlled valve allows directs the flow of fluid
exiting the torque converter to pass through the cooler before it enters the lube circuits.
FRONT LUBE
REAR LUBE
CENTER LUBE
arnffn00000359
End Of Sie
05-13–26

FLUID PUMP CONSTRUCTION [5R55S]
id0513c1323500
• The 5R55S transmission has a gear type pump that supplies fluid under pressure to the hydraulic system.
• The fluid pump provides the fluid pressure necessary to charge the torque converter, main control assembly,
transmission cooling system, lubrication system and apply devices.
• The torque converter impeller hub rotates the drive gear of the pump. The drive gear has an O-ring on its
impeller hub contact surface.
• The fluid pump has the following parts:
— Pump cover
— Adapter plate
— Pump assembly, with drive and driven gears and an integral stator support
STATOR SUPPORT
SEAL FLUID PUMP BODY
WITH GEARS
FLUID PUMP COVER,
ADAPTER PLATE AND
GASKET
IMPELLER HUB
SEAL
TORQUE CONVERTER
FLUID PUMP
CONTROL VALVE
FLUID PUMP INNER AND SEAL
GEAR O-RING SEAL
FLUID PUMP BODY

OUTER SEAL
arnffn00000360 05
End Of Sie
05-13–27

FLUID FILTER CONSTRUCTION [5R55S]
id0513c1321600
• Fluid in a sump area formed by the fluid pan flows from a filter, through passages in the valve body and
transmission case, to the suction port of the fluid pump.
• The transmission fluid filter and its accompanying seals are part of the fluid path from the sump (pan) to the
fluid pump.
— The transmission fluid filter has a bypass section which allows fluid vented at the main regulator valve to be
recirculated to the fluid pump, without passing through the transmission fluid filter.
• A magnet attached to the inside of the fluid pan collects unwanted magnetic material.
TRANSMISSION
CASE
FROM MAIN
REGULATOR
VALVE
FLUID PUMP
SUCTION
FLUID
FILTER
MAGNET
FLUID PAN AND

GASKET
FLUID LEVEL
INDICATOR PLUG
DRAIN PLUG
arnffn00000361
End Of Sie
05-13–28

CONTROL VALVE BODY OUTLINE [5R55S]
id0513c1636600
• The control valve body component and related components are part of the pressure side of the hydraulic
system.
• The control valve body component consists of the solenoids, the valve body assembly and the separator plate.
• These components combine to convert electrical signals into hydraulic actions.
— All valves in the control valve body component are anodized aluminum and cannot be sanded, filed or
dressed in any other way. If there is any damage to the valves that prevents or restricts their movement,
install a new control valve body component.
TRANSMISSION CASE
SEPARATOR PLATE WITH

BONDED GASKET
CONTROL
VALVE BODY
COMPONENT
05
SOLENOID BODY
COMPONENT AND
O-RING SEALS LOW/REVERSE
SERVO ASSEMBLY
LOW/REVERSE SERVO
CONTROL VALVE
arnffn00000362
05-13–29

Control Valve Body Component Exploded View
80 36
80 37
38
80 39 40
76 41
42
43
45
21 47
22 32
28 44
23 33 46
29 34
24 30 48
10 25 35
31 49
11 26 50
12 27 51
1 13
2 15
17 78 77 52
14 53
16 18 54 55
3 19
4 7 20 59
5 9 58
6 57
56
8 79 63
62
67 61
74 66 60
72 70 65
75 71 69 64
73 68
b5r5za00000083
.
1 Retainer clip 30 Reverse modulator valve

2 Retainer plug 31 Reverse modulator valve spring
3 Thermo valve component 32 Retainer clip
4 Fluid cooler bypass valve 33 Retainer plug
5 Fluid cooler bypass spring 34 Reverse engagement valve
6 Retainer clip 35 Reverse engagement valve spring
7 Retainer plug 36 Retainer clip
8 Converter clutch control valve spring 37 Retainer plug
9 Converter clutch control valve 38 VFS1 modulator valve
10 Plate 39 VFS1 modulator valve spring
11 Coast clutch control spring 40 Retainer clip
12 Coast clutch control valve 41 Sleeve
13 Retainer clip 42 Booster valve
14 Retainer plug 43 Booster valve
15 Converter clutch back pressure valve 44 Inner spring
16 Converter clutch back pressure spring 45 Outer spring
17 Retainer clip 46 Retainer spring
18 Retainer plug 47 Main regulator valve
19 VFS2 modulator valve 48 Retainer clip
20 VFS2 modulator valve spring 49 Retainer plug
21 Retainer clip 50 Converter limit spring
22 Retainer plug 51 Converter limit valve
23 Intermediate servo release valve 52 Plate
24 Intermediate servo release valve spring 53 Solenoid regulator valve spring
25 Plate 54 Solenoid regulator valve
26 High clutch control spring 55 Manual valve
27 High clutch control Valve 56 Retainer clip
28 Retainer plug 57 Retainer plug
29 Retainer clip 58 Rear servo control valve spring
05-13–30

59 Rear servo control valve 70 Overdrive servo control valve
60 Retainer clip 71 Clip retainer
61 Retainer plug 72 Converter clutch modulator control sleeve
62 RS ISA select valve spring 73 Converter clutch modulator control valve
63 RS ISA select valve 74 Converter clutch modulator valve
64 Retainer clip 75 Converter clutch modulator control spring
65 Retainer plug 76 Separator plate
66 Forward engagement control valve spring 77 Lubrication check ball
67 Forward engagement control valve 78 Shuttle valve ball
68 Plate 79 Lower control valve body
69 Overdrive servo control spring 80 Bolt
End Of Sie
05
05-13–31

PRESSURE CONTROL HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321800
Line Pressure Hydraulic Circuit
• Fluid under pressure from the pump flows to several hydraulic controls in the valve body, including the main
regulator valve. The main regulator valve varies line pressure as part of controlling shift feel and efficient apply
component operation.
• The TCM controls the position of the main regulator valve with the pressure control solenoid A and B.
• When pressure control solenoid A and B pressures are lower, the main regulator valve position provides lower
line pressure. As the fluid pressures from pressure control solenoid A and B increase, the main regulator valve
provides higher line pressure.
• When the transmission shifter is in the R position, fluid under pressure from the manual valve to the apply
components also affects the position of the main regulator valve. This results in a pressure boost.
LINE PRESSURE CIRCUITS

(SHOWN IN P POSITION)
INTERMEDIATE
REVERSE PRESSURE
CONTROL VALVE FROM PC B
MODULATOR VALVE
FROM
REVERSE FROM PC A
CIRCUIT
MAIN
REGULATOR
VALVE
EXHAUST
CONVERTER
CLUTCH LIMIT
VALVE
SOLENOID FEED
OVERDRIVE SERVO TORQUE LIMIT VALVE
CONTROL VALVE CONVERTER
LUBE
CIRCUITS
PUMP
MANUAL
VALVE
FILTER
SUMP
FLOW CONTROL
VALVE
arnffn00000363
05-13–32

Pressure Control Solenoid A Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid A affects the operation of the main regulator valve and
the VFS1 modulator control valve.
• VFS1 pressure indirectly affects the feel of the forward clutch engagement. VFS1 pressure is directly applied to
the intermediate servo. It is also directly applied to the low/reverse servo in manual 1GR and manual 2GR.
PRESSURE CONTROL SOLENOID A LOW/REVERSE

CIRCUITS (SHOWN IN 3GR) SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
SMALL AREA
LARGE AREA
VFS1
VFS1 MODULATOR
CONTROL VALVE
MAIN
REGULATOR
VALVE
SS4 EXHAUST
VFS2
05
OVERDRIVE SERVO
CONTROL VALVE
FORWARD INTERMEDIATE REVERSE
ENGAGEMENT SERVO SELECT SERVO
CONTROL VALVE VALVE CONTROL
VALVE
LINE MANUAL
VALVE
arnffn00000364
05-13–33

Pressure Control B Solenoid B Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid B affects the operation of the main regulator valve, the
VFS2 modulator control valve, the forward engagement control valve and the reverse engagement control
valve.
• VFS2 pressure indirectly affects the feel of the forward clutch engagement, as well as the direct clutch
engagement in reverse. VFS2 pressure is directly applied to the overdrive servo or the coast clutch.

CIRCUITS (SHOWN IN 2GR)
COAST OVERDRIVE BAND
CLUTCH SERVO
DIRECT FORWARD
CLUTCH CLUTCH
REVERSE
VFS2 MODULATOR
COAST CLUTCH ENGAGEMENT
CONTROL VALVE
CONTROL VALVE CONTROL
VALVE
MAIN
REGULATOR
VALVE
EXHAUST
FORWARD
OVERDRIVE SERVO ENGAGEMENT
CONTROL VALVE CONTROL VALVE MANUAL
VALVE
LINE
arnffn00000365
05-13–34

Pressure Control Solenoid C Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid C solenoid affects the operation of the reverse pressure
modulator valve and the reverse engagement control valve.
• Pressure control solenoid C pressure indirectly affects the feel of direct clutch engagement in reverse. Pressure
control solenoid C pressure is directly applied to the direct clutch in 4GR and 5GR.
PRESSURE CONTROL SOLENOID C

CIRCUITS (SHOWN IN R POSITION)
DIRECT FORWARD
CLUTCH CLUTCH
DIRECT
REVERSE REVERSE
CLUTCH
PRESSURE ENGAGEMENT
CONTROL
MODULATOR CONTROL
VALVE
VALVE VALVE
05
MANUAL
VALVE
LINE
arnffn00000366
End Of Sie
05-13–35

SHIFT SOLENOID HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321900
Solenoid Feed Hydraulic Circuit
• In the 5R55S transmission, fluid under line pressure moves to the solenoid feed limit valve. The solenoid feed
limit valve provides fluid under a steady regulated pressure to the shift solenoids and TCC control solenoid.
• The TCM operates the shift solenoids with on/off control. When the TCM turns off each solenoid, fluid flow is
blocked. When the TCM turns on each solenoid, full fluid flow occurs.
• The TCM operates the TCC control solenoid with varying Pulse-Width Modulation (PWM) control. This results
in variable fluid flow and pressure from the TCC control solenoid to the hydraulic valve it controls.
SOLENOID FEED CIRCUITS

(SHOWN IN 1GR)
CONVERTER
CLUTCH LIMIT
VALVE
SOLENOID
FEED LIMIT
VALVE
LINE
OFF ON OFF OFF ON

arnffn00000367
05-13–36

Shift Solenoid A Hydraulic Circuit
• In the 5R55S transmission, shift solenoid A affects the operation of the direct clutch. When shift solenoid A is
on in forward speeds, the direct clutch is released. When shift solenoid A is turned off, the direct clutch is
applied. shift solenoid A is also related to the operation of the intermediate band.
• When the transmission shifter is moved to the R position under conditions that may cause transmission
damage, the TCM turns off shift solenoid A to inhibit reverse operation. This affects various hydraulic control
valves in order to keep the direct clutch released.
SHIFT SOLENOID A CIRCUITS

(SHOWN IN 4GR)
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
DIRECT CLUTCH
CONTROL VALVE
FROM RE VERSE
PRESSURE MODULATOR
VALVE
SS1
SS1
FROM VFS1 MODULATOR

CONTROL VALVE
05
INTERMEDIATE
SERVO SELECT
VALVE
FROM SOLENOID
FEED LIMIT VALVE
OFF
arnffn00000368
05-13–37

Shift Solenoid B Hydraulic Circuit
• In the 5R55S transmission, shift solenoid B affects the operation of the intermediate band. When shift solenoid
B is on, the intermediate band is applied. When shift solenoid B is turned off, the intermediate band is released.
shift solenoid B is also related to the operation of the low/reverse band in manual 1st gear and manual 2nd
gear.
• The TCM does not use shift solenoid B to inhibit reverse operation in 5R55S transmission.
SHIFT SOLENOID B CIRCUITS

(SHOWN IN 3GR)
LOW/REVERSE
SERVO
INTERMEDIATE
BAND SERVO
SMALL AREA
INTERMEDIATE LARGE AREA

CONTROL VALVE
FROM VFS1 MODULATOR

CONTROL VALVE
SS4
SS1
SS2
INTERMEDIATE REVERSE
SERVO SELECT SERVO
VALVE CONTROL
VALVE
FROM SOLENOID FEED

LIMIT VALVE
ON
arnffn00000369
05-13–38

Shift Solenoid C Hydraulic Circuit
• In the 5R55S transmission, shift solenoid C affects the operation of the overdrive band. When shift solenoid C
is on, the overdrive band is applied. When shift solenoid C is turned off, the overdrive band is released.
SHIFT SOLENOID C CIRCUITS

(SHOWN IN 2GR)
OVERDRIVE BAND
SERVO
OSR
SS3
FROM VFS2 MODULATOR

CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
FROM SOLENOID
FEED LIMIT VALVE
05
ON
arnffn00000370
05-13–39

Shift Solenoid D Hydraulic Circuit
• In the 5R55S transmission, shift solenoid D affects the operation of the coast clutch. When shift solenoid D is
on, the coast clutch is released. When shift solenoid D is turned off, the coast clutch is applied.
SHIFT SOLENOID D CIRCUITS

(SHOWN IN MANUAL 3GR)
COAST CLUTCH
COAST CLUTCH
CONTROL
VALVE
SS3
FROM VFS2 MODULATOR

CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
FROM SOLENOID
FEED LIMIT VALVE
OFF
arnffn00000371
05-13–40

Torque Converter Clutch (TCC) Control Solenoid Hydraulic Circuit
• In the 5R55S transmission, the TCC control solenoid affects the operation of the torque converter clutch in
forward speeds.
• TCC pressure affects the positions of the converter pressure modulator valve and the converter control valve.
TCC CONTROL SOLENOID CIRCUITS

(SHOWN WITH TCC APPLY)
THERMOSTAT BYPASS VALVE

CONVERTER WITH (HOT POSITION)
TORQUE CONVERTER
CLUTCH CONVERTER CONTROL
VALVE
EXHAUST
FROM CONVERTER
CLUTCH LIMIT VALVE
LINE
CONVERTER
PRESSURE
MODULATOR VALVE
MANUAL
VALVE
05
FROM SOLENOID
FEED LIMIT VALVE
arnffn00000372
End Of Sie
05-13–41

TORQUE CONVERTER/LUBE HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1322000
• In the 5R55S transmission, fluid for torque converter operation flows as follows during TCC release:
— From the LINE circuit, through the converter clutch limit valve, through the converter control valve, to the
torque converter
— From the torque converter, through the converter control valve, into the lube circuits
• The thermostat bypass valve allows fluid from the torque converter to bypass the fluid cooler and enter into the
lube circuits when fluid temperature is cold.
TORQUE CONVERTER/LUBE CIRCUITS

(SHOWN WITH TCC RELEASE)
CONVERTER WITH
TORQUE CONVERTER
CLUTCH NOT APPLIED
(COLD POSITION)
CONVERTER CONTROL
VALVE
EXHAUST
FROM MAIN
REGULATOR VALVE
REAR LUBRICATION
REAR/LUBE LINE
SHUTTLE BALL
*B
CENTER LUBRICATION
FRONT LUBRICATION CONVERTER CLUTCH

LIMIT VALVE
SOLENOID FEED
COOLER
COOLER
CONVERTER BUSHING LIMIT VALVE

LUBRICATION
OUT
(MAJORITY OF FLOW
COOLER BYPASSES COOLER) LINE
TO SUMP
arnffn00000373
05-13–42

• When TCC is applied, fluid for torque converter operation flows as follows:
— From the LINE circuit, through the converter clutch limit valve, through the converter control valve, into the
lube circuits
— From the LINE circuit, through the converter pressure modulator valve, through the converter control valve,
to the torque converter
TORQUE CONVERTER/LUBE CIRCUITS

(SHOWN WITH TCC APPLY)
CONVERTER WITH
TORQUE CONVERTER
CLUTCH
(HOT POSITION)
CONVERTER CONTROL
VALVE
EXHAUST
FROM MAIN
REGULATOR VALVE
REAR LUBRICATION
REAR/LUBE
SHUTTLE BALL
LINE 05
*B
CONVERTER PRESSURE
CENTER LUBRICATION MODULATOR VALVE
CONVERTER CLUTCH
FRONT LUBRICATION
FROM TCC LIMIT VALVE
SOLENOID SOLENOID FEED
COOLER
COOLER
CONVERTER BUSHING LIMIT VALVE

LUBRICATION
OUT
(MAJORITY OF FLOW
COOLER BYPASSES COOLER) LINE
TO SUMP
arnffn00000374
End Of Sie
05-13–43

APPLY COMPONENT HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1322100
P and N Positions (Park and Neutral)
• With the transmission in the P or N position, fluid under pressure is present at the following components:
— Overdrive servo-release
— Intermediate servo-release
LOW/REVERSE
P POSITION SERVO
COAST
OVERDRIVE BAND INTERMEDIATE
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
DIRECT CLUTCH LARGE AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
SERVO SELECT ENGAGEMENT
VALVE CONTROL
SS1 VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000375
05-13–44

R Position (Reverse)
• With the transmission in the R position, fluid under pressure is present at the following components:
— Direct clutch
— Low/reverse servo-apply
LOW/REVERSE
R POSITION SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
05
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000376
05-13–45

D Range, 1GR
• With the transmission in the D range, fluid under pressure is present at the following components in 1GR:
— Forward clutch
LOW/REVERSE
D RANGE 1GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000377
05-13–46

D Range, 2GR
— Overdrive servo-apply
— Forward clutch
LOW/REVERSE
D RANGE 2GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE 05
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000378
05-13–47

D range, 3GR
— Intermediate servo-apply
— Forward clutch
LOW/REVERSE
D RANGE 3GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000379
05-13–48

D range, 4GR
— Forward clutch
— Direct clutch
LOW/REVERSE
D RANGE 4GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
05
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000380
05-13–49

D range, 5GR
— Forward clutch
— Direct clutch
LOW/REVERSE
D RANGE 5GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000381
05-13–50

D range O/D OFF Mode, 4GR (Manual 4GR)
• With the transmission in the D range (O/D OFF mode), fluid under pressure is present at the following
components in manual 4GR:
— Forward clutch
— Direct clutch
— Coast clutch
LOW/REVERSE
D RANGE MANUAL 4GR (O/D OFF) SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
05
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000382
05-13–51

• With the transmission in the 3 range, fluid under pressure is present at the following components in manual
3GR:
— Intermediate servo-apply
— Forward clutch
— Coast clutch
LOW/REVERSE
3 RANGE MANUAL 3GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000383
05-13–52

2GR:
— Forward clutch
LOW/REVERSE
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH SMALL AREA
CONTROL VALVE LARGE AREA
212
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
05
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000384
05-13–53

1GR:
— Forward clutch
— Coast clutch
LOW/REVERSE
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
SMALL AREA
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000385
End Of Sie
05-13–54

ELECTRONIC CONTROL SYSTEM OUTLINE [5R55S]
id0513c1221600
• The TCM and its input/output network control the following transmission operations:
— Shift timing
— Line pressure (shift feel)
— Torque converter clutch
• The transmission control strategy combined with the engine control provides optimum powertrain operation
under all conditions.
• When determining the best operating strategy for transmission operation, the TCM uses input information from
the PCM via the CAN bus. In addition, the TCM receives input signals from certain transmission-related
sensors and switches.
• The TCM also uses these signals when determining transmission operating strategy.
• Using all of these input signals, the TCM can determine when the time and conditions are right for a shift or
when to apply or release the torque converter clutch.
• It will also determine the pressure needed to optimize shift feel.
• To accomplish this the PCM uses 3 pressure controls, 1 torque converter clutch and 4 shift solenoids to control
transmission operation.
End Of Sie
ELECTRONIC CONTROL SYSTEM BLOCK DIAGRAM [5R55S]

id0513c1218800
INPUT OUTPUT
TURBINE SHAFT SPEED (TSS) SENSOR PRESSURE CONTROL SOLENOID A
INTERMEDIATE SHAFT SPEED (ISS)

SENSOR
OUTPUT SHAFT SPEED (OSS) SENSOR PRESSURE CONTROL SOLENOID C
TRANSMISSION FLUID TEMPERATURE

(TFT) SENSOR SHIFT SOLENOID A
05
DIGITAL TRANSMISSION RANGE (TR)
SENSOR SHIFT SOLENOID B
TCM
O/D OFF SWITCH SHIFT SOLENOID C
PCM
SHIFT SOLENOID D
ACCELERATOR PEDAL POSITION
(APP) SENSOR
ENGINE COOLANT TEMPERATURE TORQUE CONVERTER CLUTCH (TCC)

(ECT) SENSOR CONTROL SOLENOID
MASS AIR FLOW (MAF) SENSOR
INTAKE AIR TEMPERATURE (IAT)

SENSOR
O/D OFF INDICATOR LIGHT
CRANKSHAFT POSITION (CKP)
SENSOR
BRAKE SWITCH MALFUNCTION INDICATOR LAMP (MIL)
arnffn00000386
End Of Sie
05-13–55

ELECTRONIC CONTROL SYSTEM STRUCTURE [5R55S]
id0513c1221900
TCM
• The operation of the transmission is controlled by the TCM.
• Many input sensors provide information to the TCM. The TCM then controls the actuators which determine
transmission operation.
Air Conditioning (A/C) Clutch

• An electromagnetic clutch is energized when the clutch cycling pressure switch closes.
• The switch is located on the suction accumulator/drier.
• The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor
driveshaft.
• When the A/C is engaged, operating pressures are adjusted to compensate for additional load on the engine.
Brake Switch
• The brake switch tells the PCM when the brakes are applied.
• The PCM sends this message to TCM via CAN bus.
• The torque converter clutch disengages when the brakes are applied.
• The brake switch closes when the brakes are applied and opens when they are released.
Engine Coolant Temperature (ECT) Sensor

• The ECT sensor detects temperature of engine coolant and supplies the information to the PCM.
• The ECT sensor is used to control torque converter clutch (TCC) operation.
Crankshaft Position (CKP) Sensor

• The CKP sensor detects pulse wheel rotational signals as crank angle signals.
• The PCM uses engine speed signal in the transmission strategy, wide-open throttle (WOT) shift control, torque
converter clutch control and operating pressures.
Mass Air Flow (MAF) Sensor

• The MAF sensor measures the mass of air flowing into the engine.
• The MAF sensor output signal is used by the PCM to calculate injector pulse width.
• For transmission strategies, the MAF sensor is used to regulate electronic pressure control, shift and torque
converter clutch scheduling.
O/D OFF Switch

• The O/D OFF switch is a momentary contact switch that allows the driver to cancel operation of 5GR.
• The O/D OFF switch is located on the left side of the selector lever.
• When the driver initially presses the O/D OFF switch a signal is sent to the TCM.
• The TCM uses the shift solenoids to disengage/disable 5GR operation and activate the coast clutch. At the
same time, the TCM illuminates the O/D OFF Indicator Light to notify the driver that 5GR is canceled.
• When the O/D OFF switch is pressed again, 5GR operation is enabled, the coast clutch is released and the O/
D OFF indicator light is turned off.
• Whenever the ignition is cycled (vehicle shut off, then started again), the O/D OFF switch is turned off and 5GR
will be enabled, even if the O/D OFF switch had been on when the ignition was shut off.
O/D OFF Indicator Light

• The O/D OFF indicator light is located in the instrument panel and is labeled O/D OFF. It is illuminated in
conjunction with the O/D OFF switch.
Accelerator Pedal Position (APP) Sensor

• The APP sensor is mounted on the accelerator pedal. The APP sensor detects the position of the accelerator
pedal and inputs this information as a voltage to the PCM.
• The TCM uses the APP sensor information to aid in determining shift scheduling, presser control and torque
converter control.
Digital Transmission Range (TR) Sensor

• The digital TR sensor is located on the outside of the transmission at the manual lever.
• The digital TR sensor completes the start circuit in PARK, NEUTRAL and the back-up lamp circuit in
REVERSE.
• The digital TR sensor also opens and closes a set of 4 switches that are monitored by the TCM to determine
the position of the manual lever (P, R, N, D, 3, 2, 1).
05-13–56

Turbine Shaft Speed (TSS) Sensor
• The TSS sensor is a magnetic pickup that sends the TCM torque converter turbine speed information.
• The TSS sensor is mounted externally on the case.
• The TCM uses TSS information to help determine appropriate operating pressures and TCC operation.
Output Shaft Speed (OSS) Sensor

• The OSS sensor is a magnetic pickup, located at the park gear trigger wheel assembly, that sends a signal to
the TCM to indicate transmission output shaft speed.
• The OSS sensor is mounted externally on the case.
• The OSS is used for torque converter clutch control, shift scheduling and to determine pressure control.
Intermediate Shaft Speed (ISS) Sensor

• The ISS sensor is a magnetic pickup that sends planetary sun gear speed information to the TCM.
• It is mounted externally on the center of the case.
• The TCM uses the intermediate shaft speed sensor information to aid in determining pressure requirements.
Pressure Control Solenoid A, B and C

• The pressure control solenoids are a variable-force style (VFS) solenoid. The VFS-type solenoid is an electro-
hydraulic actuator combining a solenoid and a regulating valve.
• The line pressure tap is used to verify output pressure from pressure control solenoid A or B by turning either
one off while verifying the output from the other solenoid.
• The second pressure tap is used to verify the output from the pressure control solenoid C.
• There are 3 pressure control solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
• The TCM varies the current to the pressure control solenoid.
• The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission
operating parameters may be lost. The TCM must relearn these parameters.
• During this learning process you may experience slightly firm shifts, delayed or early shifts. This operation is
considered normal and will not affect the function of the transmission. Normal operation will return once these
parameters are stored by the TCM.
Torque Converter Clutch (TCC) Control Solenoid

• The TCC control solenoid is a pulse width modulating type solenoid which is used to control the apply and
release of the TCC.
Shift Solenoid A, B, C and D

05
• Four ON/OFF shift solenoids allow the TCM to control shift scheduling.
— The solenoids are 3-way, normally open style.
— The shift solenoids shift solenoid A, B, C and D provide gear selection of 1GR through 5GR and REVERSE
gears by directing pressure control pressures to the appropriate elements.
• Coast braking and manual gears are also controlled by the shift solenoids.
Transmission Fluid Temperature (TFT) Sensor

• The TFT sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT
varies with temperature.
• The TCM monitors the voltage signal across the TFT and uses this information to determine the transmission
fluid temperature.
• The TFT is located on the solenoid body.
• The TCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and
pressure control requirements.
• It sends a voltage signal to the TCM. The voltage signal varies with transmission fluid temperature. The TCM
uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is
compensated when the transmission fluid temperature is cold. The TCM also inhibits TCC operation at low
transmission fluid temperatures and uses it to determine PC solenoid operations.
End Of Sie
05-13–57

OIL COOLER CONSTRUCTION [5R55S]
id0513c1221500
• A water-cooling type AT oil cooler has been adopted and is installed in the radiator. The oil cooler cools the
heated ATF in the AT.
• An air-cooling type AT oil cooler has also adopted.
FRONT
RADIATOR
(IN TANK OIL COOLER)
OIL COOLER
FRONT
B
AUTOMATIC
TRANSMISSION
A
arnffn00000398
End Of Sie
05-13–58
F340-10-05L(05-14).fm 1 ページ２００６年８月１０日　木曜日　午後５時１３分
AUTOMATIC TRANSMISSION SHIFT MECHANISM
05-14 AUTOMATIC TRANSMISSION SHIFT MECHANISM

AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION
SHIFT MECHANISM OUTLINE. . . . . . . 05-14–1 SHIFT MECHANISM
STRUCTURAL VIEW . . . . . . . . . . . . . . . 05-14–1
End of Toc
AUTOMATIC TRANSMISSION SHIFT MECHANISM OUTLINE
SOKYU_WM: SHIFT MECHANISM
id051400219700
• The cable type shift mechanism has been adopted.
• The floor-shift type selector lever has been adopted.
End Of Sie
AUTOMATIC TRANSMISSION SHIFT MECHANISM STRUCTURAL VIEW

id051400219800
ILLUMINATION
BULB
O/D OFF
SWITCH
SELECTOR
LEVER
05
DIGITAL TR
SENSOR
SELECTOR CABLE
arnffn00000334
End Of Sie
05-14–1
HEATER, VENTILATION &

AIR CONDITIONING (HVAC) 07
SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 07-00

OUTLINE CONTROL SYSTEM . . . . . . . . . 07-40
BASIC SYSTEM. . . . . . . . . . . . 07-11
Toc of SCT
07-00 OUTLINE
HVAC FEATURES[EVEREST] . . . . . . . . 07-00–1 HVAC SPECIFICATIONS[EVEREST] . . . 07-00–1
End of Toc
HVAC FEATURES[EVEREST]
NG: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
id0700001002c1
Improved comfort
• A reusable air filter has been adopted.
• A climate control unit with rear A/C main switch has been adopted.
Improved quality
• A rear cooling system has been added.
Improved air conditioning performance
• A sub-cooling system integrating the condenser and receiver drier has been adopted to facilitate evaporator
operation. This system also reduces the number of parts and amount of refrigerant.
End Of Sie
HVAC SPECIFICATIONS[EVEREST]
id0700001003c1
Item Specification
Heating capacity (kW {kcal/h}) 4.186 {3,600}
Airflow volume Front blower motor
260
(during heater operation) (m3/h)
Electricity consumption Front blower motor
221
(during heater operation) (W)
Front (kW {kcal/h}) 4.012 {3,450}
Cooling capacity
Rear (kW {kcal/h}) 2.400 {2,064}
Airflow volume (during air conditioner Front blower motor (m3/h) 450
operation) Rear blower motor (m3/h) 240
Front blower motor (W) 220
Electricity consumption (during air Rear blower motor (W) 145
conditioner operation) Magnetic clutch (W) 40 or less
Condenser fan* (W) 65
Fan type
Front and rear blower motor Sirocco fan 07
Condenser fan* Axial flowed fan
Type R-134a
Refrigerant Regular amount
(approximate quantity) 675 {23.8}
(g {oz})
Type Swash plate
Discharge capacity
180 {180, 6.08}
(ml {cc, fl oz})
Max. allowable speed
7,000
(rpm)
A/C compressor Type FD46XG
Lube oil Sealed volume
(approximate quantity) 180 {180, 6.08}
(ml {cc, fl oz})
Magnetic clutch clearance
0.35—0.75 {0.014—0.029}
(mm {in})
07-00–1
OUTLINE
Item Specification
Type Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h}) 5.35 {4,600}
Condenser Receiver/drier
(ml {cc, fl oz}) 220 {220, 7.44}
capacity
Desiccant XH-7
Front Internal pressure equalizer
Expansion valve Type
Rear Internal pressure equalizer
Front Single-tank drawn cup
Evaporator Type
Rear Single-tank drawn cup
Type Dual-pressure
Operating pressure 0.176—0.216 2.94—3.34
(MPa {kgf/cm2, psi}) {1.80—2.20, {30.0—34.0,
25.5—31.3} 427—484}
ON
OFF
0.025 0.39—0.79
{0.25, 3.62} {3.98—8.05,
or less 56.6—114.5}
Refrigerant pressure switch
Type Single-pressure
Operating pressure 2.65—2.85
(MPa {kgf/cm2, psi}) {27.1—29.0,
385—413}
ON
OFF
2.06—2.26
{21.0—23.0,
299—327}
*
: For coastal areas and other places with intense heat
End Of Sie
07-00–2
F340-10-05L(07-11).fm 1 ページ２００６年８月３日　木曜日　午後２時４３分
BASIC SYSTEM
07-11 BASIC SYSTEM

BASIC SYSTEM STRUCTURAL VIEW REAR A/C UNIT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-11–1 CONSTRUCTION/OPERATION
AIR FILTER CONSTRUCTION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–2
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-11–2 CONDENSER
CONSTRUCTION/OPERATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–2
End of Toc
BASIC SYSTEM STRUCTURAL VIEW[EVEREST]
NG: HVAC BASIC SYSTEM
id0711001002b7
REAR COOLER DUCT
HEATER UNIT REAR A/C UNIT
HEATER HOSE
A/C COMPRESSOR
COOLING UNIT
CONDENSER REFRIGERANT LINES 07
BLOWER UNIT
arnffn00000300
End Of Sie
07-11–1
F340-10-05L(07-11).fm 2 ページ２００６年８月３日　木曜日　午前１１時３８分
BASIC SYSTEM
AIR FILTER CONSTRUCTION[EVEREST]
id0711001020b7
• An air filter that can be reused after cleaning has been adopted.
• An air filter that can remove pollen and dust has been added.
FRESH AIR
TO COOLING UNIT
AIR FILTER
arnffn00000277
End Of Sie
REAR A/C UNIT CONSTRUCTION/OPERATION[EVEREST]
id0711001009b7
• The rear A/C unit which integrates the rear cooling and rear blower units has been adopted.
Airflow Operation
• When the rear blower motor is operated, the air in the cabin is drawn into the rear A/C unit, cooled in the rear
evaporator, and then blown from the rear vents through the rear cooler duct into the cabin.
REAR EVAPORATOR
REAR BLOWER MOTOR
CABIN AIR
TO REAR COOLER DUCT
arnffn00000276
End Of Sie
CONDENSER CONSTRUCTION/OPERATION[EVEREST]
id0711001032b7
• A sub cool condenser has been adopted. It is a multi-flow condenser which is equipped with a sub cooling part
and integrated with a receiver/drier.
• The sub cool condenser separates liquid-gas refrigerant initially cooled at the condenser via the receiver/drier,
where it returns again to the condenser sub cooling part and is cooled, accelerating liquefaction and improving
cooling capacity.
RECEIVER/DRIER CONDENSER
COOLING PART
SUB COOLING PART
arnffn00000280
End Of Sie
07-11–2
F340-10-05L(07-40).fm 1 ページ２００６年８月３日　木曜日　午前１１時３９分
CONTROL SYSTEM
07-40 CONTROL SYSTEM

CONTROL SYSTEM STRUCTURAL CLIMATE CONTROL UNIT
VIEW[EVEREST]. . . . . . . . . . . . . . . . . . 07-40–1 CONSTRUCTION[EVEREST] . . . . . . . . 07-40–2
End of Toc
CONTROL SYSTEM STRUCTURAL VIEW[EVEREST]
NG: HVAC CONTROL SYSTEM
id0740001002b7
Front
MAGNETIC CLUTCH
REFRIGERANT
PRESSURE SWITCH
CLIMATE CONTROL UNIT
A/C RELAY
EVAPORATOR TEMPERATURE SENSOR

FRONT
RESISTOR
FRONT BLOWER MOTOR
arnffn00000301
Rear
REAR
BLOWER MOTOR
REAR BLOWER RELAY
07
REAR RESISTOR
REAR FAN SWITCH
arnffn00000302
End Of Sie
07-40–1
CONTROL SYSTEM
CLIMATE CONTROL UNIT CONSTRUCTION[EVEREST]
id0740001009b7
Front
• Each switches and dials have been enlarged to improve ease of operation.
A/C SWITCH
AIRFLOW MODE
SELECTOR DIAL
A/C
TEMPERATURE
CONTROL DIAL
CLIMATE CONTROL
UNIT
REC/FRESH LEVER FAN SWITCH
arnffn00000306
Rear
Rear A/C main switch
• The rear A/C main switch is located on the instrument panel and controls the rear A/C system ON/OFF.
REAR A/C MAIN SWITCH
arnffn00000307
Rear fan switch

• The rear fan switch is located on the roof above
the second-row seat and controls the air volume
to the rear part of the cabin.
End Of Sie Fast
Slow
arnffn00000308
07-40–2
BODY & ACCESSORIES 09

SECTION
Toc of SCT . . . . . . . . . . . . . . . . . 09-00

OUTLINE WIPER/WASHER SYSTEM . . . 09-19
SEATS . . . . . . . . . . . . . . . . . . . 09-13 INSTRUMENTATION/
LIGHTING SYSTEMS . . . . . . . 09-18 DRIVER INFO. . . . . . . . . . . . . 09-22
Toc of SCT
09-00 OUTLINE
BODY AND ACCESSORIES FEATURES
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-00–1
End of Toc
BODY AND ACCESSORIES FEATURES[EVEREST]
NG: BODY AND ACCESSORIES
id0900001003b6
Improved Marketability
• A wagon-shaped body with a side-hinged back door has been adopted.
• A power fuel-filler lid opener has been adopted.
• A rear spoiler with a built in high-mount brake light has been adopted.
• A roof rail has been adopted.
• A third-row seat has been adopted.
Improved Convenience
• A foldable second-row seat has been adopted.
End Of Sie
09
09-00–1
F340-10-05L(09-13).fm 1 ページ２００６年８月３日　木曜日　午前１１時４０分
SEATS
09-13 SEATS
SEATS OUTLINE[EVEREST] . . . . . . . . . 09-13–1 SECOND-ROW SEAT CONSTRUCTION
SEATS STRUCTURAL VIEW [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-13–1
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-13–1 THIRD-ROW SEAT CONSTRUCTION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-13–2
End of Toc
SEATS OUTLINE[EVEREST]
NG: SEATS
id0913001008z2
• A foldable seat has been adopted on the second-row seat.
• A detachable type third-row seat has been adopted.
End Of Sie
SEATS STRUCTURAL VIEW[EVEREST]
id0913001003z2
End Of Sie
THIRD-ROW SEAT
SECOND-ROW SEAT
FRONT SEAT
arnffn00000311
SECOND-ROW SEAT CONSTRUCTION[EVEREST]

id0913001023z2
1. Move headrest to the lowest position.
2. Releasing recliner lever, fold the seat back to forward.
3. Tumble the seat to forward.
HEADREST
RECLINER
LEVER 09
arnffn00000281
End Of Sie
09-13–1
F340-10-05L(09-13).fm 2 ページ２００６年８月３日　木曜日　午前１１時４０分
SEATS
THIRD-ROW SEAT CONSTRUCTION[EVEREST]
id0913001024z2
Detachable Type
1. Releasing lever, fold the seat back to forward.
2. Releasing rear lock by operating the lever, tumble the seat to forward.
3. Releasing front lock by operating the lever.
4. Lift the seat to upward and then remove from floor.
REAR LOCK
LEVER LOCK
UNLOCK
LEVER
LOCK UNLOCK
FRONT LOCK
LEVER
arnffn00000282
End Of Sie
09-13–2
F340-10-05L(09-18).fm 1 ページ２００６年８月３日　木曜日　午前１１時４１分
LIGHTING SYSTEMS
09-18 LIGHTING SYSTEMS

LIGHTING SYSTEM OUTLINE LIGHTING SYSTEM STRUCTURAL
LIGHTING SYSTEMS SPECIFICATION REAR COMBINATION LIGHT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–1 CONSTRUCTION[EVEREST] . . . . . . . . 09-18–2
HIGH-MOUNT BRAKE LIGHT
CONSTRUCTION[EVEREST] . . . . . . . . 09-18–3
End of Toc
LIGHTING SYSTEM OUTLINE[EVEREST]
NG: LIGHTING SYSTEMS
id0918001068z2
• A rear spoiler with a built in high-mount brake light has been adopted.
• A rear combination light has been changed.
End Of Sie
LIGHTING SYSTEMS SPECIFICATION[EVEREST]
id0918001002z2
Item Specifications (W) × number

High-beam 60 × 2
Headlight bulb
Low-beam 55 × 2
Front turn light bulb 21 × 2
Parking light bulb 5×2
Front fog light bulb 55 × 2
Exterior light bulb capacity Front side turn light bulb 5×2
Brake light/taillight bulb 21/5 × 2
Rear turn light bulb 21 × 2
Back-up light bulb 21 × 2
License plate light bulb 5×2
High-mount brake light bulb 4 × 20
Interior and map light bulb 8 × 1, 5 × 2
Cargo compartment light bulb 10 × 2
Interior light bulb capacity Glove compartment light bulb 1.7 × 1
IG key illumination bulb 1.4 × 1
Console illumination bulb 1.4 × 1
End Of Sie
LIGHTING SYSTEM STRUCTURAL VIEW[EVEREST]
id0918001069z2
Front
REAR COMBINATION
LIGHT
LICENSE PLATE
LIGHT
09
BACK-UP LIGHT
arnffn00000312
09-18–1
LIGHTING SYSTEMS
Rear
CARGO
COMPARTMENT LIGHT
REAR MAP LIGHT
INTERIOR AND MAP

LIGHT
BACK DOOR
SWITCH
arnffn00000313
End Of Sie
REAR COMBINATION LIGHT CONSTRUCTION[EVEREST]
id0918001008z2
Outline
• A rear combination light has been changed due to a change in the shape of the vehicle rear end.
Structural View
REAR TURN
LIGHT BULB
BRAKE LIGHT /
TAILLIGHT BULB
arnffn00000283
End Of Sie
09-18–2
LIGHTING SYSTEMS
HIGH-MOUNT BRAKE LIGHT CONSTRUCTION[EVEREST]
id0918001015z2
Outline
• A high-mount brake light has been adopted for the rear spoiler.
Structural View
arnffn00000284
End Of Sie
09
09-18–3
F340-10-05L(09-19).fm 1 ページ２００６年８月３日　木曜日　午前１１時４３分
WIPER/WASHER SYSTEM
09-19 WIPER/WASHER SYSTEM

WIPER/WASHER SYSTEM OUTLINE WIPER/WASHER SYSTEM STRUCTURAL
REAR WIPER AND WASHER SYSTEM
OPERATION[EVEREST] . . . . . . . . . . . . 09-19–1
End of Toc
WIPER/WASHER SYSTEM OUTLINE[EVEREST]
NG: WIPER/WASHER SYSTEMS
id0919001025z2
• A rear wiper and washer has been adopted due to a change in the shape of the vehicle rear end.
End Of Sie
WIPER/WASHER SYSTEM STRUCTURAL VIEW[EVEREST]
id0919001003z2
REAR WIPER
ARM AND BLADE
REAR WIPER AND

WASHER SWITCH
REAR WIPER
MOTOR
ON
OFF
REAR WASHER
HOSE
REAR WASHER REAR WASHER REAR WASHER
NOZZLE TANK MOTOR
arnffn00000285
End Of Sie
REAR WIPER AND WASHER SYSTEM OPERATION[EVEREST]
id0919001031z2
System Wiring Diagram
IG 2
REAR
M AUTO STOP
WIPER
REAR WASHER M SWITCH
MOTOR
MOTOR
REAR WIPER AND ON

WASHER
SWITCH
OFF R. WASH 09
R. WASH
arnffn00000286
09-19–1
WIPER/WASHER SYSTEM
System Operation
Low speed operation
• When the rear wiper switch is turned on, current flows to operate the rear wiper motor continuously.
• When the rear wiper switch is turned off, the auto stop function activates and the rear wiper stops at the park
position.
IG 2
REAR
M AUTO STOP
WIPER
MOTOR
MOTOR
REAR WIPER AND ON

WASHER OFF R. WASH
SWITCH
R. WASH
arnffn00000296
Auto stop function

• When the rear wiper switch is turned off while the rear wiper is operating, current flows to the auto stop switch
(which is on), and the rear wiper operates until it returns to the park position and then stops.
IG 2
REAR
M AUTO STOP
WIPER
MOTOR
MOTOR
REAR WIPER AND ON

WASHER OFF R. WASH
SWITCH
R. WASH
arnffn00000297
09-19–2
WIPER/WASHER SYSTEM
Synchronized Washer And Wiper Operation
• While turning the rear wiper switch upward from the on position, current (2) flows, the rear washer motor
operates and washer fluid is sprayed from the rear washer nozzle. Current (1) flows at the same time according
to the control signal from rear wiper switch and the rear wiper motor operates continuously.
IG 2
(1)
(2)
REAR
M AUTO STOP
WIPER
MOTOR
MOTOR
REAR WIPER AND ON

WASHER OFF R. WASH
SWITCH
R. WASH
arnffn00000298
• When the rear wiper switch is turned downward from the off position, current (2) flows, the rear washer motor
operates and washer fluid is sprayed from the rear washer nozzle.
IG 2
(1)
(2)
REAR
M AUTO STOP
WIPER
MOTOR
MOTOR
REAR WIPER AND ON

WASHER OFF R. WASH
SWITCH
R. WASH
arnffn00000299
End Of Sie
09
09-19–3
F340-10-05L(09-22).fm 1 ページ２００６年８月３日　木曜日　午前１１時４４分
INSTRUMENTATION/DRIVER INFO.
09-22 INSTRUMENTATION/DRIVER INFO.

INSTRUMENT CLUSTER SPECIFICATIONS INSTRUMENT CLUSTER STRUCTURAL
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 09-22–1 VIEW[5R55S] . . . . . . . . . . . . . . . . . . . . . 09-22–2
INSTRUMENT CLUSTER SYSTEM WIRING
DIAGRAM[5R55S] . . . . . . . . . . . . . . . . . 09-22–4
End of Toc
INSTRUMENT CLUSTER SPECIFICATIONS[5R55S]
NG: INSTRUMENT CLUSTER
id0922001011z3
Instrument Cluster
Item Specification
Meter type Stepping motor type
Indication range (mph {km/h}) 0—110 {0—180}
Speedometer
Input signal source Speedometer sensor
Rated voltage (V) DC 12
Indication range (rpm) 0—5,000
(rpm) 4,500—5,000 (WL-C)
Tachometer Red zone
4,250—5,000(WE-C)
Input signal source PCM
Meter type Stepping motor type (Reset-to-zero type)
Fuel gauge Input signal source Fuel gauge sender unit
Water (Medium range stabilized type)
temperature
Input signal source ECT sensor
gauge
Display LCD
Odometer/
Indication digits Odometer: 6 digits, Tripmeter: 4 digits
Tripmeter
Warning Sound frequency (Hz) 2,000—2,200
alarms Output sound pressure level (dB) 67.5
Clock
Item Specification
Clock accuracy (Reference value)* (s/day) -1.5—1.5
* : If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit (base unit)
malfunction may have occurred.
End Of Sie
09
09-22–1
INSTRUMENT CLUSTER STRUCTURAL VIEW[5R55S]
id0922001012z3
Meter And Gauge
TACHOMETER SPEEDOMETER WATER TEMPERATURE GAUGE
ODOMETER/TRIPMETER TRIPMETER SWITCH FUEL GAUGE

arnffn00000291
Warning And Indicator Light
1 2 3 3 4
15 14 13 12 11 10 9 8 16 7 6 17 5
arnffn00000292
No. Warning and indicator light Input signal source Note

1 4L indicator light TCM 4WD
2 4x4 indicator light TCM 4WD
3 Turn indicator light Flasher control module —
4 High-beam indicator light Headlight (HI) —
5 Fuel-level warning light Fuel gauge sender unit —
• ABS HU/CM (with 4-W ABS)
6 ABS warning light With ABS
• ABS control module (with rear ABS)
• Parking brake switch
• Brake fluid level sensor
7 Brake system warning light —
• ABS HU/CM (with 4-W ABS)
• ABS control module (with rear ABS)
8 Air bag system warning light SAS control module With air bag system
9 Generator warning light Generator —
• Immobilizer unit
10 Security light —
• Theft deterrent control module
11 Oil pressure warning light Oil pressure switch —
12 Door ajar warning light Door switches —
13 Sedimentor warning light Sediment switch —
14 MIL PCM —
15 Glow indicator light PCM —
09-22–2
No. Warning and indicator light Input signal source Note
16 Selector indicator light TCM —
17 O/D OFF indicator light TCM —
End Of Sie
09
09-22–3
INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM[5R55S]
id0922001013z3
WATER TEMPERATURE GAUGE TACHOMETER

FUEL GAUGE SPEEDOMETER
FUEL GAUGE SENDER UNIT

ODOMETER/TRIPMETER
2K
2X TRIPMETER SWITCH
2W
2B
BZ
2N
2P
2R
B+
2A
TCM IG1
2C
VEHICLE SPEED 2F MICRO- KEY REMINDER SWITCH B+
SIGNAL OUTPUT COMPUTER 2J
ENGINE KEY ILLUMINATION B+
PANEL LIGHT 2Q
2D
CONTROL SWITCH
2T
PCM 2S
2O
2I
2M
WATER TEMPERATURE SENDER UNIT
OR ECT SENSOR 2E
INSTRUMENT
CLUSTER
ILLUMINATION
FUEL-LEVEL
DOOR SWITCH WARNING LIGHT
(DRIVER-SIDE)
DOOR SWITCH DOOR AJAR
(PASSENGER-SIDE) LIGHT TNS RELAY
WARNING LIGHT B+
2H
SWITCH
B+
DOOR SWITCH (LR)

DOOR SWITCH (RR) B+
SECURITY LIGHT B+
IMMOBILIZER UNIT 1J HEADLIGHT (HI)
THEFT-DETERRENT
CONTROL MODULE
HEADLIGHT (LO)
GENERATOR 1C HEADLIGHT
GENERATOR RELAY
WARNING LIGHT
SEDIMENT SWITCH
1G SEDIMENTOR
WARNING LIGHT TNS
FRONT FOG
INDICATOR LIGHT B+
2G
REAR FOG FRONT FOG
INDICATOR LIGHT B+ FRONT LIGHT RELAY
FOG
B+
LIGHT
2V
HIGH-BEAM
REAR REAR FOG
INDICATOR LIGHT
1O FOG LIGHT RELAY
TURN INDICATOR LIGHT
B+
LIGHT (LH)
1M
TURN INDICATOR TURN LIGHT (LH) FLASHER
LIGHT (RH) CONTROL
1K MODULE
a TURN LIGHT (RH)
arnffn00000293
09-22–4
4L INDICATOR LIGHT
1F
TCM
4X4 INDICATOR LIGHT
1D
ABS HU/CM (WITH

4W-ABS) or ABS 2L
CONTROL MODULE
(WITH REAR ABS)
ABS WARNING
LIGHT
WITHOUT ABS
(WL-C, WE-C, WLT-1, WLT-2)
BRAKE FLUID
LEVEL SENSOR
1P
BRAKE SYSTEM
WARNING LIGHT
1N
PARKING
BRAKE SWITCH
1B
BUCKLE SWITCH SEAT BELT
WARNING LIGHT
O/D OFF
2W
O/D OFF INDICATOR LIGHT
TCM
WITH AIR
BAG SYSTEM
SAS CONTROL
1H
MODULE
AIR BAG SYSTEM

WITHOUT AIR WARNING LIGHT
BAG SYSTEM
OIL PRESSURE
OIL PRESSURE SWITCH WARNING LIGHT
1E
MIL
1I
PCM
1A
GLOW INDICATOR LIGHT
09
SELECTOR INDICATOR LIGHT
arnffn00000294
End Of Sie
09-22–5
F340-10-05L(AI).fm 1 ページ２００６年８月１１日　金曜日　午前１０時４１分
ALPHABETICAL INDEX AI
SECTION
0–9 C
4x4 CONTROL SYSTEM CLIMATE CONTROL UNIT CONSTRUCTION
COMPONENTS AND FUNCTIONS [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–2
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–2 CLUTCH COIL
4x4 CONTROL SYSTEM CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 03-16–11
CONSTRUCTION [AT (5R55S)] . . . . . . . . . . . . . . 03-18–1 CONDENSER
4x4 CONTROL SYSTEM CONSTRUCTION/OPERATION
OPERATION [AT (5R55S)] . . . . . . . . . . . . . . . . . . 03-18–4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2
4x4 CONTROL SYSTEM CONTROL SYSTEM STRUCTURAL VIEW
OUTLINE [AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-18–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–1
4x4 CONTROL SYSTEM CONTROL VALVE BODY
SYSTEM DIAGRAM [AT (5R55S)] . . . . . . . . . . . . 03-18–3 OUTLINE [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . 05-13–29
4x4 CONTROL SYSTEM CONVENTIONAL BRAKE SYSTEM OUTLINE
SYSTEM WIRING DIAGRAM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–1
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–4 CONVENTIONAL BRAKE SYSTEM
STRUCTURAL VIEW[EVEREST] . . . . . . . . . . . . . 04-11–1
A
D
ABS CONTROL OUTLINE
[4W-ABS (EVEREST)]. . . . . . . . . . . . . . . . . . . . . 04-13B–3 DLC-2 OUTLINE [5R55S]. . . . . . . . . . . . . . . . . . . . . 05-02–5
ABS STRUCTURAL VIEW DRIVELINE/AXLE FEATURES
[4W-ABS (EVEREST)]. . . . . . . . . . . . . . . . . . . . . 04-13B–1 [AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-00–1
ABS SYSTEM WIRING DIAGRAM DRIVELINE/AXLE SPECIFICATIONS
[4W-ABS (EVEREST)]. . . . . . . . . . . . . . . . . . . . . 04-13B–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-00–4
ABS WHEEL-SPEED SENSOR AND DRIVELINE/AXLE SPECIFICATIONS
ABS SENSOR ROTOR [RANGER (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . 03-00–2
CONSTRUCTION/OPERATION
[4W-ABS (EVEREST)]. . . . . . . . . . . . . . . . . . . . . 04-13B–4
AIM OF DEVELOPMENT [AT (5R55S)] . . . . . . . . . 00-00–1 E
AIM OF DEVELOPMENT [EVEREST]. . . . . . . . . . . 00-00–5
AIR FILTER CONSTRUCTION EC-AT OPERATION CHART
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–4
APPLY COMPONENT ELECTRONIC CONTROL
HYDRAULIC CIRCUITS SYSTEM BLOCK DIAGRAM
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–44 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–55
APPLY COMPONENTS ELECTRONIC CONTROL
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–18 SYSTEM OUTLINE [5R55S] . . . . . . . . . . . . . . . . 05-13–55
AUTOMATIC TRANSMISSION ELECTRONIC CONTROL
CONTROL SYSTEM SYSTEM STRUCTURE [5R55S] . . . . . . . . . . . . . 05-13–56
WIRING DIAGRAM [5R55S] . . . . . . . . . . . . . . . . . 05-13–3 EMISSION SYSTEM STRUCTURAL VIEW
AUTOMATIC TRANSMISSION [WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . .01-16B–1
CROSS-SECTIONAL VIEW [5R55S] . . . . . . . . . . 05-13–2 EXHAUST SYSTEM STRUCTURAL VIEW
AUTOMATIC TRANSMISSION [WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . .01-15B–2
OUTLINE [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–1 EXHAUST SYSTEM STRUCTURAL VIEW
AUTOMATIC TRANSMISSION [WL-C, WE-C (RANGER (AT))] . . . . . . . . . . . . . .01-15B–1
SHIFT MECHANISM OUTLINE. . . . . . . . . . . . . . . 05-14–1
AUTOMATIC TRANSMISSION
SHIFT MECHANISM
F
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . 05-14–1
FAIL-SAFE FUNCTION [5R55S] . . . . . . . . . . . . . . . 05-02–3
FLUID FILTER
B CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–28
FLUID PUMP CONSTRUCTION [5R55S] . . . . . . . 05-13–27
FRONT AXLE CROSS-SECTIONAL VIEW
AI
BASIC SYSTEM STRUCTURAL VIEW
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-11–1
BODY AND ACCESSORIES FEATURES FRONT BRAKE (DISC) CONSTRUCTION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-00–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–1
BRAKE FEATURES[EVEREST] . . . . . . . . . . . . . . . 04-00–1 FRONT SUSPENSION DESCRIPTION
BRAKE SPECIFICATIONS[EVEREST] . . . . . . . . . . 04-00–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–2
AI–1
ALPHABETICAL INDEX
FRONT SUSPENSION OUTLINE
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–1
FRONT SUSPENSION STRUCTURAL VIEW O
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–1
FRONT WHEEL ALIGNMENT DESCRIPTION OIL COOLER CONSTRUCTION
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–1 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–58
FUEL SYSTEM OUTLINE ON-BOARD DIAGNOSTIC (OBD)
[WL-C, WE-C (EVEREST)]. . . . . . . . . . . . . . . . . .01-14B–1 SYSTEM BLOCK DIAGRAM
FUEL SYSTEM STRUCTURAL VIEW [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–1
[WL-C, WE-C (EVEREST)]. . . . . . . . . . . . . . . . . .01-14B–2 ON-BOARD DIAGNOSTIC (OBD)
FUEL TANK CONSTRUCTION SYSTEM OUTLINE [5R55S]. . . . . . . . . . . . . . . . . 05-02–1
[WL-C, WE-C (EVEREST)]. . . . . . . . . . . . . . . . . .01-14B–2 ON-BOARD DIAGNOSTIC OUTLINE
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . 03-02–1
ON-BOARD DIAGNOSTIC SYSTEM
G FUNCTION[4W-ABS (EVEREST)] . . . . . . . . . . . 04-02B–1
ON-BOARD DIAGNOSTIC SYSTEM
G SENSOR FUNCTION PID/DATA MONITOR FUNCTION
[4W-ABS (EVEREST)] . . . . . . . . . . . . . . . . . . . . .04-13B–4 [4W-ABS (EVEREST)] . . . . . . . . . . . . . . . . . . . . 04-02B–2
H P
HIGH-MOUNT BRAKE LIGHT CONSTRUCTION PARAMETER IDENTIFICATION (PID)
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–3 DATA MONITORING FUNCTION
HVAC FEATURES[EVEREST]. . . . . . . . . . . . . . . . . 07-00–1 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–4
HVAC SPECIFICATIONS[EVEREST] . . . . . . . . . . . 07-00–1 PARKING BRAKE SYSTEM STRUCTURAL
VIEW[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . 04-12–1
I PARKING LOCK
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–25
PLANETARY GEARSETS
IDENTIFICATION TAG OUTLINE CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–17
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–5 POWERFLOW OPERATION
INSTRUMENT CLUSTER SPECIFICATIONS [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–8
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-22–1 PRESSURE CONTROL
INSTRUMENT CLUSTER STRUCTURAL VIEW HYDRAULIC CIRCUITS
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-22–2 CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–32
INSTRUMENT CLUSTER SYSTEM WIRING
DIAGRAM[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 09-22–4
R
L RANGE SELECTION [5R55S] . . . . . . . . . . . . . . . . 05-13–6
REAR A/C UNIT
LIGHTING SYSTEM OUTLINE CONSTRUCTION/OPERATION
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2
LIGHTING SYSTEM STRUCTURAL VIEW REAR BRAKE (DRUM) CONSTRUCTION
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–2
LIGHTING SYSTEMS SPECIFICATION REAR COMBINATION LIGHT CONSTRUCTION
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–2
LUBRICATION [5R55S] . . . . . . . . . . . . . . . . . . . . . 05-13–26 REAR SUSPENSION OUTLINE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–1
M REAR SUSPENSION STRUCTURAL VIEW
[RANGER [5R55S], EVEREST] . . . . . . . . . . . . . . 02-14–1
REAR WIPER AND WASHER SYSTEM
MALFUNCTION DETECTION OPERATION[EVEREST] . . . . . . . . . . . . . . . . . . . 09-19–1
FUNCTION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . 05-02–2
MALFUNCTION INDICATION
FUNCTION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . 05-02–3
MEMORY FUNCTION [5R55S] . . . . . . . . . . . . . . . . 05-02–3
S
MOTOR CONSTRUCTION [5R55S] . . . . . . . . . . . 03-16–10 SEATS OUTLINE[EVEREST] . . . . . . . . . . . . . . . . . 09-13–1
MOTOR POSITION DETECTION SWITCH SEATS STRUCTURAL VIEW[EVEREST] . . . . . . . 09-13–1
CONSTRUCTION/OPERATION [5R55S] . . . . . . 03-16–10 SECOND-ROW SEAT CONSTRUCTION
MOTOR POSITION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–1
DETECTION SWITCH SHIFT PATTERNS [5R55S] . . . . . . . . . . . . . . . . . . 05-13–7
FUNCTION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . 03-16–9 SHIFT SOLENOID
HYDRAULIC CIRCUITS
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–36
AI–2
ALPHABETICAL INDEX
SIMULATION FUNCTION [5R55S] . . . . . . . . . . . . . 05-02–4 TRANSFER CASE
SPEED SENSOR SYSTEM WIRING DIAGRAM
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . . 03-16–9 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–8
SUSPENSION SPECIFICATIONS TRANSMISSION/TRANSAXLE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-00–1 FEATURES [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-00–1
TRANSMISSION/TRANSAXLE
T SPECIFICATIONS [5R55S] . . . . . . . . . . . . . . . . . . 05-00–1
THIRD-ROW SEAT CONSTRUCTION V

[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–2
TORQUE CONVERTER OUTLINE VEHICLE IDENTIFICATION NUMBER (VIN)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–16 CODE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . 00-00–14
TORQUE CONVERTER/LUBE VEHICLE IDENTIFICATION NUMBER
HYDRAULIC CIRCUITS (VIN) CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–14
CONSTRUCTION [5R55S] . . . . . . . . . . . . . . . . . 05-13–42 VEHICLE IDENTIFICATION NUMBERS
TRANSFER CASE (VIN) [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–15
ELECTRONIC CONTROL SYSTEM WHEEL AND TIRES STRUCTURAL VIEW
OUTLINE [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–8 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-12–1
TRANSFER CASE OUTLINE [5R55S] . . . . . . . . . . 03-16–1 WIPER/WASHER SYSTEM OUTLINE
TRANSFER CASE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–1
POWER FLOW [5R55S] . . . . . . . . . . . . . . . . . . . . 03-16–4 WIPER/WASHER SYSTEM STRUCTURAL VIEW
TRANSFER CASE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–1
STRUCTURAL VIEW [5R55S] . . . . . . . . . . . . . . . 03-16–1
AI
AI–3
SERVICE
F198-10-05L(00-00).fm 1 ページ２００６年８月３日　木曜日　午前１０時５６分
GENERAL INFORMATION 00SECTION

00
Toc of SCT INFORMATION . . . 00-00
GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) VEHICLE IDENTIFICATION NUMBERS
CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1 (VIN)[EVEREST]. . . . . . . . . . . . . . . . . . . 00-00–2
VEHICLE IDENTIFICATION NUMBER (VIN) ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–2
CODE[EVEREST] . . . . . . . . . . . . . . . . . 00-00–2 SCHEDULED MAINTENANCE . . . . . . . . 00-00–4
End of Toc
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
SOKYU_WM: GENERAL INFORMATION
id000000100200
M N B B S 1 D 1 0 6W 1 2 3 4 5 6
Serial No.
Production year 6= 2006, 7= 2007, 8=2008...
No meaning 0
1= WL-C (2.5 L-DI)

D= 2268—2721 kg {5001—6000 lbs}

E= Double cab.-without box

F= Double cab.-with box
1= Stretch cab.
(with Rear Access System) -without box
2= Stretch cab.
Body style (with Rear Access System) -with box
Product sorce S= Japan (for Thailand)
B= Seatbelt only
D= with Air bag (Driver side)

arnffw00001648
End Of Sie
00-00–1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE[EVEREST]
id0000001002a3
M N B L S 4 D 1 0 6W 1 2 3 4 5 6
Serial No.
Production year 6= 2006, 7= 2007, 8=2008...
No meaning 0
1= WL-C (2.5 L-DI)

D= 2268—2721 kg {5001—6000 lbs}

Body style 4= New Wagon
Product sorce S= Japan


arnffw00001880
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN)[EVEREST]
id0000006001a3
MNB LS******
MNB US******
End Of Sie
ABBREVIATIONS
id000000157200
ABS Antilock Brake System

ATDC After Top Dead Center
ATF Automatic Transmission Fluid
BTDC Before Top Dead Center
CM Control Module
ELR Emergency Locking Retractor
EX Exhaust
HI High
HU Hydraulic Unit
IDS Integrated Diagnostic Software
IN Intake
INT Intermittent
KOEO Key On Engine Off
KOER Key On Engine Running
LCD Liquid Crystal Display
LED Light Emitting Diode
LF Left Front
LH Left Hand
LO Low
LR Left Rear
LSD Limited Slip Differential
LSPV Load Sensing Proportioning Valve
M Motor
MAX Maximum
MIN Minimum
00-00–2
GENERAL INFORMATION
PDS Portable Diagnostic Software
PID Parameter Identification
P/S Power Steering
00
P/W Power Window
RF Right Front
RFW Remote Freewheel
RH Right Hand
RR Right Rear
SAS Sophisticated Air Bag Sensor
SST Special Service Tool
SW Switch
TDC Top Dead Center
TNS Tail Number Side Lights
VBC Variable Boost Control
VENT Ventilation
WDS Worldwide Diagnostic System
W/M Workshop manual
4W-ABS 4-Wheel Antilock Brake System
4×2 4-wheel 2-drive
4×4 4-wheel 4-drive
End Of Sie
00-00–3
GENERAL INFORMATION
SCHEDULED MAINTENANCE
id000000801200
Scheduled Maintenance Table for Thailand
Number of months or kilometers, whichever comes first
Maintenance Interval Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
×1000 km 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
for WL3 engine I I I I I I I I
Engine valve clearance for WLC/WEC
I I
engine
for WL3 engine Replace every 100,000 km
Engine timing belt *1 for WLC/WEC
Replace every 120,000 km
engine
Engine timing belt auto tensioner
(for WLC/WEC engine)
Engine oil *2 R R R R R R R R R R R R R R R R
*2 R R R R R R R R R R R R R R R R
Engine oil filter
*3 I I I I I I I I I I I I I I I I
Drive belts
Cooling system *4 I I I I I I I I
*5 R
FL22 type
Engine coolant
Others Replace every 2 years
Air cleaner element *6 C C R C C R C C R C C R C C R C
Fuel filter R R R R R
Fuel lines and hoses I I I I I I I I I I I I I I I I
Air intake system I I I I I I I I
Battery electrolyte level and specific
I I I I I I I I
gravity
Brake lines, hoses and connections I I I I I I I I
*7 I I I R I I I R I I I R I I I R
Brake fluid
Clutch fluid (for WL3 engine) I I I I I I I I I I I I I I I I
Parking brake I I I I I I I I I I I I I I I I
Power brake unit (Brake booster) and
I I I I I I I I
hoses
Disc brakes *8 I I I I I I I I I I I I I I I I
Drum brakes *8 I I I I I I I I
Power steering fluid, lines, hoses and
I I I I I I I I I I I I I I I I
connections
Steering operation and linkages *8 I I I I I I I I
for WL3 engine
*4 I I I R I I I R I I I R I I I R
Manual transmission oil
for WLC/WEC
I I R I
engine
Automatic transmission fluid *9 Replace every 240,000 km
*4 R R R R
Rear differential oil (for 4×2)
Front and rear differential oil (for 4×4) *4 R R R R
for WL3 engine
*4 R R R R
Transfer oil (for Manual
Transmission 4×4) for WLC/WEC
I I R I
engine
Transfer oil
(for Automatic Transmission 4×4) *9
Front propeller shaft joints
L L L L L L L L
(for Manual Transmission 4×4)
Rear propeller shaft joints (for 4×4) L L L L L L L L
Front and rear suspension and ball joints
*8 I I I I
00-00–4
GENERAL INFORMATION
Number of months or kilometers, whichever comes first
Maintenance Interval Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
×1000 km 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
00
Front wheel bearing grease (for 4×2
R R R R
except Hi-Rider) *10
Wheel bearing axial play I I I I I I I I
Driveshaft dust boots (for 4×4) *4 I I I I
Exhaust system and heat shields Inspect every 80,000 km
Bolts and nuts on chassis and body *8 T T T T T T T T
Body condition
Inspect annually
(for rust, corrosion and perforation)
Tires (Including spare tire)
I I I I I I I I I I I I I I I I
(with inflation pressure adjustment)
Chart symbols
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace
T: Tighten
L: Lubricate
C: Clean
Remarks
• To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel
systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be
done by an authorized Mazda Dealer.
• After the described period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1
: Replacement of the timing belt is required at every 100,000 km (WL3 engine) or 120,000 km (WLC/WEC
engine). Failure to replace the timing belt may result in damage to the engine.
*2
: If the vehicle is operated primarily under any of the following conditions, replace the engine oil and oil filter
more often than the recommended intervals.
a. Driving in dusty condition
b. Extended periods of idling or low speed operation
c. Driving for long period in cold temperatures or driving regularly at short distance (less than 8 km) only
*3
: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*4
: If the vehicle is operated primarily under any of the following conditions, inspect or replace relevant items,
such as oil, fluid, etc., twice as often as this table recommends. (e.g. For manual transmission oil, inspect at
every 5,000 km or 3 months instead of 10,000 km or 6 months and replace at every 20,000 km or 12
months instead of 40,000 km or 24 months.)
a. Repeated short-distance driving
b. Driving in dusty conditions
c. Driving with extended use of brakes
d. Driving in areas where road salt or other corrosive materials are used
e. Driving on rough or muddy roads
f. Extended periods of idling or low-speed operation
g. Driving for long periods in cold temperatures or extremely humid climates
*5
: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*6: If the vehicle is operated in very dusty or sandy areas, clean the air cleaner element more often than the
recommended intervals. Replace the air cleaner element at every 20,000 km or 12 months.
*7: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle
is operated in extremely humid climates, replace the brake fluid annually.
*8: If the vehicle is operated primarily under any of the following conditions, inspect the these items more often
than the recommended intervals.
a. Driving on bumpy roads, gravel roads, snowy roads or dirt roads
b. Driving uphill and downhill frequently
c. Repeated short-distance driving
00-00–5
GENERAL INFORMATION
*9
: If the vehicle is operated primarily under any of the following conditions, replace the fluid as follows.
— Automatic transmission: Every 50,000 km.
— Transfer case (attached to automatic transmission): Every 100,000 km.
a. Towing a trailer
b. Extension idling and/or low speed driving for long distances as in heavy commercial use such as
delivery, taxi, patrol car or livery
c. Operating in dusty conditions such as unpaved or dusty roads
d. Off-road operations
*10: If the vehicle is operated primarily under any of the following conditions, replace the front wheel bearing
grease more often than the recommended intervals.
a. Driving in dusty conditions
b. Driving in rough, muddy or snow - melted conditions
c. Towing a trailer
Scheduled Maintenance Service (Specific Work Required)

• The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Inspect engine vale clearance.
Engine timing belt Replace engine timing belt.
Engine timing belt auto tensioner Replace engine timing belt auto tensioner.
Drive belts Inspect for wear, cracks, fraying and tension.
Engine oil Replace engine oil and inspect for leakage.
Engine oil filter Replace engine oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
Check engine coolant level and quality, and inspect for leakage.
(Including coolant level adjustment)
Radiator cap Inspect radiator cap.
Engine coolant Replace engine coolant.
FUEL SYSTEM
Idle speed Check engine idle rpm.
Idle mixture Inspect the CO and HC concentrations (see W/M).
Choke system Check system operation.
Inspect dirt, oil and damage.
Air cleaner element Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel injection pump inlet filter Clean fuel injection pump inlet filter.
Fuel lines and hoses
Inspect for cracks, leakage and loose connection.
Fuel lines, hoses and connections
Update to injection amount correction with current diagnostic tool
Fuel injection system
(see W/M).
Fuel system (Drain water) Drain water in fuel system.
Diesel particulate filter Replace diesel particulate filter.
Fuel additive for diesel particulate filter Fill up fuel additive.
IGNITION SYSTEM
Initial ignition timing Check initial ignition timing.
Inspect for wear, damage, carbon, plug gap and high-tension lead
Spark plugs condition.
Replace spark plugs.
Ignition cables condition/security Inspect for damage, condition and connection.
EMISSION CONTROL SYSTEM
Evaporative system Check system operation (see W/M), vapor lines, vacuum fitting hoses and
Evaporative emission control system connection.
Check system operation (see W/M), PCV valve, blow-by lines, vacuum
Crankcase emission control system
fitting hoses and connection.
Check system operation (see W/M), vacuum fitting hoses and connection.
E.G.R system MZR-CD (RF turbo) engine: Update to MAF correction for E.G.R control
with current diagnostic tool (see W/M).
00-00–6
GENERAL INFORMATION
Air intake system Update to MAF correction (see W/M).
Check the diaphragm and system operation, vacuum fitting hoses and
00
Throttle positioner system
connection.
Dash pot Check system operation.
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check battery electrolyte level and specific gravity.
Battery condition Check battery for corroded or loose connections and cracks.
Battery Check battery for leakage and corrosion.
All electrical system
Check function of lighting system, windshield wiper (including wiper blade
Lighting system and windshield wipers and
condition), washer and power windows.
washer
Head light alignment Check head light alignment.
CHASSIS AND BODY
Brake and clutch pedals
Check pedal height and free play.
Brake pedals
Check brake fluid level and for leakage.
Brake fluid
Replace brake fluid.
Clutch fluid Check Clutch fluid level and for leakage.
Inspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
Brake lines, hoses and connections
leakage.
Parking brake Check parking lever stroke.
Power brake unit and hoses Check vacuum lines, connections, and check valve for improper
Power brake unit (Brake booster) and hoses attachment, air tightness, cracks chafing and deterioration.
Inspect caliper for correct operation and fluid leakage, brake pads for wear.
Disc brakes Check disc plate condition and thickness.
Test for judder and noise.
Inspect brake drum for wear and scratches: brake lining for wear, peeling
Drum brakes and cracks; wheel cylinder for fluid leakage.
Test for judder and noise.
Manual steering gear oil Check manual gear oil level.
Power steering fluid, lines, hoses and
Check power steering fluid level and lines for improper attachment,
connections
leakage, cracks, damage, loose connections, chafing and deterioration.
Power steering fluid and lines
Check that the steering wheel has the specified play.
Be sure to check for changes, such as excessive play, hard steering or
Steering operation and gear housing
strange noises.
Steering linkages tie rod ends and arms
Check gear housing and boots for looseness, damage and grease/gear oil
Steering operation and linkages
leakage.
Check ball joint, dust cover and o
Front and rear suspension and ball joints
Inspect for grease leakage, crack, damage and looseness.
Front suspension ball joints
Inspect for grease leakage, crack, damage, looseness and wheel bearing
Front and rear suspension, ball joints and wheel
play/noise.
bearing axial play
Wheel bearing axial play Inspect for wheel bearing play/noise.
Check manual transmission/transaxle oil level and for leakage.
Manual transmission/transaxle oil
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check automatic transmission/transaxle fluid level.
Automatic transmission/transaxle fluid Replace automatic transmission/transaxle fluid.
Front and rear differential oil
Front differential oil
Check front and rear differential oil level and inspect for leakage.
Front axle oil
Replace front and rear differential oil.
Rear differential oil
Rear axle oil
Check transfer oil level inspect for leakage.
Transfer oil
Replace transfer oil
Front and rear wheel bearing grease
Remove wheel bearing and replace wheel bearing grease.
Front wheel bearing grease
Wheel bearing axial play
Wheel bearing axial play (rear) and lateral play Inspect wheel bearing play and noise.
(front)
00-00–7
GENERAL INFORMATION
Propeller shaft joints
Front propeller shaft joints Lubricate propeller shaft joints.
Rear propeller shaft joints
Driveshaft dust boots Inspect for grease leakage, crack, damage and looseness.
Wheel nuts Tighten wheel nuts.
Bolts and nuts on chassis and body Tighten bolts and nuts fastening suspension components, members and
Bolts and nuts on seats seat frames.
Body condition
Inspect body surface for paint damage, rust, corrosion and perforation.
(for rust, corrosion and perforation)
Exhaust system and heat shields
Inspect for damage, corrosion, looseness of connections and gas leakage.
Exhaust pipe connections
Tire rotation Rotate tires.
Tires (Including spare tire) Check air pressure and inspect tires for tread wear, damage, cracks; and
(with inflation pressure adjustment) wheels for damage and corrosion.
Flat tire repair kit Check tire repair fluid expiration date.
Hinges and catches Lubricate hinges and catches of doors, trunk lid and hood.
Inspect underside of vehicle (floor pans, frames, fuel lines, around exhaust
Underside of vehicle
system etc.) for damage and corrosion.
Check brake operation/clutch operation/steering control/operation of
Road test meters and gauges/squeaks, rattles, or unusual noises/engine general
performance/emergency locking retractors.
Diagnostic trouble code by current diagnostic tool Check diagnostic trouble code with current diagnostic tool (see W/M).
Check the items below with M-MDS (see W/M).
(1) Retrieve All CMDTCs
M-MDS check of Vehicle Management and Safety (2) PCM function test (except Tribute and diesel engine models)
Systems (3) PCM Input/Output Data Monitor (except Tribute and diesel engine
models)
(4) Adviser Comment (except Tribute and diesel
AIR CONDITIONER SYSTEM
Cabin air filter Replace cabin air filter.
End Of Sie
00-00–8
F198-10-05L(01-10).fm 1 ページ２００６年８月３日　木曜日　午前１１時５５分
ENGINE 01
SECTION
Toc of SCT
MECHANICAL EXHAUST SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-10B [WL-C, WE-C] . . . . . . . . . . . . . 01-15B
COOLING SYSTEM EMISSION SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-12B [WL-C, WE-C] . . . . . . . . . . . . . 01-16B
INTAKE-AIR SYSTEM CONTROL SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-13B [WL-C, WE-C] . . . . . . . . . . . . . 01-40B
FUEL SYSTEM TECHNICAL DATA 01
[WL-C, WE-C] . . . . . . . . . . . . 01-14B [WL-C, WE-C] . . . . . . . . . . . . . 01-50B
Toc of SCT
01-10B MECHANICAL [WL-C, WE-C]
DRIVE BELT INSPECTION[WL-C, WE-C ENGINE TUNE-UP
(EVEREST)]. . . . . . . . . . . . . . . . . . . . . . 01-10B–1 [WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . . 01-10B–2
End of Toc
DRIVE BELT INSPECTION[WL-C, WE-C (EVEREST)]
WM: DRIVE BELT
id011098801500
Drive Belt Deflection Check
1. Check the drive belt deflection when the engine is GENERATOR MEASURING
cold, or at least 30 minutes after the engine has
stopped. Apply pressure 98 N {10 kgf, 22 lbf}
midway between the specified pulleys.
WATER
PUMP
GENERATOR
CRANKSHAFT
PULLEY
MEASURING
POINT a
A/C
A/C
COMPRESSOR
CRANKSHAFT
PULLEY
MEASURING
POINT b
arnffw00001555
Drive Belt Deflection

(mm {in})
Drive Belt New* Used Limit
7.4—9.4 8.7—10.4
Generator 14.3 {0.56} or more
{0.30—0.37} {0.35—0.40}
5.0—6.2 6.0—6.5
a 11.3 {0.44} or more
{0.20—0.24} {0.24—0.25}
A/C
9.5—11.8 11.0—12.5
b 18.0 {0.70} or more
{0.38—0.46} {0.44—0.49}
*
: A belt that has been on a running engine for less than five minutes.
2. If the deflection is not within the specification, adjust it.

01-10B–1
F198-10-05L(01-10).fm 2 ページ２００６年８月３日　木曜日　午前１０時５７分
MECHANICAL [WL-C, WE-C]

Drive Belt Tension Check
1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when the
engine is cold, or at least 30 minutes after the 49 9200 020A
engine has stopped. Using the SST, check the
belt tension between any two pulleys.
WHEN MEASURED
WHEN SET
arnffw00001556
Drive Belt Tension

(N {kgf, lbf})
490—637 431—539
Generator 225 {22.9, 50.6} or less
{50.0—64.9, 111—143} {44.0—54.9, 96.9—121}
455—572 353—431
A/C 181 {18.5, 40.7} or less
{46.4—58.3, 103—128} {36.0—43.9, 79.4—96.8}
*
2. If the tension is not within the specification, adjust it.

End Of Sie
ENGINE TUNE-UP[WL-C, WE-C (AT)]
id011099800600
Engine Tune-up Preparation
1. Start the engine and warm up completely.
2. Verify that the selector lever is in P position.
3. Verify that the accelerator pedal is released.
4. Turn off the A/C switch. (if equipped)
5. Turn off all electrical loads.
6. Verify that no DTC is present.
7. Connect the PDS/IDS to the DLC-2.
DLC-2
arnffw00001573
01-10B–2

Idle Speed Inspection
1. Perform “Engine Tune-up Preparation”. (See 01-10B-2 Engine Tune-up Preparation.)
Note
• Idle speed is not adjustable.
• Idle speed verification requires PDS/IDS.
2. Verify that the idling speed (PDS/IDS: RPM PID) is within the specification using the PDS/IDS function.
Specification
No load: 725—775 rpm
A/C ON: 725—775 rpm
• If not as specified, inspect the following parts.

01
— APP sensor
— ECT sensor
— CMP sensor
— CKP sensor
— Fuel pressure sensor
— Fuel injector
— Supply pump
• If the parts are normal, replace the PCM.
Correction Procedure
MAF correction
Using PDS/IDS
Note
• Perform this procedure after replacing the MAF/IAT sensor No.2 or at the recommended interval as
described under “E.G.R. system” in “SCHEDULED MAINTENANCE.”
1. Perform “Engine Tune-up Preparation”. (See 01-10B-2 Engine Tune-up Preparation.)

2. After the vehicle is identified, select the following items from the initial screen of the PDS/IDS.
• When using the IDS (notebook PC)
1. Select the “Powertrain”.
2. Select the “Engine Checks”.
• When using the PDS (pocket PC)
1. Select “All Tests and Calibrations”.
3. Then, select the “Learning”, “MAF Correction” and perform procedures according to directions on the PDS/IDS
screen.
4. Perform the MAF correction according to the directions on the PDS/IDS screen.
01-10B–3

Without using PDS/IDS
Note
• The glow indicator light illuminates while MAF learning is performed, and flashes five times after it is
completed.
1. Short the DLC terminal TEN to body ground using

a jumper wire. DLC
arnffw00001558
2. Short circuit the DLC terminal TEN five times

within 5 s.
End Of Sie
TEN JUMPER
FEN WIRE
GND
B+
BODY GROUND
DLC
IG—
arnffw00001559
01-10B–4
COOLING SYSTEM [WL-C, WE-C]
01-12B COOLING SYSTEM [WL-C, WE-C]

RADIATOR REMOVAL/INSTALLATION
[WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . 01-12B–1
End of Toc
RADIATOR REMOVAL/INSTALLATION[WL-C, WE-C (AT)]
WM: RADIATOR
id0112b7801400
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
01
1. Drain the engine coolant.
2. Remove in the order indicated in the table.
3. Remove the oil hose.
4. Install in the reverse order of removal.
5. Fill the radiator with the specified amount and 7.8—10.8 N·m {80—110 kgf·cm,
type of engine coolant. . 1 69.1—95.5 in·lbf}
1 Radiator upper seal 18.6—25.5

A {1.9—2.6,
2 Radiator hose
13.8—18.8}
3 Lower radiator cowling 18.6—25.5
4 Radiator cowling {1.9—2.6, 3
13.8—18.8}
5 Radiator
End Of Sie 4
A
2
5
B
2
N·m {kgf·m, ft·lbf}

arnffw00001702
01-12B–1
F198-10-05L(01-13).fm 1 ページ２００６年８月１０日　木曜日　午後５時１４分
INTAKE-AIR SYSTEM [WL-C, WE-C]
01-13B INTAKE-AIR SYSTEM [WL-C, WE-C]

ACCELERATOR PEDAL COMPONENT
REMOVAL/INSTALLATION
[WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . 01-13B–1
End of Toc
ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION[WL-C, WE-C (AT)]
WM: INTAKE-AIR SYSTEM
id011398807300
1. Disconnect the negative battery cable.
2. Remove the 4x4 control module. (4x4) (See 03-18-5 4x4 CONTROL MODULE REMOVAL/INSTALLATION [AT
(5R55S)].)
3. Remove in the order indicated in the table. .
01
R
1 Brake switch connector 4
2 Idle switch connector
3 APP sensor connector
4 Spring pin 5
5 Clevis pin
18.6—25.5
Pedal component (See 01-13B-1 Pedal Component {1.90—2.60,
6
Installation Note.) 13.8—18.8}
GREASE
18.6—25.5
4. Install in the reverse order of removal. {1.90—2.60, 3
13.8—18.8}
6
1
2
arnffw00001574
Pedal Component Installation Note

1. Carry out the “BRAKE PEDAL INSPECTION” procedure after installing the pedal component.
End Of Sie
01-13B–1
F198-10-05L(01-14).fm 1 ページ２００６年８月３日　木曜日　午前１１時１分
01-14B FUEL SYSTEM [WL-C, WE-C]

FUEL SYSTEM LOCATION INDEX FUEL TANK REMOVAL/INSTALLATION
[WL-C, WE-C (EVEREST)] . . . . . . . . . . 01-14B–1 [WL-C, WE-C (EVEREST)]. . . . . . . . . . . 01-14B–2
End of Toc
FUEL SYSTEM LOCATION INDEX[WL-C, WE-C (EVEREST)]
WM: FUEL SYSTEM
id011498800100
Engine Room Side
6
7 01
9
1
2
4 5
3
absggw00000461
.
1 Fuel filter 6 Common rail

2 Sedimentor switch 7 Fuel injector
3 Supply pump 8 Check valve
4 Fuel metering valve 9 Fuel warmer (European (L.H.D.) specs.)
5 Fuel-inlet filter
01-14B–1

Fuel Tank Side
arnffw00001575
.
1 Fuel tank
End Of Sie
FUEL TANK REMOVAL/INSTALLATION[WL-C, WE-C (EVEREST)]
id011498801600
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.

2. Complete the “BEFORE REPAIR PROCEDURE”
3. Remove the drain plug and drain the fuel from the fuel tank.
4. Remove the rear flap.
5. Remove in the reverse order indicated in the table.
6. Install in the reverse order indicated of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
01-14B–2
1.1—2.1 N·m 6
{11—22 kgf·cm,
10— ·lbf} 110 8
1.1—2.1 N·m
R 9 {11— ·cm,
10— ·lbf}
SEAL RUBBER
B 2
R
3 01
A 5
2.5—4.6 N·m
{25— ·cm,
13
22—40 in·lbf} R 7
11.8—16.6 N·m
{120— ·cm,
105—147 in·lbf}
11 12
2.5— ·m
{25— ·cm,
22—26 in·lbf} 11.8—16.6 N·m 11.8—16.6 N·m
{120— ·cm, {120— ·cm,
105—147 in·lbf} 105—147 in·lbf}
7.9—10.7 N· —110 kgf·cm, 16—22 {1.6—2.3, 16— —2.3,

69.5— ·lbf} 12—16} —16}
32—46 {3.2—4.7,
24—33} R
1
DRAIN PLUG
— —3.3, 4
19—23} 4x4
32—46 {3.2—4.7, 24—33}
4x2
arnffw00001577
1 Fuel filler pipe protector 7 Fuel tank

2 Joint hose (See 01-14B-5 Joint Hose Installation 8 Fuel gauge sender unit
Note.) 9 Evaporative hose (See 01-14B-4 Evaporative Hose
3 Breather hose (See 01-14B-4 Breather Hose Installation Note.)
Installation Note.) 10 Rollover valve
4 Under guard 11 Dust cover
5 Drain hose plug 12 Fuel-filler pipe
6 Fuel hose 13 Fuel inlet pipe
(See 01-14B-4 Fuel Hose Installation Note.)
01-14B–3

Evaporative Hose Installation Note
1. Fit each hose onto the respective fittings within the specification, and install clamps as shown.
Length
Evaporative hose: 25 mm {0.98 in}
10 mm {0.39 in}
BREATHER HOSE
arnffw00000444
Fuel Hose Installation Note

1. Fit each onto the respective fittings within the specification, and install camp as shown.
Length
Fuel hose: 25mm {0.98 in}
10 mm {0.39 in}
FUEL HOSE
arnffw00000445
Breather Hose Installation Note

1. Fit each hose onto the respective fittings within the specification, and install clamp as shown.
Length
Breather hose: 25 mm {0.98 in}
10 mm {0.39 in}
EVAPORATIVE HOSE
arnffw00000446
01-14B–4

Joint Hose Installation Note
1. Fit the joint hose onto the respective fittings within the specification, and install clamps as shown.
Length
Joint hose: 35 {1.4 in]
End Of Sie
01
9 12 mm 9 12 mm
{0.36 0.47 in} {0.36 0.47 in}
VIEW A VIEW B
arnffw00000447
01-14B–5
F198-10-05L(01-15).fm 1 ページ２００６年８月３日　木曜日　午前１１時２分
01-15B EXHAUST SYSTEM [WL-C, WE-C]

EXHAUST SYSTEM EXHAUST SYSTEM
REMOVAL/INSTALLATION[WL-C, WE-C REMOVAL/INSTALLATION[WL-C, WE-C
(RANGER (AT))] . . . . . . . . . . . . . . . . . . 01-15B–1 (EVEREST)] . . . . . . . . . . . . . . . . . . . . . . 01-15B–4
End of Toc
EXHAUST SYSTEM REMOVAL/INSTALLATION[WL-C, WE-C (RANGER (AT))]
WM: EXHAUST SYSTEM
id011599800200
Warning
• When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing the exhaust system. 01
2. Remove the engine cover.
3. Remove the air cleaner.
4. Remove the EGR cooler.
7. Start the engine and:
(1) Inspect the exhaust gas leakage.
(2) If any servicing around the turbocharger is performed, inspect around the turbocharger for oil or engine
coolant leakage.
01-15B–1

Type A
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
4
22—27 {2.3—2.7,
17—19} 7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
R
5
R
6 A
11
22—27
{2.3—2.7, 9 1
17—19}
7.8—10.8 N·m
{80—110 kgf·cm, R
70—95 in·lbf} R
11.8—17.6 N·m R
{121—179 kgf·cm,
22—27 {2.3—2.7,
105—155 in·lbf} 7
14.7—20.6 N·m 64—89 {6.6—9.0, 48—65}
17—19}
{150—210 kgf·cm,
10 131—182 in·lbf}
8
R
2
R
A
3
37—52 {3.8—5.3, 28—38}
19—25 {2.0—2.5, 15—18}
22—27 {2.3—2.7, 17—19}

arnffw00001600
1 Main silencer 7 Oil pipe

2 Oxidation catalytic converter 8 Oil hose (supply)
3 Front pipe (See 01-15B-4 Oil Hose (Supply) Installation Note.)
4 Exhaust manifold insulator 9 Turbocharger
5 Turbocharger insulator 10 Joint pipe
6 Water pipe 11 Exhaust manifold
(See 01-15B-3 Water Pipe Removal Note.)
(See 01-15B-4 Water Pipe Installation Note.)
01-15B–2

Type B
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
5
22—27 {2.3—2.7,
17—19} 7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
R
6
R
01
7 A
12
22—27
10 1
{2.3—2.7,
17—19}
7.8—10.8 N·m
{80—110 kgf·cm, R R
70—95 in·lbf}
11.8—17.6 N·m R
{121—179 kgf·cm,
22—27 {2.3—2.7,
105—155 in·lbf} 8 64—89 {6.6—9.0, 48—65}
17—19} 14.7—20.6 N·m
{150—210 kgf·cm,
11 131—182 in·lbf}
9
R 2
R
4
A
37—52 {3.8—5.3, 28—38} 3

19—25 {2.0—2.5, 15—18}
22—27 {2.3—2.7, 17—19}

arnffw00001601
1 Main silencer 7 Water pipe

2 Oxidation catalytic converter (See 01-15B-3 Water Pipe Removal Note.)
3 Middle pipe
8 Oil pipe
4 Front pipe
9 Oil hose (supply)
5 Exhaust manifold insulator (See 01-15B-4 Oil Hose (Supply) Installation Note.)
6 Turbocharger insulator 10 Turbocharger
11 Joint pipe
12 Exhaust manifold
Water Pipe Removal Note

1. Drain the engine coolant before removing the water pipe.
01-15B–3

Oil Hose (Supply) Installation Note
1. Secure section A using a spanner.
2. Tighten the nut at B.
Tightening torque:
B, D: 14.7—20.6 N·m {150—210 kg·cm, 131—
182 in·lbf}
3. Hold section C using pliers.

4. Tighten the nut at D.
A B C D
arnffw00000458
Water Pipe Installation Note

1. Refill the engine coolant after Installing the water pipe.
End Of Sie
EXHAUST SYSTEM REMOVAL/INSTALLATION[WL-C, WE-C (EVEREST)]
id011598800200
Warning
• When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing the exhaust system.

2. Remove the engine cover.
3. Remove the air cleaner.
4. Remove the EGR cooler.
7. Start the engine and:
(1) Inspect the exhaust gas leakage.
(2) If any servicing around the turbocharger is performed, inspect around the turbocharger for oil or engine
coolant leakage.
01-15B–4

MT
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
4
22—27 {2.3—2.7,
17—19} 7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
R
5
R
01
6 A
11
22—27
{2.3—2.7, 9
17—19}
7.8—10.8 N·m
{80—110 kgf·cm, R
70—95 in·lbf}
11.8—17.6 N·m R 1
{121—179 kgf·cm,
22—27 {2.3—2.7,
105—155 in·lbf} 7
14.7—20.6 N·m R
17—19}
{150—210 kgf·cm,
10 131—182 in·lbf}
8
R
64—89 {6.6—9.0, 48—65}
R
A
2
37—52 {3.8—5.3, 28—38}
19—25 {2.0—2.5, 15—18}
22—27 {2.3—2.7, 17—19}

arnffw00001598
01-15B–5

AT
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
4
22—27 {2.3—2.7,
17—19} 7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
R
5
R
6 A
11
22—27
{2.3—2.7, 9 1
17—19}
7.8—10.8 N·m
{80—110 kgf·cm, R
70—95 in·lbf} R
11.8—17.6 N·m R
{121—179 kgf·cm,
22—27 {2.3—2.7,
105—155 in·lbf} 7
14.7—20.6 N·m 64—89 {6.6—9.0, 48—65}
17—19}
{150—210 kgf·cm,
10 131—182 in·lbf}
8
R
2
R
A
3
37—52 {3.8—5.3, 28—38}
19—25 {2.0—2.5, 15—18}
22—27 {2.3—2.7, 17—19}

arnffw00001599
1 Main silencer 7 Oil pipe

2 Oxidation catalytic converter 8 Oil hose (supply)
3 Front pipe (See 01-15B-7 Oil Hose (Supply) Installation Note.)
(See 01-15B-7 Front Pipe Installation Note.) 9 Turbocharger
4 Exhaust manifold insulator 10 Joint pipe
5 Turbocharger insulator 11 Exhaust manifold
6 Water pipe
(See 01-15B-6 Water Pipe Removal Note.)
Water Pipe Removal Note

1. Drain the engine coolant before removing the water pipe.
01-15B–6

Oil Hose (Supply) Installation Note
1. Secure section A using a spanner.
2. Tighten the nut at B.
Tightening torque:
B, D: 14.7—20.6 N·m {150—210 kg·cm, 131—
182 in·lbf}
3. Hold section C using pliers.

4. Tighten the nut at D.
A B C D
arnffw00000458
01
Water Pipe Installation Note
1. Refill the engine coolant after Installing the water pipe.
Front Pipe Installation Note

1. Temporarily tighten the nuts A.
Tightening torque:
A, B: 37—52 N·m {3.8—5.3 kg·m, 28—38
ft·lbf}
C: 19—25 N·m {2.0—2.5 kg·m, 15—18 ft·lbf}
2. Temporarily tighten the bolts B and C. C

3. Completely tighten the nuts A.
4. Completely tighten the bolts B and C.
End Of Sie
A
arnffw00000459
01-15B–7
F198-10-05L(01-16).fm 1 ページ２００６年８月３日　木曜日　午前１１時３分
01-16B EMISSION SYSTEM [WL-C, WE-C]

EMISSION SYSTEM LOCATION INDEX
[WL-C, WE-C (EVEREST)] . . . . . . . . . . 01-16B–1
End of Toc
EMISSION SYSTEM LOCATION INDEX[WL-C, WE-C (EVEREST)]
WM: EMISSION SYSTEM
id011698803700
Engine Room Side
9
01
2
2
4
3
5
7
8
arnffw00000460
.
1 EGR valve 6 Air filter

2 EGR cooler 7 Intake shutter solenoid valve (half)
3 Intake shutter valve 8 Intake shutter solenoid valve (full)
4 EGR solenoid valve 9 Oxidation catalytic converter
5 EGR control solenoid valve
01-16B–1
F198-10-05L(01-16).fm 2 ページ２００６年８月３日　木曜日　午前１１時３分

Fuel Tank Side
arnffw00001576
.
1 Rollover valve
End Of Sie
01-16B–2
(.
HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧠ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧟㧟ಽ
CONTROL SYSTEM [WL-C, WE-C]
01-40B CONTROL SYSTEM [WL-C, WE-C]

CRANKSHAFT POSITION (CKP) SENSOR
[WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . 01-40B–1
End of Toc
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION[WL-C, WE-C (AT)]
WM: CRANKSHAFT POSITION PLATE
id014099800600
Caution
x When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect engine control. Be sure there is 01
no foreign material on the CKP sensor when replacing.
x Do not forcefully pull the wiring harness of the CKP sensor. Doing so will break the wiring
harness.

2. Remove the under cover.
3. Remove the insulator.
1 CKP sensor installation bolt
2 CKP sensor (See 01-40B-1 CKP Sensor Installation 2
Note.)
5. Install in the reverse order of removal. 1
6.0—10.0 N·m
{62—101 kgf·cm,
54—88 in·lbf}
arnffw00001561
CKP Sensor Installation Note

1. Verify that there is no foreign material on the CKP sensor flange surface and the installation surface.
2. Verify that the O-ring is not damaged.
x If there is a damage, replace the CKP sensor.
3. Apply a small amount of clean oil to the O-ring.
4. Press in the CKP sensor until the CKP sensor flange surface firmly adheres to the installation surface.
5. Verify that the O-ring is installed correctly to the sensor installation hole.
6. Tighten the bolt.
End Of Sie
01-40B–1
F198-10-05L(01-50).fm 1 ページ２００６年８月３日　木曜日　午前１１時４分
TECHNICAL DATA [WL-C, WE-C]
01-50B TECHNICAL DATA [WL-C, WE-C]

ENGINE TECHNICAL DATA
[WL-C, WE-C (EVEREST)] . . . . . . . . . . 01-50B–1
End of Toc
ENGINE TECHNICAL DATA[WL-C, WE-C (EVEREST)]
WM: ENGINE
id0150e3800100
Item Specification
IN: 0.10—0.16 mm {0.0040—0.0062 in}
Valve clearance [Engine cold]
EX: 0.17—0.23 mm {0.0067—0.0090 in}
Compression (kPa {kgf/cm2, psi} [rpm])

Standard: 2,942 {30, 427} [200] 01
Minimum: 2,648 {27, 384} [200]
Bolt head mark W
Standard length: 101.2—101.8 mm {3.985—4.007 in}
Maximum length: 102.5 mm {4.035 in}
Bolt head mark N
Cylinder head bolt length Standard length: 113.2—113.8 mm {4.457—4.480 in}
Bolt head mark I
Standard length: 149—150 mm {5.867—5.905 in}
Pushing distance of the camshaft cap lower oil seal 0.0—0.4 mm {0.0—0.015 in}
Camshaft oil seal press-in amount 0.5—1.0 mm {0.02—0.03 in}
Pushing distance of the front oil seal 0.0—0.4 mm {0.0—0.015 in}
Pushing distance of the rear oil seal 0.0—0.5 mm {0.0—0.019 in}
Oil pressure [2,500 rpm] 410—570 kPa {4.19—5.81 kgf/cm2, 59.6—82.6 psi}
Oil replacement: 6.8 {7.2 US qt, 6.0 lmp qt}
Oil capacity (approx. quantity) Oil and oil filter replacement: 7.0 {7.4 US qt, 6.2 lmp qt}
Total (dry engine): 8.0 {8.5 US qt, 7.0 lmp qt}
Front oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}
Fuel injection pump oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}
Standard oil pump tip clearance 0.10—0.19 mm {0.0040—0.0074 in}
Maximum oil pump tip clearance 0.20 mm {0.0079 in}
Standard oil pump side clearance 0.04—0.09 mm {0.0016—0.0035 in}
Maximum oil pump side clearance 0.15 mm {0.0059 in}
Standard plunger spring length 43.8 mm {1.72 in}
Engine coolant capacity (approx. quantity) 9.4 L {9.9 US qt, 8.3 Imp qt}
Cooling system cap valve opening pressure 93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi}
Initial-opening temperature and lift of the valve 80—84 °C {176—183 °F}
Full open temperature 95 °C {203 °F}
Full open life 8.5 mm {0.33 in} or more
Battery electrolyte specific gravity [20 °C {68 °F}] 1.22—1.29
Battery load test current 95D31R (64): 250 A
Vehicles with immobilizer system: 5—25 mA
Battery back-up current
Vehicles without immobilizer system: 10 mA or less
Battery slow charge current 95D31R (64): 6.5—8.0 A
Battery quick charge current [30 min.] 95D31R (64): 40 A
Terminal B: B+
Generator standard voltage [Engine switch ON] Terminal L: Approx. 1 V
Terminal S: B+
Terminal B: 14.1—14.7 V
Generator standard voltage [Idle, 20 °C {68 °F}] Terminal L: 13.0—14.0 V
Terminal S: 14.1—14.7 V
Generator rotor resistance (between slip rings) [20 °C
2.3—2.7 ohms
{68 °F}]
Standard: 18.5 mm {0.73 in}
Generator brush length
Minimum: 5.0 mm {0.2 in}
Standard: 4.8—6.0 N {0.49—0.61 kgf, 1.08—1.34 lbf}
Generator brush spring force
Minimum: 2.16 N {0.22 kgf, 0.49 lbf}
01-50B–1
F198-10-05L(01-50).fm 2 ページ２００６年８月３日　木曜日　午前１１時４分
TECHNICAL DATA [WL-C, WE-C]

Item Specification
Starter no load test voltage 11 V
Starter no load test current 130 A or less
Starter pinion gap 0 mm {0 in}
Starter armature runout 0.1 mm {0.039 in} max.
Standard: 32 mm {1.26 in}
Starter commutator diameter
Segment groove depth of starter commutator
Starter brush length
Minimum: 11 mm {0.43 in}
Standard: 26.7—36.1 N {2.73—3.68 kgf, 6.01—8.11 lbf}
Starter brush spring force
Minimum: 14.7 N {1.5 kgf, 3.3 lbf}
Drive Belt Deflection

(mm {in})
Drive Belt * Used Limit
New
7.4—9.4 8.7—10.4
Generator 14.3 {0.56} or more
{0.30—0.37} {0.35—0.40}
6.1—6.9 7.1—8.0
a 11.3 {0.44} or more
{0.24—0.27} {0.28—0.31}
A/C
10.0—11.0 11.3—12.6
b 17.4 {0.69} or more
{0.40—0.43} {0.45—0.49}
* : A belt that has been on a running engine for less than five minutes.
Drive Belt Tension

(N {kgf, lbf})
490—637 431—539
Generator 225 {22.9, 50.6} or less
{50.0—64.9, 111—143} {44.0—54.9, 96.9—121}
455—572 353—431
A/C 181 {18.5, 40.7} or less
{46.4—58.3, 103—128} {36.0—43.9, 79.4—96.8}
*
Recommended engine oil

Item Specification
Grade API CF–4 or ACEA B1/B3/B5
Viscosity (SAE) 5W–30
Generator generated current (reference value) [Conditions] Ambient temperature: 20 °C {68 °F}, Voltage:
13.5 V, Engine hot
Engine speed (rpm) Terminal B current (Lower limit of current must be more than 0 A.)
1,000 0—55 A
2,000 0—70 A
End Of Sie
01-50B–2
F198-10-05L(02-11).fm 1 ページ２００６年８月１０日　木曜日　午後５時１５分
SUSPENSION 02
SECTION
Toc of SCTALIGNMENT . . . . . . . 02-11

WHEEL REAR SUSPENSION . . . . . . . . 02-14
WHEEL AND TIRES . . . . . . . . 02-12 TECHNICAL DATA . . . . . . . . . . 02-50
FRONT SUSPENSION. . . . . . . 02-13
Toc of SCT
02-11 WHEEL ALIGNMENT
VEHICLE HEIGHT ADJUSTMENT WHEEL ALIGNMENT PRE-INSPECTION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-11–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 02-11–2
FRONT WHEEL ALIGNMENT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 02-11–2
End of Toc
VEHICLE HEIGHT ADJUSTMENT[EVEREST]
WM: SUSPENSION
id021100800515
Caution
• If the vehicle height on a winch or towbar (bullbar or similar accessory) equipped vehicle is 02
adjusted, it is possible that the vehicle height will drop below specification again or the tires will
be subject to uneven wear. Without adjusting the vehicle height, adjust only the difference
between the left and right sides and perform a wheel alignment to specification.

2. Inspect the front and rear tire pressure and adjust it as necessary.
3. Measure the distance from the center of each
front wheel to the fender brim. MEASURING POINT
A
Standard vehicle height
502—542 mm {19.8—21.3 in} A
SEC.
A—A
Left/right difference
10 mm {0.39 in} max.
Caution
• Adjust the vehicle height at the left and
right wheels at the same time. Otherwise,
arnffw00001891
the vehicle height may not be adjusted
correctly.
4. If the difference between left and right is not

within the specification, adjust the vehicle height
by turning the torsion bar spring anchor bolt.
Note
• The vehicle height increases/decreases 3.3
mm {0.13 in} per anchor bolt rotation.
5. Move the vehicle forward and back to seat each

part.
6. Verify that the vehicle height is within the ANCHOR BOLT
standard.
• If not, readjust the vehicle height.
arnffw00001892
End Of Sie
02-11–1
WHEEL ALIGNMENT
WHEEL ALIGNMENT PRE-INSPECTION[EVEREST]
id021100800115
1. Inspect the tire pressure.
• Adjust to the recommended pressure if necessary. (See 02-50-1 SUSPENSION TECHNICAL
DATA[EVEREST].)
2. Inspect the wheel bearing play.
• Correct if necessary. (See 03-11-1 WHEEL HUB, STEERING KNUCKLE INSPECTION[EVEREST].)
3. Inspect the wheel runout.
• Correct if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA[EVEREST].)
4. Inspect the ball joints and steering linkage for excessive looseness.
5. Park the vehicle on a level ground, in an unloaded condition*, and with the wheels straight forward.
Unloaded vehicle.....Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are in
designated position.
6. Measure height H from the center of the wheel to FENDER BRIM
the fender brim. SEC. A-A MEASUREMENT POINT
7. Verify that the difference between the left and
A
right dimension H is within the specification.
• If it exceeds the specification, repeat the Step
2—6.
H
A
Standard
10 mm {0.39 in} or less
End Of Sie
arnffw00001894
FRONT WHEEL ALIGNMENT[EVEREST]

id021100800215
Front wheel alignment (Unloaded)

Item Specifications
Tire
Total toe-in (mm {in}) 6 {0.23}
[Tolerance ±3 {0.12}]
Inner 31°30′—35°30′
Maximum steering angle
Outer 27°00′—32°00′
Camber angle (reference value) [Tolerance ±1°] 0°45′
Caster angle (reference value) [Tolerance ±1°] 2°06′
Steering axis inclination (reference value) 10°35′
Note
• Unloaded vehicle: Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are
in designated position.
• Difference between the left and right dimension for camber is within 30′.
• Difference between the left and right dimension for caster is within 45′.
02-11–2
WHEEL ALIGNMENT
Maximum Steering Angle Adjustment
1. Remove the cap.
2. Loosen the adjusting bolt locknut.
3. Turn the adjusting bolt to provide the correct turning angle.
Standard steering angle

Inner: 31°30′—35°30′
Outer: 27°00′—32°00′
4. After adjustment, tighten the locknut to the

specified torque.
Tightening torque
39—59 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf}
5. Install the cap.
ADJUSTING BOLT
arnffw00001895
Caster and Camber Adjustment 02

1. Loosen the upper arm shaft bolt and insert or No.1—5
remove adjustment shims to provide the correct
No.6—11
angle.
Adjusting shim
No. Thickness (mm {in})
1 1.0 {0.039}
2 1.6 {0.063}
3 2.0 {0.079} FRONT
4 3.2 {0.126}
5 4.0 {0.157}
6 0.6 {0.024}
7 1.0 {0.039}
8 1.6 {0.063}
9 2.0 {0.079}
10 3.2 {0.126}
11 4.0 {0.157}
Note
• Shims No.1—5 are used on either side. Do
not use more than two.
• Shims No.6—11 are used at the front and
rear of either sides. Do not use more than arnffw00001896
one.
• Camber (Shims No.1—5): A change of shim
thickness of 1 mm {0.039 in} results as follows:
Shim thickness Variation/1 mm {0.039 in}
Add Negative 15′
Reduce Positive 15′
• Caster (Shims No.6—11): A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results as
follows:
Shim
Variation/1 mm {0.039 in}
thickness
Add Increase 30′
Front side
Reduce Decrease 30′
Add Decrease 30′
Rear side
Reduce Increase 30′
02-11–3
WHEEL ALIGNMENT
2. After adjustment, tighten the upper arm shaft bolt to the specified torque.
Tightening torque
150—172 N·m {15.3—17.5 kgf·m, 111—126 ft·lbf}
3. Confirm the front wheel alignment as in the specification.

• If not within the specification, adjust the front wheel alignment again.
Total Toe-in Adjustment

1. Loosen the tie-rod end locknuts.
2. Turn the tie rods by the same amount in the opposite direction.
Total Toe-in Standard

3—9 mm {0.12—0.35 in}
Note
• One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}.
• The left and right tie rods are both right threaded, to increase the toe-in, turn the right tie rod toward the
front of the vehicle and the left tie rod equally toward the rear.
3. Tighten the tie-rod end locknuts. TIE ROD
Tightening torque
68.6—78.5 N·m {7.00—8.00 kgf·m, 50.6—57.8
ft·lbf}
End Of Sie
arnffw00001897
02-11–4
F198-10-05L(02-12).fm 1 ページ２００６年８月３日　木曜日　午前１１時６分
WHEEL AND TIRES
02-12 WHEEL AND TIRES

WHEEL AND TIRE SPECIFICATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-12–1
End of Toc
WHEEL AND TIRE SPECIFICATION[EVEREST]
WM: WHEELS AND TIRES
id0212008001b4
Wheel and tires

Item Specification
Size 16 × 7J
Offset (mm {in}) 10 {0.39}
Wheel
Size 245/70R16 111S
Air pressure Front 210 {2.1, 30}
Tire
(kPa {kgf/cm2, psi}) Rear 220 {2.2, 32}
Remaining tread (mm {in}) 1.6 {0.06}
(N·m {kgf·m,
Lug nut tightening torque 88.2—117.6 {9.00—11.99, 65.06—86.73}
ft·lbf})
Wheel Wheel and tire runout Radial direction 1.5 {0.06} max. 02
and tire
(mm {in}) Lateral direction 2.0 {0.08} max.
Wheel imbalance*2 (g {oz}) 10 {0.35} max.
*1 : Total weight exceeds 120 g {4.24 oz}.

*2 : One balance weight: 60 g {2.12 oz} max. If the total weight exceeds 120 g {4.24 oz} on one side, rebalance
after moving the tire around on the rim. Do not use three or more balance weights.
End Of Sie
02-12–1
FRONT SUSPENSION
02-13 FRONT SUSPENSION

FRONT SUSPENSION LOCATION INDEX FRONT STABILIZER
[EVEREST [4x2]] . . . . . . . . . . . . . . . . . 02-13–1 REMOVAL/INSTALLATION
TORSION BAR SPRING AND LOWER ARM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 02-13–6
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-13–2
End of Toc
FRONT SUSPENSION LOCATION INDEX[EVEREST [4x2]]
WM: SUSPENSION
id0213008001a8
1 3
2
02
arnffw00001890
1 Front shock absorber 4 Front stabilizer

2 Torsion bar spring, lower arm (See 02-13-6 FRONT STABILIZER REMOVAL/
(See 02-13-2 TORSION BAR SPRING AND INSTALLATION[EVEREST].)
LOWER ARM REMOVAL/
INSTALLATION[EVEREST].)
3 Front upper arm
End Of Sie
02-13–1
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION[EVEREST]
id0213008030a7
1. Remove the ABS sensor wiring harness brackets
installed to the upper arm and steering knuckle,
then move aside the ABS sensor.
19—25
2. Remove in the order indicated in the table. {2.0—2.5,
3. Install in the reverse order of removal. 19—25
15—18}
{2.0—2.5,
4. Inspect the vehicle height and adjust it as 15—18}
necessary.
5. Inspect the front wheel alignment as necessary.

arnffw00001293
124—155
{12.7—15.8, 92—114}
9
38—52 8 6
{3.9—5.3, 7
29—38} 11
16
13
SEALANT
14 10
12
5
14
APPLY THREAD
118—157
13 157—209 LOCKING COMPOUND
{12.0—16.0, 87—116} {16.1—21.3, 116—154}
12 2
4
190—235 VEHICLE
FORWARD
{19.4—23.9, 1 R
141—173} DIRECTION
55—67
{5.6—6.9, 41—49}
INSERT COTTER PIN

FROM VEHICLE FORWARD
15 DIRECTION
SST 20 14
R 4 17 18 SST R
70—93
{7.2—9.4, 19 R 3 SST
52—68}
GREASE
arnffw00001294
1 Cotter pin 10 Torsion bar spring

2 Nut (See 02-13-3 Torsion Bar Spring Removal Note.)
(See 02-13-4 Torsion Bar Spring Installation Note.)
3 Front lower arm ball joint
11 Torque plate
4 Shock absorber lower bolt and nut
12 Lower arm spindle (rear), washer and nut
5 Anchor bolt
(See 02-13-5 Anchor Bolt Installation Note.) 13 Lower arm spindle (front), washer and nut
6 Anchor swivel 14 Stabilizer bolt, bushing, retainer, spacer and nut
7 Bolt and washer 15 Front lower arm
8 Torsion bar spring component 16 Bound stopper
9 Anchor arm 17 Front lower arm ball joint
(See 02-13-3 Anchor Arm Removal Note.) 18 Clip
(See 02-13-4 Anchor Arm Installation Note.) 19 Dust boot
02-13–2
FRONT SUSPENSION
20 Front lower arm bushing
(See 02-13-3 Front Lower Arm Bushing Removal
Note.)
(See 02-13-4 Front Lower Arm Bushing Installation
Note.)
Anchor Arm Removal Note

1. Mark the anchor arm and body for reference
during installation.
arnffw00001295
Torsion Bar Spring Removal Note

1. Mark the torsion bar spring and anchor arm, and
torsion bar spring and torque plate for reference 02
during installation.
arnffw00001296
Front Lower Arm Bushing Removal Note

1. Remove the front lower arm bushing using the
SST.
49 U034 2A0
arnffw00001297
02-13–3
FRONT SUSPENSION
Front Lower Arm Bushing Installation Note
1. Apply soapy water to the new bushing.
2. Install the bushing using the SST.
49 U034 2A0
arnffw00001298
Torsion Bar Spring Installation Note

1. Before installation, check the identification mark
on the end of the torsion bar spring.
OUT SIDE OUT SIDE

OF THE OF THE
VEHICLE VEHICLE
LEFT SIDE RIGHT SIDE
arnffw00001299
2. Align the marks made during removal, and

connect the torsion bar spring to the torque plate.
arnffw00001300
Anchor Arm Installation Note

1. Align the marks made during removal, and install
the anchor arm onto the torsion bar spring.
arnffw00001301
02-13–4
FRONT SUSPENSION
Anchor Bolt Installation Note
1. Install the anchor bolt, and tighten it until the
marks made during removal are aligned.
Note
• If the anchor bolt was not marked during
removal, install it as follows:
1. Lower the front suspension until the
upper arm contacts the rebound stopper.
arnffw00001302
2. Install the anchor arm so that the angle

A is 55°30′—64°30′.
End Of Sie
02
A
arnffw00001303
02-13–5
FRONT SUSPENSION
FRONT STABILIZER REMOVAL/INSTALLATION[EVEREST]
id0213008004a7
.
34.5—36.2
{2.50—3.69,
18.1—26.6}
2 4
7 5
8
22—26 6
{2.2—2.7,
16—19}
arnffw00001290
1 Nut 5 Retainer, bushing, and spacer

2 Retainer and bushing 6 Stabilizer bracket
3 Bolt 7 Stabilizer bushing
4 Retainer and bushing 8 Front stabilizer
End Of Sie
02-13–6
F198-10-05L(02-14).fm 1 ページ２００６年８月３日　木曜日　午前１１時７分
REAR SUSPENSION
02-14 REAR SUSPENSION

REAR SUSPENSION LOCATION INDEX REAR SHOCK ABSORBER AND LEAF
[RANGER [5R55S], EVEREST] . . . . . . 02-14–1 SPRING REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 02-14–2
End of Toc
REAR SUSPENSION LOCATION INDEX[RANGER [5R55S], EVEREST]
WM: REAR SUSPENSION
id0214008004a6
2
RANGER [4x2 (EXPECT Hi-Rider)]
02
RANGER [Hi-Rider, 4x4]

EVEREST
arnffw00001893
1 Leaf spring 2 Rear shock absorber

(See 02-14-2 REAR SHOCK ABSORBER AND 3 Rear stabilizer (WL-C and WE-C)
LEAF SPRING REMOVAL/
End Of Sie
02-14–1
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION[EVEREST]
id0214008040a7
Warning
• Use safety stands for support of the left and right axle casings, and while supporting the
differential casing with a jack, raise or lower the jack as necessary.
1. Support the frame with safety stands and place a jack under the differential casing.
4. After installation, tighten the bolt (leaf spring front side) completely on the ground.
APPLY THREAD
LOCKING COMPOUND 99—113 10
GREASE
{10.1—11.5,
73.1—83.3} 13 R
7 11
4
2
A 8
59—78 {6.1—7.9, 44—57}

3
12
64—78 1
{6.6—7.9,
48—57}
78—98
{8.0—9.9, 58—72}
13
GREASE
6
R 9
A
5
20—26
{2.1—2.6,
15—19}
arnffw00001308
1 Bolt, washer and nut 8 Bound stopper

2 Nut, washer, and retainer 9 Bolt
3 Shock absorber 10 Shackle pin
4 Nut and washer 11 Shackle plate
5 U-bolt 12 Leaf spring component
6 Set plate 13 Leaf spring bushing
7 Spring clamp
End Of Sie
02-14–2
TECHNICAL DATA
02-50 TECHNICAL DATA

SUSPENSION TECHNICAL DATA
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 02-50–1
End of Toc
SUSPENSION TECHNICAL DATA[EVEREST]
WM: SUSPENSION
id025000800103
Front wheel alignment (Unloaded)
Item Specifications
Tire
Total toe-in (mm {in}) 6 {0.23}
[Tolerance ±3 {0.12}]
Inner 31°30′—35°30′
Maximum steering angle
Outer 27°00′—32°00′
Camber angle (reference value) [Tolerance ±1°] 0°45′
Caster angle (reference value) [Tolerance ±1°] 2°06′
Steering axis inclination (reference value) 10°35′
Note
• Unloaded vehicle: Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are
in designated position.
• Difference between the left and right dimension for camber is within 30′. 02
• Difference between the left and right dimension for caster is within 45′.
Wheel and tires

Item Specification
Size 16 × 7J
Offset (mm {in}) 10 {0.39}
Wheel
Size 245/70R16 111S
Air pressure Front 210 {2.1, 30}
Tire
(kPa {kgf/cm2, psi}) Rear 220 {2.2, 32}
Remaining tread (mm {in}) 1.6 {0.06}
(N·m {kgf·m,
Lug nut tightening torque 88.2—117.6 {9.00—11.99, 65.06—86.73}
ft·lbf})
Wheel Wheel and tire runout Radial direction 1.5 {0.06} max.
and tire
(mm {in}) Lateral direction 2.0 {0.08} max.
Wheel imbalance*2 (g {oz}) 10 {0.35} max.
*1 : Total weight exceeds 120 g {4.24 oz}.

*2 : One balance weight: 60 g {2.12 oz} max. If the total weight exceeds 120 g {4.24 oz} on one side, rebalance
after moving the tire around on the rim. Do not use three or more balance weights.
End Of Sie
02-50–1
F198-10-05L(03-02).fm 1 ページ２００６年８月１１日　金曜日　午前１１時３分
DRIVELINE/AXLE 03
SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC DIFFERENTIAL. . . . . . . . . . . . . 03-14
[4x4 control module] . . . . . . 03-02 PROPELLER SHAFT[5AT]. . . . 03-15
SYMPTOM TRANSFER[5R55S] . . . . . . . . . 03-16
TROUBLESHOOTING 4-WHEEL DRIVE . . . . . . . . . . . 03-18
[4x4 control module] . . . . . . 03-03 TECHNICAL DATA . . . . . . . . . . 03-50
FRONT AXLE. . . . . . . . . . . . . . 03-11 SERVICE TOOLS . . . . . . . . . . . 03-60
REAR AXLE. . . . . . . . . . . . . . . 03-12
Toc of SCT
03-02 ON-BOARD DIAGNOSTIC [4x4 control module]
4x4 CONTROL SYSTEM WIRING DIAGRAM DTC No.3 [4x4 control module] . . . . . . . 03-02–6
[4x4 control module]. . . . . . . . . . . . . . 03-02–2 DTC No.4 [4x4 control module] . . . . . . . 03-02–8
4x4 CONTROL SYSTEM ON-BOARD DTC No.5 [4x4 control module] . . . . . . . 03-02–9
DIAGNOSIS [4x4 control module]. . . . 03-02–2 DTC No.6 [4x4 control module] . . . . . . . 03-02–11
DTC No.1 [4x4 control module]. . . . . . . 03-02–4 DTC No.7 [4x4 control module] . . . . . . . 03-02–12
DTC No.2 [4x4 control module]. . . . . . . 03-02–5
End of Toc
WM: DIFFERENTIAL (FF/FR)
03
03-02–1
F198-10-05L(03-02).fm 2 ページ２００６年８月１０日　木曜日　午後５時５６分
ON-BOARD DIAGNOSTIC [4x4 control module]

4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]
id0302a1801500
4x4
B+ CONTROL
IG1
MODULE
TRANSFER CASE
Y T
U C
Z CLUTCH COIL
TCM N A SENSOR
BA R 4x4 HI
MOTOR COMPONENT
DLC Q
G
4x4 SWITCH J E
4x2 HI POSITION 1
A G
4x4 HI I B
D
4x4 LO POSITION 2
C F
L A
F POSITION 3
H D
POSITION 4
A
B C
B V
LOCK SOLENOID
A
C F
A E D
D
B X
B+
4x4 RELAY W
A B
FREE SOLENOID
arnffw00001937
End Of Sie
4x4 CONTROL SYSTEM ON-BOARD DIAGNOSIS[4x4 control module]
id0302a1801600
Reading DTC procedure
1. Turn the engine switch off.
2. Connect an inspection lamp to the DLC terminal
FAT and battery.
3. Turn the engine switch to the ON position.
(Engine off)
4. The inspection lamp will indicate a DTC by DLC
flashing.
INSPECTION LAMP
Note
• A verified DTC is flashed 3 times repeatedly
by the inspection lamp.
• If more than one DTC is detected, the first FAT
DTC is displayed, and then next one is
displayed.
5. Repair the malfunctioning part using the verified

BATTERY
DTC.
6. After completion of repairs, clear all DTCs from
memory. arnffw00001958
03-02–2

Clearing DTC procedure
1. Turn the engine switch off.
2. Attach a jumper wire to the DLC terminal FAT and
DLC
ground. JUMPER
3. Turn the engine switch to the ON position. WIRE
(Engine off)
4. Turn the engine switch off after 5 s or more has FAT
elapsed.
5. Remove the jumper wire.
6. Verify that the same DTC is not present.
BODY GROUND
arnffw00001899
DTC Table
DTC
Inspection lamp flashing pattern Possible cause Page
No.
1 ENGINE SWITCH ON DEFECTIVE CODE 4x4 control module (See DTC No.1 [4x4
malfunction control module].)
0.5 sec.
0.6 sec. 1 sec.
ON
OFF
3 sec. 0.5 sec. 3 sec.
2 ENGINE SWITCH ON DEFECTIVE CODE Motor component (See DTC No.2 [4x4
0.5 sec.
(shift motor) control module].) 03
0.6 sec. 1 sec. 0.5 sec. malfunction
ON
OFF
3 sec. 0.5 sec. 0.5 sec. 3 sec.
3 ENGINE SWITCH ON DEFECTIVE CODE Clutch coil (See DTC No.3 [4x4
0.5 sec.
0.6 sec. 1 sec. 1 sec.
ON
OFF
3 sec. 0.5 sec. 0.5 sec. 3 sec.
4 ENGINE SWITCH ON DEFECTIVE CODE Speed sensor (See DTC No.4 [4x4
0.5 sec.
0.6 sec. 1 sec.
ON
OFF
3 sec. 3 sec.
0.5 sec.
5 ENGINE SWITCH ON DEFECTIVE CODE Solenoid valve (See DTC No.5 [4x4
0.6 sec. 1 sec. 0.5 sec. 1 sec.
ON
OFF
3 sec. 3 sec.
0.5 sec.
6 ENGINE SWITCH ON DEFECTIVE CODE 4x4 switch (See DTC No.6 [4x4
0.6 sec. 1 sec. 1 sec. 0.5 sec.
ON
OFF
3 sec. 3 sec.
0.5 sec.
7 ENGINE SWITCH ON DEFECTIVE CODE Motor component (See DTC No.7 [4x4
(position sensor) control module].)
0.6 sec. 1 sec. 1 sec. 1 sec. malfunction
ON
OFF
3 sec. 3 sec.
0.5 sec.
End Of Sie
03-02–3

DTC No.1 [4x4 control module]
id0302a1801700
DTC No.1 4x4 CM malfunction

DETECTION
• Open circuit or short to ground has been detected in the 4x4 CM wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals T, Y, Z and
battery
POSSIBLE
• Open circuit in the wiring harness between the following 4x4 CM terminals W, X and ground
CAUSE
• 4x4 CM malfunction
• Poor connection at connector (female terminal)
ENGINE SWITCH
BATTERY
W X Y Z T
4x4 CM
4x4 CM
WIRING HARNESS-SIDE CONNECTOR
Y W U S Q O M K I G E C A
Z X V T R P N L J H F D B
Diagnostic procedure
STEP INSPECTION ACTION
1 MEASURE VOLTAGE BETWEEN 4x4 CONTROL Yes Go to the next step.
MODULE CONNECTOR TERMINAL T, Y, Z AND No Repair or replace the wiring harness, then go to step 3.
GROUND
• Turn engine switch ON.
• Is the voltage greater than 10 V?
2 INSPECT FOR CONTINUITY BETWEEN 4x4 Yes Go to the next step.
CONTROL MODULE CONNECTOR TERMINAL No Repair or replace the wiring harness, then go to next step.
W, X AND GROUND
• Turn engine switch OFF.
• Is there continuity?
3 VERIFY THAT THE SAME DTC IS NOT Yes If the malfunction recurs, replace the 4x4 CM, then go to
PRESENT the next step.
• Clear the DTCs from the memory. (See 03-18-5 4x4 CONTROL MODULE REMOVAL/
(See 03-02-2 4x4 CONTROL SYSTEM ON- INSTALLATION [AT (5R55S)].)
BOARD DIAGNOSIS[4x4 control module].) No Go to the next step.
• Are any DTCs present?
2 VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.
• Are any DTCs present? (See 03-02-2 4x4 CONTROL SYSTEM ON-BOARD
DIAGNOSIS[4x4 control module].)
No Troubleshooting completed.
End Of Sie
03-02–4

id0302a1801800
DTC No.2 Motor component (shift motor) malfunction

DETECTION
• Open circuit or short to ground has been detected in the motor component (shift motor) wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (shift motor) terminals:
— 4x4 CM terminal A— motor component (shift motor) terminal C
POSSIBLE — 4x4 CM terminal B— motor component (shift motor) terminal C
CAUSE — 4x4 CM terminal C— motor component (shift motor) terminal F
— 4x4 CM terminal D— motor component (shift motor) terminal F
• Motor component (shift motor) malfunction
4x4 CM TRANSFER CASE
MOTOR COMPONENT
A
B C
C F
4x4 CM MOTOR COMPONENT

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR
03
E B
Z X V T R P N L J H F D B G D A
F C
1 INSPECT MOTOR COMPONENT (SHIFT Yes Go to the next step.
MOTOR) No Replace the motor component, then go to step 4.
• Turn the engine switch off.
• Inspect the motor component (shift motor).
(See 03-16-4 MOTOR INSPECTION [5R55S].)
• Is the motor component (shift motor)?
2 INSPECT MOTOR COMPONENT (SHIFT Yes Repair or replace the wiring harness, then go to Step 4.
MOTOR) WIRING HARNESS FOR SHORT TO No Go to the next step.
GROUND
• Disconnect the 4x4 CM connector.
• Disconnect the motor component connector.
• Inspect for continuity between the motor
component connector terminals A, B, C, D
(vehicle harness-side) and body ground.
03-02–5

3 INSPECT MOTOR COMPONENT (SHIFT Yes Go to the next step.
MOTOR) WIRING HARNESS FOR OPEN No Repair or replace the wiring harness, then go to next step.
CIRCUIT
• Inspect for continuity between the 4x4 CM
connector (vehicle harness-side) and the
following vehicle harness-side terminals of
motor component:
— 4x4 CM connector A— Motor component
(shift motor) terminal C
— 4x4 CM connector B— Motor component
(shift motor) terminal C
— 4x4 CM connector C— Motor component
(shift motor) terminal F
— 4x4 CM connector D— Motor component
(shift motor) terminal F
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the 4x4 CM, then go to
• Reconnect all disconnected connectors. the next step.
• Change the current transfer mode by operating
the 4x4 switch.(2H-4H-4L)
End Of Sie
id0302a1801900
DTC No.3 Clutch coil malfunction

DETECTION
• Open circuit, short to ground or short to battery has been detected in the clutch coil wiring harness.
CONDITION
• Open circuit in the wiring harness between 4x4 CM terminal U and clutch coil terminal C, short to battery or
POSSIBLE to ground
CAUSE • Clutch coil malfunction
U C CLUTCH COIL
4x4 CM SPEED SENSOR

C B A
03-02–6

1 INSPECT CLUTCH COIL Yes Go to the next step.
• Turn the engine switch off. No Replace the clutch coil, then go to step 5.
• Inspect the clutch coil.
(See 03-16-6 CLUTCH COIL INSPECTION
[5R55S].)
• Is the clutch coil normal?
2 INSPECT CLUTCH COIL WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 5.
FOR SHORT TO GROUND No Go to the next step.
• Disconnect the clutch coil connector.
connector terminal U (vehicle harness-side)
and body ground.
3 INSPECT CLUTCH COIL WIRING HARNESS Yes Go to the next step.
FOR SHORT TO POWER SUPPLY CIRCUIT No Repair or replace the wiring harness, then go to step 5.
• Measure voltage between the clutch coil
connector terminal C (vehicle harness-side)
and body ground.
• Is the voltage 1 V or less?
4 INSPECT CLUTCH COIL WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 5.
connector U (vehicle harness-side) and the
vehicle harness-side terminal C of clutch coil.
• Is there continuity? 03
5 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from step 1.
the 4x4 switch.(2H-4H)
End Of Sie
03-02–7

id0302a1802000
DTC No.4 Speed sensor malfunction

DETECTION
• Open circuit or short to ground has been detected in the speed sensor wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the
speed sensor terminals:
POSSIBLE — 4x4 CM terminal M— speed sensor terminal B
CAUSE — 4x4 CM terminal N— speed sensor terminal A
• Speed sensor malfunction
M B SPEED
N A SENSOR
4x4 CM SPEED SENSOR

C B A
1 INSPECT SPEED SENSOR Yes Go to the next step.
• Turn the engine switch off. No Replace the speed sensor, then go to step 4.
• Inspect the speed sensor. (See 03-16-4 SPEED SENSOR REMOVAL/INSTALLATION
(See 03-16-3 SPEED SENSOR INSPECTION [5R55S].)
[5R55S].)
• Is the speed sensor normal?
2 INSPECT SPEED SENSOR WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 4.
• Disconnect the speed sensor connector.
connector terminals M, N (vehicle harness-
side) and body ground.
3 INSPECT SPEED SENSOR WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to next step.
speed sensor:
— 4x4 CM connector M— speed sensor
terminal B
— 4x4 CM connector N— speed sensor
terminal A
03-02–8

End Of Sie
id0302a1802100
DTC No.5 Solenoid valve malfunction

DETECTION
• Open circuit or short to ground has been detected in the solenoid valve wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the lock solenoid
valve terminal B
• Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the 4x4 relay
terminal E
• Open circuit or short to ground in the wiring harness between the free solenoid valve terminal B and the
POSSIBLE
4x4 relay terminal B
CAUSE
• Open circuit in the wiring harness between the lock solenoid valve terminal A and ground
• Open circuit in the wiring harness between the 4x4 relay terminal A, D and ground
• Open circuit in the wiring harness between the free solenoid valve terminal A and battery
• lock solenoid malfunction
B
LOCK SOLENOID 4x4 CM
A
ENGINE SWITCH
A E
V
03
BATTERY
D
B
4x4 RELAY
A B
FREE SOLENOID
4x4 CM 4x4 RELAY WIRING LOCK AND FREE SOLENOID

WIRING HARNESS-SIDE CONNECTOR HARNESS-SIDE VALVES WIRING HARNESS-SIDE
CONNECTOR CONNECTOR
Y W U S Q O M K I G E C A E B A
C B A
D
1 INSPECT SOLENOID VALVE WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 6.
• Turn the engine switch off.
• Disconnect the lock solenoid connector.
• Disconnect the 4x4 relay connector.
connector terminal V (vehicle harness-side)
and body ground.
• Inspect for continuity between the 4x4 relay
connector terminal B (vehicle harness-side)
and body ground.
03-02–9

2 INSPECT SOLENOID VALVE WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 6.
and the vehicle harness-side terminal B of lock
solenoid.
and the vehicle harness-side terminal E of 4x4
relay.
• Inspect for continuity between the lock solenoid
connector terminal A (vehicle harness-side)
and body ground.
• Inspect for continuity between the 4x4 relay
connector terminals A, D (vehicle harness-
• Inspect for continuity between the free solenoid
connector terminal B (vehicle harness-side)
and the vehicle harness-side terminal B of 4x4
relay.
3 MEASURE VOLTAGE BETWEEN FREE Yes Go to the next step.
SOLENOID VALVE CONNECTOR TERMINAL A No Repair or replace the wiring harness, then go to step 6.
AND GROUND
4 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the lock and free solenoid valves. No Replace the solenoid valve, then go to the step 6.
• Is the lock and free solenoid valves normal?
5 INSPECT 4x4 RELAY Yes Go to the next step.
• Inspect the 4x4 relay. No Replace the 4x4 relay, then go to the next step.
• Is the 4x4 relay normal?
the 4x4 switch.(2H-4H)
End Of Sie
03-02–10

id0302a1802200
DTC No.6 4x4 switch malfunction

DETECTION
• Open circuit or short to ground has been detected in the 4x4 switch wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the 4x4
switch terminals:
POSSIBLE — 4x4 CM terminal G— 4x4 switch terminal A
CAUSE — 4x4 CM terminal F— 4x4 switch terminal C
• 4x4 switch malfunction
4x4 CM 4x4 SWITCH
4x2 HI
G A
4x4 HI
D
4x4 LO
F C
4x4 CM 4x4 SWITCH

Y W U S Q O M K I G E C A E C A
Z X V T R P N L J H F D B F D B 03
1 INSPECT 4x4 SWITCH Yes Go to the next step.
• Turn the engine switch off. No Replace the 4x4 switch, then go to step 4.
• Inspect the 4x4 switch. (See 03-18-3 4x4 SWITCH REMOVAL/INSTALLATION [AT
(See 03-18-2 4x4 SWITCH INSPECTION [AT (5R55S)].)
(5R55S)].)
• Is the 4x4 switch normal?
2 INSPECT 4x4 SWITCH WIRING HARNESS FOR Yes Repair or replace the wiring harness, then go to step 4.
SHORT TO GROUND No Go to the next step.
• Disconnect the 4x4 switch connector.
connector terminals G, F (vehicle harness-
3 INSPECT 4x4 SWITCH WIRING HARNESS FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 4.
following vehicle harness-side terminals of 4x4
switch:
— 4x4 CM connector G— 4x4 switch terminal
A
— 4x4 CM connector F— 4x4 switch terminal
C
03-02–11

• Clear the DTCs from the memory. (See 03-18-3 4x4 SWITCH REMOVAL/INSTALLATION [AT
(See 03-02-2 4x4 CONTROL SYSTEM ON- (5R55S)].)
End Of Sie
id0302a1802300
DTC No.2 Motor component (position sensor) malfunction

DETECTION • Open circuit or short to ground has been detected in the motor component (position sensor) wiring
CONDITION harness.
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (position sensor) terminals:
— 4x4 CM terminal N— motor component (position sensor) terminal G
— 4x4 CM terminal J— motor component (position sensor) terminal E
POSSIBLE
— 4x4 CM terminal I— motor component (position sensor) terminal B
CAUSE
— 4x4 CM terminal L— motor component (position sensor) terminal A
— 4x4 CM terminal H— motor component (position sensor) terminal D
• Motor component (position sensor) malfunction
M B SPEED
N A SENSOR
MOTOR COMPONENT
J E
POSITION 1
I B
POSITION 2
L A
POSITION 3
H D
POSITION 4
4x4 CM MOTOR COMPONENT

E B
Z X V T R P N L J H F D B G D A
F C
03-02–12

1 INSPECT MOTOR COMPONENT (POSITION Yes Go to the next step.
SENSOR) No Replace the motor component, then go to the next step.
• Turn the engine switch off. (See 03-16-5 MOTOR REMOVAL/INSTALLATION
• Inspect the Motor component (position sensor) [5R55S].)
(See 03-16-4 MOTOR INSPECTION [5R55S].)
• Is the Motor component (position sensor)
normal?
2 INSPECT MOTOR COMPONENT (POSITION Yes Repair or replace the wiring harness, then go to step 4.
SENSOR) FOR SHORT TO GROUND No Go to the next step.
• Disconnect the motor component connector.
• Inspect for continuity between the motor
component connector terminals N, J, I, L, H
(vehicle harness-side) and body ground.
3 INSPECT MOTOR COMPONENT (POSITION Yes Go to the next step.
SENSOR) WIRING HARNESS FOR OPEN No Repair or replace the wiring harness, then go to step 4.
CIRCUIT
motor component:
— 4x4 CM connector N— Motor component
terminal G
— 4x4 CM connector J— Motor component
terminal E
— 4x4 CM connector I— Motor component
03
terminal B
— 4x4 CM connector L— Motor component
terminal A
— 4x4 CM connector H— Motor component
terminal D
End Of Sie
03-02–13
F198-10-05L(03-03).fm 1 ページ２００６年８月１０日　木曜日　午後５時１７分
SYMPTOM TROUBLESHOOTING [4x4 control module]
03-03 SYMPTOM TROUBLESHOOTING [4x4 control

module]
4x4 CONTROL SYSTEM WIRING DIAGRAM NO.2 4x4/4L INDICATOR DOSE NOT
[4x4 control module] . . . . . . . . . . . . . . 03-03–1 ILLUMINATE [4x4 control module] . . . 03-03–5
PRECAUTION [4x4 control module] . . . 03-03–2 NO.3 NO CHANGE FORM 4x2 TO 4x4
SYMPTOM TROUBLESHOOTING [4x4 control module] . . . . . . . . . . . . . . . 03-03–6
[4x4 control module] . . . . . . . . . . . . . . 03-03–2 NO.4 NO CHANGE FORM 4H TO 4L
NO.1 NO RFW OPERATION [4x4 control module] . . . . . . . . . . . . . . . 03-03–7
[4x4 control module] . . . . . . . . . . . . . . 03-03–3 NO.5 NOISE [4x4 control module] . . . . . 03-03–9
NO.6 OIL LEAKAGE
[4x4 control module] . . . . . . . . . . . . . . . 03-03–10
End of Toc
4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]
id030310802800
4x4
B+ CONTROL
IG1
MODULE
TRANSFER CASE
Y T
U C
Z CLUTCH COIL
TCM
BA R 4x4 HI
N A SENSOR
03
MOTOR COMPONENT
DLC Q
G
4x4 SWITCH J E
4x2 HI POSITION 1
A G
4x4 HI I B
D
4x4 LO POSITION 2
C F
L A
F POSITION 3
H D
POSITION 4
A
B C
B V
LOCK SOLENOID
A
C F
A E D
D
B X
B+
4x4 RELAY W
A B
FREE SOLENOID
arnffw00001937
End Of Sie
03-03–1

PRECAUTION [4x4 control module]
id030310801500
• This section only mentions unique symptoms of the trouble caused by 4x4 system.
Inspect and repair if necessary for trouble caused by other sources.
• Inspect the connector and terminal connections when inspecting the wiring harness.
(The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harness.)
Quick Diagnosis Chart
x: Applicable
Possible factor
Conventional front differential parts

Motor component (position sensor)
Digital TR sensor (neutral signal)
Related fuse and/or harnesses

Motor component (shift motor)
One-way check valve

Transfer drive chain
Lock solenoid valve

Free solenoid valve
4x4 control module
Joint shaft bearing

Instrument cluster
RFW control box
RFW control box

Transfer bearing
RFW actuator
Vacuum hose
Transfer case
Tire pressure
Transfer gear
Sealing bolts
4x4 switch
Joint shaft
RFW hub
Breather
Oil level
Oil seal
TCM
Troubleshooting item
1 No RFW operation X X X X X X X X X X X X
2 4x4/4L indicator dose not illuminate X X X
3 No change from 4x2 to 4x4 X X X X X X
4 No change from 4H to 4L X X X X X X
5 Noise X X X X X X X X X
6 Oil leakage X X X X X X X X
arnffw00001938
End Of Sie
id030310800300
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom Description
1 • Motor component (position sensor) malfunction
• 4x4 control module malfunction
• Lock solenoid valve malfunction
No RFW operation • Free solenoid valve malfunction
• RFW actuator malfunction
• RFW control box malfunction
• One-way check valve malfunction
• Air leakage from vacuum hose
• Related fuses and /or harnesses malfunction
2 • Instrument cluster malfunction
4x4/4L indicator dose not illuminate • TCM malfunction
• TCM malfunction
No change form 4x2 to 4x4
• Drive chain malfunction
• TCM malfunction
No change form 4H to 4L
• Digital TR sensor malfunction
03-03–2

No. Symptom Description
5 • Joint shaft bearing abrasion or damage
• RFW hub abrasion
• Joint shaft abrasion
• Conventional front differential parts malfunction
Noise • Incorrect tire pressure
• Improper oil level
• Transfer bearing damaged
• Transfer gear damaged
• Transfer drive chain damaged
6 • RFW control box malfunction
• Transfer case malfunction
Oil leakage • Improper oil level
• Loosened sealing bolts
• Breather clogging
• Improper oil seal
End Of Sie
NO.1 NO RFW OPERATION [4x4 control module]
WM: ELECTRONIC 4WD CONTROL SYSTEM
id030310802000
1 NO RFW OPERATION
DESCRIPTION RFW dose not change from lock to free or from free to lock.
TROUBLESHO
• Lock solenoid valve malfunction
• Free solenoid valve malfunction
03
OTING HINTS
• RFW actuator malfunction
• One-way check valve malfunction
• Air leakage from vacuum hose
• Related fuses and/or harnesses malfunction
1 MEASURE VOLTAGE BETWEEN FREE Yes Connect free solenoid valve, then go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Repair wiring harness between main relay and free solenoid
A AND GROUND valve connector.
• Disconnect free solenoid valve connector. Then go to Step 14.
• Measure voltage between free solenoid valve
connector terminal A and ground.
2 MEASURE VOLTAGE BETWEEN FREE Yes Go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect free solenoid valve.
B AND GROUND Then go to Step 14.
3 MEASURE VOLTAGE BETWEEN 4x4 Yes Go to next step.
CONTROL MODULE CONNECTOR No Repair wiring harness between free solenoid valve and 4x4
TERMINAL V AND GROUND control module.
• Is the voltage greater than 10 V? Then go to Step 14.
4 MEASURE VOLTAGE BETWEEN LOCK Yes Connect lock solenoid valve, then go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Repair wiring harness between main relay and lock solenoid
A AND GROUND valve connector.
• Disconnect free solenoid valve connector. Then go to Step 14.
• Measure voltage between free solenoid valve
connector terminal A and ground.
5 MEASURE VOLTAGE BETWEEN LOCK Yes Go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect lock solenoid valve.
B AND GROUND Then go to Step 14.
03-03–3

CONTROL MODULE CONNECTOR No Repair wiring harness between lock solenoid valve and 4x4
TERMINAL V AND GROUND control module.
• Is the voltage greater than 10 V? Then go to Step 14.
7 INSPECT FOR CONTINUITY BETWEEN 4x4 Yes Go to next step.
CONTROL MODULE CONNECTOR No Repair wiring harness between 4x4 control module and
TERMINAL W, X AND GROUND ground.
• Turn engine switch OFF. Then go to Step 14.
CONTROL MODULE CONNECTOR No Repair related wiring harness and related fuses.
TERMINAL T, Y, Z AND GROUND Then go to Step 14.
9 INSPECT 4x4 SWITCH Yes Go to next step.
• Is 4x4 switch OK? No Repair or replace 4x4 switch.
Then go to step 14.
10 INSPECT CONTINUITY FOR 4x4 SWITCH Yes Go to next step.
• Between 4x4 switch connector terminal A No Repair wiring harness between 4x4 switch and 4x4 control
and 4x4 control module terminal G. module.
• Between 4x4 switch connector terminal C Then go to Step 14.
and 4x4 control module terminal F.
• Between 4x4 switch connector terminal F
and ground.
11 INSPECT ONE-WAY CHECK VALVE Yes Go to next step.
• Is one-way check valve OK? No Replace one-way check valve.
Then go to step 14.
12 INSPECT RFW ACTUATOR Yes Go to next step.
• Is RFW actuator OK? No Replace RFW actuator.
Then go to step 14.
13 INSPECT VACUUM HOSE Yes Go to next step.
• Is vacuum hose OK? No Repair or Replace vacuum hose.
Then go to step 14.
14 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 control module.
End Of Sie
03-03–4

NO.2 4x4/4L INDICATOR DOSE NOT ILLUMINATE [4x4 control module]
id030310802600
2 4x4/4L INDICATOR DOSE NOT ILLUMINATE

DESCRIPTION 4x4/4L indicator dose not illuminate when select 4H or 4L position.
• Instrument cluster malfunction
TROUBLESHO
• TCM malfunction
OTING HINTS
1 INSPECT CONTINUITY FOR 4x4 CONTROL Yes Go to next step.
MODULE AND TCM No Repair wiring harness between 4x4 control module terminal
• Between 4x4 control module terminal S and and TCM.
TCM terminal BB. Then go to Step 5.
• Between 4x4 control module terminal R and
TCM terminal BA.
2 INSPECT CONTINUITY FOR TCM AND Yes Inspect the instrument cluster.
INSTRUMENT CLUSTER Then go to next step.
• Between TCM terminal N and instrument No Repair wiring harness between TCM and instrument cluster.
cluster terminal 1D. Then go to Step 5.
• Between TCM terminal R and instrument
cluster terminal 1F.
TERMINAL W, X AND GROUND
• Turn engine switch OFF.
ground.
Then go to Step 5.
03
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
03-03–5

NO.3 NO CHANGE FORM 4x2 TO 4x4 [4x4 control module]
id030310802700
3 NO CHANGE FORM 4x2 TO 4x4

DESCRIPTION 4x4 system dose not operate when select 4H position.
TROUBLESHO • TCM malfunction
OTING HINTS • 4x4 control module malfunction
• Drive chain malfunction
Then go to step 10.
AND 4x4 CONTROL MODULE No Repair wiring harness between 4x4 switch and 4x4 control
• Between 4x4 switch connector terminal A module.
and 4x4 control module terminal G. Then go to Step 10.
• Between 4x4 switch connector terminal C
and ground.
MODULE AND MOTOR COMPONENT (SHIFT No Repair wiring harness between 4x4 control module and
MOTOR) transfer case connector.
• Between 4x4 control module connector Then go to Step 10.
terminal A, B and transfer case connector
terminal C.
• Between 4x4 control module connector
terminal C, D and transfer case connector
terminal F.
4 INSPECT MOTOR COMPONENT (SHIFT Yes Go to next step.
MOTOR) No Repair or replace motor component.
• Is motor component (shift motor) OK? Then go to Step 10.
MODULE AND MOTOR COMPONENT No Repair wiring harness between 4x4 control module and
(POSITION SENSOR) transfer case connector.
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
6 INSPECT MOTOR COMPONENT (POSITION Yes Go to next step.
SENSOR) No Repair or replace motor component.
• Is motor component (position sensor) OK? Then go to Step 10.
03-03–6

9 INSPECT TRANSFER Yes Go to next step.
• Is transfer OK? No Overhaul and check for wear and damage.
Replace if necessary.
Then go to Step 10.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
End Of Sie
NO.4 NO CHANGE FORM 4H TO 4L [4x4 control module]
id030310802900
4 NO CHANGE FORM 4H TO 4L
DESCRIPTION No change form 4H to 4L at neutral position.
TROUBLESHO • TCM malfunction
OTING HINTS • 4x4 control module malfunction
03
Then go to step 11.
AND 4x4 CONTROL MODULE No Repair wiring harness between 4x4 switch and 4x4 control
• Between 4x4 switch connector terminal A module.
and 4x4 control module terminal G. Then go to Step 11.
• Between 4x4 switch connector terminal B
and ground.
3 INSPECT DIGITAL TR SENSOR Yes Go to next step.
• Is digital TR sensor OK? No Repair or replace digital TR sensor.
Then go to step 11.
4 INSPECT CONTINUITY FOR DIGITAL TR Yes Go to next step.
SENSOR AND 4x4 CONTROL MODULE No Repair wiring harness between digital TR sensor and 4x4
• Between digital TR sensor connector control module.
terminal J and 4x4 control module terminal Then go to Step 11.
E.
MODULE AND MOTOR COMPONENT (SHIFT No Repair wiring harness between 4x4 control module and
MOTOR) transfer case connector.
terminal A, B and transfer case connector
terminal C.
terminal C, D and transfer case connector
terminal F.
6 INSPECT MOTOR COMPONENT (SHIFT Yes Go to next step.
MOTOR) No Repair or replace motor component.
• Is motor component (shift motor) OK? Then go to Step 11.
03-03–7

MODULE AND MOTOR COMPONENT No Repair wiring harness between 4x4 control module and
(POSITION SENSOR) transfer case connector.
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
8 INSPECT MOTOR COMPONENT (POSITION Yes Go to next step.
SENSOR) No Repair or replace motor component.
• Is motor component (position sensor) OK? Then go to Step 11.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
End Of Sie
03-03–8

NO.5 NOISE [4x4 control module]
id030310802400
5 NOISE
DESCRIPTION Noise is heard from front differential or transfer case.
• Joint shaft bearing abrasion or damage
• RFW hub abrasion
• Joint shaft abrasion
TROUBLESHO
• Incorrect tire pressure
OTING HINTS
• Transfer bearing damaged
• Transfer gear damaged
• Transfer drive chain damaged
1 INSPECT JOINT SHAFT BEARING Yes Go to next step.
• Is it OK? No Replace joint shaft bearing.
2 INSPECT RFW HUB Yes Go to next step.
• Is it OK? No Replace RFW hub.
3 INSPECT JOINT SHAFT Yes Go to next step.
• Is it OK? No Replace joint shaft.
4 INSPECT CONVENTIONAL FRONT Yes Go to next step.
DIFFERENTIAL PARTS No Replace defective part (s).
• Are they OK?
5 INSPECT TIRE PRESSURE
• Are they OK?
Yes
No
Go to next step.
Adjust the tire pressure.
03
6 INSPECT TRANSFER OIL LEVEL Yes Go to next step.
• Is oil level OK? No Adjust the oil level.
7 INSPECT TRANSFER INNER PARTS Yes Go to next step.
• Transfer bearing No Overhaul and check for wear and damage.
• Transfer gear Replace if necessary.
• Transfer drive chain
• Are they OK?
• If the vehicle is not repaired or additional diagnostic information is not available.
End Of Sie
03-03–9

NO.6 OIL LEAKAGE [4x4 control module]
id030310802500
6 OIL LEAKEGE
DESCRIPTION The oil leaks from front differential or transfer case.
• Transfer case malfunction
TROUBLESHO
OTING HINTS
• Loosened sealing bolts
• Breather clogging
• Improper oil seal
1 VERIFY RFW CONTROL BOX INSTALLATION Yes Go to next step.
CONDITION No Install RFW control box securely, then go to Step.
• Is RFW control box installed completely?
2 INSPECT CONVENTIONAL FRONT Yes Go to next step.
DIFFERENTIAL PARTS No Replace defective part (s).
• Are they OK?
3 INSPECT TRANSFER CASE Yes Go to next step.
• Is it OK? No Replace transfer case.
4 INSPECT TRANSFER OIL LEVEL Yes Go to next step.
• Is oil level OK? No Adjust the oil level.
5 INSPECT TRANSFER SEALING BOLTS Yes Go to next step.
• Are sealing bolts OK? No Re-tighten the sealing bolts.
6 INSPECT BREATHER NIPPLE FOR Yes Go to next step.
CLOGGING No Clean or replace breather nipple.
• Is it OK?
7 INSPECT OIL SEAL Yes Go to next step.
• Is it OK? No Replace damaged oil seal.
• If the vehicle is not repaired or additional diagnostic information is not available.
End Of Sie
03-03–10
F198-10-05L(03-11).fm 1 ページ２００６年８月１０日　木曜日　午後６時０分
FRONT AXLE
03-11 FRONT AXLE

FRONT AXLE LOCATION INDEX WHEEL HUB, STEERING KNUCKLE
[EVEREST (4X2)] . . . . . . . . . . . . . . . . . 03-11–1 REMOVAL/INSTALLATION
WHEEL HUB, STEERING KNUCKLE [EVEREST (4X2)] . . . . . . . . . . . . . . . . . . 03-11–2
INSPECTION[EVEREST] . . . . . . . . . . . 03-11–1 WHEEL HUB BOLT REPLACEMENT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 03-11–7
End of Toc
FRONT AXLE LOCATION INDEX[EVEREST (4X2)]
WM: FRONT AXLE
id0311008001b2
03
1
DBG311ZWB003
1 Wheel hub bolt 2 Wheel hub, steering knuckle

(See WHEEL HUB BOLT REPLACEMENT [Hi- (See WHEEL HUB, STEERING KNUCKLE
Rider, 4x4].) INSPECTION [Hi-Rider, 4x4])
(See WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION [Hi-Rider])
End Of Sie
WHEEL HUB, STEERING KNUCKLE INSPECTION[EVEREST]
id0311008003b1
Wheel Bearing Play Inspection
1. After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable
bearing play by holding the top and bottom of the tire.
Maximum front wheel bearing play

0.05 mm {0.002 in}
End Of Sie
03-11–1
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION[EVEREST (4X2)]
id0311008004b2
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

24.5—36.2 {2.5—3.6, 18.1—26.6}
SST
10 19—25 {2.0—2.5, 15—18}
108—127 {11.1—12.9, 79.7—93.6}

9 37.3—51.0
SST {3.81—5.20, 27.6—37.6}
7 5
1 B
B R
R
6 4
A
2
R
A 19—25
3 {2.0—2.5,
R 15—18}
69.2—93.2 235—314
{7.06—9.50, {24.0—32.0,
51.1—68.7} 174—231}
8 11
44.1—58.8 157—209
SST {4.50—5.99, R {16.1—21.3,
54.9—67.6 32.6—43.3} 116—154}
{5.6—6.8, 40.5—49.8}
R
18
R
SST
R R
16 15 SST
14 17
88.2—117.6
{9.00—11.99,
12 65.06—86.73}
SST
13
WHEEL
BEARING
SIDE
R 19
arnffw00001369
1 ABS wheel-speed sensor (with ABS) 5 Brake caliper component

2 Hub cap (See 03-11-3 Brake Caliper Component Removal
Note)
3 Locknut
(See 03-11-3 Locknut Removal Note) 6 Disc plate
(See 03-11-7 Locknut Installation Note) 7 Tie-rod end ball joint
4 Wheel and tire (See 03-11-4 Tie-rod End Ball Joint Removal Note)
03-11–2
FRONT AXLE
8 Bolt (stabilizer) 14 ABS sensor rotor (with ABS) or spacer (without
(See FRONT STABILIZER REMOVAL/ ABS)
INSTALLATION [Hi-Rider, 4x4].) 15 Retaining ring
9 Bolt (shock absorber) 16 Wheel bearing
10 Upper arm ball joint (See 03-11-4 Wheel Bearing Removal Note)
(See FRONT UPPER ARM REMOVAL/ (See 03-11-6 Wheel Bearing Installation Note)
INSTALLATION.) 17 Dust cover
11 Lower arm ball joint (See 03-11-5 Dust Cover Removal Note)
(See TORSION BAR SPRING AND LOWER ARM (See 03-11-6 Dust Cover Installation Note)
REMOVAL/INSTALLATION [Hi-Rider, 4x4] 18 Steering knuckle
12 Wheel hub, steering knuckle, dust cover 19 Hub bolt
13 Wheel hub component (See 03-11-5 Hub Bolt Removal Note)
(See 03-11-4 Wheel Hub Component Removal (See 03-11-5 Hub Bolt Installation Note)
Note)
(See 03-11-6 Wheel Hub Component Installation
Note)
Locknut Removal Note
Note
• Remove the locknut with the vehicle on level ground.
1. Knock the crimped portion of the locknut outward

using a small chisel and a hammer.
03
arnffw00001370
2. Remove the locknut.
arnffw00001371
Brake Caliper Component Removal Note

1. Remove the brake caliper component, and
suspend it with rope.
arnffw00001372
03-11–3
FRONT AXLE
Tie-rod End Ball Joint Removal Note
1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
49 T028 304
49 T028 303
arnffw00001373
Wheel Hub Component Removal Note

1. Remove the wheel hub component using the
SSTs and a press.
49 G033 102
49 F026 103
arnffw00001374
2. If the bearing inner race remains on the front

wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
arnffw00001375
Wheel Bearing Removal Note

1. Remove the wheel bearing using the SSTs and a
press. 49 G030 797
49 S033 106
49 F026 103
arnffw00001376
03-11–4
FRONT AXLE
Dust Cover Removal Note
Note
• The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for

proper installation.
MARK
arnffw00001377
2. Remove the dust cover using a chisel.
03
arnffw00001378
Hub Bolt Removal Note
Note
• The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolts using a press.
arnffw00001379
Hub Bolt Installation Note

1. Install the new hub bolts using a press.
arnffw00001380
03-11–5
FRONT AXLE
Dust Cover Installation Note
1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
MARK
arnffw00001381
3. Install the new dust cover using the SSTs and a

press.
49 W010 107A
49 D026 102
arnffw00001382
Wheel Bearing Installation Note

1. Install the new wheel bearing using the SSTs and
a press.
49 S033 107
49 G030 797
49 D026 102
arnffw00001383
Wheel Hub Component Installation Note

1. Install the wheel hub component using the SSTs
and a press.
49 G019 011
49 F027 009
arnffw00001384
03-11–6
FRONT AXLE
Locknut Installation Note
Note
• Install the locknut with the vehicle on level ground.
1. Install a new locknut and stake it as shown.

End Of Sie
0.5mm {0.02 in}
OR MORE
arnffw00001385
WHEEL HUB BOLT REPLACEMENT[EVEREST]

id0311008007b1
1. Remove the brake caliper component and disc plate.
2. Remove the hub bolt using the SST.
3. Place a new wheel hub bolt in the wheel hub.
03
49 T028 305 49 T028 303

ABR6312W024
4. Install the wheel hub bolt by placing a proper

sized washer on the hub, and tightening the nut HUB BOLT
as shown in the figure.
End Of Sie
WHEEL WHEEL
NUT NUT
BRASS BAR WASHER
ABR6312W025
03-11–7
F198-10-05L(03-12).fm 1 ページ２００６年８月１１日　金曜日　午前９時４２分
REAR AXLE
03-12 REAR AXLE

REAR AXLE LOCATION INDEX
[RANGER [5R55S], EVEREST] . . . . . . 03-12–1
End of Toc
REAR AXLE LOCATION INDEX [RANGER [5R55S], EVEREST]
WM: REAR AXLE
id0312008001a4
RANGER [4x2 (EXPECT Hi-Rider)]
RANGER [Hi-Rider, 4x4]

EVEREST [4x2, 4x4] 03
arnffw00001889
1 Axle shaft
End Of Sie
03-12–1
F198-10-05L(03-14).fm 1 ページ２００６年８月１０日　木曜日　午後５時１９分
DIFFERENTIAL
03-14 DIFFERENTIAL
REAR DIFFERENTIAL OIL REPLACEMENT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 03-14–1
End of Toc
REAR DIFFERENTIAL OIL REPLACEMENT [EVEREST]
id0314008015d7
1. Position the vehicle on level ground.
2. Remove the oil-fill plug.
3. Remove the drain plug and drain the oil.
4. Install the drain plug with a new washer and
tighten.
Tightening torque
39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7
ft·lbf}
5. Add the specified oil through the oil-fill plug hole.
Rear differential oil

Type: API service GL-5
arnffw00000177
Viscosity: SAE 90
Oil capacity (approx. quantity): 2.35—2.55 L
{2.23—2.41 US qt, 1.96—2.12 lmp qt} [4x2]
Oil capacity (approx. quantity): 2.25—2.45 L {2.13—2.31 US qt, 1.88—2.03 lmp qt} [4x4]
03
6. After adding the oil, perform the oil level inspection.
7. Install the oil-fill plug with a new washer and tighten.
Tightening torque
39.2—53.9 N·m {4.00—5.49 kgf·m, 29.0—39.7 ft·lbf}
End Of Sie
03-14–1
F198-10-05L(03-15).fm 1 ページ２００６年８月１０日　木曜日　午後５時２２分
PROPELLER SHAFT [5AT]
03-15 PROPELLER SHAFT [5AT]

PROPELLER SHAFT LOCATION INDEX PROPELLER SHAFT
[5AT] . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-15–1 REMOVAL/INSTALLATION [5AT] . . . . . 03-15–2
PROPELLER SHAFT INSPECTION
[5AT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-15–6
End of Toc
PROPELLER SHAFT LOCATION INDEX [5AT]
WM: PROPELLER SHAFT
id0315b3800100
4x2
03
4x4
absggw00000989
1 Front propeller shaft 2 Rear propeller shaft

(See 03-15-2 PROPELLER SHAFT REMOVAL/ (See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION [5AT].) INSTALLATION [5AT].)
(See 03-15-6 PROPELLER SHAFT INSPECTION (See 03-15-6 PROPELLER SHAFT INSPECTION
[5AT].) [5AT].)
End Of Sie
03-15–1

PROPELLER SHAFT REMOVAL/INSTALLATION [5AT]
id0315b3800300
1. Remove the member.
4x2
98—117
{10.0—11.9, 72.3—86.2} 1
2 36—52
{3.7—5.3, 27—38}
absggw00000990
1 Nut 3 Propeller shaft

(See 03-15-4 Propeller Shaft Removal Note.)
2 Nut
(See 03-15-5 Propeller Shaft Installation Note.)
03-15–2

4x4
98—117
{10.0—11.9, 72.3—86.2} 3
49—58
{5.0—5.9, 37—42} 4 36—52
{3.7—5.3, 27—38}
1
3 98—117
{10.0—11.9, 72.3—86.2}
03
arnffw00001947
1 Nut 4 Nut
2 Front propeller shaft 5 Rear propeller shaft
(See 03-15-4 Propeller Shaft Removal Note.) (See 03-15-4 Propeller Shaft Removal Note.)
(See 03-15-5 Propeller Shaft Installation Note.) (See 03-15-5 Propeller Shaft Installation Note.)
3 Nut
03-15–3

Propeller Shaft Removal Note
Caution
• When replacing with a new propeller shaft, mark the companion flange to match the position of the
tag on the propeller shaft.
1. Before removing the propeller shaft, make alignment marks on the yoke and differential or transfer companion
flange.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
MARKING
TRANSFER SIDE
MARKING
absggw00000995

TRANSFER SIDE
MARKING
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15–4

Propeller Shaft Installation Note
1. Align the marks and install the propeller shaft.
2. When installing a new propeller shaft, align the differential or transfer companion flange mark with the tag on
the propeller shaft and assemble.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
MARKING
TRANSFER SIDE
MARKING
03
absggw00000995

End Of Sie TRANSFER SIDE
MARKING
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15–5

PROPELLER SHAFT INSPECTION [5AT]
id0315b3800500
Front Propeller Shaft (4x4) Inspection
1. Use a dial gauge to measure the runout of the
propeller shaft at each position.
• If it exceeds the maximum specification,
replace the propeller shaft. MEASURE
POSITION
Front propeller shaft maximum runout
0.4 mm {0.016 in}
absggw00001007
Rear Propeller Shaft (4x2,4x4) Inspection

1. Use a dial gauge to measure the runout of the
propeller shaft at each position.
• If it exceeds the maximum specification,
replace the propeller shaft. MEASURE MEASURE MEASURE
POSITION POSITION POSITION
Rear propeller shaft maximum runout
0.4 mm {0.016 in}
absggw00001003
2. Inspect the play and rotation of the joint by turning

the universal joint in the direction shown by the
arrow.
Rear propeller shaft initial torque (Reference

value)
0.29—1.76 N·m {3.0—17.9 kgf·cm, 2.6—15.5
in·lbf}
• If there is excessive play or initial torque,

replace the propeller shaft.
End Of Sie absggw00001004
03-15–6
F198-10-05L(03-16).fm 1 ページ２００６年８月１０日　木曜日　午後５時２４分
TRANSFER [5R55S]
03-16 TRANSFER [5R55S]

TRANSFER LOCATION INDEX SPEED SENSOR REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–1 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–4
TRANSFER CASE OIL INSPECTION MOTOR INSPECTION [5R55S] . . . . . . . . 03-16–4
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–2 MOTOR REMOVAL/INSTALLATION
TRANSFER CASE OIL REPLACEMENT [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–5
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–2 CLUTCH COIL INSPECTION [5R55S]. . . 03-16–6
SPEED SENSOR INSPECTION TRANSFER CASE REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–3 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–7
End of Toc
TRANSFER LOCATION INDEX [5R55S]
WM: TRANSFER
id0316c1800100
5
4
03
2
arnffw00001907
1 Transfer case oil 3 Speed sensor

(See 03-16-2 TRANSFER CASE OIL INSPECTION (See 03-16-3 SPEED SENSOR INSPECTION
[5R55S].) [5R55S].)
(See 03-16-2 TRANSFER CASE OIL (See 03-16-4 SPEED SENSOR REMOVAL/
REPLACEMENT [5R55S].) INSTALLATION [5R55S].)
2 Motor 4 Clutch coil
(See 03-16-4 MOTOR INSPECTION [5R55S].) (See 03-16-6 CLUTCH COIL INSPECTION
(See 03-16-5 MOTOR REMOVAL/INSTALLATION [5R55S].)
[5R55S].) 5 Transfer case
(See 03-16-7 TRANSFER CASE REMOVAL/
INSTALLATION [5R55S].)
End Of Sie
03-16–1
TRANSFER [5R55S]
TRANSFER CASE OIL INSPECTION [5R55S]
id0316c1816200
1. Warm up the transfer case.
Caution
• Do not use an impact wrench when removing the filler plug. It may damage the transfer case.
2. Remove the filler plug from the transfer case.

3. Verify that the oil is near the brim of the plug port.
• If the oil level is low, add the specified amount FILLER PLUG
and type of oil through the filler plug hole.
Transfer case oil

Type: Mercon® V
4. Tighten the new filler plug.
Tightening torque
19—30 N·m {2.0—3.0 kgf·m, 15—22 ft·lbf} arnffw00001908
End Of Sie
TRANSFER CASE OIL REPLACEMENT [5R55S]
id0316c1816300
1. Warm up the transfer case.
2. Remove the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
Caution
• Do not use an impact wrench when removing the filler plug or drain plug. It may damage the
transfer case.
3. Remove the drain plug from the transfer case.

4. Drain the oil into a suitable container.
FILLER PLUG
5. Tighten the new drain plug.
Tightening torque
19—30 N·m {2.0—3.0 kgf·m, 15—22 ft·lbf}
6. Remove the filler plug and add the specified

amount and type of oil through the filler plug hole
until the level reaches the bottom of the filler plug
hole. DRAIN PLUG
arnffw00001909
Transfer case oil
Type: Mercon® V
Capacity (approx. quantity): 1.2 L {1.3 US qt, 1.1 lmp qt}
7. Tighten the new filler plug.
Tightening torque
19—30 N·m {2.0—3.0 kgf·m, 15—22 ft·lbf}
8. Install the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
End Of Sie
03-16–2
TRANSFER [5R55S]
SPEED SENSOR INSPECTION [5R55S]
id0316c1816000
Caution
• Water or foreign material entering the connector can cause poor connections or corrosion. Be
sure that water or foreign material do not enter the connector when disconnecting it.

3. Disconnect the speed sensor connector.
Caution
• Do not apply a shock in the speed
sensor.
• Do not damage the terminals.
SPEED SENSOR
SPEED SENSOR
CONNECTOR
arnffw00001910
4. Measure the resistance between the speed

sensor terminals A and B.
• If there is any malfunction, replace the speed
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAL/
C B A 03
Transfer case speed sensor resistance
Approx. 300 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-13-
arnffw00001911
45 AUTOMATIC TRANSMISSION REMOVAL/
7. Connect the negative battery cable.
End Of Sie
03-16–3
TRANSFER [5R55S]
SPEED SENSOR REMOVAL/INSTALLATION [5R55S]
id0316c1815700
Caution
• Do not damage the speed sensor.

8—11 N·m {82—112 kgf·cm,
71—97 in·lbf} 3
1 Connector (wiring harness-side) 1
2 Connector (part side) 2
3 Connector cover
4 Clutch coil terminal 5 6
5 Speed sensor bracket
6 Wiring harness bracket 4
7 Speed sensor

End Of Sie
arnffw00001914
MOTOR INSPECTION [5R55S]

id0316c1815900
Motor Operating Inspection
Caution

3. Remove the motor. (See 03-16-5 MOTOR REMOVAL/INSTALLATION [5R55S].)
Caution
• Do not apply a shock in the speed sensor.
4. Connect battery positive voltage to motor terminal

F, connect terminal C to ground, and then verify
that the motor operates as shown in the table.
5. Connect battery positive voltage to motor terminal
C, connect terminal F to ground, and then verify
that the motor operates as shown in the table.
• If the operation condition is not normal, E B
replace the motor. (See 03-16-5 MOTOR G D A
REMOVAL/INSTALLATION [5R55S].) F C
Terminal
Motor position
C F
Ground B+ 2H→4H→4L arnffw00001912
B+ Ground 4L→4H→2H
6. Measure the resistance between the motor terminals C and F.

• If there is any malfunction, replace the motor. (See 03-16-5 MOTOR REMOVAL/INSTALLATION [5R55S].)
Transfer case motor resistance

approx. 117 ohms
03-16–4
TRANSFER [5R55S]
7. Install the motor. (See 03-16-5 MOTOR REMOVAL/INSTALLATION [5R55S].)
8. Install the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
Motor Position Inspection

3. Measure the resistance between the motor
terminals
• If there is any malfunction, replace the motor.
(See 03-16-5 MOTOR REMOVAL/
E B
: Continuity G D A
F C
Terminal
Motor position
A B D E G
2H arnffw00001912
4H
4L
arnffw00001913
4. Install the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION 03
[5R55S].)
End Of Sie
MOTOR REMOVAL/INSTALLATION [5R55S]
id0316c1815800
Caution
• Do not damage the motor.

8—11 N·m 1
1 Speed sensor connector {82—112 kgf·cm,
71—97 in·lbf}
2 Connector
2
3 Speed sensor bracket
4 Motor
3
8—11 N·m
End Of Sie {82—112 kgf·cm,
71—97 in·lbf}
arnffw00001915
03-16–5
TRANSFER [5R55S]
CLUTCH COIL INSPECTION [5R55S]
id0316c1816100
Caution

3. Disconnect the speed sensor connector.
Caution
• Do not apply a shock in the speed
sensor.
SPEED SENSOR
SPEED SENSOR
CONNECTOR
arnffw00001910
4. Measure the resistance between the speed

sensor terminal C and body ground.
• If there is any malfunction, replace the clutch
coil.
C B A
Transfer case clutch coil resistance
Approx. 3 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-13-
45 AUTOMATIC TRANSMISSION REMOVAL/
arnffw00001911
End Of Sie
03-16–6
F198-10-05L(03-16).fm 7 ページ２００６年８月１０日　木曜日　午後６時３分
TRANSFER [5R55S]
TRANSFER CASE REMOVAL/INSTALLATION [5R55S]
id0316c1816400
3. Remove the oxidation catalytic converter (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [WL-C,
WE-C (RANGER (AT))].)
4. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
5. Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
REMOVAL/INSTALLATION [5R55S])
6. Lower the transmission slightly.
38.0—52.0 N·m
{3.9—5.3 kgf·m,
28.1—38.3 ft·lbf} 5
03
4
6 3
2
arnffw00001916
1 Speed sensor connector 4 Bolt

2 Motor connector 5 Bracket
3 Breather hose 6 Transfer case
End Of Sie
03-16–7
F198-10-05L(03-18).fm 1 ページ２００６年８月１０日　木曜日　午後５時２５分
4-WHEEL DRIVE
03-18 4-WHEEL DRIVE

4-WHEEL DRIVE LOCATION INDEX 4x4 CONTROL MODULE INSPECTION
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-18–1 [AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . 03-18–3
4x4 SWITCH INSPECTION 4x4 CONTROL MODULE
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-18–2 REMOVAL/INSTALLATION
4x4 SWITCH REMOVAL/INSTALLATION [AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . 03-18–5
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . 03-18–3
End of Toc
4-WHEEL DRIVE LOCATION INDEX [AT (5R55S)]
WM: REMOTE FREEWHEEL
id0318008005d2
6
7
03
10
3
8
9
11 2
arnffw00001888
1 Motor component 5 4x4 switch

(See 03-16-4 MOTOR INSPECTION [5R55S].) (See 03-18-2 4x4 SWITCH INSPECTION [AT
(See 03-16-5 MOTOR REMOVAL/INSTALLATION (5R55S)].)
[5R55S].) (See 03-18-3 4x4 SWITCH REMOVAL/
2 Speed sensor INSTALLATION [AT (5R55S)].)
(See 03-16-3 SPEED SENSOR INSPECTION 6 4x4 control module
[5R55S].) (See 03-18-3 4x4 CONTROL MODULE
(See 03-16-4 SPEED SENSOR REMOVAL/ INSPECTION [AT (5R55S)].)
INSTALLATION [5R55S].) (See 03-18-5 4x4 CONTROL MODULE REMOVAL/
3 Clutch coil INSTALLATION [AT (5R55S)].)
(See 03-16-6 CLUTCH COIL INSPECTION 7 Lock and free solenoid valve
[5R55S].) 8 One-way check valve
4 Digital TR sensor 9 Joint shaft component
(See 05-13-20 DIGITAL TRANSMISSION RANGE
(TR) SENSOR INSPECTION [5R55S].) 10 Control box
(See 05-13-22 DIGITAL TRANSMISSION RANGE 11 RFW actuator
(TR) SENSOR REMOVAL/INSTALLATION
[5R55S].)
03-18–1
4-WHEEL DRIVE
End Of Sie
4x4 SWITCH INSPECTION [AT (5R55S)]

id0318008050d2
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign material on the connector when disconnecting it.

2. Remove the boot panel.
3. Verify that the continuity is as indicated in the
table.
E C A
F D B
: Continuity
Connector terminal
Position
A D C F
2H
4H
4L
arnffw00001882
• If there is any malfunction, replace the 4x4

switch. (See 03-18-3 4x4 SWITCH
REMOVAL/INSTALLATION [AT (5R55S)].)
4. Install the boot panel. B A
End Of Sie
: Continuity
Connector terminal
A B
arnffw00001883
03-18–2
4-WHEEL DRIVE
4x4 SWITCH REMOVAL/INSTALLATION [AT (5R55S)]
id0318008051d2
2. Remove the boot panel. (See .)
.
1 knob
2 4x4 switch
End Of Sie 1
03
arnffw00001878
4x4 CONTROL MODULE INSPECTION [AT (5R55S)]

id0318008049d2
1. Remove the lower panel.
2. Turn the engine switch to the ON position (Engine off).
3. Attach the tester lead to the control module connector and inspect the voltage and continuity according to the
Terminal Voltage Table (Reference).
Terminal Voltage Table (Reference)
arnffw00001875
Terminal Signal name Connected to condition Voltage (V) Inspection item(s)

Motor operating Below 1.0 • Inspect related wiring
Motor control (4L- Motor component harness
A
4H-2H) (shift motor) Motor not operating B+ • Motor component (shift
motor)
Motor control (4L- Motor component harness
B
4H-2H) (shift motor) Motor not operating B+ • Motor component (shift
motor)
Motor control (2H- Motor component harness
C
4H-4L) (shift motor) Motor not operating B+ • Motor component (shift
motor)
03-18–3
4-WHEEL DRIVE
Motor control (2H- Motor component harness
D
4H-4L) (shift motor) Motor not operating B+ • Motor component (shift
motor)
N position Below 1.0 • Inspect related wiring
E Neutral signal Digital TR sensor harness
Except N position Approx. 4.3 • Digital TR sensor
2H or 4H position B+ • Inspect related wiring
4H or 4L mode
F 4x4 switch harness
signal 4L position Below 1.0 • 4x4 switch
2H position Below 1.0 • Inspect related wiring
2H or 4H mode
G 4x4 switch harness
signal 4H or 4L position B+ • 4x4 switch
2H position Approx. 5.0 • Inspect related wiring
Motor component 4H position Approx. 5.0 harness
H Position 4
(position sensor) • Motor component
4L position Approx. 4.2 (position sensor)
I Position 2
4H position Approx. 5.0 harness
J Position 1 Motor component
• Motor component
4L position Below 1.0 (position sensor)
K — — — — —
L Position 3
Engine switch OFF Below 1.0 • Inspect related wiring
M Vehicle speed Speed sensor harness
Engine switch ON Approx. 5.0 • Speed sensor
Speed sensor or harness
N Ground
motor component Engine switch ON Approx. 5.0 • Speed sensor
• Motor component
O — — — — —
P — — — — —
Data link connector Engine switch OFF Below 1.0 • Inspect related wiring
Q DTC output
(DLC) Engine switch ON Approx. 5.0 harness
4x4 indicator light • Inspect related wiring
B+
OFF harness
R 4x4 indicator light 4x4 indicator light • 4x4 indicator light
4x4 indicator light
Below 1.0
ON
4L indicator light • Inspect related wiring
B+
S 4L indicator light 4L indicator light OFF harness
4L indicator light ON Below 1.0 • 4L indicator light
T IG 1 Engine fuse harness
Engine switch ON B+ • Engine fuse
Clutch coil operating B+ • Inspect related wiring
U Clutch coil Clutch coil Clutch coil not harness
operating
Below 1.0 • Clutch coil
Lock solenoid valve • Inspect related wiring
Below 1.0
operating harness
V Lock solenoid valve Lock solenoid valve • Lock solenoid valve
Lock solenoid valve
B+
not operating
• Inspect related wiring
W Ground Body ground Under any condition Below 1.0 harness
(W—ground)
03-18–4
4-WHEEL DRIVE
• Inspect related wiring
X Ground Body ground Under any condition Below 1.0 harness
(X—ground)
Engine switch OFF • Inspect related wiring
Y B+ PTC/AT fuse B+
Engine switch ON harness
Engine switch OFF • Inspect related wiring
Z B+ PTC/AT fuse B+
Engine switch ON harness
End Of Sie
4x4 CONTROL MODULE REMOVAL/INSTALLATION [AT (5R55S)]
id0318008048d2
2. Remove the lower panel.
18.6—25.5 N·m
{1.90—2.60 kgf·m,
13.8—18.8 ft·lbf}
03
2
1
3
7.8—10.8 N·m {80—110 kgf·cm, 70—95 in·lbf}
arnffw00001874
1 Connector 3 Bracket
2 4x4 CM
03-18–5
TECHNICAL DATA

DRIVELINE/AXLE TECHNICAL DATA
End of Toc
DRIVELINE/AXLE TECHNICAL DATA [RANGER [5R55S], EVEREST]
WM: DRIVELINE/AXLE
id0350008001c2
Item Specification
Maximum front wheel bearing play [EVEREST] 0.05 mm {0.002 in}
Type: API service GL-5
Viscosity: SAE 90
Oil capacity (approx. quantity): 2.35—2.55 L {2.23—2.41 US qt,
Rear differential oil [EVEREST]
1.96—2.12 lmp qt} [4x2]
Oil capacity (approx. quantity): 2.25—2.45 L {2.13—2.31 US qt,
1.88—2.03 lmp qt} [4x4]
Front propeller shaft maximum runout [5R55S] 0.4 mm {0.016 in}
Rear propeller shaft initial torque (Reference value)
0.29—1.76 N·m {3.0—17.9 kgf·cm, 2.6—15.5 in·lbf}
[5R55S]
Transfer case oil Type: Mercon® V

Transfer case speed sensor resistance Approx. 300 ohms
Transfer case motor resistance Approx. 117 ohms
Transfer case clutch coil resistance Approx. 3 ohms
End Of Sie 03
03-50–1
F198-10-05L(03-60).fm 1 ページ２００６年８月１１日　金曜日　午前９時５１分
SERVICE TOOLS
03-60 SERVICE TOOLS

DRIVELINE/AXLE SST
End of Toc
DRIVELINE/AXLE SST [RANGER [5R55S], EVEREST]
WM: DRIVELINE/AXLE
id0360008002e2
49 T028 3A0 49 G030 797 49 G019 011
Ball joint puller Handle Bearing installer

set
49 S033 107 49 F026 103 49 S033 106
Oil seal installer Wheel hub Oil seal installer

puller
49 W010 107A 49 D026 102 49 F027 009
Oil seal installer Sensor rotor Attachment for

installer ø68&77
03
49 G033 102
Handle
— —
End Of Sie
03-60–1
F198-10-05L(04-02).fm 1 ページ２００６年８月３日　木曜日　午前１１時８分
BRAKES 04
SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC PARKING BRAKE SYSTEM. . . 04-12
[4W-ABS]. . . . . . . . . . . . . . . . 04-02B ANTILOCK BRAKE SYSTEM
SYMPTOM TROUBLESHOOTING [4W-ABS] . . . . . . . . . . . . . . . . 04-13B
[4W-ABS]. . . . . . . . . . . . . . . . 04-03B TECHNICAL DATA . . . . . . . . . . 04-50
CONVENTIONAL BRAKE SERVICE TOOLS . . . . . . . . . . . 04-60
SYSTEM . . . . . . . . . . . . . . . . 04-11
Toc of SCT
04-02B ON-BOARD DIAGNOSTIC [4W-ABS]
ABS SYSTEM WIRING DIAGRAM[4W-ABS ON-BOARD DIAGNOSIS[4W-ABS
(EVEREST)]. . . . . . . . . . . . . . . . . . . . . . 04-02B–2 (EVEREST)] . . . . . . . . . . . . . . . . . . . . . . 04-02B–2
DTC C1414[4W-ABS (EVEREST)]. . . . . . 04-02B–6
End of Toc
WM: ANTILOCK BRAKE SYSTEM
04
04-02B–1

ABS SYSTEM WIRING DIAGRAM[4W-ABS (EVEREST)]
id0402d5802300
ABS/SOL 20A
C
V
P G SENSOR
ABS 40A W
B
A
J
BRAKE SWITCH
BATTERY N
BRAKE
LIGHT
ABS WARNING
LIGHT
ABS HU/CM
S Q DLC-2
INSTRUMENT CLUSTER
O
RF
M
E
LF
ABS WHEEL- F
SPEED SENSOR L
RR
K D
I
LR
G
arnffw00001465
End Of Sie
ON-BOARD DIAGNOSIS[4W-ABS (EVEREST)]
id0402d5805500
On-Board Diagnostic (OBD) Test Description
• The OBD test inspects the integrity and function of the ABS and outputs the results when requested by the
specific tests.
• On-board diagnostic test also:
— Provides a quick inspection of the ABS usually performed at the start of each diagnostic procedure.
— Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and record and active command modes.
Read/clear diagnostic results

• This function allows you to read or clear DTCs in the ABS HU/CM memory.
PID/Data monitor and record

• This function allows you to access certain data values, input signals, calculated values, and system status
information.
04-02B–2

Active command modes
• This function allows you to control devices through the current diagnostic tool.
Reading DTCs Procedure

1. Connect the IDS/PDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the IDS/
PDS.
1. Select the "Toolbox" tab.
2. Select "Self Test".
3. Select "Module".
4. Select "ABS".
1. Select "Module Tests". DLC-2
2. Select "ABS".
arnffw00001280
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the ABS HU/CM. (See 04-02B-3 Clearing DTCs
Procedures.)
Clearing DTCs Procedures

1. Connect the IDS/PDS to the vehicle DLC-2
connector.
PDS.
1. Select the “Toolbox” tab.
2. Select “Self Test”.
04
3. Select “Module”.
4. Select “ABS”.
• When using the PDS (pocket PC) DLC-2
1. Select “Module Tests”.
arnffw00001280
3. Select “Self Test”.
3. Verify the DTC according to the directions on the screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
PID/Data Monitor and Record Procedure

PDS.
2. Select “DataLogger”.
1. Select “Module Tests”. DLC-2
arnffw00001280
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on the screen.
Note
• The PID data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.
04-02B–3

Active Command Modes Procedure
PDS.
1. Select “Module Tests”. DLC-2
arnffw00001280
3. Select the active command modes from the PID
table.
4. Perform the active commands modes, inspect the operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the active commands mode
inspection is performed, it is possible that there ia an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.
DTC Table
DTC System malfunction location Page
B1317 Power supply system
B1318 Power supply system
B1342 ABS HU/CM system
B1484 Brake switch system
C1095 Pump motor, motor relay system
C1096 Pump motor, motor relay system
C1145 RF ABS wheel-speed sensor system
C1155 LF ABS wheel-speed sensor system
C1165 RR ABS wheel-speed sensor system
C1175 LR ABS wheel-speed sensor system
C1186 Fail-safe relay system
C1194 LF outlet solenoid valve system
C1198 LF inlet solenoid valve system
C1202 Rear outlet solenoid valve system
C1206 Rear inlet solenoid valve system
C1210 RF outlet solenoid valve system
C1214 RF inlet solenoid valve system
C1222 ABS wheel-speed sensor (slip monitor) system
C1233 LF ABS wheel-speed sensor/ABS sensor rotor system
C1234 RF ABS wheel-speed sensor/ABS sensor rotor system
C1235 RR ABS wheel-speed sensor/ABS sensor rotor system
C1236 LR ABS wheel-speed sensor/ABS sensor rotor system
C1414 Incorrect ABS HU/CM installed (See 04-02B-6 DTC C1414[4W-ABS (EVEREST)].)
C1730 G sensor system
04-02B–4

PID/DATA Monitor Table
PID name Operation condition ABS HU/CM
Unit/Condition Action
(definition) (reference) terminal
• ABS warning light is
ABS_LAMP
illuminated: ON
(ABS warning light On/Off Inspect the ABS warning light. S
• ABS warning light is not
driver output state)
illuminated: Off
Inspect the power supply circuit.
ABS_VOLT • Engine switch at ON:
(See 04-13B-2 ABS HU/CM
(System battery V Approx. 12.2 V J
INSPECTION[4W-ABS
voltage value) • Idling: Approx. 14.1 V
(EVEREST)].)
• Vehicle is stopped or
driving at a constant
speed: 0 G
ACCLMTR
• Cornering to left: Changes
(Forward-G sensor G Inspect the G sensor. P
between 0 G and 1.5 G
input)
• Cornering to right:
Changes between 0 G and
-1.5 G
BOO_ABS • Brake pedal depressed:
(Brake pedal switch On/Off On Inspect the brake switch. N
input) • Brake pedal released: Off
CCNTABS • DTCs detected:
(Number of continuous — 1—255 Perform the DTC inspection. —
codes) • No DTCs detected: 0
PMP_MOTOR • Pump motor activated: On
(Pump motor output On/Off • Pump motor not activated: Inspect the ABS HU/CM. —
state) Off
RLY_PMP
• Relay activated: On
(Pump motor relay On/Off Inspect the ABS HU/CM. —
• Relay not activated: Off
output state)
RLY_VLV
• Solenoid valve relay is 04
activated: On
(Solenoid valve relay On/Off Inspect ABS HU/CM. —
• Solenoid valve relay is
output state)
deactivated: Off
• Solenoid valve activated:
V_LF_INL
On
(Left front inlet solenoid On/Off Inspect the ABS HU/CM. —
• Solenoid valve not
valve output state)
activated: Off
V_LF_OTL • Solenoid valve activated:
(Left front outlet On
On/Off Inspect the ABS HU/CM. —
solenoid valve output • Solenoid valve not
state) activated: Off
V_RF_INL • Solenoid valve activated:
(Right front inlet On
V_RF_OTL • Solenoid valve activated:
(Right front outlet On
V_Rear_ INL
On
(Rear inlet solenoid On/Off Inspect the ABS HU/CM. —
valve output state)
activated: Off
V_Rear_OTL
On
(Rear outlet solenoid On/Off Inspect the ABS HU/CM. —
valve output state)
activated: Off
• Vehicle stopped: 0 KPH, 0
WSPD_LF
MPH Inspect the ABS wheel-speed
(Left front ABS wheel- KPH, MPH E, F
• Vehicle running: Vehicle sensor.
speed sensor input)
speed
04-02B–5

PID name Operation condition ABS HU/CM
Unit/Condition Action
(definition) (reference) terminal
WSPD_LR
(Left rear ABS wheel- KPH, MPH I, G
speed sensor input)
speed
WSPD_RF
(Right front ABS wheel- KPH, MPH O, M
speed sensor input)
speed
WSPD_RR
(Right rear ABS wheel- KPH, MPH L, K
speed sensor input)
speed
Active Command Modes Table

Operating
Command name Output part Operation
condition
PMP_MOTOR Pump motor
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
Engine switch at
V_Rear_INL Rear inlet solenoid valve On/Off
ON
V_Rear_OTL Rear outlet solenoid valve
V_RF_INL RF inlet solenoid valve
V_RF_OTL RF outlet solenoid valve
End Of Sie
DTC C1414[4W-ABS (EVEREST)]
id0402d5805200
DTC C1414 ABS HU/CM unit mismatched installation

DETECTION
• When G sensor signal input for more than 1 s to 4x2 vehicle-type ABS HU/CM.
CONDITION
POSSIBLE • Mismatched installation of ABS HU/CM
CAUSE — 4x2 vehicle type ABS HU/CM is mismatched installed.
1 INSPECT ABS HU/CM FOR MISMATCHED Yes Go to next step.
INSTALLATION No Replace with correct ABS HU/CM part number, then go to
• Verify ABS HU/CM part number next step.
• Has a ABS HU/CM with the correct part
number been installed?
2 VERIFY CURRENT STATUS OF Yes Replace ABS HU/CM.
MALFUNCTION No Go to next step.
• Clear DTC from memory.
(See 04-02B-2 ON-BOARD
DIAGNOSIS[4W-ABS (EVEREST)])
• Is same DTC present?
3 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02B-2 ON-BOARD DIAGNOSIS[4W-ABS
• Are any other DTCs output? (EVEREST)].)
No DTC troubleshooting completed.
End Of Sie
04-02B–6
F198-10-05L(04-03).fm 1 ページ２００６年８月３日　木曜日　午前１１時９分
SYMPTOM TROUBLESHOOTING [4W-ABS]
04-03B SYMPTOM TROUBLESHOOTING [4W-ABS]

SYSTEM WIRING DIAGRAM
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-03B–1
End of Toc
SYSTEM WIRING DIAGRAM[4W-ABS (EVEREST)]
WM: DYNAMIC STABILITY CONTROL
id0403c1800100
ABS/SOL 20A
C
V
P G SENSOR
ABS 40A W
B
A
J
BRAKE SWITCH
BATTERY N
BRAKE
LIGHT
ABS WARNING
LIGHT 04
ABS HU/CM
S Q DLC-2
INSTRUMENT CLUSTER
O
RF
M
E
LF
ABS WHEEL- F
SPEED SENSOR L
RR
K D
I
LR
G
arnffw00001466
End Of Sie
04-03B–1
F198-10-05L(04-11).fm 1 ページ２００６年８月３日　木曜日　午後１時６分
04-11 CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) INSPECTION
LOCATION INDEX[RANGER (AT)]. . . . 04-11–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–7
CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC)
LOCATION INDEX[EVEREST] . . . . . . . 04-11–2 REMOVAL/INSTALLATION
AIR BLEEDING[EVEREST] . . . . . . . . . . 04-11–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–8
BRAKE PEDAL REMOVAL/INSTALLATION DISC PAD (FRONT) REPLACEMENT
[AT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–11
LOAD SENSING PROPORTIONING VALVE CALIPER (FRONT)
(LSPV) INSPECTION[EVEREST] . . . . . 04-11–4 DISASSEMBLY/ASSEMBLY
LOAD SENSING PROPORTIONING VALVE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–11
(LSPV) ADJUSTMENT[EVEREST]. . . . 04-11–5 REAR BRAKE (DRUM) INSPECTION
LOAD SENSING PROPORTIONING VALVE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–12
(LSPV) REMOVAL/INSTALLATION REAR BRAKE (DRUM)
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 04-11–6 REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-11–13
End of Toc
CONVENTIONAL BRAKE SYSTEM LOCATION INDEX[RANGER (AT)]
WM: BRAKES
id0411008001c6
2 04
1 4 10
5 3
6
arnffw00001049
1 Brake fluid 5 Master cylinder

2 Vacuum line 6 Power brake unit
3 Brake pedal 7 Vacuum pump
(See 04-11-3 BRAKE PEDAL REMOVAL/ 8 Load sensing proportioning valve (LSPV)
INSTALLATION[AT].)
9 Front brake (disc)
4 Brake switch
10 Rear brake (drum)
End Of Sie
04-11–1

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX[EVEREST]
id0411008001d4
2
1 4
10
3
5
6
arnffw00001560
1 Brake fluid 9 Front brake (disc)

(See 04-11-3 AIR BLEEDING[EVEREST].) (See 04-11-7 FRONT BRAKE (DISC)
2 Vacuum line INSPECTION[EVEREST].)
(See 04-11-8 FRONT BRAKE (DISC) REMOVAL/
3 Brake pedal INSTALLATION[EVEREST].)
(See 04-11-3 BRAKE PEDAL REMOVAL/ (See 04-11-11 DISC PAD (FRONT)
INSTALLATION[AT].) REPLACEMENT[EVEREST].)
4 Brake switch (See 04-11-11 CALIPER (FRONT) DISASSEMBLY/
5 Master cylinder ASSEMBLY[EVEREST].)
6 Power brake unit 10 Rear brake (drum)
7 Vacuum pump (See 04-11-12 REAR BRAKE (DRUM)
INSPECTION[EVEREST].)
8 Load sensing proportioning valve (LSPV) (See 04-11-13 REAR BRAKE (DRUM) REMOVAL/
(See 04-11-4 LOAD SENSING PROPORTIONING INSTALLATION[EVEREST].)
VALVE (LSPV) INSPECTION[EVEREST].)
(See 04-11-5 LOAD SENSING PROPORTIONING
VALVE (LSPV) ADJUSTMENT[EVEREST].)
(See 04-11-6 LOAD SENSING PROPORTIONING
VALVE (LSPV) REMOVAL/
End Of Sie
04-11–2

AIR BLEEDING[EVEREST]
id0411008002d4
Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.
Note
• Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.
• Begin air bleeding with the brake caliper that is furthest from the master cylinder.
Brake fluid type

SAE J1703, FMVSS 116 DOT-3
1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal
down.
4. While the brake pedal is depressed, the other 49 0259 770B
should loosen the bleeder screw using the SST,
drain out any fluid containing air bubbles, and
tighten the bleeder screw.
Tightening torque
Front: 5.9—8.8 N·m {61—89 kgf·cm, 53—77
in·lbf}
Rear: 5.9—8.8 N·m {61—89 kgf·cm, 53—77
in·lbf}
5. Repeat Steps 3 and 4 until no air bubbles are

arnffw00000986
seen.
6. Perform air bleeding as described in the above 04
procedures for all brake calipers.
7. After air bleeding, inspect the following:
• Brake operation
• Fluid leakage
• Fluid level
End Of Sie
BRAKE PEDAL REMOVAL/INSTALLATION[AT]
id0411008012d3
1. The brake pedal is mounted on the bracket integrated with the accelerator pedal. Refer to section 01, INTAKE
AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation.
(See 01-13B-1 ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION[WL-C, WE-C (AT)].)
End Of Sie
04-11–3

LOAD SENSING PROPORTIONING VALVE (LSPV) INSPECTION[EVEREST]
id0411008112d4
2. Check the tire inflations and set them to the recommended pressure if necessary.
• If not as specified, replace or adjust.
3. Check the vehicle with a person in the driver’s seat; include the standard vehicle tools, the spare wheel and tire,
and a full tank of fuel.
4. Install the SST to the front wheel cylinder and rear
wheel cylinder, then bleed the air in the brake line
and LSPV using a air bleed valve A.
49 U043 0A0A
A A
arnffw00001007
5. Inspect the fluid pressure of rear wheel cylinder

while the fluid pressure of front wheel cylinder is
4,900 kPa {50 kgf/cm2, 711 psi} and 9,800 kPa REAR LOADED
PRESSURE
{100 kgf/cm2, 1,421 psi}.
• If not as specified, adjust the LSPV. A PERSON IN
DRIVER'S SEAT
4,900 {50, 711} 9,800 {100, 1,421}

FRONT PRESSURE
kPa {kgf/cm2, psi}
arnffw00001008
Load sensing proportioning valve (LSPV) fluid pressure

Front wheel cylinder fluid pressure (kPa {kgf/cm2, psi}) Rear wheel cylinder (kPa {kgf/cm2, psi})
4,900 {50, 711} 2,650—3,450 {28—35, 385—500}
9,800 {100, 1,421} 4,700—5,900 {48—60, 682—855}
Note
• When applying the specified pressure, the brake pedal must not be “double pumped” or released.
• Read the rear pressure. After approx. 2 s elapse from setting the front wheel cylinder fluid pressure.
End Of Sie
04-11–4

LOAD SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT[EVEREST]
id0411008113d4
1. Place the unloaded vehicle on level ground. Unloaded: Fuel tank is full. Engine coolant and tire, jack and tools
are in designated position.
Note
• A change of 5 mm {0.20 in} in dimension L results in a change of 1,080 kPa {11 kgf/cm2, 157 psi}.
2. Adjust main spring dimension L between the

LSPV and the adjustment link loosening and
repositioning the LSPV.
• Decrease dimension L if the fluid pressure is
low.
• Increase dimension L if the fluid pressure is
high.
Dimension L
175.5—182.5 mm {6.910—7.185 in} MAIN SPRING
3. Tightening the nut.
Specification
18.6—25.4 N·m {1.90—2.59 kgf·m, 13.8—18.7
ft·lbf}
4. After adjustment, recheck the fluid pressure. NUT ADJUSTMENT LINK

• If not as specified, replace the LSPV as a
component.
End Of Sie
arnffw00001009
04
04-11–5

LOAD SENSING PROPORTIONING VALVE (LSPV) REMOVAL/INSTALLATION[EVEREST]
id0411008114d4
Caution
• Do not disassemble the load sensing proportioning valve (LSPV) or move nut A, otherwise the
LSPV may not function properly.

3. After installation, adjust the main spring dimension. (See 04-11-5 LOAD SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT[EVEREST].)
12.8—21.6 N·m 1 SST *

{131—220 kgf·cm,
114—191 in·lbf}
A
3
18.6—25.4
{1.90—2.59, 13.8—18.7} 4
18.6—25.4
{1.90—2.59, 13.8—18.7}
2
*
SST 49 0259 770B
arnffw00001010
1 Brake pipe 3 Bolt

(See 04-11-6 Brake Pipe Installation Note) 4 Load sensing proportioning valve (LSPV)
2 Nut
Brake Pipe Installation Note

1. Install the brake pipe to the LSPV and align yellow
painting on the brake pipe and LSPV.
End Of Sie RH
FRONT
YELLOW PAINTING
arnffw00001011
04-11–6

FRONT BRAKE (DISC) INSPECTION[EVEREST]
id0411008008d4
Disc Pad Thickness Inspection
1. Jack up the front of the vehicle on level ground and support it with safety stands.
2. Remove the wheels.
3. Look through the caliper inspection hole and
verify the remaining thickness of the pad.
Minimum front disc pad thickness

2.0 mm {0.079 in} min.
arnffw00000988
Disc Plate Thickness Inspection

1. Measure the thickness of the disc plate.
• If the thickness is not within the specification,
replace the disc plate.
Caution
• When it is necessary to machine the disc
plate, make sure the disc plate is not
removed from the vehicle when
machined, excessive runout may result.
Machine the disc plate with it installed on
the vehicle.
04
arnffw00000989
Standard front disc plate thickness
28.0 mm {1.11 in}
Minimum front disc plate thickness

26.0 mm {1.03 in}
Minimum front disc plate thickness after machining using a brake lathe on-vehicle
26.8 mm {1.06 in}
Disc Plate Runout Inspection

1. Tighten the disc plate to the wheel hub using two
wheel nuts. When measuring runout, measure at
the outer edge of the disc plate surface.
Front disc plate runout limit

0.05 mm {0.002 in} max.
End Of Sie
arnffw00000990
04-11–7

FRONT BRAKE (DISC) REMOVAL/INSTALLATION[EVEREST]
id0411008009d4
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
29—34
{3.0—3.4, 22—25} 1
2
22—29
{2.3—2.9, 17—21}
108—127
{11.1—12.9, 79.7—93.6}
R
A
GREASE
SST 4 3
7 8
5
B 9
GREASE
11 A
GREASE
R
A 6 B
GREASE
GREASE
RUBBER GREASE
19—25 {2.0—2.5, 15—18}
B 10
GREASE
BRAKE GREASE 12
arnffw00000991
1 Brake hose 7 Inner shim (cover shim)

2 Caliper (See 04-11-10 Outer Shim, Inner shim Installation
Note)
3 Guide pin
8 Inner shim (rubber coated shim)
Disc pad (See 04-11-10 Outer Shim, Inner shim Installation
4
(See 04-11-10 Disc Pad Installation Note) Note)
5 Outer shim (cover shim) 9 Guide plate
(See 04-11-10 Outer Shim, Inner shim Installation (See 04-11-9 Guide Plate Removal Note)
Note)
10 Mounting support
6 Outer shim (rubber coated shim)
(See 04-11-10 Outer Shim, Inner shim Installation 11 Dust boot
Note) 12 Disc plate
(See 04-11-9 Disc Plate Removal Note)
(See 04-11-9 Disc Plate Installation Note)
04-11–8
F198-10-05L(04-11).fm 9 ページ２００６年８月３日　木曜日　午後１時７分

Guide Plate Removal Note
1. Pull up and at a slant on the supporting part of the
guide plate in the direction indicated by the arrow
(1) and (2) as shown in the figure, to remove the
guide plate from the mounting support.
2
1
arnffw00000992
Caution
• If the guide plate is removed by pulling in
the direction indicated by the arrow as GUIDE PLATE
shown in the figure, the stopper may be
deformed and not able to be reused. Do STOPPER
not remove in this manner.
arnffw00000993
Disc Plate Removal Note

1. Mark the wheel hub bolt and disc plate before
04
removal for reference during installation.
MARK
arnffw00000994
Disc Plate Installation Note

1. Remove any rust or grime on the contact face of the disc plate and wheel hub.
2. Install the disc plate and align the marks made before removal.
04-11–9

Outer Shim, Inner shim Installation Note
1. Assemble the rubber coated shim to the back plate of the disc pad.
2. Apply brake grease to the rubber coated shim as
RUBBER COATED SHIM
shown in the figure.
APPLICATION LOCATION
OF GREASE (3 PLACES)
arnffw00000995
3. Assemble the cover-shim to the grease-applied

rubber coated shim. COVER-SHIM
Caution
• Be careful not to get any grease on the
pad lining surface.
arnffw00000996
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
End Of Sie
49 0221 600C
arnffw00000997
04-11–10
F198-10-05L(04-11).fm 11 ページ２００６年８月３日　木曜日　午後１時８分

DISC PAD (FRONT) REPLACEMENT[EVEREST]
id0411008007d4
29—34
1 Bolt 1 {3.0—3.4, 22—25}
2 Caliper 2
3 Guide pin A
A
GREASE
4 Disc pad
(See 04-11-8 FRONT BRAKE (DISC) REMOVAL/ 9 3
INSTALLATION[EVEREST])
A
5 Outer shim (cover shim)
INSTALLATION[EVEREST]) 8 7
6 Outer shim (rubber coated shim) 9
7 Inner shim (cover shim)
(See 04-11-8 FRONT BRAKE (DISC) REMOVAL/ 6
INSTALLATION[EVEREST]) 5
8 Inner shim (rubber coated shim)
(See 04-11-8 FRONT BRAKE (DISC) REMOVAL/ A B
GREASE
GREASE
INSTALLATION[EVEREST]) RUBBER GREASE
4 SST
9 Guide plate
(See 04-11-8 FRONT BRAKE (DISC) REMOVAL/ B B
GREASE
GREASE
INSTALLATION[EVEREST]) BRAKE GREASE
arnffw00000987
End Of Sie
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY[EVEREST]
id0411008010d4
1. Disassemble in the order indicated in the table.
1 Dust seal 4 SST
* 5.9—8.8 N·m {61—89 kgf·cm, 53—77 in·lbf} 04
2 Piston
(See 04-11-12 Piston Disassembly Note) 6
3 Piston seal
4 Bleeder cap 3 R
5 Bleeder screw
6 Caliper SST BRAKE
FLUID
5 2
2. Assemble in the reverse order of removal. 1 R
GREASE
GREASE
RUBBER GREASE
GREASE
*
SST 49 0259 770B
arnffw00000998
04-11–11

Piston Disassembly Note
Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1. Place the SST in the caliper, then blow

compressed air through the hole to force the 49 T033 001A
piston out of the caliper.
End Of Sie
arnffw00000999
REAR BRAKE (DRUM) INSPECTION[EVEREST]

id0411008100d4
Brake Lining Thickness Inspection
1. Remove the brake drum. (See 04-11-13 REAR BRAKE (DRUM) REMOVAL/INSTALLATION[EVEREST].)
2. Inspect the brake lining thickness.
• If it less than the minimum specification,
replace the brake shoe. (See 04-11-13 REAR
BRAKE (DRUM) REMOVAL/
Minimum rear brake lining thickness

1.0 mm {0.04 in}
arnffw00001000
Brake Drum Inspection

1. Remove the brake drum. (See 04-11-13 REAR BRAKE (DRUM) REMOVAL/INSTALLATION[EVEREST].)
2. Inspect the inner diameter of the brake drum.
• If t exceeds the maximum specification,
replace the brake drum. (See 04-11-13 REAR
BRAKE (DRUM) REMOVAL/
Maximum rear brake drum diameter

296.5 mm {11.67 in}
arnffw00001001
3. Apply chalk to the inside of the brake drum, rub it

against the brake shoe, and then inspect for
scratches and uneven or abnormal wear inside
the drum.
• If there is significant uneven wear of the brake
drum, repair it within the maximum brake
drum inner diameter or replace. (See 04-11-
13 REAR BRAKE (DRUM) REMOVAL/
4. After inspection, wipe the chalk off.
End Of Sie
arnffw00001002
04-11–12

REAR BRAKE (DRUM) REMOVAL/INSTALLATION[EVEREST]
id0411008101d4
Warning
• When removing/installing the brake drum component parts, the spring could fly off and cause
injury. Remove/install the spring being careful not to allow the spring to fly off. Wear protective
equipment such as safety glasses if necessary.

3. After installation, pump the brake pedal a few times and inspect the following:
— Parking brake lever stroke
— Brake drag
9.8—12.7
{100—129, 87—112}
11
12.8—21.6
{131—220,
114—191}
SST * 16 15
18 APPLY TO SHADED AREA
GREASE
13
7
6 14
A 10
A
17 4 1
12 3 04
2
9 9.8—14
8 {100—149,
87—130}
5
SST * 49 0259 770B

N·m {kgf·cm, in·lbf}
arnffw00001003
1 Brake drum 9 Lower return spring

(See 04-11-14 Brake Drum Installation Note.) 10 Hold spring (trailing shoe side)
2 Pawl spring 11 Hold pin (trailing shoe side)
3 Pawl lever 12 Parking brake cable
4 Upper return spring 13 Brake shoe (trailing shoe)
(See 04-11-14 Upper Return Spring Removal Note.)
(See 04-11-14 Upper Return Spring Installation 14 U-ring
Note.) 15 Operating lever
5 Hold spring (leading shoe side) 16 Brake pipe
6 Hold pin (leading shoe side) 17 Wheel cylinder
7 Adjust strut 18 Gasket
8 Brake shoe (leading shoe)
04-11–13

Upper Return Spring Removal Note
1. Remove the return spring using a flathead
screwdriver while supporting it with the hand, as
shown in the figure, to prevent it from flying off.
arnffw00001004
Upper Return Spring Installation Note

1. Install the return spring using a flathead
screwdriver while supporting it with the hand, as
shown in the figure, to prevent it from flying off.
arnffw00001004
Brake Drum Installation Note

1. Verify that each component part of the rear brake
(drum) is properly installed as shown in the figure.
arnffw00001005
04-11–14

2. Turn the adjuster on the adjustment strut to adjust M
the brake shoe until the outer diameter (M) of the
brake shoe is as specified below.
Brake shoe adjustment value

294.3—294.7 mm {11.59—10.60 in}
3. Install the brake drum.

4. Depress the brake pedal five times and operate
the auto adjuster.
5. Verify there is no brake drag.
• If there is any brake drag, readjust the brake
arnffw00001006
adjustment
End Of Sie
04
04-11–15
F198-10-05L(04-12).fm 1 ページ２００６年８月３日　木曜日　午前１１時１１分
04-12 PARKING BRAKE SYSTEM

PARKING BRAKE SYSTEM LOCATION PARKING BRAKE CABLE
INDEX[EVEREST] . . . . . . . . . . . . . . . . . 04-12–1 REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 04-12–2
End of Toc
PARKING BRAKE SYSTEM LOCATION INDEX[EVEREST]
WM: PARKING BRAKE SYSTEM
id0412008001c2
3 1 2
2
arnffw00001053
1 Parking brake lever 3 Parking brake switch

2 Parking brake cable 04
(See 04-12-2 PARKING BRAKE CABLE
REMOVAL/INSTALLATION[EVEREST].)
End Of Sie
04-12–1

PARKING BRAKE CABLE REMOVAL/INSTALLATION[EVEREST]
id0412008017c2
1. Remove the fuel tank cover.
2. Remove the brake shoe (trailing shoe). (See 04-11-13 REAR BRAKE (DRUM) REMOVAL/
5. After installation, inspect the parking brake lever stroke.
15.68—21.54
9 {1.599—2.196,
11.57—15.88}
8 7
9 15.68—21.54
{1.599—2.196,
11 11.57—15.88} 10
7
12
15.68—21.54
7 {1.599—2.196,
11.57—15.88}
8 1
1
15.68—21.54
{1.599—2.196,
INSIDE 11.57—15.88}
OF 4
VEHICLE 6
10 11
5
10 4 2
15.68—21.54
11 INSIDE {1.599—2.196,
3 2 6.9—9.8 N·m
{71—99 kgf·cm,
OF 11.57—15.88} 5 15.68—21.54
62—86 in·lbf}
VEHICLE {1.599—2.196,
11.57—15.88}

arnffw00001054
1 Clip 7 Bolt
2 Bolt 8 Spring
3 Spring 9 Clip
4 Bolt 10 Rear parking brake cable (left)
5 Bracket 11 Rear parking brake cable (right)
6 Front parking brake cable 12 Grommet
(See 04-12-2 Front Parking Brake Cable Removal
Note.)
(See 04-12-3 Front Parking Brake Cable Installation
Note.)
Front Parking Brake Cable Removal Note

1. Slide the clip installed to the cable connector in
the direction shown by the arrow.
2. Remove the end of the front parking brake cable
from the cable connector. CABLE
CONNECTER
CLIP
FRONT PARKING BRAKE CABLE

arnffw00000495
04-12–2

Front Parking Brake Cable Installation Note
1. Install the front parking brake cable with the
spring installation area of the equalizer pointed
towards the inside of the vehicle.
End Of Sie
INSIDE
OF
VEHICLE
arnffw00001055
04
04-12–3
F198-10-05L(04-13).fm 1 ページ２００６年８月３日　木曜日　午前１１時１２分
04-13B ANTILOCK BRAKE SYSTEM [4W-ABS]

ABS LOCATION INDEX FRONT ABS WHEEL-SPEED SENSOR
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-13B–1 REMOVAL/INSTALLATION
ABS HU/CM INSPECTION [4W-ABS (EVEREST)] . . . . . . . . . . . . . . 04-13B–4
[4W-ABS (EVEREST)] . . . . . . . . . . . . . 04-13B–2 REAR ABS WHEEL-SPEED SENSOR
[4W-ABS (EVEREST)] . . . . . . . . . . . . . . 04-13B–5
End of Toc
ABS LOCATION INDEX[4W-ABS (EVEREST)]
WM: ANTILOCK BRAKE SYSTEM
id0413c5801100
2
04
arnffw00001319
1 ABS HU/CM 3 Rear ABS wheel-speed sensor

(See 04-13B-2 ABS HU/CM INSPECTION[4W-ABS (See 04-13B-5 REAR ABS WHEEL-SPEED
(EVEREST)]) SENSOR REMOVAL/INSTALLATION[4W-ABS
2 Front ABS wheel-speed sensor (EVEREST)])
(See 04-13B-4 FRONT ABS WHEEL-SPEED 4 G sensor
SENSOR REMOVAL/INSTALLATION[4W-ABS
(EVEREST)])
End Of Sie
04-13B–1

ABS HU/CM INSPECTION[4W-ABS (EVEREST)]
id0413c5801000
1. Disconnect the ABS HU/CM connector.
3. Attach the tester lead to the ABS HU/CM harness side connector, then inspect voltage, continuity or resistance
according to the standard (reference value) on the table.
Standard (Reference Value)

ABS HU/CM WIRING HARNESS-SIDE CONNECTOR
Y W U S Q O M K I G E
D C B A
Z X V T R P N L J H F
arnffw00001320
Measured Measured terminal

Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
Ground Continuity • Wiring harness (A—
A Ground point Continuity A—ground point
(ABS motor) detected ground point)
Power supply
• Wiring harness (B—
B (ABS motor Battery Voltage Under any condition B+
battery)
operation)
Power supply • Wiring harness
C Battery Voltage Under any condition B+
(solenoid) (Cbattery)
Ground Continuity • Wiring harness (D—
D Ground point Continuity D—ground point
(ABS system) detected ground point)
• Wiring harness (E—LF
LF wheel- E—LF ABS wheel-
LF ABS wheel- Continuity ABS wheel-speed
E speed sensor Continuity speed sensor
speed sensor detected sensor connector
(single) connector terminal A
terminal A)
• Wiring harness (F—LF
LF wheel- F—LF ABS wheel-
LF ABS wheel- Continuity ABS wheel-speed
F speed sensor Continuity speed sensor
(ground) connector terminal B
terminal B)
• Wiring harness (G—LR
LR wheel- G—LR ABS wheel-
LR ABS wheel- Continuity ABS wheel-speed
G speed sensor Continuity speed sensor
terminal B)
H — — — — — —
• Wiring harness (I—LR
LR wheel- I—LR ABS wheel-
LR ABS wheel- Continuity ABS wheel-speed
I speed sensor Continuity speed sensor
(signal) connector terminal A
terminal A)
• Wiring harness (J—
Power supply Ignition switch at ON B+
J Ignition switch Voltage ignition switch)
(system)
Ignition switch is off. 1 V or less —
• Wiring harness (K—RR
RR wheel- K—RR ABS wheel-
RR ABS wheel- Continuity ABS wheel-speed
K speed sensor Continuity speed sensor
terminal B)
• Wiring harness (L—RR
RR wheel- L—RR ABS wheel-
RR ABS wheel- Continuity ABS wheel-speed
L speed sensor Continuity speed sensor
terminal A)
• Wiring harness (M—RF
RF wheel- M—RF ABS wheel-
RF ABS wheel- Continuity ABS wheel-speed
M speed sensor Continuity speed sensor
terminal B)
04-13B–2

Measured Measured terminal
Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
N—brake switch
(Brake pedal B+
depressed) • Wiring harness (N—
N Brake switch Brake switch Voltage brake switch)
Y—brake switch • Brake switch
(Brake pedal not 1 V or less
depressed)
• Wiring harness (O—RF
RF wheel- O—RF ABS wheel-
RF ABS wheel- Continuity ABS wheel-speed
O speed sensor Continuity speed sensor
terminal A)
• Wiring harness (P—G
G sensor P—G sensor connector Continuity
P G sensor Continuity sensor connector
(signal) terminal B detected
terminal B)
• Wiring harness (Q—
On-board KLN terminal of Q—DLC-2 connector Continuity
Q Continuity DLC-2 connector
diagnostic DLC-2 terminal KLN detected
terminal KLN)
R — — — — — —
S — — — — — —
T — — — — — —
U — — — — — —
• Wiring harness (V—G
G sensor V—G sensor connector Continuity
V G sensor Continuity sensor connector
(power supply terminal A detected
terminal A)
• Wiring harness (W—G
G sensor W—G sensor
W G sensor Continuity — sensor connector
(ground) connector terminal C
terminal C)
X — — — — — —
Y
Z
—
—
—
—
—
—
—
—
—
—
—
—
04
End Of Sie
04-13B–3

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION[4W-ABS (EVEREST)]
id0413c5800700
1. When removing the ABS wheel-speed sensor on the right side, remove the washer tank installation bolts and
the connector, then move the washer tank to a place out of the way.
VIEW FROM LEFT SIDE
INSERT CLIP SURELY
19—25
2 {2.0—2.5, 15—18}
VIEW FROM FRONT SIDE 19—25

{2.0—2.5, 2
15—18}
2 19—25
{2.0—2.5,
15—18}
2 19—25
{2.0—2.5, 15—18}
DBR413ZWB009
1 Connector 3 Front ABS wheel-speed sensor

2 Bolt
End Of Sie
04-13B–4

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION[4W-ABS (EVEREST)]
id0413c5800500
1
2
18.6—25.5
{1.9—2.6,
13.8—18.8} CLIP
18.6—25.5
2 {1.9—2.6,
7.8—10.8 N·m 13.8—18.8}
2 {80—110 kgf·cm,
70—95 in·lbf}
ABS SENSOR HARNESS SHALL BE
ROUTED ABOVE BRAKE PIPE
7.8—10.8 N·m
2 {80—110 kgf·cm,
3 2 19—25 {1.9—2.6, 14—18}
VIEW FROM ABOVE 70—95 in·lbf}
2 3
1 19—25
{1.9—2.6,
14—18}
2
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
04
18.6—25.5
2 {1.9—2.6,
13.8—18.8}
DBR413ZWB013
1 Connector 3 Rear ABS wheel-speed sensor

2 Bolt
End Of Sie
04-13B–5
F198-10-05L(04-50).fm 1 ページ２００６年８月３日　木曜日　午後１時１３分
TECHNICAL DATA

BRAKE TECHNICAL DATA
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 04-50–1
End of Toc
BRAKE TECHNICAL DATA[EVEREST]
WM: BRAKES
id0450008003b1
Item Specification
Brake fluid type SAE J1703, FMVSS 116 DOT-3
Minimum front disc pad thickness 2.0 mm {0.079 in} min.
Minimum front disc plate thickness 26.0 mm {1.03 in}
Minimum front disc plate thickness after machining
26.8 mm {1.06 in}
using a brake lathe on-vehicle
Front disc plate runout limit 0.05 mm {0.002 in} max.
Minimum rear brake lining thickness 1.0 mm {0.04 in}
Maximum rear brake drum diameter 296.5 mm {11.67 in}
Load sensing proportioning valve (LSPV) fluid pressure

Front wheel cylinder fluid pressure (kPa {kgf/cm2, psi}) Rear wheel cylinder (kPa {kgf/cm2, psi})
4,900 {50, 711} 2,650—3,450 {28—35, 385—500}
9,800 {100, 1,421} 4,700—5,900 {48—60, 682—855}
End Of Sie
04
04-50–1
F198-10-05L(04-60).fm 1 ページ２００６年８月３日　木曜日　午前１１時１３分
SERVICE TOOLS
04-60 SERVICE TOOLS

BRAKES SST[EVEREST]. . . . . . . . . . . . 04-60–1
End of Toc
BRAKES SST[EVEREST]
WM: BRAKES
id0460008001b1
49 0259 770B 49 U043 0A0A 49 U043 004A
Flare nut Oil pressure Oil pressure

wrench gauge set gauge
(Part of 49
U043 0A0A)
49 U043 005 49 U043 006 49 0221 600C
Joint Hose Disc brake

(Part of 49 (Part of 49 expand tool
U043 0A0A) U043 0A0A)
49 T033 001A
Disc brake
piston stopper
— —
04
End Of Sie
04-60–1
F198-10-05L(05-02).fm 1 ページ２００６年８月１０日　木曜日　午後５時２７分
TRANSMISSION/TRANSAXLE 05SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC AUTOMATIC TRANSMISSION
[5R55S] . . . . . . . . . . . . . . . . . 05-02 SHIFT MECHANISM. . . . . . . . 05-14
SYMPTOM TROUBLESHOOTING TECHNICAL DATA[5R55S] . . . 05-50
[5R55S] . . . . . . . . . . . . . . . . . 05-03 SERVICE TOOLS[5R55S] . . . . 05-60
[5R55S] . . . . . . . . . . . . . . . . . 05-13
Toc of SCT
05-02 ON-BOARD DIAGNOSTIC [5R55S]
AUTOMATIC TRANSMISSION DTC P0745, P0748, P0960,
CONTROL SYSTEM P0962, P0963 [5R55S] . . . . . . . . . . . . . . 05-02–22
WIRING DIAGRAM [5R55S] . . . . . . . . . 05-02–2 DTC P0750, P0753 [5R55S]. . . . . . . . . . . 05-02–24
FOREWORD [5R55S] . . . . . . . . . . . . . . . 05-02–3 DTC P0755, P0757, P0758 [5R55S] . . . . 05-02–26
AUTOMATIC TRANSMISSION DTC P0760, P0762, P0763 [5R55S] . . . . 05-02–28
ON-BOARD DIAGNOSTIC DTC P0765, P0768 [5R55S]. . . . . . . . . . . 05-02–30
FUNCTION [5R55S] . . . . . . . . . . . . . . . 05-02–3 DTC P0775, P0778, P0964,
AFTER REPAIR PROCEDURE P0966, P0967 [5R55S] . . . . . . . . . . . . . . 05-02–32
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–4 DTC P0791, P0794 [5R55S]. . . . . . . . . . . 05-02–34
DTC TABLE [5R55S]. . . . . . . . . . . . . . . . 05-02–5 DTC P0795, P0798, P0968,
DTC P0657, P0658 [5R55S] . . . . . . . . . . 05-02–7 P0970, P0971 [5R55S] . . . . . . . . . . . . . . 05-02–36
DTC P0705, P0708, P1702, DTC P1635 [5R55S] . . . . . . . . . . . . . . . . . 05-02–38
P1704, P1705 [5R55S] . . . . . . . . . . . . . 05-02–9 DTC P1700 [5R55S] . . . . . . . . . . . . . . . . . 05-02–38
DTC P0711, P0712, P0713 [5R55S] . . . . 05-02–13 DTC P1711 [5R55S] . . . . . . . . . . . . . . . . . 05-02–39
DTC P0715, P0717, P0718 [5R55S] . . . . 05-02–15 DTC P1780 [5R55S] . . . . . . . . . . . . . . . . . 05-02–40
DTC P0720, P0721, P0722 [5R55S] . . . . 05-02–17 DTC P1783 [5R55S] . . . . . . . . . . . . . . . . . 05-02–42
DTC P0731, P0732, P0733, DTC U0100, U0297 [5R55S] . . . . . . . . . . 05-02–43
P0734, P0735 [5R55S] . . . . . . . . . . . . . 05-02–19 PID/DATA MONITOR INSPECTION
DTC P0740, P0741, P0742,
P0743, P0744 [5R55S] . . . . . . . . . . . . . 05-02–20
[5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–45
05
End of Toc
WM: AUTOMATIC TRANSAXLE
05-02–1

id0502c1811000
IG1 B+ B+
TCM
AT RELAY
BT
CM
CP
CK
OTHER CB CAN_H A
MODULE
SHIFT SOLENOID A
CF CAN_L
B
SHIFT SOLENOID B
C
4x4 BA 4x4 HI
F
MODULE
BB 4x4 LO
SHIFT SOLENOID D
IG1 D
N I
4x4 LO J
M
O/D OFF TFT SENSOR
E AY
BH
K
DIGITAL TR SENSOR
Q
INSTRUMENT
CLUSTER TR3A AX
G
TR1 BY
U
IG1 TR2 BU
O/D OFF SWITCH
TR4 CA
BM
AG
OSS SENSOR CL
AD
CO
AS
ISS SENSOR AO
AM
AK
AP
TSS SENSOR BS
AH
arnffw00001941
End Of Sie
05-02–2

FOREWORD [5R55S]
id0502c1800200
• When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, O/D
OFF indicator light flashing, and TCM memory for diagnostic trouble code (DTC), then diagnose the
malfunction according to following flowchart.
— If the DTC exists, diagnose the applicable DTC. (See 05-02-5 DTC TABLE [5R55S].)
— If the DTC does not exist and the MIL does not illuminate, and the O/D OFF indicator light flashes, diagnose
the applicable symptom troubleshooting. (See05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
VALIDATE CONCERN
WARNING LIGHT* NO WARNING LIGHT*

ON /FLASHING WITH SYMPTOM
INSPECT DTC
INSPECT FOR
IGNITION ON TEST, IDLING
PRIORITIZED DTC
TEST
DTC
NO DTC
DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM

(ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING)
DTC TABLE 1. DIAGNOSTIC INDEX
DTC TROUBLESHOOTING FLOW 2. QUICK DIAGNOSIS CHART
3. SYMPTOM TROUBLESHOOTING
atraaw00003385
*: Malfunction Indicator Lamp (MIL), O/D OFF indicator light 05

End Of Sie
AUTOMATIC TRANSMISSION ON-BOARD DIAGNOSTIC FUNCTION [5R55S]

id0502c1811100
DTC Reading Procedure
1. Perform necessary vehicle preparation and visual inspection.
2. Connect the IDS/PDS to the DLC-2.
items from the initial screen of the IDS/PDS.
• When using the IDS (laptop PC)
1. Select the "Toolbox" tab.
3. Select "Modules".
4. Select "TCM".
• When using the PDS (Pocket PC)
1. Select "Module Tests".
2. Select "TCM". DLC-2
absggw00000987
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the TCM. (See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
End Of Sie
05-02–3

AFTER REPAIR PROCEDURE [5R55S]
id0502c1800400
Caution
• After repairing a malfunction, perform this procedure to verify that the malfunction has been
corrected.
• When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention
to other vehicles.

2. Select “SelfTest”.
3. Select “Modules”.
4. Select “TCM”.
2. Select “TCM”. DLC-2
3. Select “SelfTest”.
absggw00000987
IDS/PDS screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
6. Verify that the ATF level is normal.
7. Turn the O/D OFF switch on (O/D OFF indicator illuminates) and gradually accelerate vehicle speed to 64 km/
h {40 mph}.
• Verify that the transmission shifts to 4GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
8. Turn the O/D OFF switch off (O/D OFF indicator turns off) and accelerate the vehicle speed to 80 km/h {50
mph}.
• Verify that the transmission shifts to 5GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
9. Decelerate using light brake pedal force (Brake light illuminates). Maintain this condition for 5 s or more.
10. Stop the vehicle for approx. 20 s.
11. Repeat Steps 7—10 five times.
12. Gradually slow down and stop the vehicle.
13. Make sure that the repaired DTC does not recur.
End Of Sie
05-02–4

DTC TABLE [5R55S]
id0502c1800500
DTC No. Condition Page

P0657 Solenoid valve power supply circuit open (See 05-02-7 DTC P0657, P0658 [5R55S].)
P0658 Solenoid valve power supply circuit voltage low (See 05-02-7 DTC P0657, P0658 [5R55S].)
Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P0705
(invalid bit pattern) P1705 [5R55S].)
Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P0708
(TR3A circuit open) P1705 [5R55S].)
Transmission fluid temperature (TFT) sensor malfunction
P0711 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
(ATF temperature no change)
Transmission fluid temperature (TFT) sensor circuit
P0712 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
malfunction (short to ground)
Transmission fluid temperature (TFT) sensor circuit
P0713 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
malfunction (open circuit)
P0715 Turbine shaft speed (TSS) sensor malfunction (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0717 Turbine shaft speed (TSS) sensor signal is not input (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0718 Turbine shaft speed (TSS) sensor signal noise (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0720 Output shaft speed (OSS) sensor malfunction (See 05-02-17 DTC P0720, P0721, P0722 [5R55S].)
P0721 Output shaft speed (OSS) sensor signal noise (See 05-02-17 DTC P0720, P0721, P0722 [5R55S].)
P0722 Output shaft speed (OSS) sensor signal is not input (See 05-02-17 DTC P0720, P0721, P0722 [5R55S].)
(See 05-02-19 DTC P0731, P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731, P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731, P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731, P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731, P0732, P0733, P0734,
P0735 [5R55S].)
Torque converter clutch (TCC) control solenoid circuit (See 05-02-20 DTC P0740, P0741, P0742, P0743,
P0740
malfunction (open circuit) P0744 [5R55S].)
P0741
Torque converter clutch (TCC) control solenoid circuit (See 05-02-20 DTC P0740, P0741, P0742, P0743, 05
malfunction (stuck off) P0744 [5R55S].)
P0742
malfunction (stuck on) P0744 [5R55S].)
P0743
malfunction (open or short circuit) P0744 [5R55S].)
P0744
malfunction (short to power) P0744 [5R55S].)
(See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0745 Pressure control solenoid A malfunction (low pressure)
P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (non- (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0748
operation) P0963 [5R55S].)
P0750 Shift solenoid A circuit malfunction (open or short circuit) (See 05-02-24 DTC P0750, P0753 [5R55S].)
P0753 Shift solenoid A circuit malfunction (open or short circuit) (See 05-02-24 DTC P0750, P0753 [5R55S].)
P0755 Shift solenoid B circuit malfunction (open or short circuit) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0757 Shift solenoid B malfunction (stuck on) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0758 Shift solenoid B circuit malfunction (open or short circuit) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0760 Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0762 Shift solenoid C malfunction (stuck on) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0763 Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0765 Shift solenoid D circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
P0768 Shift solenoid D circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
(See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0775 Pressure control solenoid B malfunction (low pressure)
P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (non- (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0778
P0791 Intermediate shaft speed (ISS) sensor malfunction (See 05-02-34 DTC P0791, P0794 [5R55S].)
05-02–5

DTC No. Condition Page
P0794 Intermediate shaft speed (ISS) sensor signal noise (See 05-02-34 DTC P0791, P0794 [5R55S].)
(See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0795 Pressure control solenoid C malfunction (low pressure)
P0971 [5R55S].)
Pressure control solenoid C circuit malfunction (non- (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0798
Pressure control solenoid A circuit malfunction (open (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0960
circuit) P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0962
ground) P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0963
power supply) P0963 [5R55S].)
Pressure control solenoid B circuit malfunction (open (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0964
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0966
ground) P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0967
Pressure control solenoid C circuit malfunction (open (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0968
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0970
ground) P0971 [5R55S].)
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0971
P1635 Tire/axle ratio out of acceptable range (See 05-02-38 DTC P1635 [5R55S].)
P1700 Transmission indeterminate malfunction (See 05-02-38 DTC P1700 [5R55S].)
(See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1702 Digital transmission range (TR) sensor circuit intermittent
P1705 [5R55S].)
Digital transmission range (TR) sensor circuit not (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1704
indicating P or N position during on-board diagnostic P1705 [5R55S].)
Digital transmission range (TR) sensor circuit not (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1705
indicating P or N position during on-board diagnostic P1705 [5R55S].)
P1711 ATF temperature out of on-board diagnostic range (See 05-02-39 DTC P1711 [5R55S].)
P1780 O/D OFF switch circuit malfunction (open or short circuit) (See 05-02-40 DTC P1780 [5R55S].)
P1783 ATF overheating (See 05-02-42 DTC P1783 [5R55S].)
U0100 Communication error to PCM (See 05-02-43 DTC U0100, U0297 [5R55S].)
U0294 Communication error to PCM (See 05-02-43 DTC U0100, U0297 [5R55S].)
End Of Sie
05-02–6

DTC P0657, P0658 [5R55S]
id0502c1814400
DTC P0657 Solenoid valve power supply circuit open

DTC P0658 Solenoid valve power supply circuit voltage low
DETECTION • P0657: Open circuit in circuit between solenoid valve and TCM
CONDITION • P0658: Short circuit in circuit between solenoid valve and TCM
• Short to ground in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal
CK (wiring harness-side).
POSSIBLE • Open circuit in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal CK
CAUSE (wiring harness-side).
• Damaged connector between shift AT connector and TCM.
• TCM malfunction.
TCM AT AT CONNECTOR WIRING

HARNESS-SIDE CONNECTOR
4
5 3
6 7 SOLENOID VALVE
CK I
B E G I K M
C P
A N
D F H J L O
* *
TCM WIRING HARNESS-SIDE

CONNECTOR
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
CK CN
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
CL CO
C
D
G
H
K
L
O S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ
CM CP 05
05-02–7

1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Information.
• Verify related Service Information availability. • If the vehicle is not repaired, go to the next step.
• Is any related Service Information available? No Go to the next step.
3 INSPECT AT CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace the connector and/or terminals, then go
• Turn the engine switch to the LOCK position. to Step 8.
• Inspect AT connector connection.
• Disconnect the AT connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is the connection normal?
4 INSPECT POWER SUPPLY CIRCUIT Yes Go to Step 8.
• Turn the engine switch to the ON position No Go to the next step.
(engine off).
• Inspect voltage at AT connector terminal H
(wiring harness-side).
• Is the voltage approx. 12 V?
5 INSPECT TCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace connector and/or terminals, then go to
• Turn the engine switch to the LOCK position. Step 8.
• Disconnect the TCM connector.
6 INSPECT SOLENOID POWER SUPPLY CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between the TCM
terminal CK (wiring harness-side) and the AT
connector terminal I (wiring harness-side).
• Is there continuity between terminals?
7 INSPECT SOLENOID POWER SUPPLY CIRCUIT Yes Repair or replace the wiring harness, then go to the Step 8.
• Inspect continuity between AT connector
terminal H (wiring harness-side) and body
ground.
8 VERIFY TROUBLESHOOTING OF DTC P0657 Yes Replace the TCM, then go to the next step.
OR P0658 COMPLETED (See 05-13-44 TCM REMOVAL/INSTALLATION [5R55S].)
• Make sure to reconnect all the disconnected No Go to the next step.
connectors.
• Clear the DTC from memory using the IDS/
PDS.
• Perform the “After Repair Procedure”.
(See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
9 VERIFY DTCS Yes Go to the applicable DTC inspection.
• Are DTCs except for P0657 and P0658 output? (See 05-02-5 DTC TABLE [5R55S].)
End Of Sie
05-02–8

DTC P0705, P0708, P1702, P1704, P1705 [5R55S]
id0502c1814500
DTC P0705Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
DTC P0708Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
DTC P1702Digital transmission range (TR) sensor circuit intermittent
Digital transmission range (TR) sensor circuit not indicating P or N position during on-board
DTC P1704
diagnostic
DTC P1705
diagnostic
• P0705: Open circuit or short to ground in wiring harness between digital TR sensor terminal and TCM
terminal or in digital TR sensor internal circuit (invalid bit pattern)
• P0708: Open circuit in wiring harness between digital TR sensor and TCM terminal or in digital TR sensor
DETECTION
internal circuit (TR3 circuit)
CONDITION
• P1702: TCM cannot detect a signal from digital TR sensor
• P1704: PID TR_D not indicating P or N position, digital TR sensor or selector cable misalignment
• P1705: On-board diagnostic not performed in P or N position
• Digital TR sensor or selector cable misadjustment
• Short to ground in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Short to ground in wiring harness between digital TR sensor terminal E and TCM terminal BY
• Short to ground in wiring harness between digital TR sensor terminal C and TCM terminal BU
• Short to ground in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Short to ground in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Open circuit in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Open circuit in wiring harness between digital TR sensor terminal E and TCM terminal BY
POSSIBLE
• Open circuit in wiring harness between digital TR sensor terminal C and TCM terminal BU
CAUSE
• Open circuit in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Open circuit in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Short to power supply in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Short to power supply in wiring harness between digital TR sensor terminal E and TCM terminal BY
• Short to power supply in wiring harness between digital TR sensor terminal C and TCM terminal BU
• Short to power supply in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Short to power supply in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Damaged connectors between digital TR sensor and TCM
• TCM malfunction
05
05-02–9

DTC P0705 Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
DTC P0708 Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
DTC P1702 Digital transmission range (TR) sensor circuit intermittent
DTC P1704
diagnostic
DTC P1705
diagnostic
DIGITAL TR SENSOR WIRING DIGITAL TR SENSOR 3 7 TCM

6 9 10 11 8
A C E G I K G AX TR3A
B D F H J L
6 9 10 11 8
E BY TR1
6 8
9 10 11
C BU TR2
AT CONNECTOR WIRING 6 9 10 11 8
A CA TR4
6 8
9 10 11
B E G I K M I BH
C P
A N
D F H J L O
CONNECTOR
CK CN
CL CO
C G K O S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
CM CP
D H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ
05-02–10

recorded?
3 VERIFY DIGITAL TR SENSOR ALIGNMENT Yes Connect the selector cable to the manual lever, then go to
• Select the N position. the next step.
• Turn the engine switch to the LOCK position. No Adjust the digital TR sensor, then go to Step 12.
• Disconnect the selector cable from the manual (See 05-13-24 DIGITAL TRANSMISSION RANGE (TR)
lever. SENSOR ADJUSTMENT [5R55S].)
• Verify that the SST (307-351 (49 UN30 7351))
fits in the appropriate slots of digital TR sensor.
• Is the digital TR sensor correctly adjusted?
4 VERIFY SELECTOR CABLE ADJUSTMENT Yes Go to the next step.
• Turn the engine switch to the ON position. No Adjust the selector cable, then go to Step 12.
• Verify that the selector cable is correctly (See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
adjusted.
(See 05-14-2 SELECTOR CABLE
ADJUSTMENT.)
• Is the selector cable is correctly adjusted?
5 INSPECT ELECTRICAL SYSTEM OPERATION Yes Go to Step 12.
• Connect the IDS/PDS to DLC-2. No Go to the next step.
• Access TR_D and TR_V PIDs.
• Move the selector lever into each range and
position (P, R, N, D, 3, 2, 1).
• Observe the PIDs, TR D and TR V (vehicle-
dependent) while wiggling wiring harness,
tapping on sensor or driving the vehicle.
— Use PIDs TR_D for DTCs P0705, P1704
and P1705.
— Use PIDs TR_V for DTC P0708.
6
• Are the PIDs within the specification?
INSPECT DIGITAL TR SENSOR CONNECTOR Yes Go to the next step.
05
FOR POOR CONNECTION No Repair or replace connector and/or terminal, then go to
• Disconnect the digital TR sensor connector.
pulled-out pins, corrosion)
7 INSPECT DIGITAL TR SENSOR Yes Go to the next step.
• Inspect the digital TR sensor. No Replace the digital TR sensor, then go to Step 12.
(See 05-13-20 DIGITAL TRANSMISSION (See 05-13-22 DIGITAL TRANSMISSION RANGE (TR)
RANGE (TR) SENSOR INSPECTION SENSOR REMOVAL/INSTALLATION [5R55S].)
[5R55S].)
• Is digital TR sensor normal?
• Disconnect the TCM connector. to Step 12.
9 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Repair or replace the wiring harness, then go to Step 12.
SHORT TO GROUND No Go to the next step.
• Inspect continuity between digital TR sensor
terminals (wiring harness-side) and body
ground.
— G and body ground
— E and body ground
— C and body ground
— A and body ground
— I and body ground
05-02–11

10 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Go to the next step.
SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to Step 12.
• Turn the engine switch to the ON position
(engine off).
• Inspect the voltage at digital TR sensor
terminals G, E, C, A and I (wiring harness-
side).
• Is the voltage 0 V?
11 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to the next
• Inspect the following digital TR sensor step.
terminals (wiring harness-side) and TCM
terminals (wiring harness-side):
— G and AX
— E and BY
— C and BU
— A and CA
— I and BH
12 VERIFY TROUBLESHOOTING OF DTC P0705, Yes Replace the TCM, then go to the next step.
P0708, P1702, P1704 OR P1705 COMPLETED (See 05-13-44 TCM REMOVAL/INSTALLATION [5R55S].)
connectors.
• Clear the DTC from the memory using the IDS/
PDS.
[5R55S].)
• Is the same DTC present?
• Are DTCs except for P0705, P0708, P1702, (See 05-02-5 DTC TABLE [5R55S].)
P1704 and P1705 output? No DTC troubleshooting completed.
End Of Sie
05-02–12

DTC P0711, P0712, P0713 [5R55S]
id0502c1814600
DTC P0711Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
DTC P0712Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
DTC P0713Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
• P0711: ATF temperature signal continually reading cold or hot
DETECTION
• P0712: TCM detects that ATF signal output from ATF sensor is 157° C {315° F} or more
CONDITION
• P0713: TCM detects ATF signal from ATF sensor is –40° C {–40° F} or less
• TFT sensor malfunction
• Short to ground in wiring harness between AT connector terminal K and TCM terminal AY
• Short to ground in wiring harness between AT connector terminal L and TCM terminal BH
POSSIBLE
• Open circuit supply in wiring harness between AT connector terminal K and TCM terminal AY
CAUSE
• Open circuit supply in wiring harness between AT connector terminal L and TCM terminal BH
• Damaged connectors between AT connector and TCM
• TCM malfunction
AT CONNECTOR WIRING AT TCM

4 3 5
TFT SENSOR 6 7
K AY
B E G I K M
C P
A N
D F H J L O
3 5
6 7
L BH

CONNECTOR
CK CN
05
CL CO
CM CP
05-02–13

recorded?
• Inspect the AT connector connection.
4 INSPECT TFT SENSOR Yes Go to the next step.
• Inspect the TFT sensor. No Replace the TFT sensor, then go to Step 8.
(See 05-13-26 TRANSMISSION FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [5R55S])
• Is the digital TR sensor normal?
6 INSPECT TFT SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
TO GROUND No Go to the next step.
• Inspect for continuity between the AT terminals
(wiring harness-side) and body ground.
— K and body ground
— L and body ground
7 INSPECT TFT SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness, then go to Step 8.
• Inspect the following AT terminals (wiring
harness-side) and TCM terminals (wiring
harness-side):
— K and AY
— L and BH
P0712 OR P0713 COMPLETED (See 05-13-44 TCM REMOVAL/INSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
• Is the same DTC present?
• Are DTCs except for P0711, P0712 and P0713 (See 05-02-5 DTC TABLE [5R55S].)
output? No DTC troubleshooting completed.
End Of Sie
05-02–14

DTC P0715, P0717, P0718 [5R55S]
id0502c1806200
DTC P0715Turbine shaft speed (TSS) sensor malfunction

DTC P0717Turbine shaft speed (TSS) sensor signal is not input.
DTC P0718Turbine shaft speed (TSS) sensor signal noise
• P0715: TCM detects insufficient TSS sensor signal while driving
DETECTION
• P0717: TCM detects that TSS sensor is not input while driving
CONDITION
• P0718: TCM detects intermittent TSS sensor signal input while driving
• TSS sensor malfunction.
• Short to ground in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal
AP (wiring harness-side).
• Open circuit in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal AP
POSSIBLE
CAUSE
• Open circuit in wiring harness between TSS sensor terminal B (wiring harness-side) and TCM terminal AH
• Damaged connectors between TSS sensor and TCM.
TCM
TSS SENSOR WIRING TSS SENSOR 5

4 6
AP
3
A
A B 7
B
5
3 6
AH

CONNECTOR 05
CK CN
B F J N R Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
V
CL CO
CM CP
05-02–15

recorded?
3 INSPECT TSS SENSOR CONNECTOR FOR Yes Go to the next step.
POOR CONNECTION No Repair or replace connector and/or terminal, then go to
• Disconnect the TSS sensor connector.
4 INSPECT TSS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between TSS sensor
connector A (wiring harness-side) and body
ground.
6 INSPECT TSS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following TSS sensor terminals
(wiring harness-side) and TCM terminals
(wiring harness-side):
— A and AP
— B and AH
7 INSPECT TSS SENSOR Yes Go to the next step.
• Inspect the TSS sensor. No Replace the TSS sensor, then go to the next step.
(See 05-13-28 TURBINE SHAFT SPEED (See 05-13-29 TURBINE SHAFT SPEED (TSS) SENSOR
(TSS) SENSOR INSPECTION [5R55S]) REMOVAL/INSTALLATION [5R55S].)
• Is TSS sensor normal?
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–16

DTC P0720, P0721, P0722 [5R55S]
id0502c1806300
DTC P0720Output shaft speed (OSS) sensor malfunction

DTC P0721Output shaft speed (OSS) sensor signal noise
DTC P0722Output shaft speed (OSS) sensor signal is not input.
• P0720: TCM detects insufficient OSS sensor signal while driving
DETECTION
• P0721: TCM detects intermittent OSS sensor signal input while driving
CONDITION
• P0722: TCM detects that OSS sensor is not input while driving
• OSS sensor malfunction.
• Short to ground in wiring harness between OSS sensor terminal A (wiring harness-side) and TCM terminal
AG (wiring harness-side).
• Open circuit in wiring harness between OSS sensor terminal A (wiring harness-side) and TCM terminal AG
POSSIBLE
CAUSE
• Open circuit in wiring harness between OSS sensor terminal B (wiring harness-side) and TCM terminal AD
• Damaged connectors between OSS sensor and TCM.
TCM
OSS SENSOR WIRING OSS SENSOR 5

4 6
AG
3
A
A B 7
B
5
3 6
AD

CONNECTOR 05
CK CN
V
CL CO
CM CP
05-02–17

recorded?
3 INSPECT OSS SENSOR CONNECTOR FOR Yes Go to the next step.
• Disconnect the OSS sensor connector.
4 INSPECT OSS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 9.
• Inspect for continuity between OSS sensor
ground.
6 INSPECT OSS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following OSS sensor terminals
— A and AG
— B and AD
7 INSPECT OSS SENSOR Yes Go to the next step.
• Inspect the OSS sensor. No Replace the OSS sensor, then go to the next step.
(See 05-13-32 OUTPUT SHAFT SPEED (See 05-13-33 OUTPUT SHAFT SPEED (OSS) SENSOR
(OSS) SENSOR INSPECTION [5R55S]) REMOVAL/INSTALLATION [5R55S].)
• Is OSS sensor normal?
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–18

DTC P0731, P0732, P0733, P0734, P0735 [5R55S]
id0502c1814700
DTC P0731Gear 1 incorrect

• P0731: Does not shift to 1st gear while driving
• P0732: Does not shift to 2nd gear while driving
DETECTION
• P0733: Does not shift to 3rd gear while driving
CONDITION
• P0734: Does not shift to 4th gear while driving
• P0735: Does not shift to 5th gear while driving
• Shift solenoid A malfunction
• Shift solenoid B malfunction
POSSIBLE • Shift solenoid C malfunction
CAUSE • Shift solenoid D malfunction
• Transmission internal malfunction
• TCM malfunction
• Turn the engine switch to the LOCK position, (See 05-02-5 DTC TABLE [5R55S].)
then to the ON position. No Go to the next step.
• Verify the DTCs in the TCM memory.
• Are DTCs except for P0731, P0732, P0733,
P0734 and P0735 output?
3 SHIFT SOLENOID OPERATION INSPECTION Yes Go to the next step.
• Drive in D range. No Replace the solenoid body component, then go to Step 5.
• Connect the IDS/PDS to the DLC-2 and select (See 05-13-35 SOLENOID BODY REMOVAL/
the following PIDs. INSTALLATION [5R55S].)
— SSA
— SSB
05
— SSC
— SSD
• Using the IDS/PDS, verify the operation status
of shift solenoid A, B, C and D while driving.
— 1GR: SSA on, SSB off, SSC off, SSD on
— 2GR: SSA on, SSB off, SSC on, SSD on
— 3GR: SSA on, SSB on, SSC off, SSD on
— 4GR: SSA off, SSB off, SSC off, SSD on
— 5GR: SSA off, SSB off, SSC on, SSD on
• Is the shift solenoid operation normal?
4 INSPECT ROAD TEST Yes Go to the next step.
• Road-test the vehicle to verify the respective No Inspect the symptom troubleshooting, then go to the next
shift points. step.
(See 05-13-8 ROAD TEST [5R55S].) (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
• Are the shift points normal? TABLE [5R55S].)
connectors.
• Clear the DTC using the IDS/PDS.
• Start the engine.
[5R55S].)
05-02–19

End
DTC Of Sie P0741, P0742, P0743, P0744 [5R55S]
P0740,
id0502c1814800
DTC P0740Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
DTC P0741Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
DTC P0742Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
DTC P0743Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
DTC P0744Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
• P0740: Open circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid internal
circuit.
• P0741: Torque converter clutch slipping indicating a mechanical or hydraulic concern.
• P0742: Short to ground in circuit between TCC control solenoid and TCM, or in TCC control solenoid
DETECTION
internal circuit.
CONDITION
• P0743: Open or short circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
• P0744: Short to power supply in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
• TCC control solenoid malfunction.
• Short to ground in wiring harness between AT connector terminal H (wiring harness-side) and TCM
terminal A (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal H (wiring harness-side) and TCM
POSSIBLE
terminal A (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal CK
• Open circuit in wiring harness between AT connector terminal H (wiring harness-side) and TCM terminal A
• Damaged connector between AT connector and TCM.

4 HARNESS-SIDE CONNECTOR
TCC CONTROL
6 7 8 3 SOLENOID
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
A H

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–20

4 INSPECT POWER SUPPLY CIRCUIT Yes Go to the next step.
• Turn the engine switch to the ON position No Go to Step 6.
(engine off).
• Inspect voltage at AT connector terminal I
5 INSPECT RESISTANCE Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Replace the TCC control solenoid, then go to Step 10.
• Inspect resistance between AT terminal I and H
(transmission case side).
• Is resistance within 9—16 ohms?
(See 05-13-34 SOLENOID VALVE
INSPECTION [5R55S].)
• Disconnect the TCM connector. Step 10.
7 INSPECT TCC CONTROL SOLENOID CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
terminal (wiring harness-side) and the AT
connector terminal (wiring harness-side).
— CK and I 05
— A and H
8 INSPECT TCC CONTROL SOLENOID CIRCUIT Yes Repair or replace the wiring harness, then go to the Step
FOR SHORT TO GROUND 10.
• Inspect for continuity between AT connector No Go to the next step.
terminal (wiring harness-side) and body
ground.
— H and body ground
9 INSPECT TCC CONTROL SOLENOID CIRCUIT Yes Go to the next step.
FOR SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to the next
• Turn the engine switch to the ON position step.
(engine off).
• Inspect voltage at AT connector terminal H
connectors.
PDS.
[5R55S].)
05-02–21

End
DTC Of Sie P0748, P0960, P0962, P0963 [5R55S]
P0745,
id0502c1815300
DTC P0745Pressure control solenoid A malfunction (low pressure)

DTC P0748Pressure control solenoid A circuit malfunction (not operation)
DTC P0960Pressure control solenoid A circuit malfunction (open circuit)
DTC P0962Pressure control solenoid A circuit malfunction (short to ground)
DTC P0963Pressure control solenoid A circuit malfunction (short to power supply)
• P0745: Incorrect shift pattern indicating mechanical or hydraulic failure in the transmission.
• P0748: Possible slip in gear and/or 3GR ratio.
• P0960: Open circuit in circuit between pressure control solenoid O and TCM, or in pressure control
DETECTION solenoid A internal circuit.
CONDITION • P0962: Short to ground in circuit between pressure control solenoid A and TCM, or in pressure control
solenoid A internal circuit.
• P0963: Short to power supply in circuit between pressure control solenoid A and TCM, or in pressure
control solenoid A internal circuit.
• Pressure control solenoid A malfunction.
• Short to ground in wiring harness between AT connector terminal O (wiring harness-side) and TCM
terminal I (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal O (wiring harness-side) and TCM
POSSIBLE
terminal I (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal O (wiring harness-side) and TCM terminal I

PRESSURE CONTROL
6 7 8 3 SOLENOID A
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
I O

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–22

(engine off).
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid A, then go to Step
• Inspect resistance between AT terminal I and O 10.
• Is resistance within 3.3—7.5 ohms?
7 INSPECT PRESSURE CONTROL SOLENOID A Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
— CK and I 05
— I and O
8 INSPECT PRESSURE CONTROL SOLENOID A Yes Repair or replace the wiring harness, then go to the Step
CIRCUIT FOR SHORT TO GROUND 10.
• Inspect continuity between AT connector No Go to the next step.
ground.
— O and body ground
9 INSPECT PRESSURE CONTROL SOLENOID A Yes Go to the next step.
CIRCUIT FOR SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect voltage at AT connector terminal O
connectors.
PDS.
[5R55S].)
05-02–23

End
DTC Of Sie P0753 [5R55S]
P0750,
id0502c1814900
DTC P0750Shift solenoid A circuit malfunction (open or short circuit)

DTC P0753Shift solenoid A circuit malfunction (open or short circuit)
• P0750: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
DETECTION circuit.
CONDITION • P0753: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
circuit.
• Shift solenoid A malfunction.
• Short to ground in wiring harness between AT connector terminal D (wiring harness-side) and TCM
terminal B (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal D (wiring harness-side) and TCM
POSSIBLE
terminal B (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal D (wiring harness-side) and TCM terminal B

6 7 8 3 SHIFT SOLENOID A
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
B D

CONNECTOR
J CK CN
B F N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
CL CO
CM CP
recorded?
05-02–24

(engine off).
• Inspect the voltage at AT connector terminal I
• Turn the engine switch to the LOCK position. No Replace the shift solenoid A, then go to Step 10.
• Inspect resistance between AT terminal I and D
7 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
— CK and I
— B and D
8 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step 05
SHORT TO GROUND 10.
ground.
— D and body ground
9 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Go to the next step.
SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect voltage at AT connector terminal D
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–25

DTC P0755, P0757, P0758 [5R55S]
id0502c1815000
DTC P0755Shift solenoid B circuit malfunction (open or short circuit)

DTC P0757Shift solenoid B malfunction (stuck on)
DTC P0758Shift solenoid B circuit malfunction (open or short circuit)
• P0755: Open or short circuit in circuit between shift solenoid B and TCM, or in shift solenoid B internal
circuit.
DETECTION
• P0757: Shift solenoid B mechanically stuck on.
CONDITION
• P0758: Open or short circuit in circuit between shift solenoid B and TCM, or in shift solenoid B internal
circuit.
• Shift solenoid B malfunction.
• Short to ground in wiring harness between AT connector terminal F (wiring harness-side) and TCM
terminal C (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal F (wiring harness-side) and TCM
POSSIBLE
terminal C (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal F (wiring harness-side) and TCM terminal C

6 7 8 3 SHIFT SOLENOID B
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
C F

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–26

(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid B, then go to Step 10.
• Inspect resistance between AT terminal I and F
7 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Go to the next step.
— CK and I
— C and F
8 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step 05
SHORT TO GROUND 10.
• Inspect continuity between AT connector No Go to the next step.
ground.
— F and body ground
9 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect voltage at AT connector terminal F
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–27

DTC P0760, P0762, P0763 [5R55S]
id0502c1815100
DTC P0760Shift solenoid C circuit malfunction (open or short circuit)

DTC P0762Shift solenoid C malfunction (stuck on)
DTC P0763Shift solenoid C circuit malfunction (open or short circuit)
• P0760: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
DETECTION
• P0762: Shift solenoid C mechanically stuck on.
CONDITION
• P0763: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
• Shift solenoid C malfunction.
• Short to ground in wiring harness between AT connector terminal B (wiring harness-side) and TCM
terminal F (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal B (wiring harness-side) and TCM
POSSIBLE
terminal F (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal B (wiring harness-side) and TCM terminal F

6 7 8 3 SHIFT SOLENOID C
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
F B

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–28

(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid C, then go to Step 10.
• Inspect the resistance between AT terminal I
and B (transmission case side).
7 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Go to the next step.
— CK and I
— F and B
8 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step 05
SHORT TO GROUND 10.
ground.
— B and body ground
9 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal B
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–29

DTC P0765, P0768 [5R55S]
id0502c1815200
DTC P0765Shift solenoid D circuit malfunction (open or short circuit)

DTC P0768Shift solenoid D circuit malfunction (open or short circuit)
• P0765: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
DETECTION circuit.
CONDITION • P0768: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
circuit.
• Shift solenoid D malfunction.
• Short to ground in wiring harness between AT connector terminal E (wiring harness-side) and TCM
terminal D (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal E (wiring harness-side) and TCM
POSSIBLE
terminal D (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal E (wiring harness-side) and TCM terminal D

6 7 8 3 SHIFT SOLENOID D
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
D E

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–30

(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid D, then go to Step 10.
• Inspect resistance between AT terminal I and E
7 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Go to the next step.
— CK and I
— D and E
8 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step 05
SHORT TO GROUND 10.
ground.
— E and body ground
9 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal E
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–31

DTC P0775, P0778, P0964, P0966, P0967 [5R55S]
id0502c1815400
DTC P0775Pressure control solenoid B malfunction (low pressure)

DTC P0778Pressure control solenoid B circuit malfunction (not operation)
DTC P0964Pressure control solenoid B circuit malfunction (open circuit)
DTC P0966Pressure control solenoid B circuit malfunction (short to ground)
DTC P0967Pressure control solenoid B circuit malfunction (short to power supply)
• P0778: Incorrect gear ratio in 2GR and 5GR.
• P0964: Open circuit in circuit between pressure control solenoid B and TCM, or in pressure control
DETECTION solenoid B internal circuit.
CONDITION • P0966: Short to ground in circuit between pressure control solenoid B and TCM, or in pressure control
solenoid B internal circuit.
• P0967: Short to power supply in circuit between pressure control solenoid B and TCM, or in pressure
control solenoid B internal circuit.
• Pressure control solenoid B malfunction.
• Short to ground in wiring harness between AT connector terminal M (wiring harness-side) and TCM
terminal J (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal M (wiring harness-side) and TCM
POSSIBLE
terminal J (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal M (wiring harness-side) and TCM terminal J

PRESSURE CONTROL
6 7 8 3 SOLENOID B
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
J M

CONNECTOR
B F J N R VZ AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH CK CN
CL CO
CM CP
recorded?
05-02–32

(engine off).
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid B, then go to Step
• Inspect resistance between AT terminal I and 10.
M (transmission case side).
7 INSPECT PRESSURE CONTROL SOLENOID B Yes Go to the next step.
— CK and I 05
— J and M
8 INSPECT PRESSURE CONTROL SOLENOID B Yes Repair or replace the wiring harness, then go to the Step
ground.
— M and body ground
9 INSPECT PRESSURE CONTROL SOLENOID B Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal M
connectors.
PDS.
[5R55S].)
05-02–33

End
DTC Of Sie P0794 [5R55S]
P0791,
id0502c1814100
DTC P0791 Intermediate shaft speed (ISS) sensor malfunction

DTC P0794 Intermediate shaft speed (ISS) sensor signal noise
DETECTION • P0791: TCM detects insufficient ISS sensor signal while driving
CONDITION • P0794: TCM detects intermittent ISS sensor signal input while driving
• ISS sensor malfunction.
• Short to ground in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal
AS (wiring harness-side).
• Open circuit in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal AS
POSSIBLE
CAUSE
• Open circuit in wiring harness between ISS sensor terminal B (wiring harness-side) and TCM terminal AM
• Damaged connectors between ISS sensor and TCM.
TCM
ISS SENSOR WIRING ISS SENSOR 5

4 6
AS
3
A
A B 7
B
5
3 6
AM

CONNECTOR
A E I M Q Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
U
CK CN
V
CL CO
CM CP
05-02–34

recorded?
3 INSPECT ISS SENSOR CONNECTOR FOR Yes Go to the next step.
• Disconnect the ISS sensor connector.
4 INSPECT ISS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between ISS sensor
ground.
6 INSPECT ISS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following ISS sensor terminals
— A and AS
— B and AM
• Is there continuity? 05
7 INSPECT ISS SENSOR Yes Go to the next step.
• Inspect the ISS sensor. No Replace the ISS sensor, then go to the next step.
(See 05-13-30 INTERMEDIATE SHAFT (See 05-13-31 INTERMEDIATE SHAFT SPEED (ISS)
SPEED (ISS) SENSOR INSPECTION SENSOR REMOVAL/INSTALLATION [5R55S].)
[5R55S])
• Is ISS sensor normal?
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–35

DTC P0795, P0798, P0968, P0970, P0971 [5R55S]
id0502c1815500
DTC P0795Pressure control solenoid C malfunction (low pressure)

DTC P0798Pressure control solenoid C circuit malfunction (not operation)
DTC P0968Pressure control solenoid C circuit malfunction (open circuit)
DTC P0970Pressure control solenoid C circuit malfunction (short to ground)
DTC P0971Pressure control solenoid C circuit malfunction (short to power supply)
• P0798: Incorrect gear ratio in 4GR and 5GR.
• P0968: Open circuit in circuit between pressure control solenoid C and TCM, or in pressure control
DETECTION solenoid C internal circuit.
CONDITION • P0970: Short to ground in circuit between pressure control solenoid C and TCM, or in pressure control
solenoid C internal circuit.
• P0971: Short to power supply in circuit between pressure control solenoid C and TCM, or in pressure
control solenoid C internal circuit.
• Pressure control solenoid C malfunction.
• Short to ground in wiring harness between AT connector terminal G (wiring harness-side) and TCM
terminal M (wiring harness-side).
• Short to power supply in wiring harness between AT connector terminal G (wiring harness-side) and TCM
POSSIBLE
terminal M (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal G (wiring harness-side) and TCM terminal M

PRESSURE CONTROL
6 7 8 3 SOLENOID C
CK I
B E G I K M
C P
5 A N
D F H J L O
6 7 8 9 3
M G

CONNECTOR
CK CN
CL CO
CM CP
recorded?
05-02–36

(engine off).
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid C, then go to Step
• Inspect resistance between AT terminal I and G 10.
7 INSPECT PRESSURE CONTROL SOLENOID C Yes Go to the next step.
— CK and I 05
— M and G
8 INSPECT PRESSURE CONTROL SOLENOID C Yes Repair or replace the wiring harness, then go to the Step
ground.
— G and body ground
9 INSPECT PRESSURE CONTROL SOLENOID C Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal G
connectors.
PDS.
[5R55S].)
05-02–37

End
DTC Of Sie [5R55S]
P1635
id0502c1813800
DTC P1635 Tire/axle ratio out of acceptable range

DETECTION
• Tire size or axle ratio message from the PCM corrupt or invalid.
CONDITION
• CAN malfunction
POSSIBLE
• PCM malfunction
CAUSE
• TCM malfunction
2 VERIFY STORED DTC IN PCM AND ABS HU/CM Yes Go to the applicable DTC inspection.
• Turn the engine switch to the LOCK position, (See 04-02-2 ON-BOARD DIAGNOSIS [4W-ABS
then to the ON position. (EVEREST)].)
• Verify stored DTCs in PCM and ABS HU/CM. No Go to the next step.
• Are DTCs stored?
• Are DTCs except for P1635 output?
4 ROAD TEST INSPECTION Yes Go to the next step.
• Road-test the vehicle to verify the respective No Inspect the symptom troubleshooting, then go to the next
shift points. step.
(See 05-13-8 ROAD TEST [5R55S].) (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
• Are the shift points normal? TABLE [5R55S].)
COMPLETED (See 05-13-44 TCM REMOVAL/INSTALLATION [5R55S].)
connectors.
[5R55S].)
• Are DTCs except for P1635 output? (See 05-02-5 DTC TABLE [5R55S].)
End Of Sie
DTC P1700 [5R55S]

id0502c1805000
DTC P1700 Transmission indeterminate malfunction

• Direct one-way clutch malfunction.
DETECTION Note
CONDITION • Engine rpm limited to 4,000 rpm. Failed a NEUTRAL condition in 1GR, 3GR or 4GR in automatic mode.
Only 2GR and 5GR available.
• Other DTCs that may set: P1700: P0745, P0750, P0755
• Direct one-way clutch malfunction
POSSIBLE • Shift solenoid B malfunction
CAUSE • Pressure control solenoid A malfunction
• Transmission internal malfunction
• TCM malfunction
05-02–38

3 VERIFY DTC P1700 OUTPUT Yes Inspect the direct one-way clutch, then go to the next step.
• Drive in D range. No Go to the next step.
• Verify the DTC in the TCM memory.
• Are DTC P1700 output?
connectors.
[5R55S].)
End Of Sie
DTC P1711 [5R55S]
id0502c1814200
DTC P1711 ATF temperature out of on-board diagnostic range

DETECTION
• ATF temperature range too high or too low during on-board diagnostic.
CONDITION
POSSIBLE
CAUSE
• TFT sensor malfunction.
05
recorded?
then to the ON position. No Warm or cool vehicle to normal operating temperature, then
• Verify the DTCs in the TCM memory. go to the next step.
connectors.
PDS.
[5R55S].)
05-02–39

End
DTC Of Sie [5R55S]
P1780
id0502c1807600
DTC P1780 O/D OFF switch circuit malfunction (open or short circuit)
DETECTION
• Open or short circuit in circuit between O/D OFF switch and TCM, or in O/D OFF switch internal circuit
CONDITION
• O/D OFF switch malfunction.
• Short to ground in wiring harness between engine switch and O/D OFF switch terminal C (wiring harness-
side).
• Open circuit in wiring harness between engine switch and O/D OFF switch terminal C (wiring harness-
side).
• Short to ground in wiring harness between O/D OFF switch terminal D (wiring harness-side) and TCM
POSSIBLE
terminal BM (wiring harness-side).
CAUSE
• Open circuit in wiring harness between O/D OFF switch terminal D (wiring harness-side) and TCM terminal
BM (wiring harness-side).
• Short to power supply in wiring harness between O/D OFF switch terminal D (wiring harness-side) and
TCM terminal BM (wiring harness-side).
• Damaged connector between O/D OFF switch and TCM.
SELECTOR LEVER
WIRING HARNESS-
SIDE CONNECTOR TCM
IG1 5
O/D OFF SWITCH
C A
4 7 8 9
C D BM
D B 3 3 6
TCM WIRING HARNESS-SIDE CONNECTOR
CK CN
CL CO
CM CP
recorded?
3 INSPECT SELECTOR LEVER CONNECTOR Yes Go to the next step.
FOR POOR CONNECTION No Repair or replace the connector and/or terminals, then go
• Inspect the selector lever connector
connection.
• Disconnect the selector lever connector.
05-02–40

• Turn the engine switch to the ON position No Inspect the engine switch and wiring harness, then go to
(engine off). Step 10.
• Inspect the voltage at O/D OFF switch terminal
C (wiring harness-side).
5 INSPECT O/D OFF SWITCH Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Replace the selector lever, then go to Step 10.
• Inspect the O/D OFF switch. (See 05-14-4 SELECTOR LEVER REMOVAL/
(See 05-13-19 O/D OFF SWITCH INSTALLATION.)
• Is the O/D OFF switch normal?
7 INSPECT O/D OFF SWITCH CIRCUIT FOR Yes Go to the next step.
terminal BM (wiring harness-side) and O/D
OFF switch terminal D (wiring harness-side).
8 INSPECT O/D OFF SWITCH CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
• Turn the engine switch to the LOCK position. No Go to the next step.
• Inspect for continuity between O/D OFF switch
terminal D (wiring harness-side) and body
ground.
9 INSPECT O/D OFF SWITCH CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect the voltage at O/D OFF switch terminal 05
D (wiring harness-side).
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–41

DTC P1783 [5R55S]
id0502c1807700
DTC P1783 ATF overheating

DETECTION
• ATF temperature signal is 127° C {270 °F} or more
CONDITION
• ATF level low
POSSIBLE • Deteriorated ATF
CAUSE • TFT sensor malfunction.
recorded?
then to the ON position. No Go to SYMPTOM TROUBLESHOOTING, “NO.22
• Verify the DTCs in the TCM memory. TRANSMISSION OVERHEATS”, then go to the next step.
• Are DTCs except for P1783 output? (See 05-03-24 NO.22 TRANSMISSION OVERHEATS
[5R55S].)
4 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the ATF, then go to Step 6.
(See 05-13-13 AUTOMATIC TRANSMISSION (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF)
FLUID (ATF) INSPECTION [5R55S].) INSPECTION [5R55S].)
• Is it normal?
5 NSPECT ATF LEVELVE Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to the next step.
• Warm up the AT. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF)
• Is the ATF level within the specification? REPLACEMENT [5R55S].)
(See 05-13-13 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION [5R55S].)
connectors.
PDS.
[5R55S].)
End Of Sie
05-02–42

DTC U0100, U0297 [5R55S]
id0502c1815600
DTC U0100 Communication error to PCM

DTC U0297 Communication error to PCM
DETECTION
• TCM cannot receive any signals from PCM.
CONDITION
• Short to ground in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
• Short to ground in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
• Short to power supply in wiring harness between PCM terminal 195 (wiring harness-side) and TCM
terminal CB (wiring harness-side).
• Short to power supply in wiring harness between PCM terminal 171 (wiring harness-side) and TCM
POSSIBLE
terminal CF (wiring harness-side).
CAUSE
• Open circuit in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
• Open circuit in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
• Damaged connector between PCM and TCM.
• PCM malfunction.
PCM TCM
3 5 6 7 4
195 CB CAN_H
3 4
171 CF CAN_L
5 6 7
05
TCM WIRING HARNESS-SIDE CONNECTOR
A E I M Q Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
U
J CK CN
B F N R Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
V
CL CO
CM CP
PCM WIRING HARNESS-SIDE CONNECTOR
124 123122 121 120 119 118 117 116 115114 113 112 111 110 109 108 107 106 105104 103102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129128 127126 125
172171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153152 151150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177176 175174 173
05-02–43

recorded?
3 INSPECT PCM FOR POOR CONNECTION Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Repair or replace the connector and/or terminals, then go
• Inspect the PCM connection. to Step 8.
• Disconnect the PCM.
5 INSPECT CAN CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.
• Inspect for continuity between the TCM No Repair or replace the wiring harness, then go to Step 8.
terminal (wiring harness-side) and the PCM
terminal (wiring harness-side).
— CB and 195
— CF and 171
6 INSPECT CAN CIRCUIT FOR SHORT TO Yes Repair or replace the wiring harness, then go to the Step 8.
GROUND No Go to the next step.
• Inspect for continuity between TCM terminal
(wiring harness-side) and body ground.
— CB and body ground
— CF and body ground
7 INSPECT CAN CIRCUIT FOR SHORT TO Yes Go to the next step.
POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect the voltage at TCM terminal CB and CF
8 VERIFY TROUBLESHOOTING OF DTC U0100 Yes Replace the TCM, then go to the next step.
OR U0297 COMPLETED (See 05-13-44 TCM REMOVAL/INSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
• Are DTCs except for U0100 and U0297 (See 05-02-5 DTC TABLE [5R55S].)
End Of Sie
05-02–44

PID/DATA MONITOR INSPECTION [5R55S]
id0502c1805600
absggw00000987
3. Select the PID from the PID table
4. Verify the PID data according to the directions on
the IDS/PDS screen.
Note
• Perform part inspection for the output device after TCM inspection.
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function.
PID/DATA MONITOR AND RECORD function table

Unit/ TCM
Monitor item Definition Condition/Specification
Condition terminal
• Brake pedal depressed: on
BPP Brake switch on/off N/A
• Other: off
• FSC not commanded by IDS/PDS PID output (off):
Firm shaft control (FSC)
FIRM_ST 0/1 0 N/A
status requested
• FSC commanded by IDS/PDS PID output (on): 1
• 1GR: 1
• 2GR: 2
GEAR
Calculated gear range in
1/2/3/4/5 • 3GR: 3 N/A
05
TCM
• 4GR: 4
• 5GR: 5
• 1GR: 1
PID used to command • 2GR: 2
GEAR_OSC gear changes during 1/2/3/4/5 • 3GR: 3 N/A
Simulation Function • 4GR: 4
• 5GR: 5
ISS ISS sensor rpm Indicates intermediate shaft speed AM, AS
OSS OSS sensor rpm Indicates output shaft speed AD, AG
Pressure control solenoid Indicates pressure control solenoid A commanded
PCA pis I, CK
A pressure
Pressure control solenoid Indicates pressure control solenoid B commanded
PCB pis J, CK
B pressure
Pressure control solenoid Indicates pressure control solenoid C commanded
PCC pis M, CK
C pressure
RPM Engine speed rpm Indicates engine speed N/A
• Shift solenoid A operation: on
• Shift solenoid A not operation: off
• Shift solenoid B operation: on
• Shift solenoid B not operation: off
• Shift solenoid C operation: on
• Shift solenoid C not operation: off
• Shift solenoid D operation: on
• Shift solenoid D not operation: off
TCC TCC control solenoid % Indicates TCC control solenoid operation A, CK
Torque converter speed Indicates torque converter speed ratio (engine speed
TCCRAT ratio N/A
ratio compared with turbine shaft speed)
05-02–45

Unit/ TCM
Monitor item Definition Condition/Specification
Condition terminal
TFT ATF temperature °C, °F Indicates ATF temperature AY, BH
AX, BU, BY,
TR_D Digital TR sensor signal Indicates digital TR sensor signal
CA
Digital TR sensor signal AX, BU, BY,
TR_V V Indicates digital TR sensor signal voltage
voltage CA
• TR1 switch open: 1
TR1 TR1 switch 0/1 BY
• TR1 switch close: 0
TR2 TR2 switch 0/1 BU
TR3A TR3 switch 0/1 AX
TR4 TR4 switch 0/1 CA
TSS TSS sensor rpm Indicates turbine shaft speed AH, AP
VSS Vehicle speed mph Indicates vehicle speed AD, AG
Simulation Function Procedure

absggw00000987
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
• If there is no operation sound from the solenoid after the simulation function inspection is performed, it is
possible that there is an open or short circuit in the wiring harness, or solenoid, or sticking and operation
malfunction.
Simulation item table
Simulation item Applicable component Unit TCM terminal
End Of Sie
05-02–46
F198-10-05L(05-03).fm 1 ページ２００６年８月１０日　木曜日　午後５時２８分
SYMPTOM TROUBLESHOOTING [5R55S]
05-03 SYMPTOM TROUBLESHOOTING [5R55S]

AUTOMATIC TRANSMISSION NO.14 ENGINE FLARES UP OR SLIPS
CONTROL SYSTEM WHEN UPSHIFTING OR DOWNSHIFTING
WIRING DIAGRAM [5R55S] . . . . . . . . . 05-03–2 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–17
FOREWORD [5R55S] . . . . . . . . . . . . . . . 05-03–3 NO.15 ENGINE FLARES UP OR SLIPS
BASIC INSPECTION [5R55S]. . . . . . . . . 05-03–4 WHEN ACCELERATING VEHICLE
SYMPTOM TROUBLESHOOTING [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–18
ITEM TABLE [5R55S] . . . . . . . . . . . . . . 05-03–5 NO.16 JUDDER UPON TORQUE
QUICK DIAGNOSIS CHART CONVERTER CLUTCH (TCC)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–7 OPERATION [5R55S]. . . . . . . . . . . . . . . 05-03–18
NO.1 VEHICLE DOES NOT NO.17 EXCESSIVE SHIFT SHOCK
MOVE IN D RANGE, FROM N TO D OR N TO R
OR IN R POSITION [5R55S] . . . . . . . . . 05-03–9 POSITION/RANGE [5R55S]. . . . . . . . . . 05-03–19
NO.2 VEHICLE MOVES NO.18 EXCESSIVE SHIFT SHOCK IS FELT
IN N POSITION [5R55S] . . . . . . . . . . . . 05-03–10 WHEN UPSHIFTING AND DOWNSHIFTING
NO.3 VEHICLE MOVES IN P POSITION, [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–20
OR PARKING GEAR DOES NOT NO.19 EXCESSIVE SHIFT SHOCK ON
DISENGAGE WHEN P IS DISENGAGED TORQUE CONVERTER CLUTCH (TCC)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–10 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–21
NO.4 EXCESSIVE CREEP [5R55S] . . . . 05-03–11 NO.20 NOISE/VIBRATION FORWARD
NO.5 NO CREEP AT ALL [5R55S] . . . . . 05-03–11 OR REVERSE [5R55S] . . . . . . . . . . . . . 05-03–22
NO.6 LOW MAXIMUM SPEED AND NO.21 NO ENGINE BRAKING IN
POOR ACCELERATION [5R55S] . . . . . 05-03–12 1GR POSITION OF MANUAL 1 RANGE
NO.7 NO SHIFTING [5R55S] . . . . . . . . . 05-03–13 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–23
NO.8 NO 2ND AND 5TH GEARS NO.22 TRANSMISSION OVERHEATS
(MANUAL 2ND IS OK) [5R55S] . . . . . . 05-03–14 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–24
NO.9 ABNORMAL SHIFTING NO.23 ENGINE STALLS WHEN
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–14 SHIFTED TO D RANGE, OR IN R POSITION
NO.10 FREQUENT SHIFTING [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–25
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–15 NO.24 ENGINE STALLS WHEN DRIVING
NO.11 SHIFT POINT IS HIGH OR LOW AT SLOW SPEEDS OR STOPPING
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–15 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–25
NO.12 TORQUE CONVERTER CLUTCH NO.25 STARTER DOES NOT WORK
(TCC) NON-OPERATION [5R55S] . . . . 05-03–16 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–25
NO.13 NO KICKDOWN [5R55S] . . . . . . . 05-03–17 05
End of Toc
WM: AUTOMATIC TRANSAXLE
05-03–1

id0503c1809500
IG1 B+ B+
TCM
AT RELAY
BT
CM
CP
CK
OTHER CB CAN_H A
MODULE
SHIFT SOLENOID A
CF CAN_L
B
SHIFT SOLENOID B
C
4x4 BA 4x4 HI
F
MODULE
BB 4x4 LO
SHIFT SOLENOID D
IG1 D
N I
4x4 LO J
M
O/D OFF TFT SENSOR
E AY
BH
K
DIGITAL TR SENSOR
Q
INSTRUMENT
CLUSTER TR3A AX
G
TR1 BY
U
IG1 TR2 BU
O/D OFF SWITCH
TR4 CA
BM
AG
OSS SENSOR CL
AD
CO
AS
ISS SENSOR AO
AM
AK
AP
TSS SENSOR BS
AH
arnffw00001943
End Of Sie
05-03–2

FOREWORD [5R55S]
id0503c1800200
• When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, O/D
OFF indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to the
following flowchart.
— If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE [5R55S].)
— If a DTC does not exist, the MIL does not illuminate and O/D OFF indicator light flash, diagnose the
applicable symptom troubleshooting. (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
CUSTOMER ARRIVES
WARNING LIGHT* NO WARNING LIGHT*

ON/FLASHING WITH SYMPTOM
CHECK FOR CHECK DTC

PRIORITIZED DTC IGNITION ON TEST, IDLING
TEST
DTC
WITHOUT DTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING
acxuuw00002535
05
*: Malfunction Indicator Lamp (MIL), O/D OFF indicator light.
End Of Sie
05-03–3

BASIC INSPECTION [5R55S]
id0503c1800300

1 Perform the mechanical system test. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts according to the
[5R55S].) inspection result.
Is the mechanical system normal?
2 Turn the engine switch to the ON position. Yes Go to the next step.
When the selector lever is moved, does the No Inspect the selector lever and digital TR sensor. Repair or
selector illumination indicate a synchronized replace malfunctioning areas.
position to the lever location? Also, when other If the selector lever and digital TR sensor are normal, go to
ranges are selected from N or P during idling, the next step.
does the vehicle move within 1—2 s?
3 Inspect the ATF color, condition and level. Yes Go to the next step.
(See 05-13-13 AUTOMATIC TRANSMISSION No Repair or replace any malfunctioning parts according to the
FLUID (ATF) INSPECTION [5R55S].) inspection result.
Are the ATF color, odor and level normal? Flush the AT and cooler line if necessary.
4 Perform the line pressure test. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Adjust the accelerator cable if necessary.
[5R55S].) Repair or replace any malfunctioning parts according to the
Is the line pressure normal? inspection result.
5 Perform the stall test. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any normal parts according to the
[5R55S].) inspection result.
Is the stall speed normal?
6 Inspect the value at the following PCM and TCM Yes Perform the symptom troubleshooting and the follow
PIDs using the IDS/PDS. procedures.
(See 05-02-45 PID/DATA MONITOR No Repair or replace any malfunctioning parts according to the
INSPECTION [5R55S].) inspection result.
PCM PIDs:
• APP1
• APP2
• ECT
• RPM
• VPWR
TCM PIDs:
• TFT
• TR_D
• TR_V
• TSS
• ISS
• OSS
Is the PID value normal?
End Of Sie
05-03–4

SYMPTOM TROUBLESHOOTING ITEM TABLE [5R55S]
id0503c1800400
• Use the chart below to verify the trouble symptoms to diagnose the appropriate area.
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
1 Vehicle does not move in D range, or Vehicle does not move when AP is (See 05-03-9 NO.1 VEHICLE
in R position depressed. DOES NOT MOVE IN D
RANGE, OR IN R POSITION
[5R55S].)
2 Vehicle moves in N position Vehicle creeps in N position. (See 05-03-10 NO.2 VEHICLE
Vehicle creeps if brake pedal is not MOVES IN N POSITION
depressed in N position. [5R55S].)
3 Vehicle moves in P position, or parking Vehicle rolls when on a downward slope and (See 05-03-10 NO.3 VEHICLE
gear does not disengage when P tires do not lock in P position. MOVES IN P POSITION, OR
position is disengaged Tires locked when P position is disengaged, PARKING GEAR DOES NOT
vehicle does not move in D range, and R DISENGAGE WHEN P IS
position when AP is depressed, and engine DISENGAGED [5R55S].)
remains in stall condition.
4 Excessive creep Vehicle accelerates in D range, and R (See 05-03-11 NO.4
position without depressing accelerator EXCESSIVE CREEP [5R55S].)
pedal.
5 No creep at all Vehicle does not move in D range, or R (See 05-03-11 NO.5 NO
position when idling on flat, paved road. CREEP AT ALL [5R55S].)
6 Low maximum speed and poor Vehicle acceleration poor at start. (See 05-03-12 NO.6 LOW
acceleration Delayed acceleration when accelerator MAXIMUM SPEED AND
pedal depressed while driving. POOR ACCELERATION
[5R55S].)
7 No shifting Single shift range only. (See 05-03-13 NO.7 NO
Sometimes shifts correctly. SHIFTING [5R55S].)
8 No 2nd and 5th gears (Manual 2nd is Vehicle dose not shift to 2nd or 5th gear. (See 05-03-14 NO.8 NO 2ND
OK) AND 5TH GEARS (MANUAL
2ND IS OK) [5R55S].)
9 Abnormal shifting Shifts incorrectly (incorrect shift pattern). (See 05-03-14 NO.9
ABNORMAL SHIFTING
[5R55S].)
10 Frequent shifting Downshifting occurs immediately even when (See 05-03-15 NO.10
the accelerator pedal is depressed slightly in FREQUENT SHIFTING
D range. [5R55S].)
05
11 Shifts point is high or low Shift point is considerably different from (See 05-03-15 NO.11 SHIFT
automatic shift diagram. POINT IS HIGH OR LOW
Shift delays when accelerating. [5R55S].)
Shift occurs quickly when accelerating and
engine speed does not increase.
12 Torque converter clutch (TCC) non- TCC does not operate when vehicle reaches (See 05-03-16 NO.12
operation TCC operation range. TORQUE CONVERTER
CLUTCH (TCC) NON-
OPERATION [5R55S].)
13 No kickdown Does not downshift when accelerator pedal (See 05-03-17 NO.13 NO
is fully depressed within kickdown range. KICKDOWN [5R55S].)
14 Engine flares up or slips when When accelerator pedal is depressed, (See 05-03-17 NO.14 ENGINE
upshifting or downshifting engine speed increases but vehicle speed FLARES UP OR SLIPS WHEN
increases slowly. UPSHIFTING OR
When accelerator pedal is depressed while DOWNSHIFTING [5R55S].)
driving, engine speed increases but vehicle
speed does not.
15 Engine flares up or slips when Engine flares up when accelerator pedal is (See 05-03-18 NO.15 ENGINE
accelerating vehicle depressed for upshifting. FLARES UP OR SLIPS WHEN
Engine flares up suddenly when accelerator ACCELERATING VEHICLE
pedal is depressed for downshifting. [5R55S].)
16 Judder upon torque converter clutch Vehicle jolts when TCC is engaged. (See 05-03-18 NO.16
(TCC) operation JUDDER UPON TORQUE
CONVERTER CLUTCH (TCC)
OPERATION [5R55S].)
17 Excessive shift shock from N to D or N Strong shock is felt when shifting from N to (See 05-03-19 NO.17
to R position/range D or N to R position/range at idle. EXCESSIVE SHIFT SHOCK
FROM N TO D OR N TO R
POSITION/RANGE [5R55S].)
05-03–5

No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
18 Excessive shift shock is felt when Excessive shift shock is felt when (See 05-03-20 NO.18
upshifting and downshifting depressing accelerator pedal to accelerate EXCESSIVE SHIFT SHOCK IS
at upshifting. FELT WHEN UPSHIFTING
During cruising, excessive shift shock is felt AND DOWNSHIFTING
when depressing accelerator pedal at [5R55S].)
downshifting.
19 Excessive shift shock on torque Strong shock is felt when TCC is engaged. (See 05-03-21 NO.19
converter clutch (TCC) EXCESSIVE SHIFT SHOCK
ON TORQUE CONVERTER
CLUTCH (TCC) [5R55S].)
20 Noise/vibration forward or reverse Transmission noisy in all positions and (See 05-03-22 NO.20 NOISE/
ranges. VIBRATION FORWARD OR
REVERSE [5R55S].)
21 No engine braking in 1GR position of Engine speed drops to idle but vehicle (See 05-03-23 NO.21 NO
manual 1 range coasts when accelerator pedal is released ENGINE BRAKING IN 1GR
when in 1GR position of manual 1 range at POSITION OF MANUAL 1
low vehicle speed. RANGE [5R55S].)
22 Transmission overheats Burnt smell emitted from transmission. (See 05-03-24 NO.22
Smoke is emitted from transmission. TRANSMISSION OVERHEATS
[5R55S].)
23 Engine stalls when shifted to D range, Engine stalls when shifting from N or P (See 05-03-25 NO.23 ENGINE
or in R position position to D range or R position at idle. STALLS WHEN SHIFTED TO
D RANGE, OR IN R POSITION
[5R55S].)
24 Engine stalls when driving at slow Engine stalls when brake pedal is (See 05-03-25 NO.24 ENGINE
speeds or stopping depressed while driving at low speed or STALLS WHEN DRIVING AT
stopping. SLOW SPEEDS OR
STOPPING [5R55S].)
25 Starter does not work Starter does not work even when P or N (See 05-03-25 NO.25
position is selected. STARTER DOES NOT WORK
[5R55S].)
End Of Sie
05-03–6

QUICK DIAGNOSIS CHART [5R55S]
id0503c1800500
X: Applied
1 Vehicle does not move in D range, or in R position X X X
2 Vehicle moves in N position X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged X
4 Excessive creep X X X
5 No creep at all X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X X X
7 No shifting X X X X X X X
8 No 2nd and 5th gears (Manual 2nd is OK) X X X X X X X X X X X X X X
9 Abnormal shifting X X X X X X X X X X X
10 Frequent shifting X X X X X X X X X
11 Shifts point is high or low X X X X X X X X X X X
12 Torque converter clutch (TCC) non-operation X X X X X X X X X X
13 No kickdown X X
14 Engine flares up or slips when upshifting or X X X X X X
downshifting X X
15 Engine flares up or slip when accelerating vehicle X X X X X X X X X X X X
16 Judder upon torque converter clutch (TCC) operation X X X
17 Excessive shift shock from N to D or N to R X X X X X X X X X
position/range
18 Excessive shift shock is felt when upshifting and
downshifting X X X X X X X X X
19 Excessive shift shock on torque converter X X X X X X X
clutch (TCC)
20 Noise/vibration forward or reverse
21 No engine braking in 1GR position of manual 1 range X X X X X X X
22 Transmission overheats X X
23 Engine stalls when shifted to D range, or in R position X X X X
24 Engine stalls when driving at slow speeds or stopping X
25 Starter does not work X X
Symptom item Electrical system components
AT outer parts
Digital TR sensor 05
Brake switch
OSS sensor
ECT sensor
APP sensor
TSS sensor
ISS sensor
Not within line pressure specification
Not within idle speed specification
Parking mechanism malfunction
Malfunction signal is inputted


Selector lever is misadjusted
Excessive amount of ATF
Not operating properly

Abnormal signal input
Signal is not inputted


No signal input
Misadjusted
Always ON
Cause of trouble
arnffw00001948
05-03–7
X: Applied
1 Vehicle does not move in D range, or in R position X X X X X X X X X
2 Vehicle moves in N position X X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all X X X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X X X X X
7 No shifting X X X X X X X X X
8 No 2nd and 5th gears (Manual 2nd is OK) X X X X X X X X X
9 Abnormal shifting X X X X X X X X X X X X
10 Frequent shifting X X X
11 Shifts point is high or low X X X X
12 Torque converter clutch (TCC) non-operation X X X X X X X
13 No kickdown X X X X X X X X
14 Engine flares up or slips when upshifting or downshifting X X X X X X X X
15 Engine flares up or slip when accelerating vehicle X X X X X X X X X
16 Judder upon torque converter clutch (TCC) operation X X X X X X
17 Excessive shift shock from N to D or N to R position/range X X X X X X X X X
18 Excessive shift shock is felt when upshifting and
downshifting X X X X X X X X X X X X X X X
19 Excessive shift shock on torque converter clutch (TCC) X X X X X X X
21 No engine braking in 1GR position of manual 1 range X X X X X X X X X
22 Transmission overheats X X X X X X X X
23 Engine stalls when shifted to D range, or in R position X X X
24 Engine stalls when driving at slow speeds or stopping X X X
25 Starter does not work
Electrical system components Hydraulic
Symptom item Powertrain
system
system
AT outer parts components
TFT sensor
Torque converter is not operating properly

Pressure control solenoid C malfunction
Pressure control solenoid B malfunction
Pressure control solenoid A malfunction
Forward clutch is not operating properly

Reverce servo is not operating properly
Control valve is not operating properly
Fluid pump is not operating properly

Oil cooler is not operating properly
TCC control solenoid malfunction
TCC burnt Inspection method

Shift solenoid D malfunction
Shift solenoid C malfunction

Shift solenoid A malfunction
Shift solenoid B malfunction
Slipping (Brake, clutch)

Burnt (Brake, clutch)

Poor GND
Cause of trouble
arnffw00001949
End Of Sie
05-03–8

NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITION [5R55S]
id0503c1800600
1 Vehicle does not move in D range, or in R position

DESCRIPTION • Vehicle does not move when AP is depressed.
• If the vehicle does not move in D range or R position, basically, the malfunction is in the AT. (Vehicle will
move even with a malfunction in the TCM.) Since a malfunction is in the sensor circuit or output circuit is
the cause of the malfunction in the AT, inspect the sensors, output circuit, and the related wiring
harnesses.
1. Clutch slipped, worn (D range-Forward clutch, R position-Direct clutch, Coast clutch, Reverse band)
• Fluid pump malfunction
• Pressure control solenoid B malfunction
• Pressure control solenoid C malfunction
POSSIBLE • Body ground malfunction
CAUSE • Control valve body malfunction
2. Selector lever malfunction
3. Parking mechanism not operating properly
4. Torque converter malfunction
Note
• Before the following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspections are conducted.
(See 05-03-4 BASIC INSPECTION [5R55S].)
1 When the vehicle is stopped on a flat, level road Yes Go to the next step.
and the engine is off, does the vehicle move No Check the parking mechanism.
when it is pushed? (In D range or N, R positions
and brake released)
2 Disconnect the TCM connector. Yes Go to the next step.
Is the resistance between TCM ground terminal No Repair the open ground circuit.
CO and body ground, and between TCM ground
terminal CL and body ground less than 5.0
ohms?
3 Inspect the pressure control solenoid B and C. Yes Clean and inspect main control, if parts are damaged
(See 05-13-34 SOLENOID VALVE replace main control.
INSPECTION [5R55S].) If the problem remains, overhaul the transmission and repair 05
Is it normal? or replace any malfunctioning parts.
No Repair or replace any malfunctioning parts.
— If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
• If the vehicle repaired, the troubleshooting is completed.
• If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–9

NO.2 VEHICLE MOVES IN N POSITION [5R55S]
id0503c1800700
2 Vehicle moves in N position

• Vehicle creeps in N position.
DESCRIPTION
• Vehicle creeps if brake pedal is not depressed in N position.
• If the vehicle moves in N position, basically, the malfunction is in the AT. Since a malfunction in the
sensor circuit or output circuit is the cause of the malfunction in the AT, inspect the sensors, output
circuit, and the related wiring harnesses.
1. Clutch is burned (Forward clutch)
• Control valve body malfunction
2. Selector lever position disparity. Although the selector indicator shows N position, the hydraulic
circuit shows D range or R position.
• Incorrect fluid level
POSSIBLE • Fluid pump malfunction
CAUSE • Shift control cables
• Main control
• Case and clutches
Note
1 Does the vehicle creep when the selector lever is Yes Go to the next step.
moved slightly in the N position? No Adjust the selector lever.
(See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
CO and body ground, and between TCM ground Reconnect the TCM.
ohms?
3 Inspect following items. Yes Clean and inspect main control, if parts are damaged
• Fluid level replace main control.
• Fluid pump operation If the problem remains, overhaul the transmission and repair
• Shift control cables or replace any malfunctioning parts.
• Main control No Repair or replace any malfunctioning parts.
• Case and clutches
Are they normal?
End Of Sie
NO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED [5R55S]
id0503c1800800
3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
• Vehicle rolls on a downward slope in P position.
DESCRIPTION • Tires are locked when P is disengaged. Vehicle does not move in D range, and R position when
accelerator pedal is depressed, and engine remains in stall condition.
1. Improper adjustment of selector lever
POSSIBLE 2. Transmission case damaged
CAUSE 3. Parking mechanism malfunction (May have effect on noise or shock from transmission)
4. If vehicle moves in N position, perform No.2 “VEHICLE MOVES IN N POSITION”
End Of Sie
05-03–10

NO.4 EXCESSIVE CREEP [5R55S]
id0503c1800900
4 Excessive creep
DESCRIPTION • Vehicle accelerates in D range, and R position without depressing accelerator pedal.
POSSIBLE 1. Engine idle speed high (transmission system is not cause of problem)
CAUSE 2. Go to No.9 “FAST IDLE/RUNS ON”
End Of Sie
NO.5 NO CREEP AT ALL [5R55S]

id0503c1801000
5 No creep at all
DESCRIPTION • Vehicle does not move in D range and R position when idling on flat, paved road.
• Either transmission is stuck in 4GR or clutch slippage due to a stuck 3–4 clutch.
1. Clutch is burned
• Line pressure low
• Shift solenoid D malfunction
• Shift solenoid C malfunction
• Pressure control solenoid A malfunction
• Body ground malfunction
POSSIBLE 2. Transmission fixed in 4GR (Operation of fail-safe function)
CAUSE • Short or open circuit in wiring harness
• Poor connection of connector
• Electronic parts of output and input system have malfunction
3. No engine torque
• Low engine RPM
• Torque converter malfunction
Note
05
1 Does the vehicle creep in any range/position? Yes Go to the next step.
No Inspect or adjust the selector lever.
(See 05-14-2 SELECTOR LEVER INSPECTION.) (See 05-
14-2 SELECTOR CABLE ADJUSTMENT.)
2 Check the value at the following PCM PIDs using Yes Go to the next step.
the IDS/PDS. No Repair or replace any malfunctioning parts.
• APP1
• APP2
• RPM
Are PID values normal?
ohms?
4 Inspect the pressure control solenoid A. Yes Clean and inspect main control, if parts are damaged
(See 05-13-34 SOLENOID VALVE replace main control.
INSPECTION [5R55S].) If the problem remains, overhaul the transmission and repair
End Of Sie
05-03–11

NO.6 LOW MAXIMUM SPEED AND POOR ACCELERATION [5R55S]
id0503c1801100
6 Low maximum speed and poor acceleration

• Vehicle acceleration is poor at start.
DESCRIPTION
• Delayed acceleration when accelerator pedal is depressed while driving.
• If the clutch is stuck or does not stay in 4GR, the malfunction is in the engine control system.
1. Clutch slippage, burned
• Pressure control solenoid A, B and C malfunction
2. Signal malfunction
• OSS sensor malfunction
• Sensor ground malfunction
• Accelerator pedal position sensor malfunction
POSSIBLE • TSS sensor malfunction
CAUSE 3. Transmission fixed in 4GR (Operation of fail-safe function)
• Short or open circuit in wiring
• Electronic parts of output and input system have malfunction
4. Insufficient starting torque (Suspected when in-gear condition, shift control and engine circuit are
normal)
• Torque converter have malfunction (Poor operation, stuck)
• TFT sensor malfunction (Short or open circuit)
5. Digital TR sensor adjustment incorrect
Note
1 Go to No.12 “LACK/LOSS OF POWER- Yes Go to the next step.
ACCELERATION/CRUISE”. No Repair or replace any malfunctioning parts.
Is the CIS system normal?
2 Disconnect the AT connector. Yes Go to the next step.
Does the vehicle operate as follows? No Clean and inspect main control, if parts are damaged
replace main control.
D range: 4GR (fixed) If the problem remains, overhaul the transmission and repair
R position: Reverse or replace any malfunctioning parts.
3 Drive the vehicle in D range. Yes Go to the next step.
Does the vehicle start from stop in first gear? No Check the value at the following.
Check the value at the following TCM PIDs using (See 05-02-45 PID/DATA MONITOR INSPECTION
the IDS/PDS. [5R55S].)
• GR_CM PCM PIDs (using IDS/PDS):
• GEAR
• APP1
• APP2
• VSS
TCM PIDs (using IDS/PDS):
• TSS
• ISS
• OSS
• TR_D
Repair or replace any malfunctioning parts.
05-03–12

4 Inspect the value at the following TCM PIDs Yes Inspect the shift solenoids for sticking.
using the IDS/PDS. • If the shift solenoids are normal, go to the next step.
• SSA No Check the value at the following.
• SSB PCM PIDs (using IDS/PDS):
• SSC
• APP
• SSD
Are the PID values normal? TCM PIDs (using IDS/PDS):
• OSS
• ISS
• TSS
• TR_D
5 Is the line pressure normal? Yes Go to the next step.
[5R55S].) inspection results.
6 Perform the stall test. Yes Reverify symptoms of malfunctioning.
(See 05-13-4 MECHANICAL SYSTEM TEST No Overhaul the transmission and repair or replace any
[5R55S].) malfunctioning parts.
End Of Sie
NO.7 NO SHIFTING [5R55S]

id0503c1801200
7 No shifting
• Single shift range only.
DESCRIPTION
• Sometimes it shifts correctly.
• When the gear position is fixed in 4GR due to the fail-safe operation, the malfunction is in the AT.
• Perform malfunction diagnosis according to No.6 “LOW MAXIMUM SPEED AND POOR
ACCELERATION”.
05
POSSIBLE
CAUSE
• IAT sensor malfunction
• VSS signal malfunction
3. Transmission fixed in 4GR (Operation in fail-safe function)
• Short or open circuit in wiring harness
• Disconnected shift solenoid connector
• Poor ground of shift solenoid
• Overdrive planetary malfunction
• Center support malfunction
• Direct clutch malfunction
• Overdrive servo/band malfunction
End Of Sie
05-03–13

NO.8 NO 2ND AND 5TH GEARS (MANUAL 2ND IS OK) [5R55S]
id0503c1814500
8 No 2nd and 5th gears (Manual 2nd is OK)

DESCRIPTION • Vehicle dose not shift to 2nd or 5th gear.
• TCM malfunction
• Main control malfunction
POSSIBLE
CAUSE Note
• Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
1 Verify that Manual 2nd is present and functions Yes Go to the next step.
correctly. No Go to symptom troubleshooting NO.8 “ABNORMAL
Is manual 2nd operating correctly? SHIFTING”.
2 Inspect the following solenoids. Yes Clean and inspect main control, if parts are damaged
• Pressure control solenoid B replace main control.
• Pressure control solenoid C If the problem remains, overhaul the transmission and repair
(See 05-13-34 SOLENOID VALVE or replace any malfunction parts.
INSPECTION [5R55S].) No Repair or replace any malfunction parts.
Are they normal?
End Of Sie
NO.9 ABNORMAL SHIFTING [5R55S]

id0503c1801400
9 Abnormal shifting
DESCRIPTION • Shifts incorrectly (incorrect shift pattern).
• There is a malfunction in the signal circuit which controls shifting (accelerator pedal position sensor,
TSS sensor, OSS sensor), the control valve is stuck, the accumulator (forward or servo apply) is stuck,
or the clutch circuit is stuck.
• Fluid level low
CAUSE 2. Signal malfunction
3. Digital TR sensor malfunction
• Selector lever adjustment incorrect
• Digital TR sensor adjustment incorrect
Note
05-03–14

Is the resistance between TCM ground terminal No Repair the open ground circuit. Reconnect the TCM
CO and body ground, and between TCM ground connector.
ohms?
2 Check the value at the following. Yes Clean and inspect main control, if parts are damaged
(See 05-02-45 PID/DATA MONITOR replace main control.
PCM PIDs (using IDS/PDS): or replace any malfunctioning parts.
• APP No Repair or replace any malfunctioning parts.
• TSS
• OSS
• VSS
Are they normal?
End Of Sie
NO.10 FREQUENT SHIFTING [5R55S]

id0503c1801500
10 Frequent shifting
DESCRIPTION • Downshifting occurs immediately even when the accelerator pedal is depressed slightly in D range.
• The circuit which is the cause is basically the same as No.9 “ABNORMAL SHIFTING”. However, a
POSSIBLE malfunction of the input signal to the accelerator pedal is position sensor, OSS sensor (including the
CAUSE sensor ground, sensor harness and connector), or clutch slippage (clutch stuck, low pressure in line)
may also be the cause.
End Of Sie
05
NO.11 SHIFT POINT IS HIGH OR LOW [5R55S]
id0503c1801600
11 Shift point is high or low

• Shift point is considerably different from automatic shift diagram.
DESCRIPTION • Shift delays when accelerating.
• Shift occurs quickly when accelerating and engine speed does not increase.
• If the transmission does not shift abnormally, there is a malfunction of the input signal to the accelerator
pedal position sensor, TSS sensor, or OSS sensor (including sensor ground).
POSSIBLE • If the engine speed is high or low, regardless of normal shifting, inspect the tachometer.
CAUSE • Verify that the output signal of the accelerator pedal position sensor change linearly.
• Verify fluid level and conditions.
• Verify main control operation.
End Of Sie
05-03–15

NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION [5R55S]
id0503c1801700
12 Torque converter clutch (TCC) non-operation

DESCRIPTION • TCC does not operate when vehicle reaches TCC operation range.
• Basically, the TCC does not operate when the fail-safe is operating. Verify the DTC first.
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. TCC is burned
(1) Input sensor system malfunction
• ECT sensor
• TFT sensor
• Sensor ground
(2) Output solenoid valve system malfunction (Sticking)
• TCC control solenoid malfunction
POSSIBLE
(3) Main control malfunction (Poor operation, stuck)
CAUSE
• TCC hydraulic pressure system
• Improper pressures
• Converter malfunction
2. Accelerator pedal position sensor malfunction (Not operating linearly)
3. Brake switch malfunction (Always ON)
4. TCM malfunction
Note
1 Check the value at the following. Yes Go to the next step.
(See 05-02-45 PID/DATA MONITOR No Repair or replace any malfunctioning parts.
PCM PIDs (using IDS/PDS):
• APP
• VSS
• TFT
Are they normal?
Is the resistance between TCM ground terminal No Repair the wiring harness.
ohms?
3 Measure the resistance between TCM terminal Yes Go to the next step.
A and AT connector terminal H, and between No Repair the TCC control solenoid circuit. Reconnect the TCM
TCM terminal CK and AT connector terminal F. connector.
Are the resistances less than 5.0 ohms?
4 Inspect the TCC control solenoid. Yes Replace TCM.
(See 05-13-34 SOLENOID VALVE No Replace TCC control solenoid.
Are the TCC control solenoids operating or replace any malfunctioning parts.
properly?
End Of Sie
05-03–16

NO.13 NO KICKDOWN [5R55S]
id0503c1801800
13 No kickdown
DESCRIPTION • Does not downshift when accelerator pedal is fully depressed within kickdown range.
POSSIBLE • If the transmission does not downshift though shifting is normal, the malfunction is in accelerator pedal
CAUSE position sensor circuit (including sensor ground, sensor harness and connector).
End Of Sie
NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING [5R55S]

id0503c1801900
14 Engine flares up or slips when upshifting or downshifting

• When accelerator pedal is depressed for driving, engine speed increases but vehicle speed increases
slowly.
DESCRIPTION
• When accelerator pedal is depressed while driving, engine speed increases but vehicle speed does
not.
• The clutch is slipping because it is stuck or it line pressure is low.
1. Clutch stuck, slippage (forward clutch, 3–4 clutch, 2–4 brake band, one-way clutch)
POSSIBLE • OSS sensor malfunction
CAUSE • Sensor ground malfunction
3. Poor operation of mechanical pressure
Note
05
1 Is the shift point normal? Yes Go to the next step.
No Go to symptom troubleshooting No.9 “ABNORMAL
SHIFTING”.
• APP
• ACT
Are the PID values normal?
Is the resistance between TCM ground terminal No Repair the wiring harness. Reconnect the TCM connector.
ohms?
4 Inspect PCA, PCB and PCC PIDs value. Yes Clean and inspect main control, if parts are damaged
Are the PCA, PCB and PCC PID values normal? or replace any malfunctioning parts.
End Of Sie
05-03–17

NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE [5R55S]
id0503c1802000
15 Engine flares up or slips when accelerating vehicle

• Engine flares up when accelerator pedal is depressed for upshifting.
DESCRIPTION
• Engine flares up suddenly when accelerator pedal is depressed for downshifting.
• The malfunction is basically the same as for No.14 “ENGINE FLARES UP OR SLIPS WHEN
POSSIBLE
UPSHIFTING OR DOWNSHIFTING”. If conditions for No.14 worsen, the malfunction will develop to
CAUSE
No.15.
End Of Sie
NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION [5R55S]

id0503c1802100
16 Judder upon torque converter clutch (TCC) operation

DESCRIPTION • Vehicle jolts when TCC is engaged.
• Poor TCC engagement due to either slippage because the TCC is stuck or the line pressure is low
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. Torque converter clutch piston slipped, burned

• Line pressure high
• TCC control solenoid malfunction
POSSIBLE • Control valve body malfunction
CAUSE • Body ground malfunction
Note
1 Disconnect TCM. Yes Go to the next step.
ohms?
2 Measure the resistance between the following Yes Go to the next step.
TCM and AT connector terminals. No Repair the TCC control solenoid circuit.
• TCM terminal A and AT connector terminal F
• TCM terminal CK and AT connector terminal
H
Is the resistance less than 5.0 ohms?
3 Inspect the TCC control solenoid. Yes Go to the next step.
(See 05-13-34 SOLENOID VALVE No Replace TCC control solenoid.
Is the solenoid valve operating properly? or replace any malfunctioning parts.
4 Inspect the PCA, PCB and PCC PID values. Yes Clean and inspect main control, if parts are damaged
No Replace the TCM.
End Of Sie
05-03–18

NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE [5R55S]
id0503c1802200
17 Excessive shift shock from N to D or N to R position/range

DESCRIPTION • Strong shock felt when shifting from N to D or N to R position/range.
• Shift shock may worsen when the fail-safe is operating. If no DTC is output, the shift shock may worsen
due to poor operation of the control valve body or sticking of the clutch.
1. Clutch burned (N→D: Forward clutch, N→R: Reverse servo or Direct clutch)
• Line pressure low, high
• TFT sensor malfunction
• Pressure control solenoid A malfunction (N→D only)
• Pressure control solenoid C malfunction (N→R only)
• Main control malfunction
CAUSE • Digital TR sensor misadjustment or malfunction
2. Poor hydraulic operation (Malfunction in range change)
• Forward clutch malfunction
• Reverse servo malfunction
3. Idle speed high
4. Poor tightening torque of engine mount, exhaust mount
Note
1 Does the shift shock occur only when the engine Yes Go to the next step.
is cold? No Go to Step 3.
2 Disconnect the TCM connector. Yes Check the value at the following.
Is the resistance between the TCM ground (See 05-02-45 PID/DATA MONITOR INSPECTION
terminal CO and body ground, and between [5R55S].)
TCM ground terminal CL and body ground less PCM PIDs (using IDS/PDS):
than 5.0 ohms? • APP
05
• TFT
Repair or replace any malfunctioning parts.
No Repair the wiring harness. Reconnect the TCM connector.
3 Is the pressure normal? Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Go to Step 5.
[5R55S].)
Is stall speed normal?
5 Inspect the voltage at the following TCM PID Yes Clean and inspect main control, if parts are damaged
using the IDS/PDS. replace main control.
(See05-02-45 PID/DATA MONITOR If the problem remains, overhaul the transmission and repair
INSPECTION [5R55S].) or replace any malfunctioning parts.
• TR_D No Repair or replace any malfunctioning parts.
Is the PID value normal?
• APP
ohms?
05-03–19

8 Inspect the PCA and PCC PID values. Yes Clean and inspect main control, if parts are damaged
Are the PCA and PCC PID values normal? or replace any malfunctioning parts.
End Of Sie
NO.18 EXCESSIVE SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING [5R55S]
id0503c1804600
18 Excessive shift shock is felt when upshifting and downshifting

• Excessive shift shock felt when depressing accelerator pedal to accelerate at upshifting. During
DESCRIPTION
cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting.
• Shift shock may worsen when fail-safe is operating. The shift shock may worsen if the signal from the
accelerator pedal position sensor, TSS sensor, or OSS sensor has a malfunction.
1. Clutch slipped, burned
• Line pressure low, high
• Pressure control solenoid A malfunction
• Accelerator pedal position sensor misadjustment
POSSIBLE • TFT sensor malfunction
CAUSE • ISS sensor malfunction
• VSS signal malfunction
• IAT sendor malfunction
3. Poor hydraulic operation (Malfunction in range change)
• Low fluid pressure
4. Engine mounts installation
• Loose attaching bolts
• Worn parts
Note
05-03–20

1 Inspect the engine mounts for loose tightening Yes Go to the next step.
bolts or worn parts. No Readjust, tighten or replace engine mounts.
Are all engine mounts normal?
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts.
[5R55S].)
Is stall speed normal?
• APP
ohms?
5 Inspect the PCA, PCB and PCC PID values. Yes Clean and inspect main control, if parts are damaged
End Of Sie
NO.19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH (TCC) [5R55S]

id0503c1802400
19 Excessive shift shock on torque converter clutch (TCC)

• Strong shock is felt when TCC is engaged.
DESCRIPTION
POSSIBLE • The troubleshooting flow is the same as No.16 “JUDDER UPON TORQUE CONVERTER CLUTCH
05
CAUSE (TCC) OPERATION”.
End Of Sie
05-03–21

NO.20 NOISE/VIBRATION FORWARD OR REVERSE [5R55S]
id0503c1814600

DESCRIPTION • Transmission noisy in all positions and ranges.
• Improper fluid level
• Transmission shift cable and bracket damaged or misadjusted.
• Digital transmission range (TR) sensor damaged
• Line pressure high/low
• One-way clutch
• Transmission oil cooler
POSSIBLE • Gear
CAUSE • Torque converter
Note
• Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
1 FLUID Yes Adjust to proper level.
• Does the following problem exist? No Go to Step 2.
• Improper level.
2 SHIFT LINKAGES (INTERNAL/ Yes Inspect for damage. Readjust as required.
EXTERNAL) Repair all damaged components.
• Does the following problem exist? After repairing linkages, readjust the digital TR sensor.
• Transmission shift cable and bracket (See 05-13-22 DIGITAL TRANSMISSION RANGE (TR)
damaged or misadjusted. Digital SENSOR REMOVAL/INSTALLATION [5R55S].)
transmission range (TR) sensor damaged. No Go to Step 3.
3 IMPROPER PRESSURES Yes Perform line pressure and stall speed tests.
• Does the following problem exist? If pressure is high/low, check the pump assembly.
• Improper band/clutch application pressures, No Go to Step 4.
line pressure high/low.
4 PUMP ASSEMBLY Yes Inspect and repair as required.
• Do any of the following problems exist? Tighten screws to specification.
• Internal leakage, cavitations. No Go to Step 5.
• Screws out of torque specification.
5 OVERDRIVE ONE-WAY CLUTCH Yes Repair one-way clutch.
ASSEMBLY No Go to step 6.
• Does the following problem exist?
• One-way clutch damaged, worn,
misassembled.
6 REAR ONE-WAY CLUTCH ASSEMBLY Yes Repair one-way clutch.
• One-way clutch damaged, worn,
misassembled.
7 OTHER Yes Relocate transmission oil cooler lines or fill tube properly.
• Transmission oil cooler lines fill tube
grounding.
8 GEAR Yes Repair planetary gear assemblies.
• Gear noise.
9 TORQUE CONVERTER CLUTCH Yes Go to symptom troubleshooting NO.16 “JUDDER UPON
ASSEMBLY TORQUE CONVERTER CLUTCH (TCC) OPERATION”.
• Does the following problem exist? No Go to symptom troubleshooting “SYMPTOM
• Torque converter internal malfunction TROUBLESHOOTING ITEM TABLE”.
preventing lockup piston application.
End Of Sie
05-03–22

NO.21 NO ENGINE BRAKING IN 1GR POSITION OF MANUAL 1 RANGE [5R55S]
id0503c1814000
21 No engine braking in 1GR position of manual 1 range

• Engine speed drops to idle but vehicle coasts when accelerator pedal is released when in 1GR of
DESCRIPTION
manual 1 range at low vehicle speed.
• Pressure control solenoid A and B malfunction
• Reverse servo malfunction
POSSIBLE • Reverse band malfunction
CAUSE • Body ground malfunction
Note
1 • Do the following symptoms concurrently Yes Go to symptom troubleshooting NO.14 “ENGINE FLARES
occur? UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING”
— Engine flares up or slips during or NO.15 “ENGINE FLARES UP OR SLIPS WHEN
acceleration. ACCELERATING VEHICLE”.
— Engine flares up or slips when shifting. No Repeat the basic inspection and repair or replace any
malfunctioning parts according to the inspection result.
• If the vehicle repaired, the troubleshooting is completed. 05
End Of Sie
05-03–23

NO.22 TRANSMISSION OVERHEATS [5R55S]
id0503c1814100
22 Transmission overheats
• Burnt smell emitted from transmission.
DESCRIPTION
• Smoke emitted from transmission.
• The malfunction maybe restriction in the cooling system. The technician needs to diagnose the
complete cooling system. Include coolers, line, and hoses. In addition, overheating of the transmission
may be caused by a malfunction of the TFT sensor.
1. Burning (TCC)
• Line pressure
• Improper fluid level
2. Oil cooler malfunction (Foreign material mixed ATF)
3. Excessive amount of ATF
POSSIBLE • TCC control solenoid malfunction
CAUSE • Pressure control solenoid A malfunction
• Excessive tow load
• Vehicle over load
• Engine concern
Note
1 Inspect oil cooler pipes for bending, damage, Yes Go to the next step.
corrosion or kinks. No Replace any malfunctioning parts.
Are the oil cooler pipes normal?
2 Is the line pressure normal. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts.
[5R55S].)
• TFT
• TCC
• PCA
• PCB
• PCC
CO and body ground, and between TCM ground Reconnect the TCM connector.
ohms?
6 Inspect pressure control solenoid A, B and C. Yes Clean and inspect main control and the thermo static
(See 05-13-34 SOLENOID VALVE bypass valve. If parts are damaged, replace main control.
End Of Sie
05-03–24

NO.23 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITION [5R55S]
id0503c1814200
23 Engine stalls when shifted to D range, or in R position

DESCRIPTION • Engine stalls when shifting from N or P position to D range or R position at idle.
POSSIBLE • The malfunction is on the engine control side (i.e. Electronic throttle control system). Otherwise, the
CAUSE malfunction is in the TSS sensor (engine sometimes starts).
1 Go to symptom troubleshooting No.10 “LOW Yes Repeat basic inspection and repair or replace any
IDLE/STALLS DURING DECELERATION”. malfunctioning parts according to the inspection result.
Is the engine control system normal? (See 05-03-4 BASIC INSPECTION [5R55S].)
No Repair or replace any malfunctioning parts according to the
inspection results.
End Of Sie
NO.24 ENGINE STALLS WHEN DRIVING AT SLOW SPEEDS OR STOPPING [5R55S]

id0503c1814300
24 Engine stalls when driving at slow speeds or stopping

DESCRIPTION • Engine stalls when brake pedal is depressed while driving at low speed or stopping.
• The malfunction on engine control side (e.g. Fuel injection control, Electronic throttle control system)
POSSIBLE
Otherwise, the malfunction is in the control valve body, TCC control solenoid or TCC and one-way
CAUSE
clutch.
1 Go to symptom troubleshooting No.10 “LOW Yes Go to the next step.
IDLE/STALLS DURING DECELERATION”.
Is the engine control system normal?
No Repair or replace any malfunctioning parts according to
inspection results. 05
2 Go to symptom troubleshooting No.5 “ENGINE Yes Repeat the basic inspection and repair or replace any
STALLS-AFTER START/AT IDLE”. malfunctioning parts according to the inspection result.
Is the engine control system normal? (See 05-03-4 BASIC INSPECTION [5R55S].)
No Repair or replace any malfunctioning parts according to the
inspection results.
End Of Sie
NO.25 STARTER DOES NOT WORK [5R55S]

id0503c1814400
25 Starter does not work

DESCRIPTION • Starter does not work even when in P or N position.
• Selector lever misadjustment
• Digital TR sensor misadjustment
• Open or short circuit in digital TR sensor
POSSIBLE • TCM malfunction
CAUSE • Vehicle harnesses
• Shift cable misadjustment
• Fluid pump
• Torque converter
End Of Sie
05-03–25
F198-10-05L(05-13).fm 1 ページ２００６年８月１０日　木曜日　午後５時２９分
05-13 AUTOMATIC TRANSMISSION [5R55S]

AUTOMATIC TRANSMISSION OUTPUT SHAFT SPEED (OSS)
LOCATION INDEX [5R55S] . . . . . . . . . 05-13–2 SENSOR REMOVAL/INSTALLATION
MECHANICAL SYSTEM TEST [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–33
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–4 SOLENOID VALVE INSPECTION
ROAD TEST [5R55S] . . . . . . . . . . . . . . . 05-13–8 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–34
AIR PRESSURE TEST [5R55S] . . . . . . . 05-13–10 SOLENOID BODY
LEAKAGE INSPECTION [5R55S] . . . . . 05-13–11 REMOVAL/INSTALLATION
AUTOMATIC TRANSMISSION FLUID [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–35
(ATF) INSPECTION [5R55S]. . . . . . . . . 05-13–13 AT RELAY LOCATION [5R55S] . . . . . . . . 05-13–38
AUTOMATIC TRANSMISSION FLUID AT RELAY INSPECTION [5R55S] . . . . . . 05-13–38
(ATF) REPLACEMENT [5R55S] . . . . . . 05-13–16 TCM INSPECTION [5R55S] . . . . . . . . . . . 05-13–39
O/D OFF SWITCH INSPECTION TCM REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–19 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–44
DIGITAL TRANSMISSION RANGE AUTOMATIC TRANSMISSION
(TR) SENSOR INSPECTION REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–20 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–45
DIGITAL TRANSMISSION RANGE TORQUE CONVERTER INSPECTION
(TR) SENSOR REMOVAL/INSTALLATION [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–54
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–22 TORQUE CONVERTER
DIGITAL TRANSMISSION RANGE REMOVAL/INSTALLATION
(TR) SENSOR ADJUSTMENT [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–55
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–24 OIL SEAL (FLUID PUMP)
TRANSMISSION FLUID TEMPERATURE REPLACEMENT [5R55S]. . . . . . . . . . . . 05-13–56
(TFT) SENSOR INSPECTION OIL SEAL (EXTENSION HOUSING)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–26 REPLACEMENT [5R55S]. . . . . . . . . . . . 05-13–57
TURBINE SHAFT SPEED (TSS) EXTENSION HOUSING GASKET
SENSOR INSPECTION [5R55S]. . . . . . 05-13–28 REPLACEMENT [5R55S]. . . . . . . . . . . . 05-13–58
TURBINE SHAFT SPEED (TSS) CONTROL VALVE BODY
SENSOR REMOVAL/INSTALLATION REMOVAL [5R55S] . . . . . . . . . . . . . . . . 05-13–61
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–29 CONTROL VALVE BODY
INTERMEDIATE SHAFT SPEED (ISS) INSTALLATION [5R55S] . . . . . . . . . . . . 05-13–63
SENSOR INSPECTION [5R55S]. . . . . . 05-13–30 OIL COOLER FLUSHING [5R55S] . . . . . 05-13–67
INTERMEDIATE SHAFT SPEED (ISS) OIL COOLER
SENSOR REMOVAL/INSTALLATION REMOVAL/INSTALLATION 05
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–31 [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–68
OUTPUT SHAFT SPEED (OSS) DRIVE PLATE
SENSOR INSPECTION [5R55S]. . . . . . 05-13–32 REMOVAL/INSTALLATION
[5R55S]. . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–71
End of Toc
SOKYU_WM: TRANSMISSION/TRANSAXLE
05-13–1

AUTOMATIC TRANSMISSION LOCATION INDEX [5R55S]
id0513c1249000
17
18
4
3
16
15
1
5
6
2
10 11 12
13
14
absggw00001006
05-13–2

1 O/D OFF switch 9 Automatic transmission fluid
(See 05-13-19 O/D OFF SWITCH INSPECTION (See 05-13-13 AUTOMATIC TRANSMISSION
[5R55S].) FLUID (ATF) INSPECTION [5R55S].)
2 Drive plate (See 05-13-16 AUTOMATIC TRANSMISSION
(See 05-13-71 DRIVE PLATE REMOVAL/ FLUID (ATF) REPLACEMENT [5R55S].)
INSTALLATION [5R55S].) 10 Transmission fluid temperature (TFT) sensor
3 Turbine shaft speed (TSS) sensor (See 05-13-26 TRANSMISSION FLUID
(See 05-13-28 TURBINE SHAFT SPEED (TSS) TEMPERATURE (TFT) SENSOR INSPECTION
SENSOR INSPECTION [5R55S].) [5R55S].)
(See 05-13-29 TURBINE SHAFT SPEED (TSS) 11 Solenoid valve
SENSOR REMOVAL/INSTALLATION [5R55S].) (See 05-13-34 SOLENOID VALVE INSPECTION
4 Intermediate shaft speed (ISS) sensor [5R55S].)
(See 05-13-30 INTERMEDIATE SHAFT SPEED (See 05-13-35 SOLENOID BODY REMOVAL/
(ISS) SENSOR INSPECTION [5R55S].) INSTALLATION [5R55S].)
(See 05-13-31 INTERMEDIATE SHAFT SPEED 12 Control valve body
(ISS) SENSOR REMOVAL/INSTALLATION (See 05-13-10 AIR PRESSURE TEST [5R55S].)
[5R55S].) (See 05-13-61 CONTROL VALVE BODY REMOVAL
5 Output shaft speed (OSS) sensor [5R55S].)
(See 05-13-32 OUTPUT SHAFT SPEED (OSS) (See 05-13-63 CONTROL VALVE BODY
SENSOR INSPECTION [5R55S].) INSTALLATION [5R55S].)
(See 05-13-33 OUTPUT SHAFT SPEED (OSS) 13 TCM
SENSOR REMOVAL/INSTALLATION [5R55S].) (See 05-13-39 TCM INSPECTION [5R55S].)
6 Digital transmission range (TR) sensor (See 05-13-44 TCM REMOVAL/INSTALLATION
(See 05-13-20 DIGITAL TRANSMISSION RANGE [5R55S].)
(TR) SENSOR INSPECTION [5R55S].) 14 AT relay
(See 05-13-22 DIGITAL TRANSMISSION RANGE (See 05-13-38 AT RELAY LOCATION [5R55S].)
(TR) SENSOR REMOVAL/INSTALLATION (See 05-13-38 AT RELAY INSPECTION [5R55S].)
[5R55S].) 15 Torque converter
(See 05-13-24 DIGITAL TRANSMISSION RANGE (See 05-13-54 TORQUE CONVERTER
(TR) SENSOR ADJUSTMENT [5R55S].) INSPECTION [5R55S].)
7 Automatic transmission (See 05-13-55 TORQUE CONVERTER REMOVAL/
(See 05-13-4 MECHANICAL SYSTEM TEST INSTALLATION [5R55S].)
[5R55S].) 16 Oil seal (fluid pump)
(See 05-13-8 ROAD TEST [5R55S].) (See 05-13-56 OIL SEAL (FLUID PUMP)
(See 05-13-11 LEAKAGE INSPECTION [5R55S].) REPLACEMENT [5R55S].)
(See 05-13-45 AUTOMATIC TRANSMISSION
REMOVAL/INSTALLATION [5R55S].) 17 Oil seal (extension housing)
8 Oil cooler
(See 05-13-57 OIL SEAL (EXTENSION HOUSING)
REPLACEMENT [5R55S].)
05
(See 05-13-67 OIL COOLER FLUSHING [5R55S].)
(See 05-13-68 OIL COOLER REMOVAL/ 18 Extension housing gasket
INSTALLATION [5R55S].) (See 05-13-58 EXTENSION HOUSING GASKET
REPLACEMENT [5R55S].)
End Of Sie
05-13–3

MECHANICAL SYSTEM TEST [5R55S]
id0513c1249100
Mechanical System Test Preparation
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level.
3. Inspect the engine oil level.
4. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
5. Inspect the idle speed.
Line Pressure Test (Pressure Control A, Pressure Control B)
Warning
• Removing the plug when the ATF is hot is dangerous. Hot ATF can discharge from the opening
and cause severe burns. Before removing the line pressure tap, allow the AT and ATF to cool.
Caution
• Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
• Do not maintain WOT in any gear position for more than 5 s.
Note
• Certain sensor failures may cause high pressure control, Failure Mode Effect Management (FMEM)
actions. Be sure that the self-test and electrical repairs have been carried out or test results may be
incorrect.
• The line pressure tap is used to verify output pressure from pressure control A or pressure control B. Use
PC PIDs and take note which solenoid, pressure control A or pressure control B, is commanded higher.
Use the higher commanded PC x value when referencing the Line Pressure Charts A and B. The second
pressure tap is used to verify the output from the pressure control solenoid C.
Pressure control A, pressure control B

1. Remove the line pressure tap.
2. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
3. Connect the diagnostic scan tool and monitor the
PC A and PC B PIDs. Note which PID is
commanded higher. Use the higher commanded
PC x value when referencing the Line Pressure
Charts A and B.
4. Start the engine and check the line pressure
reading from the gauge installed in Step 1. Refer LINE PRESSURE
to the Line Pressure Chart for the correct shift TAP
lever position.
• If the line pressure is not within ranges given
absggw00001756
in Line Charts A and B, refer to Line Pressure

Diagnosis Chart in this section for line pressure concern causes.
Line pressure (pressure control A, pressure

control B)
Line pressure (kPa {kgf/cm2, psi})
Position/range
Idle Stall
P/N 793 {8.09, 115} 793 {8.09, 115}
R 793 {8.09, 115} 2,138 {21.80, 310}
D, 3, 2, 1 793 {8.09, 115} 1,520 {15.47, 220}
05-13–4
kPa PSI
2,758 400
PND Line Commanded
2,413 350 Min Line
Max Line
2,068 300
1,724 250
Line Pressure
1,379 200
1,035 150
690 100
345 50
0 0
0 69 138 207 276 345 414 483 552 621 690 758 827 896 kPa
0 10 20 30 40 50 60 70 80 90 100 110 120 130 PSI
Commanded PCA or PCB

absggw00001757
kPa PSI
2,758 400
R Line Commanded
2,413 350 Min Rev Line
Max Rev Line

05
2,068 300
1,724 250
Line Pressure
1,379 200
1,035 150
690 100
345 50
0 0
0 69 138 207 276 345 414 483 552 621 690 758 827 896 kPa
0 10 20 30 40 50 60 70 80 90 100 110 120 130 PSI
Commanded PCA or PCB

absggw00001758
5. Install the line pressure tap.
Tightening torque
10—15 N·m {102—152 kgf·cm, 89—132 in·lbf}
6. Go to the Pressure Control C Pressure Test in this section.

05-13–5

Pressure Control C
1. If not previously connected, install the scan tool.
2. Remove the line pressure tap.
3. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
4. Using the diagnostic scan tool, monitor the PC C
PID and note the commanded pressure.
5. Start the engine and check the PC C pressure. LINE PRESSURE
• If the gauge reading does not match within ± TAP
103 kPa {1.05 kgf/cm2, 15 psi} of the PID
value displayed for the PC C, inspect the
pressure control solenoid C. (See 05-13-34
SOLENOID VALVE INSPECTION [5R55S].)
• If pressure control solenoid C operation is absggw00001759
normal, refer to the Line Pressure Diagnosis
Chart in this section for line pressure concern
causes.
Line pressure (pressure control C)
Position/range
Idle Stall
P/N 27 {0.28, 4} 0 {0, 0}
R 793 {8.09, 115} 793 {8.09, 115}
D, 3, 2, 1 27 {0.28, 4} 0 {0, 0}
6. Install the line pressure tap.
Tightening torque
10—15 N·m {102—152 kgf·cm, 89—132 in·lbf}
Line pressure diagnosis chart

Test Results Possible Source
• Wiring harnesses
• PC C boost valve
High at Idle—All Ranges
• Pressure control solenoid C
• Main regulator valve
• Low fluid level
• Fluid inlet filter/seal
• Control valve body
Low at Idle—All Ranges • Cross leaks
• Gaskets
• Pump
• Separator plate
• Forward Clutch
• Main Control
Low—All Forward Ranges
• Overdrive brake servo
• Intermediate brake servo
Low in P position Only • Control valve body
• Separator plate
• Reverse servo piston, cover seal
• Reverse clutch
Low in R position Only • Overdrive brake servo
• Forward clutch
Low in N position Only • Overdrive brake servo
• Forward clutch
Low in D range
• Forward clutch
Low in D range Only (O/D OFF mode)
05-13–6

Test Results Possible Source
• Forward clutch
Low in 1 range
Low in 2 range • Overdrive brake servo
• Forward clutch
Low in 3 range • Overdrive brake servo
• Forward clutch
Stall Speed Test
Warning
• Apply the parking brake firmly while performing each stall test. Failure to set the brakes can result
in death or severe injury.
Caution
• Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
• The stall test should only be performed with the engine and transmission at normal operating
temperature.
Note
• The stall speed test inspects the operation of the following:
— Torque converter clutch
— Forward clutch
— Low/reverse one-way clutch
— Low one-way clutch component
— Engine driveability concerns
— Overdrive one-way clutch component
1. Connect a tachometer to the engine.
Caution
• Do not maintain WOT in any shift position for more than 5 s.
• If the engine rpm recorded by the tachometer exceeds the maximum specified rpm, release the 05
accelerator pedal immediately. Otherwise, clutch or band slippage could occur.
Note
• Prolonged use of this procedure may set DTC P0712 or P1783. After carrying out the Stall Speed Test,
run the OBD Test and clear DTCs from the memory.
2. Depress the accelerator pedal to the floor (WOT) in each shift position. Record the rpm reached in each shift
position.
Engine stall speed

Engine type rpm
WL-C 2,700
WE-C 2,900
05-13–7

3. After testing the D, 3, 2, 1 range and R position, shift the selector lever to the N position and run the engine at
1,000 rpm for 15 s to allow the torque converter to cool before testing the next gear position.
• If the stall speed is too high, refer to the stall speed diagnosis chart.
Stall speed diagnosis chart
Position/range Stall speeds high Stall speeds low
• Overdrive one-way clutch
D, D (O/D OFF mode) and 1 —
• Rear one-way clutch
• Forward clutch
D (O/D OFF mode), 2 and 1 —
• Forward clutch
D —
• General pressure concerns
• Converter one-way clutch or engine
D, D (O/D OFF mode), 2, 1 and R • Forward clutch
driveability concerns
• High/reverse
R • High clutch —
• Low/reverse band/servo
2 • Intermediate band/servo —
1 • Intermediate band/servo —
4. If the stall speed is too low, inspect the idle speed.

• If the idle speed is normal, remove the torque converter and inspect the torque converter one-way clutch for
slippage.
End Of Sie
ROAD TEST [5R55S]
id0513c1248900
Warning
• When performing a road test, be aware of other vehicles, people, and impediments to avoid an
accident.
Note
• Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
• When the legal speed limit must be exceeded, use a chassis dynamometer instead of performing a road
test.
Road Test Preparation

1. Inspect the engine coolant level.
2. Inspect the engine oil level.
3. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
4. Inspect the idle speed.
Shift Point Road Test
Note
• This test verifies that the shift control system is operating correctly.
1. Bring up the engine and transmission to normal operating temperature.

2. Shift the selector lever to the D range.
3. Apply minimum throttle and observe speeds at which up-shift occurs and the torque converter engages.
Caution
• Do not exceed posted speed limits when performing this test.
05-13–8

Shift speed (Reference) WL-C
Throttle position Gear position Vehicle speed (km/h {mph})
5—4 33—35 {20—22}
Closed
4—1 17—19 {10—12}
1—2 17—19 {10—12}
Minimum monitor PID minimum TP volt 2—3 21—24 {13—15}
1.25 3—4 28—30 {17—19}
4—5 38—40 {23—25}
1—2 42—45 {26—28}
2—3 60—62 {37—39}
Wide open
3—4 80—83 {49—52}
4—5 115—122 {71—76}
Shift speed (Reference) WE-C

Throttle position Gear position Vehicle speed (km/h {mph})
5—4 44—46 {27—29}
Closed
4—1 17—19 {10—12}
1—2 17—19 {10—12}
Minimum monitor PID minimum TP volt 2—3 26—29 {16—18}
1.25 3—4 31—33 {19—21}
4—5 52—54 {32—34}
1—2 42—45 {26—28}
2—3 61—66 {38—41}
Wide open
3—4 84—91 {52—57}
4—5 107—119 {66—74}
4. Stop the vehicle.

5. Depress O/D OFF switch to activate D range and repeat Step 3.
6. The transmission will make all upshifts except 4-5, and the torque converter clutch application should occur
above 46 km/h {29 mph}.
7. Press the accelerator pedal to the floor, wide open throttle (WOT). The transmission should shift from 3GR to
2GR or 3GR to 1GR depending on vehicle speed, and the torque converter clutch should release.
8. With the vehicle speed above 48 km/h {30 mph}, move the transmission range selector lever from D range to 1 05
range and release the accelerator pedal. The transmission should immediately downshift to 3GR. When the
vehicle speed drops below 32 km/h {20 mph}, the transmission should downshift into 1st gear.
9. If the transmission fails to up-shift/down-shift or the torque converter does not apply and release, inspect
according to “SYMPTOM TROUBLESHOOTING”. (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
TABLE [5R55S].)
End Of Sie
05-13–9

AIR PRESSURE TEST [5R55S]
id0513c1249500
Note
• A no-drive or erratic shift condition may be due to inoperative bands and clutches. To diagnose these
conditions a series of checks can be made by substituting air pressure for fluid to determine the location of
the damaged or obstructed component.
• Follow the procedure to determine the location of the inoperative clutch or band by substituting air
pressure into the various test plate passages.
• Use only dry, regulated air pressure, 276 kPa {2.8 kgf/cm2, 40 psi} maximum.
1. Remove the control valve body. (See 05-13-61 CONTROL VALVE BODY REMOVAL [5R55S].)
2. Install the transmission test plate and gasket (SST: 307-433-01, 307-433-02, 307-433-03).
Tightening torque
10 N·m {102 kgf·m, 111.6—89 ft·lbf}
Note
• Do not apply air to the test plate vent hole.
3. Apply air to the appropriate clutch or servo port.

Refer to the Air Pressure Test Diagnostic Chart 1 2 3
for conditions, possible causes and actions. 4
1 Reverse servo
2 Intermediate servo
3 Overdrive servo
4 Coast clutch
5 Forward clutch 5
6 Direct clutch
6
7 Reverse servo modulator 7
absggw00001755
4. After the testing is completed, remove the air test
plate and gasket (SST: 307-433-01, 307-433-02,
307-433-03) and proceed with any repairs that are needed.
5. After the repairs are completed, install the control valve body. (See 05-13-63 CONTROL VALVE BODY
Air pressure test diagnostic chart
Condition Possible causes Actions
Concerns may not be in the
Dull thud heard or movement felt when Clutches, bands and fluid passages are transmission. Check the powertrain
air is applied and released normal. TCM, wiring harness and non-
transmission related components.
Disassemble the transmission, clean and
No drive Clutches and bands inoperative.
inspect to locate area of concern.
Clutches and bands inoperative due to Disassemble the transmission, clean and
Erratic shifts
incorrect pressures. inspect to locate area of concern.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
No dull thud heard
be damaged or obstructed. inspect to locate area of concern.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
No movement felt
be damaged or obstructed. inspect to locate area of concern.
Clutch seals or check ball may be Disassemble the transmission, clean and
Hissing sound heard
damaged or leaking. inspect to locate area of concern.
Seals and pistons may be damaged.
Servos do not operate Supply and release ports may be
inspect to locate area of concern.
obstructed. Spring may be broken.
Fluid passages in center support or inspect to locate area of concern.Check
Multiple clutches are applied
clutch cylinders may be obstructed. fluid passages in the center support for
obstructions.
End Of Sie
05-13–10

LEAKAGE INSPECTION [5R55S]
id0513c1249600
Leak Check Test with a Black Light
Note
• Automatic Transmission/Power Steering Dye (specifically formulated for ATF) is used to detect a
transmission fluid leak.
1. Add Automatic Transmission/Power Steering Dye to the transmission fluid. Use one 30.0 mL {30.0 cc, 1 ft oz}
of dye solution for every 3.8 L {4.0 US qt, 3.3 lmp qt} of transmission fluid.
2. Start and run the engine until the transmission reaches its normal operating temperature.
3. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage.
4. Raise the vehicle on a hoist.
5. Run the engine at fast idle, then at engine idle, occasionally shifting to the D range and R position to increase
pressure within the transmission.
6. Observe the front of the flexplate, back of the cylinder block (in as far as possible), inside the torque converter
housing and the entire case until fluid leakage is evident and the probable source of leakage can be detemined.
Caution
• Do not try to stop a fluid leak by increasing the torque beyond specifications. This may cause
damage to the transmission case threads.
External fluid leaks

Leak path Possible source
• Pan bolts not tightened to specification.
Leaks at the fluid pan-to-case • Case pan rail damaged.
• Pan gasket damaged.
• Cooler line(s), cooler line fitting(s) damaged.
• Cooler line fittings-to-case union damaged.
Fluid cooler lines or fittings leaking
• Case damage at case fitting.
• Fittings not tightened to specifications.
• Damaged or missing O-rings.
Fluid cooler line nut-to-case fittings leaking
• Fittings not tightened to specifications.
• Fluid cooler damage.
Leaks at the fluid cooler
• Fitting(s) damaged or not tightened to specifications.
Leaks at the external sensors
•
•
Damaged or missing O-rings.
Screw not tightened to specifications.
05
Leaks at the manual control lever seal • Damaged or missing lever seal.
• Install a new solenoid body wiring harness connector O-
Leaks at the solenoid body harness connector ring seal. Either on the wiring harness end or the solenoid
body.
• For possible sources refer to Fluid Leakage In Torque
Fluid leakage in the torque converter area
Converter Area Chart.
05-13–11

Fluid Leakage in Torque Converter Area
• In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area, use the
following procedures to locate the exact cause of the leakage.
• Leakage at the front of the transmission, as evidenced by fluid around the torque converter housing, may have
several sources.
• By careful observation it is possible, in many instances, to pinpoint the source of leak before removing the
transmission from the vehicle.
• The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the
illustration.
Leak path Symptom Possible source
2
Leak at front of 5 1
1, 2 and 4 Pump lip seal
transmission
4
Leak at front of Converter hub
1, 2 and 4 3
transmission weld
Leak at front of External pump
1, 2 and 4
transmission seal (large)
Leak at front of Pump-to-case
1, 2 and 4
transmission screws 3
Leak at front of
1, 2 and 4 Pump gasket
transmission
Leak at front of Torque converter 6
3
transmission seal weld
Leak at front of Torque converter
3
transmission stud
Leak at front of Engine oil leak—
5
transmission rear main seal
Leak at front of Engine valve
5
transmission cover
Leak at front of
5 Oil galley
transmission
Leak at front of Engine oil
5
transmission pressure sensor absggw00001754
Leak between
6 engine and Venting
transmission case
End Of Sie
05-13–12

AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S]
id0513c1251100
Automatic Transmission Fluid (ATF) Condition Inspection
1. Hold the larger drain plug with a wrench and
remove the small (center) fluid level indicating
plug.
2. Check the ATF level.
3. Observe the color and the odor of the ATF.
• Under normal circumstances the color should
be dark reddish, not brown or black.
4. Allow the ATF to drip onto a facial tissue and
examine the stain.
• If evidence of solid material is found, the fluid
pan should be removed for further inspection.
• If ATF contamination or transmission failure is
absggw00001022
confirmed by the sediment in the bottom of
the fluid pan, the transmission must be
disassembled and completely cleaned.
5. Install the small (center) fluid level indicating plug.
Tightening torque
10 N·m {102 kgf·cm, 89 in·lbf}
Automatic Transmission Fluid (ATF) Level Inspection

1. Connect the M-MDS to the vehicle DLC-2 16-pin
connector.
2. Verify the ATF temperature using the PID/data
monitor “TFT”.
3. Warm up the automatic transmission until the ATF
temperature is 27—49 °C {80—120 °F}.
4. Move the range selector lever slowly through
each gear, stopping in each position and allowing
the transmission to engage.
5. Place the selector lever in the P position.
DLC-2
absggw00000987 05
plug.
absggw00001022
7. Install the SST into the pan.
Note
• Prior to filling the SST with clean ATF, make
sure that the canister is clean.
307-437
(49 UN30 7437)
arnffw00001950
05-13–13

8. Fill the SST with clean ATF.
307-D465
(49 UN30 7D4650)
arnffw00001951
9. Hang the SST under the vehicle. Position it

upright and close to the transmission.
307-D465
(49 UN30 7D4650)
arnffw00001952
10. Connect the SST.

• Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan. 307-437
(49 UN30 7437)
307-D465
(49 UN30 7D4650)
arnffw00001953
11. Apply a maximum of 206.85 kPa {2.11 kgf/cm2,

30.0 pis} to the open end of the vacuum/pressure 307-D465
hose from the rubber tip air nozzle. Fluid will (49 UN30 7D4650)
immediately start flowing out of the SST into the
fluid pan.
12. Add 0.5 L {0.5 US qt, 0.4 lmp qt} of ATF into the
fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the
end of the hose. 206.85 kPa
13. Inspect the ATF level in the SST. {2.11 kgf/m2,
• If the fluid drains back into the canister, the 100-D009 30.0 pis}
transmission is full. arnffw00001954
• If no fluid drains back, more fluid will need to
be added. Repeat Steps 11 and 12.
05-13–14

14. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
416-D002
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
15. Make sure that the ATF temperature is between
27—49 °C {80—120 °F}.
307-D465
(49 UN30 7D4650)
arnffw00001955
16. Allow the ATF to drain.

• When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029
Tightening torque
18. Check the operation of the transmission by

moving the selector lever slowly through each
gear, stopping in each position and allowing the
transmission to engage.
ATF
05
Type: Mercon® V absggw00001022
End Of Sie
05-13–15

AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S]
id0513c1251200
Draining
1. Place the selector lever in the P position.
2. Remove the drain plug (large plug) and allow the
ATF to drain.
absggw00001030
Refill
1. Install the drain plug (large plug).
Tightening torque
24—28 N·m {2.5—2.8 kgf·m, 18—20 ft·lbf}
absggw00001030

plug.
absggw00001022
3. Install the SST into the pan.
Note
• Prior to filling the SST with clean ATF, make
sure that the canister is clean.
307-437
(49 UN30 7437)
arnffw00001950
05-13–16

4. Fill the SST with clean ATF.
307-D465
(49 UN30 7D4650)
arnffw00001951
5. Hang the SST under the vehicle. Position it

upright and close to the transmission.
307-D465
(49 UN30 7D4650)
arnffw00001952
6. Connect the SST.

• Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan. 307-437
(49 UN30 7437)
307-D465
(49 UN30 7D4650) 05
arnffw00001953
7. Apply a maximum of 206.85 kPa {2.11 kgf/cm2,

30.0 pis} to the open end of the vacuum/pressure 307-D465
hose from the rubber tip air nozzle. Fluid will (49 UN30 7D4650)
immediately start flowing out of the SST into the
fluid pan.
8. Add 1.89—2.83 L {2.00—2.99 US qt, 1.67—2.49
imp qt} of ATF into the fluid pan. Stop the
process by releasing the air pressure and
removing the air nozzle from the end of the hose. 206.85 kPa
{2.11 kgf/m2,
100-D009 30.0 pis}
arnffw00001954
9. Connect the M-MDS to the vehicle DLC-2 16-pin

connector.
10. Verify the ATF temperature using the PID/data
monitor “TFT”.
11. Warm up the automatic transmission until the ATF
temperature is 27—49 °C {80—120 °F}.
12. Inspect the ATF level in the SST.
• If the fluid drains back into the canister, the
transmission is full.
• If no fluid drains back, more fluid will need to
be added. Repeat Steps 7 and 8. DLC-2
absggw00000987
05-13–17

13. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
416-D002
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
307-D465
(49 UN30 7D4650)
arnffw00001955
14. Allow the ATF to drain.

• When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029
Tightening torque
ATF
Type: Mercon® V
Capacity (approx. quantity): 9.93 L {10.49 US
qt, 8.74 lmp qt}
End Of Sie
absggw00001022
05-13–18

O/D OFF SWITCH INSPECTION [5R55S]
id0513c1254200
Operation Inspection
2. Verify that the O/D OFF indicator light is not illuminated. Press the O/D OFF switch and verify that the O/D OFF
indicator light illuminates.
• If there is any malfunction, inspect the terminal voltage of the O/D OFF switch. (See 05-13-19 Voltage
Inspection.)
Voltage Inspection
2. Measure the voltage at the O/D OFF switch
connector.
• If there is any malfunction, inspect for
continuity at the O/D OFF switch. (See 05-13-
19 Continuity Inspection.)
Connector terminal
Position
C D
OFF (Normal) (V) B+ 0
ON (Depressed) (V) 0 0 C A
D B
absggw00001008
Continuity Inspection
1. Disconnect the O/D OFF switch connector.
table.
• If the switch is normal, inspect the wiring
harness. (O/D OFF switch—TCM, O/D OFF
switch—Body ground)
• If there is any malfunction, replace the
selector lever component. (See 05-14-4
SELECTOR LEVER REMOVAL/
INSTALLATION.)
C A 05
: Continuity D B
Terminal
Switch absggw00001009
C D
ON (Normal)
OFF (Depressed)
absggw00001858
End Of Sie
05-13–19

DIGITAL TRANSMISSION RANGE (TR) SENSOR INSPECTION [5R55S]
id0513c1254700
Operating Inspection
1. Verify that the starter operates only when the engine switch is turned to the START position with the selector
lever in the P or N position.
• If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
(TR) SENSOR ADJUSTMENT [5R55S].)
2. Verify that the back-up lights illuminate when shifted to the R position with the engine switch at the ON position.
• If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
(TR) SENSOR ADJUSTMENT [5R55S].)
3. Verify that the positions of the selector lever and
the indicator are aligned.
• If there is any malfunction, adjust the digital
TR sensor. (See 05-13-24 DIGITAL
TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT [5R55S].)
absggw00001014
Continuity Inspection
Caution

2. Remove the digital TR sensor insulator.
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
3. Disconnect the digital TR sensor connector.
DIGITAL TR SENSOR
CONNECTOR
absggw00001812
05-13–20

table.
A C E G I K
TRANSMISSION RANGE (TR) SENSOR B D F H J L
: Continuity
Terminal
Selector
position
A B C D E F G H I J L
P absggw00001017
D
3
2
1
absggw00001018
5. Reinspect for continuity at digital TR sensor.

• If there is any malfunction, replace the digital TR sensor. (See 05-13-22 DIGITAL TRANSMISSION RANGE
(TR) SENSOR REMOVAL/INSTALLATION [5R55S].)
6. Connect the digital TR sensor connector.
7. Install the digital TR sensor insulator.
Tightening torque
7.8—10.7 N·m {80—108 kgf·cm, 69.1—94.7
in·lbf}

End Of Sie
DIGITAL TR
05
SENSOR
INSULATOR
absggw00001811
05-13–21

DIGITAL TRANSMISSION RANGE (TR) SENSOR REMOVAL/INSTALLATION [5R55S]
id0513c1254800
Caution

DIGITAL TR
SENSOR
INSULATOR
absggw00001811

4. Remove the selector cable.
DIGITAL TR SENSOR
SELECTOR CABLE
CONNECTOR
absggw00001813
5. Set the adjustable wrench as shown in the figure

to hold the manual shaft lever.
6. Remove the manual shaft nut.
7. Remove the manual shaft lever.
MANUAL SHAFT
LEVER
absggw00001032
8. Remove the digital TR sensor.
DIGITAL TR SENSOR
absggw00001814
05-13–22

9. Rotate the manual shaft to the torque converter
housing side fully and return two notches to set MANUAL SHAFT
the N position.
10. Install the digital TR sensor and loosely install the
screws.
TORQUE
CONVERTER
Caution
HOUSING SIDE
• Tightening one screw before tightening
the other may cause the digital TR sensor P 1
to bind or become damaged. R 2
N 3
D
Note
• The manual lever must be in the N position.
absggw00001034
11. Using the SST, align the digital TR sensor and

tighten the screws in an alternating sequence.
Tightening torque
6.5—9.5 N·m {67— 96 kgf·cm, 58—84 in·lbf}
Caution
• Do not use an impact wrench. Hold the
manual shaft lever when tightening the
manual shaft nut, otherwise the 307-351
transmission may be damaged. (49 UN30 7351)
absggw00001035
12. Install the manual shaft lever.
Tightening torque
61—74 N·m {6.3— 7.5 kgf·m, 45—54 ft·lbf}
13. Shift the selector lever to P position.

14. Turn the manual shaft lever to P position.
05
MANUAL SHAFT
LEVER
absggw00001032
15. Install the selector cable.

DIGITAL TR SENSOR
SELECTOR CABLE
CONNECTOR
absggw00001813
Tightening torque
7.8—10.7 N·m {80—108 kgf·cm, 69.1—94.7
in·lbf}

19. Inspect digital TR sensor operation. (See 05-13-
20 DIGITAL TRANSMISSION RANGE (TR) DIGITAL TR
SENSOR INSPECTION [5R55S].) SENSOR
End Of Sie INSULATOR
absggw00001811
05-13–23

DIGITAL TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT [5R55S]
id0513c1254900
Caution

DIGITAL TR
SENSOR
INSULATOR
absggw00001811

4. Remove the selector cable.
5. Rotate the manual shaft to the N position.
Caution
• Do not use an impact wrench. Hold the
manual shaft lever when removing the
manual shaft nut, otherwise the
transmission may be damaged.
DIGITAL TR SENSOR
SELECTOR CABLE
CONNECTOR
absggw00001813

7. Remove the manual shaft nut.
8. Remove the manual shaft lever.
MANUAL SHAFT
LEVER
absggw00001032
9. Loosen the digital TR sensor mounting bolts.
Caution
• Tightening one screw before tightening
the other may cause the digital TR sensor
to bind or become damaged.
Note
• The manual lever must be in the N position.
DIGITAL TR SENSOR
absggw00001814
05-13–24

10. Using the SST, align the digital TR sensor and
tighten the screws in an alternating sequence.
Tightening torque
6.5—9.5 N·m {67— 96 kgf·cm, 58—84 in·lbf}
307-351
(49 UN30 7351)
absggw00001035
11. Inspect for continuity between digital TR sensor
terminals A, E and I.
Caution
A C E G I K
• Do not use an impact wrench. Hold the B D F H J L
manual shaft lever when tightening the
manual shaft nut, otherwise the
transmission may be damaged.
absggw00001017
12. Install the manual shaft lever.
Tightening torque
61—74 N·m {6.3— 7.5 kgf·m, 45—54 ft·lbf}

14. Tighten the manual shaft nut using a torque
wrench.
MANUAL SHAFT
Tightening torque
14—18 N·m {1.5—1.8 kgf·m, 11—13 ft·lbf}
LEVER 05
absggw00001032
15. Shift the selector lever to P position.

16. Turn the manual shaft lever to P position.
17. Install the selector cable.
DIGITAL TR SENSOR
SELECTOR CABLE
CONNECTOR
absggw00001813
Tightening torque
7.8—10.7 N·m {80—108 kgf·cm, 69.1—94.7
in·lbf}

21. Inspect digital TR sensor operation. (See 05-13-
20 DIGITAL TRANSMISSION RANGE (TR) DIGITAL TR
SENSOR INSPECTION [5R55S].) SENSOR
End Of Sie INSULATOR
absggw00001811
05-13–25

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR INSPECTION [5R55S]
id0513c1710300
Caution
On-Vehicle Inspection
3. Remove the CKP sensor insulator.
4. Remove the insulator bracket.
5. Disconnect the AT connector.
absggw00001183
6. Measure resistance between the AT terminals K

and L.
• If there is any malfunction, perform the off-
M K I G E B
vehicle inspection for TFT sensor. (See 05- P C
13-27 Off-Vehicle Inspection.) N A
O L J H F D
Transmission fluid temperature (TFT) sensor
ATF temperature (°C {°F}) Resistance (kilohm)
-40—-20 {-40—-4} 284—967
-19—-1 {-3—30} 100—284
0—20 {32—68} 37—100
21—40 {70—104} 16—37 absggw00001184
41—70 {106—158} 5—16

71—90 {160—194} 2.7—5
91—110 {196—230} 1.5—2.7
111—130 {232—266} 0.8—1.5
131—150 {268—302} 0.54—0.8
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
05-13–26

Off-Vehicle Inspection
Warning
• A hot the transmission and ATF can cause severe burns. Turn off the engine and wait until they are
cool before replacing ATF.
1. Remove the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAL/INSTALLATION [5R55S].)
2. Place the solenoid body and a thermometer in ATF as shown in the figure, and heat the ATF gradually.
3. Measure the resistance between the solenoid
body terminals K and L.
• If there is any malfunction, replace the
M K I G E B
solenoid body. (See 05-13-35 SOLENOID P C
BODY REMOVAL/INSTALLATION [5R55S].) N A
O L J H F D
-40—-20 {-40—-4} 284—967
-19—-1 {-3—30} 100—284
0—20 {32—68} 37—100
21—40 {70—104} 16—37 absggw00001185
41—70 {106—158} 5—16

71—90 {160—194} 2.7—5
91—110 {196—230} 1.5—2.7
111—130 {232—266} 0.8—1.5
131—150 {268—302} 0.54—0.8
4. Install the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAL/INSTALLATION [5R55S].)
End Of Sie
05
05-13–27

TURBINE SHAFT SPEED (TSS) SENSOR INSPECTION [5R55S]
id0513c1252900
Caution

2. Remove the oxidation catalytic converter.
6. Disconnect the TSS sensor connector.
TSS SENSOR
Caution
• Do not apply a shock in the TSS sensor.
TSS SENSOR
CONNECTOR
absggw00001186
7. Measure the resistance between the TSS sensor

terminals.
• If there is any malfunction, replace the TSS
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAL/ B A
TSS sensor resistance

Resistance (ohm) Temperature (°C {°F})
226—390 -20 {4}
325—485 21 {70}
492—738 150 {302} absggw00001189
8. Connect the TSS sensor connector.

9. Install the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
10. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
11. Install the oxidation catalytic converter.
End Of Sie
05-13–28

TURBINE SHAFT SPEED (TSS) SENSOR REMOVAL/INSTALLATION [5R55S]
id0513c1253000
Caution
• Do not damage the TSS sensor.

6. Disconnect the TSS sensor connector.
7. Remove the TSS sensor.
TSS SENSOR
Note
• Inspect O-ring for damage. Install new O-
ring if damaged. Lubricate the O-ring with
petroleum jelly to prevent damage to the O-
ring.
TSS SENSOR
8. Install the TSS sensor. CONNECTOR
Tightening torque
8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
absggw00001186
9. Connect the TSS sensor connector.

End Of Sie
05
05-13–29

INTERMEDIATE SHAFT SPEED (ISS) SENSOR INSPECTION [5R55S]
id0513c1253400
Caution

REMOVAL/INSTALLATION [5R55S].)
6. Disconnect the ISS sensor connector.
Caution
ISS SENSOR
• Do not apply a shock in the ISS sensor. CONNECTOR
ISS SENSOR
absggw00001187
7. Measure the resistance between the ISS sensor

terminals.
• If there is any malfunction, replace the ISS
sensor. (See 05-13-31 INTERMEDIATE
SHAFT SPEED (ISS) SENSOR REMOVAL/ B A
ISS sensor resistance

226—390 -20 {4}
325—485 21 {70}
492—738 150 {302} absggw00001189
8. Connect the ISS sensor connector.

End Of Sie
05-13–30

INTERMEDIATE SHAFT SPEED (ISS) SENSOR REMOVAL/INSTALLATION [5R55S]
id0513c1253500
Caution
• Do not damage the ISS sensor.

6. Disconnect the ISS sensor connector.
7. Remove the ISS sensor.
Note
ISS SENSOR
• Inspect O-ring for damage. Install new O- CONNECTOR
ring.
8. Install the ISS sensor.
Tightening torque ISS SENSOR

8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
absggw00001187
9. Connect the ISS sensor connector.

End Of Sie
05
05-13–31

OUTPUT SHAFT SPEED (OSS) SENSOR INSPECTION [5R55S]
id0513c1254000
Caution

6. Disconnect the OSS sensor connector.
OSS SENSOR OSS SENSOR
Caution
CONNECTOR
• Do not apply a shock in the OSS sensor.
absggw00001188
7. Measure the resistance between the OSS sensor

terminals.
• If there is any malfunction, replace the OSS
sensor. (See 05-13-33 OUTPUT SHAFT
SPEED (OSS) SENSOR REMOVAL/ B A
OSS sensor resistance

226—390 -20 {4}
325—485 21 {70}
492—738 150 {302} absggw00001189
8. Connect the OSS sensor connector.

End Of Sie
05-13–32

OUTPUT SHAFT SPEED (OSS) SENSOR REMOVAL/INSTALLATION [5R55S]
id0513c1254100
Caution
• Do not damage the OSS sensor.

6. Disconnect the OSS sensor connector.
7. Remove the OSS sensor.
OSS SENSOR OSS SENSOR
Note
CONNECTOR
• Inspect O-ring for damage. Install new O-
ring.
8. Install the OSS sensor.
Tightening torque
12—16 N·m {123—163 kgf·cm, 107—141
absggw00001188
in·lbf}
9. Connect the OSS sensor connector.

End Of Sie
05
05-13–33
F198-10-05L(05-13).fm 34 ページ２００６年８月１１日　金曜日　午前１０時３１分

SOLENOID VALVE INSPECTION [5R55S]
id0513c1253200
Caution

absggw00001183
6. Measure the resistance between the following

terminals.
• If there is any malfunction, inspect the coupler
M K I G E B
component. P C
• If the coupler component is normal, replace N A
the solenoid body. (See 05-13-35 SOLENOID O L J H F D
BODY REMOVAL/INSTALLATION [5R55S].)
Solenoid valve resistance)

Resistance
Terminals Solenoid valve
(ohm)
D—I Shift solenoid A 16—45 absggw00001184
F—I Shift solenoid B 16—45
B—I Shift solenoid C 16—45
E—I Shift solenoid D 16—45
Pressure control
O—I 3.3—7.5
solenoid A
Pressure control
M—I 3.3—7.5
solenoid B
Pressure control
G—I 3.3—7.5
solenoid C
TCC control
H—I 9—16
solenoid
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
[5R55S].)
End Of Sie
05-13–34

SOLENOID BODY REMOVAL/INSTALLATION [5R55S]
id0513c1254400
On-Vehicle Removal
Warning
• A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
• Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.

2. Drain the ATF. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].)
Note
• The transmission fluid pan gasket is
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should
be reused.
absggw00001183
7. Remove the screws, transmission fluid pan and

gasket.
05
b5r5za00000014
8. Remove the transmission fluid filter and seal

component and discard.
Caution
• Do not damage solenoid body connector
pins.
b5r5za00000015
05-13–35

9. Remove the solenoid body component by lifting
on the body and pushing the connector from the
other side of the case.
b5r5za00000018
On-Vehicle Installation
1. Install new O-rings on the solenoid body
connector. Lubricate the O-rings with clean ATF.
Caution
• Inspect the transmission case bore to
make sure it is free of foreign material
and not damaged. If damaged,
transmission leak may occur.
b5r5za00000272
2. Install the solenoid body. Tighten bolts in the

sequence shown. 2 1
Tightening torque
7—9 N·m {72—91 kgf·cm, 62—79 in·lbf} 3
4
Caution
• Lubricate the transmission fluid filter
seals with clean ATF or they may be
damaged. 7
5 6 8
b5r5za00000273
3. Lubricate the seals and install the transmission

fluid filter.
Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}
Note
• Make sure that the transmission fluid filter
seals are correctly seated on the filter.
b5r5za00000275
05-13–36

4. Install the transmission fluid pan gasket on the
pan.
Note
reusable, clean and inspect for damage. If GASKET
not damaged, the gasket should be reused.
absggw00001562
5. Install the transmission fluid pump and gasket,

magnet and loosely install the bolts.
6. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5—11.5 N·m {97—117 kgf·cm, 85—101
in·lbf}
Caution
• Damage will occur to the solenoid body
component if the screw is tightened
above specification.
b5r5za00000276
7. Install and lubricate new O-rings on the AT

connector and connect the connector.
Tightening torque
Note
• Clean the area around connector to prevent
contamination of the AT connector.
• Use petroleum jelly to lubricate the O-rings 05
to aid in the installation process.
absggw00001183
8. Remove the insulator bracket. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL/
[5R55S].)
12. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
13. Perform the mechanical system test. (See 05-13-4 MECHANICAL SYSTEM TEST [5R55S].)
14. Perform the road test. (See 05-13-8 ROAD TEST [5R55S].)
End Of Sie
05-13–37

AT RELAY LOCATION [5R55S]
id0513c1254500
End Of Sie
TCM
AT RELAY
absggw00001809
AT RELAY INSPECTION [5R55S]

id0513c1254600
2. Remove the AT relay.
3. Verify the continuity between the relay terminals.
• If not as indicated in the table, replace the
relay. C A A E
: Continuity C
Terminal D
Step
A E C D
1
D E
2 B+ GND
acxuuw00002119
End Of Sie acxuuw00002118
05-13–38

TCM INSPECTION [5R55S]
id0513c1250700
Terminal Voltage/Resistance Table (Reference)
A E I M Q U
Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
J CK CN
B F N R Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
V
CL CO
CM CP
absggw00001190
Voltage/
Terminal Signal Connected to Test Condition Action
Resistance
• Inspect the TCC control
solenoid
Inspect resistance between TCM (See 05-13-34
TCC control TCC control
A terminals A and CK (wiring harness- 9—16 ohm SOLENOID VALVE
solenoid control solenoid
side). INSPECTION [5R55S])
• Inspect the related
wiring harness
• Inspect the shift
solenoid A
Shift solenoid A
B Shift solenoid A terminals B and CK (wiring harness- 16—45 ohm SOLENOID VALVE
control
wiring harness
solenoid B
Shift solenoid B
C Shift solenoid B terminals C and CK (wiring harness- 16—45 ohm SOLENOID VALVE
control
wiring harness
05
solenoid D
Shift solenoid D
D Shift solenoid D terminals D and CK (wiring harness- 16—45 ohm SOLENOID VALVE
control
wiring harness
Engine switch ON B+ • Inspect the instrument
O/D OFF Instrument cluster
E
indicator output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
solenoid C
Shift solenoid C
F Shift solenoid C terminals F and CK (wiring harness- 16—45 ohm SOLENOID VALVE
control
wiring harness
Selector
Inspect continuity between TCM and
position Instrument • Inspect the related
G instrument cluster (wiring harness- Continuity
indicator signal cluster wiring harness
side).
3
H — — — — —
05-13–39

Voltage/
Resistance
• Inspect the pressure
control solenoid A
Pressure Pressure Inspect resistance between TCM (See 05-13-34
3.3—7.5
I control solenoid control solenoid terminals I and CK (wiring harness- SOLENOID VALVE
ohm
A control A side). INSPECTION [5R55S])
wiring harness
control solenoid B
3.3—7.5
J control solenoid control solenoid terminals J and CK (wiring harness- SOLENOID VALVE
ohm
B control B side). INSPECTION [5R55S])
wiring harness
Selector
K instrument cluster (wiring harness- Continuity
side).
1
L — — — — —
control solenoid C
3.3—7.5
M control solenoid control solenoid terminals M and CK (wiring harness- SOLENOID VALVE
ohm
C control C side). INSPECTION [5R55S])
wiring harness
4x4 HI indicator Instrument cluster
N
output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
O — — — — —
P — — — — —
Selector
Q instrument cluster (wiring harness- Continuity
side).
2
4x4 LO Instrument cluster
R
indicator output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
S — — — — —
T — — — — —
Vehicle speed Instrument • Inspect the related
U instrument cluster (wiring harness- Continuity
output cluster wiring harness
side).
V — — — — —
W — — — — —
X — — — — —
Y — — — — —
Z — — — — —
AA — — — — —
AB — — — — —
AC — — — — —
• Inspect the OSS sensor
(See 05-13-32
OUTPUT SHAFT
Inspect resistance between TCM
Output shaft 325—485 SPEED (OSS)
AD OSS sensor terminals AD and AG (wiring
speed (+) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
AE — — — — —
AF — — — — —
05-13–40

Voltage/
Resistance
• Inspect the OSS sensor
(See 05-13-32
OUTPUT SHAFT
Output shaft 325—485 SPEED (OSS)
AG OSS sensor terminals AD and AG (wiring
speed (-) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
• Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT
Turbine shaft 325—485 SPEED (TSS)
AH TSS sensor terminals AH and AP (wiring
speed (-) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
AI — — — — —
AJ — — — — —
AK System GND GND Under any condition Continuity
wiring harness
AL — — — — —
• Inspect the ISS sensor
(See 05-13-30
INTERMEDIATE
Intermediate 325—485 SHAFT SPEED (ISS)
AM ISS sensor terminals AM and AS (wiring
shaft speed (-) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
AN — — — — —
AO System GND GND Under any condition Continuity
wiring harness
• Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT 05
Turbine shaft 325—485 SPEED (TSS)
AP TSS sensor terminals AH and AP (wiring
speed (+) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
AQ — — — — —
AR — — — — —
• Inspect the ISS sensor
(See 05-13-30
INTERMEDIATE
Intermediate 325—485 SHAFT SPEED (ISS)
AS ISS sensor terminals AM and AS (wiring
shaft speed (+) ohm SENSOR INSPECTION
harness-side).
[5R55S])
wiring harness
AT — — — — —
AU — — — — —
AV — — — — —
AW — — — — —
P position, 1,2 • Inspect the Digital TR
Continuity
and 3 range sensor
Inspect continuity
(See 05-13-20 DIGITAL
between TCM
Digital TR TRANSMISSION
AX TR3A signal terminals AX and
sensor Not RANGE (TR) SENSOR
BH (wiring Other
continuity INSPECTION [5R55S])
harness-side).
wiring harness
05-13–41

Voltage/
Resistance
ATF
temperature 284—967
-40—-20 °C kilohm
{-40—-4 °F}
ATF
-19—-1 °C kilohm
{-3—30 °F}
ATF
0—20 °C kilohm
{32—68 °F}
ATF
temperature 16—37
21—40 °C kilohm • Inspect the TFT sensor
{70—104 °F} (See 05-13-26
Inspect resistance
ATF TRANSMISSION
between TCM
ATF temperature 5—16 FLUID TEMPERATURE
AY TFT sensor terminals AY and
temperature 41—70 °C kilohm (TFT) SENSOR
BH (wiring
{106—158 °F} INSPECTION [5R55S])
harness-side).
ATF • Inspect the related
temperature 2.7—5 wiring harness
71—90 °C kilohm
{160—194 °F}
ATF
temperature 1.5—2.7
91—110 °C kilohm
{196—230 °F}
ATF
111—130 °C kilohm
{232—266 °F}
ATF
131—150 °C kilohm
{268—302 °F}
AZ — — — — —
• Inspect the 4x4 control
4x4 HI mode 4x4 control module
BA 4x4 control module (wiring harness- Continuity
input module • Inspect the related
side).
wiring harness
• Inspect the 4x4 control
4x4 LO mode 4x4 control module
BB 4x4 control module (wiring harness- Continuity
input module • Inspect the related
side).
wiring harness
BC — — — — —
BD — — — — —
BE — — — — —
BF — — — — —
BG — — — — —
• TFT sensor
Inspect the TCM terminals AX, AY, BU, BY and • Inspect the related
BH Sensor GND • Digital TR
CA.(wiring harness-side) wiring harness
sensor
BI — — — — —
BJ — — — — —
BK — — — — —
BL — — — — —
05-13–42

Voltage/
Resistance
O/D OFF • Inspect the O/D OFF
switch button B+ switch
depressed (See 05-13-19 O/D
O/D OFF O/D OFF
BM Engine switch ON OFF SWITCH
switch switch O/D OFF INSPECTION [5R55S])
switch button Below 1.0 V • Inspect the related
not depressed wiring harness
BN — — — — —
BO — — — — —
BP — — — — —
BQ — — — — —
BR — — — — —
BS System GND GND Under any condition Continuity
wiring harness
BT — — — — —
P, R position • Inspect the Digital TR
Continuity
and 2 range sensor
Inspect continuity
between TCM
BU TR2 signal terminals BU and
BH (wiring Other
harness-side).
wiring harness
BV — — — — —
BW — — — — —
BX — — — — —
P, R position • Inspect the Digital TR
Continuity
and 3 range sensor
Inspect continuity
between TCM
BY TR1 signal terminals BY and
BH (wiring Other
harness-side).
wiring harness 05
BZ — — — — —
P, N position • Inspect the Digital TR
Continuity
and 1 range sensor
Inspect continuity
between TCM
CA TR4 signal terminals CA and
BH (wiring Other
harness-side).
wiring harness
Because this terminal is for serial
communication, good/no good
CB CAN_H PCM judgment by terminal voltage is not —
wiring harness
possible. Carry out inspection
according to DTCs.
CC — — — — —
CD — — — — —
CE — — — — —
Because this terminal is for serial
communication, good/no good
CF CAN_L PCM judgment by terminal voltage is not —
wiring harness
possible. Carry out inspection
according to DTCs.
CG — — — — —
CH — — — — —
CI — — — — —
CJ — — — — —
05-13–43

Voltage/
Resistance
• Inspect the solenoid
valve
(See 05-13-34
Solenoid valve Inspect the TCM terminals A, B, C, D, F, I, J and M.
CK Solenoid valve SOLENOID VALVE
power supply (wiring harness-side)
INSPECTION [5R55S])
wiring harness
CL System GND GND Under any condition Continuity
wiring harness
Engine switch ON B+ • Inspect the AT relay
(See 05-13-38 AT
RELAY INSPECTION
CM IG AT relay
Engine switch OFF Below 1.0 V [5R55S])
wiring harness
CN — — — — —
CO System GND GND Under any condition Continuity
wiring harness
Engine switch ON B+ • Inspect the AT relay
(See 05-13-38 AT
RELAY INSPECTION
CP IG AT relay
Engine switch OFF Below 1.0 V [5R55S])
wiring harness
End Of Sie
TCM REMOVAL/INSTALLATION [5R55S]

id0513c1250800
7.8—10.7 {80—109, 69.1—94.7}
1 Bracket
2 TCM connector 1
3 TCM A
B
4 Wiring harness 3
5 AT relay 6
6 Bracket 4 C
A
3. Install in the reverse order of removal. B 5
D C D
End Of Sie
2
18.6—25.5 N·m
{1.9—2.6 kgf·m,
13.8—18.8 ft·lbf}
absggw00001526
05-13–44

AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [5R55S]
id0513c1249200
3. Remove the following parts.
(1) Under cover
(2) Front propeller shaft (4x4) (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
(3) Rear propeller shaft (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
(4) Oxidation catalytic converter.
(5) Front pipe
6. Add ATF and, with the engine idling, inspect the ATF level and inspect for leakage. (See 05-13-16 AUTOMATIC
TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].) (See 05-13-13 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION [5R55S].)
7. Inspect selector lever operation. (See 05-14-2 SELECTOR LEVER INSPECTION.)
8. Inspect for leakage of ATF from all connecting points.
Test item
Service item
Line pressure test Stall speed test
Automatic transmission replacement ×
Automatic transmission overhaul × ×
Control valve body replacement × ×
Torque converter replacement × ×
Fluid pump replacement ×
Clutch system replacement ×
05
05-13–45

4x2
15
E
40 {4.1, 30}
13 14
17
C D
12
11
9 B
A
10
37.0—52.0
{3.8—5.3,
27.3—38.3}
18 D
E
19 3
C
7.8—10.7 N·m
{80—109 kgf·cm,
F 69.1—94.7 in·lbf}
B 16
4
5 A 37.0—52.0
{3.8—5.3,
1 27.3—38.3}
6 2
40.0—54.5
{4.1—5.5, 18
29.6—40.1} 37.0—52.0 37.0—52.0
{3.8—5.3, {3.8—5.3, 7.8—10.7 N·m
27.3—38.3} {80—109 kgf·cm,
7.8—10.8 N·m 27.3—38.3}
69.1—94.7 in·lbf}
{80—110 kgf·cm,
69.1—95.5 in·lbf}
WE-C WL-C
F 8 F
8
78.0—98.0
78.0—98.0
{8.0—9.9,
{8.0—9.9,
57.6—72.2}
57.6—72.2}
36.5—46.1
43.0—54.0 7 {3.8—4.7, 7
{4.4—5.5, 27.0—34.0}
31.8—39.8}
31.4—46.1 31.4—46.1
{3.3—4.7, {3.3—4.7,
23.2—34.0} 23.2—34.0}

arnffw00001939
.
1 Insulator 6 Torque converter installation nuts

2 Insulator (See 05-13-50 Torque Converter Installation Nuts
Removal Note.)
3 Selector cable bracket (See 05-13-54 Torque Converter Installation Nuts
4 Selector cable Installation Note.)
5 Cover
05-13–46

7 Crossmember 15 Wiring harness
(See 05-13-51 Transmission Removal Note.) 16 Insulator bracket
8 Transmission mount rubber 17 Oil pipe
9 CKP sensor connector (See 05-13-50 Oil Pipe Removal Note.)
10 AT connector (See 05-13-53 Oil Pipe Installation Note.)
11 Digital TR sensor connector 18 Transmission installation bolt and nut
12 TSS sensor connector 19 Transmission
(See 05-13-51 Transmission Removal Note.)
13 ISS sensor connector (See 05-13-52 Transmission Installation Note.)
14 OSS sensor connector
05
05-13–47

4x4
21
E
40 {4.1, 30}
19 20
23
C D
18
17
15 B
14
A 13
16
37.0—52.0
{3.8—5.3,
27.3—38.3}
24 D
E
25 3
C
7.8—10.7 N·m
{80—109 kgf·cm,
69.1—94.7 in·lbf}
F
7
B 22
4
5 A
1
36—50
6 {3.7—5.0,
40.0—54.5 27—36}
{4.1—5.5,
29.6—40.1}
24 2 37.0—52.0 7.8—10.7 N·m
37.0—52.0 {3.8—5.3, {80—109 kgf·cm, 31.4—46.1
{3.8—5.3, 7.8—10.8 N·m 27.3—38.3} 69.1—94.7 in·lbf} {3.3—4.7,
27.3—38.3} {80—110 kgf·cm, 23.2—34.0}
69.1—95.5 in·lbf}
9
F 10
11
37.3—51.9
{3.9—5.2, 31.4—46.1
27.6—38.2}
12
{3.3—4.7,
23.2—34.0}
43.0—54.0
{4.4—5.5, 8
31.8—39.8}
31.4—46.1
{3.3—4.7,
23.2—34.0}
arnffw00001940
.
1 Insulator 4 Selector cable

2 Insulator 5 Cover
3 Selector cable bracket
05-13–48

6 Torque converter installation nuts 16 AT connector
(See 05-13-50 Torque Converter Installation Nuts 17 Digital TR sensor connector
Removal Note.)
(See 05-13-54 Torque Converter Installation Nuts 18 TSS sensor connector
Installation Note.) 19 ISS sensor connector
7 Transfer case under cover 20 OSS sensor connector
8 Crossmember 21 Wiring harness
(See 05-13-51 Transmission Removal Note.) 22 Insulator bracket
9 Transmission mount component 23 Oil pipe
10 Transmission mount upper (See 05-13-50 Oil Pipe Removal Note.)
11 Transmission rubber (See 05-13-53 Oil Pipe Installation Note.)
12 Transmission mount lower 24 Transmission installation bolt and nut
13 Transfer case motor connector 25 Transmission and transfer case
(See 05-13-51 Transmission Removal Note.)
14 Transfer case speed sensor connector (See 05-13-52 Transmission Installation Note.)
15 CKP sensor connector
4x4
38.0—52.0 N·m
{3.9—5.3 kgf·m,
28.1—38.3 ft·lbf}
27
05
26
absggw00001540
26 Transfer case 27 Transmission
05-13–49

Torque Converter Installation Nuts Removal Note
1. Remove the cooling fan.
2. Hold the crankshaft pulley to prevent the drive
plate from rotating.
absggw00001804
3. Remove the torque converter nuts.
NUT
absggw00001805
Oil Pipe Removal Note

1. Remove the oil pipe installation bolt and nut.
BOLT
NUT
OIL PIPE
absggw00001810
05-13–50

Transmission Removal Note
Warning
• Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
• To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter.
1. Remove the front differential mount rubber.

MOUNT RUBBER
MOUNT RUBBER
absggw00001541
2. Support the transfer case side securely using one 05

transmission jack.
3. Remove the crossmember.
Caution
• Do not allow the transmission jack to
interfere with the transmission mount
bracket bolts, otherwise the bolts could
be damaged.
absggw00001806
4. Support the transmission securely using a

transmission jack.
5. Support the front side of engine securely using a
transmission jack.
absggw00001807
05-13–51

6. Remove the transmission installation bolt.
BOLT
BOLT
BOLT AND NUT BOLT AND NUT

absggw00001542
7. Remove the transmission while setting it out of

the way so that it does not contact the differential.
absggw00001543
Transmission Installation Note
Warning
• Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
• To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter
1. Support the front side of engine securely using a transmission jack.

2. Support the transmission and transfer case
securely using a transmission jack.
absggw00001808
05-13–52

3. Install the transmission while setting it out of the
way so that it does not contact the differential.
absggw00001544
4. Tighten the transmission installation bolts and

nuts.
BOLT
BOLT
Tightening torque
37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
BOLT AND NUT BOLT AND NUT

absggw00001542
5. Install the front differential mount rubber.

MOUNT RUBBER
Tightening torque
54.9—80.4 N·m {5.6—8.1 kgf·m, 41—59 ft·lbf}
05
MOUNT RUBBER
absggw00001541
Oil Pipe Installation Note

1. Install the oil pipe installation bolt and nut.
BOLT
Tightening torque
7.8—10.7 N·m {80—109 kgf·cm, 69.1—94.7
in·lbf}
NUT
OIL PIPE
absggw00001810
05-13–53

Torque Converter Installation Nuts Installation Note
1. Hold the crankshaft pulley to prevent the drive
plate from rotating.
Caution
• Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.
absggw00001804
2. Tighten the new torque converter installation nuts.
Tightening torque
40.0—54.5 N·m {4.1—5.5 kgf·m, 29.6—40.1
ft·lbf}
End Of Sie
NUT
absggw00001805
TORQUE CONVERTER INSPECTION [5R55S]

id0513c1711900
Caution
• Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or
transmission damage will occur. Use only clean ATF designated for the transmission and
converter being serviced.
• The torque converter drain plug and seal are not reusable. If equipped, discard the drain plug and
seal, then install a new drain plug component.
• If a new or remanufactured torque converter is not being installed, the following steps must be completed.
1. With the torque converter on a bench, pour a small ATF from the torque converter onto an absorbent white
tissue or through a paper filter and examine the ATF.
2. Observe the color and odor of the ATF. The ATF should be red, not brown or black. Odor may indicate an
overheating condition such as clutch disc or band failure.
3. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the fluid level indicator for
signs of antifreeze (gum or varnish).
• If particles are present in the fluid or there is evidence of engine coolant or water, a new torque converter
must be installed.
• If there are no particles or contamination present, drain the remainder of the ATF from the torque converter.
4. Add 1.9 L {2.0 US qt, 1.7 lmp qt} of clean ATF into the converter and agitate by hand.
5. Thoroughly drain the fluid.
End Of Sie
05-13–54

TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S]
id0513c1710100
Removal
1. Remove the transmission. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [5R55S].)
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
2. Using the SSTs, remove the torque converter. TORQUE

CONVERTER
307-091
arnffv00000519
Installation
Caution
• Do not damage the fluid pump gear O-ring when installing torque converter.
• Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do
not damage the hub seal.
• If the torque converter slides out, the hub seal may be damaged.
1. Lubricate the converter hub with clean ATF.
Warning
• The torque converter can fall out if the 05
transmission is tipped. Failure to follow
these instructions may cause personal
injury.
b5r5za00000286
2. Using the SST, install the torque converter by TORQUE

pushing and rotating. CONVERTER
3. Install the automatic transmission. (See 05-13-45
4. Perform the mechanical system test. (See 05-13-
4 MECHANICAL SYSTEM TEST [5R55S].)
End Of Sie
307-091
arnffv00000519
05-13–55

OIL SEAL (FLUID PUMP) REPLACEMENT [5R55S]
id0513c1712000
Removal
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
2. Remove the torque converter. (See 05-13-55 TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S].)
Caution
• Do not to damage the bushing on the fluid pump body.
3. Using the SST, remove the fluid pump seal.
100-001
308-375
b5r5za00000295
Installation
1. Install a new seal onto the SST.
307-349
Note
• Check and make sure that the garter spring
in the seal has not popped off of the
converter hub seal.
arnffw00001959
2. Using the SST, install the converter hub seal.

3. Install the torque converter. (See 05-13-55
TORQUE CONVERTER REMOVAL/ 307-349
4. Install the automatic transmission. (See 05-13-45
5. Perform the mechanical system test. (See 05-13-
4 MECHANICAL SYSTEM TEST [5R55S].)
End Of Sie
arnffw00001960
05-13–56

OIL SEAL (EXTENSION HOUSING) REPLACEMENT [5R55S]
id0513c1710000
Removal (4x2)
2. Using the SST, remove the extension housing
seal. 307-309
100-001
arnffv00000522
Removal (4x4)
1. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAL/INSTALLATION [5R55S].)
2. Using the SSTs, remove the extension housing
seal.
100-001
308-375
b5r5za00000294
Installation (4x2)
1. Using the SST, install the extension housing seal.
308-002
05
Note
• Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.
2. Install the propeller shaft. (See 03-15-2

PROPELLER SHAFT REMOVAL/INSTALLATION
[5AT].)
3. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF)
arnffv00000545
Installation (4x4)
1. Using the SST, install the extension housing seal.
Note
• Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.
2. Install the transfer case. (See 03-16-7

TRANSFER CASE REMOVAL/INSTALLATION
[5R55S].)
3. Inspect the ATF level for leakage. (See 05-13-13 307-435
AUTOMATIC TRANSMISSION FLUID (ATF)
b5r5za00000280
End Of Sie
05-13–57

EXTENSION HOUSING GASKET REPLACEMENT [5R55S]
id0513c1254300
Removal (4x2)
4. Lower the transmission.
Caution
• The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
b5r5za00000011
6. Remove and discard the extension housing

gasket.
absggw00001629
Removal (4x4)
3. Remove the crossmember and Transmission mount component. (See 05-13-45 AUTOMATIC TRANSMISSION
4. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAL/INSTALLATION [5R55S].)
Caution
• The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
b5r5za00000012
05-13–58

6. Remove and discard the extension housing
gasket.
absggw00001630
Installation (4x2)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
• Make sure the parking lever actuating rod
is correctly seated into the case parking
rod guide cup.
absggw00001629
3. Install the extension housing.
Tightening torque
28—32 N·m {2.9—3.2 kgf·m, 21—23 ft·lbf}
4. Install the crossmember and transmission mount

rubber. (See 05-13-45 AUTOMATIC
TRANSMISSION REMOVAL/INSTALLATION
[5R55S])
05
[5AT].)
b5r5za00000278
7. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
Installation (4x4)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
• Make sure the parking lever actuating rod
is correctly seated into the case parking
rod guide cup.
absggw00001630
05-13–59

3. Install the extension housing.
Tightening torque
28—32 N·m {2.9—3.2 kgf·m, 21—23 ft·lbf}
4. Install the transfer case. (See 03-16-7

TRANSFER CASE REMOVAL/INSTALLATION
[5R55S].)
5. Install the crossmember and Transmission mount
component. (See 05-13-45 AUTOMATIC
TRANSMISSION REMOVAL/INSTALLATION
[5R55S])
b5r5za00000012
[5AT].)
8. Inspect the ATF level for leakage. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
End Of Sie
05-13–60

CONTROL VALVE BODY REMOVAL [5R55S]
id0513c1710600
On-Vehicle Removal
Warning
• A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
• Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.

absggw00001183
7. Remove the transmission fluid filter and seal

component and discard.
05
b5r5za00000015
8. Remove the detent spring.
b5r5za00000016
05-13–61

9. Remove the low/reverse brake servo component.
Caution
• Do not damage solenoid body connector
pins.
b5r5za00000017
10. Remove the solenoid body component by lifting

on the body and pushing the connector from the
other side of the case.
b5r5za00000018
11. Remove the control valve body.

End Of Sie
b5r5za00000019
05-13–62

CONTROL VALVE BODY INSTALLATION [5R55S]
id0513c1710700
On-Vehicle Installation
1. Install the SSTs into the transmission case.
307-334
307-334
arnffv00000542
2. Using the SSTs, Install the control valve body and

loosely install the bolts. 1
(1) Install the short bolt.
(2) Install the bolt with the larger head. 307-334
(3) Install the remaining bolts.
307-334 2
arnffv00000543
3. Remove the SSTs and loosely install the screw.

4. Tighten the bolts in the sequence shown.
Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}
05
arnffv00000544
05-13–63
14 18
10 1 6 2 8
16
19
15
7
5
20
13 4
12 17 11
b5r5za00000270
5. Install the detent spring.
Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}
b5r5za00000271
6. Install new O-rings on the solenoid body

connector. Lubricate the O-rings with clean ATF.
Caution
• Inspect the transmission case bore to
make sure it is free of foreign material
and not damaged. If damaged, a
transmission leak may occur.
b5r5za00000272
05-13–64

7. Install the solenoid body. Tighten bolts in the
sequence shown. 2 1
Tightening torque
7—9 N·m {72—91 kgf·cm, 62—79 in·lbf} 3
4
7 8
5 6
b5r5za00000273
8. Install the reverse servo. Tighten the bolts in the

sequence shown in 2 stages.
1
Tightening torque
Stage 1: 5 N·m {51 kgf·cm, 44 in·lbf}
Stage 2: 10—12 N·m {102—122 kgf·cm, 89—
106 in·lbf} 3
Caution
• Lubricate the transmission fluid filter
seals with clean ATF or they may be 4 2
damaged.
b5r5za00000274
9. Lubricate the seals and install the transmission

fluid filter.
Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}
Note
• Make sure that the transmission fluid filter
seals are correctly seated on the filter.
05
b5r5za00000275
10. Install the transmission fluid pan gasket on the

pan.
Note
reusable, clean and inspect for damage. If GASKET
not damaged, the gasket should be reused.
absggw00001562
11. Install the transmission fluid pump and gasket,

magnet and loosely install the bolts.
12. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5—11.5 N·m {97—117 kgf·cm, 85—101
in·lbf}
Caution
• Damage will occur to the solenoid body
component if the screw is tightened
above specification.
b5r5za00000276
05-13–65

13. Install and lubricate new O-rings on the AT
connector and connect the connector.
Tightening torque
Note
• Clean the area around connector to prevent
contamination of the AT connector.
• Use petroleum jelly to lubricate the O-rings
to aid in the installation process.
absggw00001183
14. Remove the insulator bracket. (See 05-13-45
[5R55S].)
18. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
End Of Sie
05-13–66

OIL COOLER FLUSHING [5R55S]
id0513c1710900
Note
• If the automatic transaxle is replaced, flush and inspect the oil cooler.
• When replacing the automatic transaxle, inspect the oil cooler together with flushing it using the following
procedure, and with the oil cooler hose removed.
1. Remove the oil cooler. (See 05-13-68 OIL COOLER REMOVAL/INSTALLATION [5R55S].)
2. Disconnect the oil cooler hose.
3. Set a clean fluid pan up to the oil cooler hose inlet.
4. Blow 491—882 kPa {5—9 kgf/cm2, 72—127 psi} of compressed air from the oil cooler hose outlet to drain
remaining oil.
5. Add new ATF from the oil cooler hose outlet and blow 491—882 kPa {5—9 kgf/cm2, 72—127 psi} of
compressed air to flush. (Repeat 2 or 3 times)
6. Verify that none of the following foreign material is mixed in with the drained ATF:
• Large metal fragments of φ 0.5 mm {0.02 mm} or more that cannot pass through the oil strainer
• Fibrous clutch facing
7. Repeat the procedures from Step 3 to 4 and flush the inside of the oil cooler.
8. If foreign material such as metal fragments or clutch facing remains even after the oil cooler is flushed
repeatedly, replace the oil cooler (radiator).
OIL COOLER
(RADIATOR) OIL PAN
COMPRESSED
AIR
FRONT FRONT
05
B
A
A
B
COMPRESSED AIR
COMPRESSED AIR
arnffw00001944
End Of Sie
05-13–67

OIL COOLER REMOVAL/INSTALLATION [5R55S]
id0513c1248700
3. Drain the engine coolant.
4. Remove the following parts.
(1) Splash shield
(2) Under cover
(3) Front bumper
7. Add the engine coolant.
8. Add ATF to the specified level. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT
[5R55S].)
9. Inspect for oil leakage from the oil pipes and oil hoses.
10. Inspect for coolant from the hoses.
11. Inspect for engine coolant leakage.
12. Inspect the ATF level and condition. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
05-13–68
18.6—25.5
{1.9—2.6,
13.8—18.8}
1
FRONT
2 R
FRONT
3
C
B
7 2 R
7.9—10.7 N·m
{81—109 kgf·cm,
70.0—94.7 in·lbf}
7.9—10.7 N·m
{81—109 kgf·cm, 1
70.0—94.7 in·lbf} D
7.9—10.7 N·m
{81—109 kgf·cm,
70.0—94.7 in·lbf} C 2 R
2
R 3
6
5
4
D
FRONT
05
8.8—12.7 N·m
{90—129 kgf·cm,
77.9—112.4 in·lbf}
7.8—10.7 N·m
{80—109 kgf·cm,
69.1—94.7 in·lbf} 2 R
3 B
2 R
A
7.8—10.7 N·m
3
{80—109 kgf·cm, 2
69.1—94.7 in·lbf} R
1
40 {4.1, 30}
arnffw00001945
1 Oil pipe 2 Hose clamp

(See 05-13-70 Oil Pipe, Hose clamp, Oil hose (See 05-13-70 Oil Pipe, Hose clamp, Oil hose
Installation Note.) Installation Note.)
05-13–69

3 Oil hose 6 Braket
(See 05-13-70 Oil Pipe, Hose clamp, Oil hose 7 Radiator (in tank oil cooler)
Installation Note.) (See 05-13-70 Radiator (In Tank Oil Cooler)
4 Cover Installation Note.)
5 Oil cooler
Radiator (In Tank Oil Cooler) Installation Note

1. The automatic transmission oil cooler flushing must be performed whenever a transmission is removed for
service because the existing fluid may be contaminated, and to prevent contamination of new fluid.
Note
• Flushing must be performed after installation of the overhauled or replaced transmission.
2. Follow the instructions in the manufacturer’s publication for flushing operation.
Oil Pipe, Hose clamp, Oil hose Installation Note

1. Apply compressed air to cooler-side opening, and
blow any remaining grime and foreign material
from the cooler pipes. Compressed air should be
applied for more than 1 min.
acxuuw00000609
2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown.
OIL MARK
3. Install the hose clamp onto the hose.
PIPE
OIL
HOSE
arnffw00001946
Note
• If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose clamp. Then apply force to the
hose clamp in the direction of the arrow in
order to fit the clamp in place.
4. Verify that the hose clamp does not interfere with

any other components.
End Of Sie
absggw00001709
05-13–70

DRIVE PLATE REMOVAL/INSTALLATION [5R55S]
id0513c1250200
1 Backing plate 4 FRONT
2 Drive plate
(See 05-13-71 Drive Plate Removal Note.) 3
(See 05-13-71 Drive Plate Installation Note.)
3 Plate CRANKSHAFT
4 Spacer
151.3—161.1 N·m 1
{15.5—16.4 kgf·m,
111.6—118.8 ft·lbf}
R
absggw00001705
Drive Plate Removal Note

1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate. 49 E011 1A0
05
absggw00001706
Drive Plate Installation Note

1. Remove the sealant from the bolt holes in the crankshaft.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
5. Tighten the drive plate mounting bolts in two or 49 E011 1A0
three steps in the order as shown in the figure.
Tightening torque 1
3 8
151.3—161.1 N·m
5 6
{15.5—16.4 kgf·m, 111.6—118.8 ft·lbf}
7 4
6. Install the transmission. (See 05-13-45 2
End Of Sie absggw00001707
05-13–71
F198-10-05L(05-14).fm 1 ページ２００６年８月１０日　木曜日　午後５時３２分
05-14 AUTOMATIC TRANSMISSION SHIFT MECHANISM

AUTOMATIC TRANSMISSION SELECTOR CABLE
SHIFT MECHANISM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 05-14–2
LOCATION INDEX. . . . . . . . . . . . . . . . . 05-14–1 SELECTOR CABLE
SELECTOR LEVER INSPECTION . . . . . 05-14–2 REMOVAL/INSTALLATION . . . . . . . . . . 05-14–3
SELECTOR LEVER
REMOVAL/INSTALLATION . . . . . . . . . . 05-14–4
End of Toc
AUTOMATIC TRANSMISSION SHIFT MECHANISM LOCATION INDEX
SOKYU_WM: TRANSMISSION/TRANSAXLE
id051400254000
05
absggw00001005
1 Selector lever 2 Selector cable

(See 05-14-2 SELECTOR LEVER INSPECTION.) (See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
(See 05-14-4 SELECTOR LEVER REMOVAL/ (See 05-14-3 SELECTOR CABLE REMOVAL/
INSTALLATION.) INSTALLATION.)
End Of Sie
05-14–1

SELECTOR LEVER INSPECTION
id051400255500
1. Turn the engine switch to the ON position (engine off).
2. With the brake pedal depressed, verify that there
is a “click” at each range when shifted. P
3. Verify that the selector lever can be shifted. R
4. Verify that there is a “click” at each position when
shifted from the P position to the 1 range. N
BUTTON MUST BE
DEPRESSED
D
BUTTON NEED NOT
3 BE DEPRESSED
2
1
arnffw00001928
5. Verify that the positions of the selector lever and

the indicator are aligned.
TRANSMISSION RANGE (TR) SENSOR
6. Verify that the vehicle operates in each selected
range.
End Of Sie
absggw00001014
SELECTOR CABLE ADJUSTMENT

id051400256100
1. Remove the console.
2. Shift the selector lever to the N position.
3. Loosen the nut at approx. 90°.
4. Adjustment the end of the selector cable position.
5. Tighten the nut.
Tightening torque
9.8—18.2 N·m {100—185 kgf·cm, 87—161
in·lbf}
6. Install the console. SELECTOR CABLE

End Of Sie
NUT
absggw00001019
05-14–2

SELECTOR CABLE REMOVAL/INSTALLATION
id051400256200
3. Shift the selector lever to the P position.
7.8—10.7
{80—109, A
69.1—94.7}
3
1
7.8—10.7
{80—109,
69.1—94.7}
arnffw00001929
.
05
1 Digital TR sensor insulator 3 Selector cable
2 Selector cable bracket (See 05-14-3 Selector Cable Installation Note.)
Selector Cable Installation Note

4. Tighten the nut.
Tightening torque
9.8—18.2 N·m {100—185 kgf·cm, 87—161
in·lbf}
End Of Sie
SELECTOR CABLE
NUT
absggw00001019
05-14–3

SELECTOR LEVER REMOVAL/INSTALLATION
id051400255700
3. Shift the selector lever to the P position.
4
1 Connector
2 Selector cable
3 9.8—14.7
(See 05-14-4 Selector Cable Installation Note.) {100—149,
86.8—130.1}
3 Selector lever
4 Bulb
5 Selector lever bracket
A
1
2
7.8—10.7
{80—109,
69.1—94.7}
5
arnffw00001930
Selector Cable Installation Note

4. Tighten the nut.
Tightening torque
9.8—18.2 N·m {100—185 kgf·cm, 87—161
in·lbf}
End Of Sie
SELECTOR CABLE
NUT
absggw00001019
05-14–4
F198-10-05L(05-50).fm 1 ページ２００６年８月１０日　木曜日　午後５時３３分
TECHNICAL DATA [5R55S]
05-50 TECHNICAL DATA [5R55S]

TRANSMISSION/TRANSAXLE
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-50–1
End of Toc
TRANSMISSION/TRANSAXLE [5R55S]
WM: TRANSMISSION/TRANSAXLE
id0550h1800400
Item Specification
ATF Type: Mercon® V

Line pressure (pressure control A, pressure control B)

Position/range
Idle Stall
P/N 793 {8.09, 115} 793 {8.09, 115}
R 793 {8.09, 115} 2,138 {21.80, 310}
D, 3, 2, 1 793 {8.09, 115} 1,520 {15.47, 220}
Line pressure (pressure control C)

Position/range
Idle Stall
P/N 27 {0.28, 4} 0 {0, 0}
R 793 {8.09, 115} 793 {8.09, 115}
D, 3, 2, 1 27 {0.28, 4} 0 {0, 0}
Engine stall speed

Engine type rpm
WL-C 2,700
WE-C 2,900

05
-40—-20 {-40—-4} 284—967
-19—-1 {-3—30} 100—284
0—20 {32—68} 37—100
21—40 {70—104} 16—37
41—70 {106—158} 5—16
71—90 {160—194} 2.7—5
91—110 {196—230} 1.5—2.7
111—130 {232—266} 0.8—1.5
131—150 {268—302} 0.54—0.8
TSS sensor resistance

226—390 -20 {4}
325—485 21 {70}
492—738 150 {302}
ISS sensor resistance

226—390 -20 {4}
325—485 21 {70}
492—738 150 {302}
05-50–1
TECHNICAL DATA [5R55S]

OSS sensor resistance
226—390 -20 {4}
325—485 21 {70}
492—738 150 {302}
Solenoid valve resistance)

Terminals Solenoid valve Resistance (ohm)
D—I Shift solenoid A 16—45
F—I Shift solenoid B 16—45
B—I Shift solenoid C 16—45
E—I Shift solenoid D 16—45
O—I Pressure control solenoid A 3.3—7.5
M—I Pressure control solenoid B 3.3—7.5
G—I Pressure control solenoid C 3.3—7.5
H—I TCC control solenoid 9—16
End Of Sie
05-50–2
SERVICE TOOLS [5R55S]
05-60 SERVICE TOOLS [5R55S]

TRANSMISSION SST [5R55S] . . . . . . . . 05-60–1
End of Toc
TRANSMISSION SST [5R55S]
AT: TRANSMISSION/TRANSAXLE
id0560h1500200
1: Mazda SST number
2: Global SST number
Example
1:49 UN20 5072
2:205-072
Holding Tool
1:– 1:– 1:–

2:100-001 2:100-D009 2:307-004
Slide Hammer Rubber Tip Air Pressure

Nozzle Gauge,
Transmission
Fluid
1:– 1:– 1:–
2:307-091 2:307-309 2:307-334
Handle, Torque Remover, Aligner, Valve

Converter Torque Body (2
Converter Fluid required)
Seal
1:– 1:49 UN30 7351 1:–

2:307-349 2:307-351 2:307-433-01,
307-433-02,
Installer, Torque Alignment 307-433-03
Converter Fluid
Seal
Gauge, TR
Sensor Transmission
05
Test Plate and
Gasket
1:– 1:49 UN30 7437 1:49 UN30
2:307-435 2:307-437 7D4650
2:307-D465
Installer, Adapter, Fluid
Transmission Level and Fill Fluid
Extension Plug Transporter/
Housing Fluid Evacuator/
Seal Injector
1:– 1:– 1:–
2:308-002 2:308-375 2:416-D002
Installer, Remover, Input Vacuum Pump

Transmission Shaft Oil Seal Kit
Extension
Housing Oil
Seal
1:49 E011 1A0
2:–
— —
Brake Set, Ring
Gear
End Of Sie
05-60–1
F198-10-05L(07-03).fm 1 ページ２００６年８月３日　木曜日　午後１時４７分
HEATER, VENTILATION &

AIR CONDITIONING (HVAC) 07
SECTION
Toc of SCT
SYMPTOM BASIC SYSTEM . . . . . . . . . . . . 07-11
TROUBLESHOOTING . . . . . . 07-03 CONTROL SYSTEM . . . . . . . . . 07-40
REFRIGERANT SYSTEM . . . . 07-10
Toc of SCT
07-03 SYMPTOM TROUBLESHOOTING
FOREWORD[EVEREST]. . . . . . . . . . . . . 07-03–1 NO.3 AIRFLOW MODE DOES NOT
TROUBLESHOOTING INDEX CHANGE.[EVEREST] . . . . . . . . . . . . . . 07-03–5
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-03–1 NO.4 IMPROPER AIR CIRCULATION
TROUBLESHOOTING INDEX AND/OR NO AIR CIRCULATION.
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-03–6
NO.1 INSUFFICIENT BLOWN AIR VOLUME NO.5 NO TEMPERATURE CONTROL.
AND/OR NO BLOWN AIR DEPENDING ON [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-03–7
AIRFLOW MODE.[EVEREST] . . . . . . . 07-03–2 NO.6 AIR FROM VENT NOT COLD
NO.2 NO BLOWN AIR IN AIRFLOW ENOUGH.[EVEREST] . . . . . . . . . . . . . . 07-03–8
MODE/BLOWN AIR VOLUME DOES NOT NO.6 AIR FROM VENT NOT COLD
CHANGE AT ANY FAN SPEED. ENOUGH.[5R55S] . . . . . . . . . . . . . . . . . 07-03–11
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-03–3 NO.7 NO COOL AIR.[EVEREST] . . . . . . . 07-03–14
NO.2 NO BLOWN AIR IN AIRFLOW NO.7 NO COOL AIR.[5R55S]. . . . . . . . . . 07-03–17
MODE/BLOWN AIR VOLUME DOES NOT NO.8 NOISE WHILE OPERATING A/C
CHANGE AT ANY FAN SPEED. SYSTEM[EVEREST] . . . . . . . . . . . . . . . 07-03–21
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–4
End of Toc
FOREWORD[EVEREST]
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
id070300800203
• The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
End Of Sie
TROUBLESHOOTING INDEX[EVEREST]
id070300800303
No. TROUBLESHOOTING ITEM DESCRIPTION

1 Insufficient blown air volume and/or no blown air • Problem with each vent and/or duct.
depending on airflow mode.
2 No blown air in airflow mode. • Malfunction in front and/or rear blower system.
Blown air volume does not change at any fan speed.
3 Airflow mode does not change. • Malfunction in heater unit airflow mode change
system. 07
4 Improper air circulation and/or no air circulation. • Malfunction is blower unit and/or climate control
unit air circulation system.
5 No temperature control. • Malfunction in blower unit and/or climate control
unit air mix system.
6 Air from vent not cold enough. • Magnetic clutch operates but A/C system
malfunctions.
7 No cool air. • Magnetic clutch does not operate.
8 Noise while operating A/C system. • Noise from magnetic clutch, A/C compressor, hose
or refrigerant line.
End Of Sie
07-03–1
SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING INDEX[5R55S]
id070300800304
No. TROUBLESHOOTING ITEM DESCRIPTION

1 Insufficient blown air volume and/or no blown air • Problem with each vent and/or duct.
depending on airflow mode.
2 No blown air in airflow mode. • Malfunction in blower system.
Blown air volume does not change at any fan speed.
3 Airflow mode does not change. • Malfunction in heater unit airflow mode change
system.
4 Improper air circulation and/or no air circulation. • Malfunction is blower unit and/or climate control
unit air circulation system.
5 No temperature control. • Malfunction in blower unit and/or climate control
unit air mix system.
6 Air from vent not cold enough. • Magnetic clutch operates but A/C system
malfunctions.
7 No cool air. • Magnetic clutch does not operate.
8 Noise while operating A/C system. • Noise from magnetic clutch, A/C compressor, hose
or refrigerant line.
End Of Sie
NO.1 INSUFFICIENT BLOWN AIR VOLUME AND/OR NO BLOWN AIR DEPENDING ON AIRFLOW
MODE.[EVEREST]
id070300804203
1 Insufficient blown air volume and/or no blown air depending on airflow mode.
DESCRIPTION • Problem with each vent and/or duct.
• Malfunction in VENT mode system (Steps 1—4)
POSSIBLE
• Malfunction in HEAT mode system (Step 5)
CAUSE
• Malfunction in DEFROSTER mode system (Steps 6—8)
1 • When airflow mode control dial is operated, Yes Go to next step.
is appropriate resistance felt and can it be No Go to Step 1 of troubleshooting No. 3.
moved throughout its full range?
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 5.
IS IN VENT MODE OR OTHER MODES No Go to next step.
• Does air blow out when in VENT mode?
3 INSPECT VENT Yes Remove obstruction, then go to Step 9.
• Is vent clogged? No Go to next step.
4 VERIFY THAT DUCT IN DASHBOARD IS Yes Inspect duct for clogging, deformity and air leakage, then go
INSTALLED to Step 9.
• Is duct in dashboard properly installed? No Install duct securely in the proper position, then go to Step
9.
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to next step.
IS IN HEAT MODE OR DEFROSTER MODE No Inspect vent for clogging, then go to Step 9.
• Does air blow out when in HEAT mode?
6 INSPECT DEFROSTER MODE Yes Operation is okay. Recheck malfunction symptoms.
• Does air blow out when in DEFROSTER No Go to next step.
mode?
7 INSPECT VENT Yes Remove obstruction, then go to Step 9.
• Is vent clogged? No Go to next step.
8 VERIFY THAT DEFROSTER DUCT IS Yes Inspect duct for clogging, deformity, and air leakage, then go
INSTALLED to next step.
• Is defroster duct properly installed? No Install duct securely in proper position, then go to next step.
9 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed.
DO NOT RECUR AFTER REPAIR Explain repairs to customer.
• Does air blow out? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.
End Of Sie
07-03–2
NO.2 NO BLOWN AIR IN AIRFLOW MODE/BLOWN AIR VOLUME DOES NOT CHANGE AT ANY FAN
SPEED.[EVEREST]
id070300804303
2 No blown air in airflow mode.Blown air volume does not change at any fan speed.
DESCRIPTION • Malfunction in front and/ or rear blower system.
POSSIBLE • Front and/ or rear blower motor, resistor, fan switch malfunction (Step 1)
CAUSE • Front and/ or rear blower unit malfunction (Steps 2—4)
1 INSPECT FRONT AND/ OR REAR BLOWER Yes Go to the next step.
SYSTEM No Repair or replace malfunctioning part, then go to Step 5.
• Inspect the following systems and electrical
parts.
— Front and/ or rear blower motor
— Resistor
— Fan switch
• Are they okay?
2 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN BLOWER UNIT OR ELSEWHERE No Go to Step 4.
• Turn engine switch to ON position.
• Turn fan switch on.
• Is noise coming from front and/ or rear
blower unit.
3 INSPECT BLOWER UNIT Yes Go to the next step.
• Inspect fan in front and/ or rear blower unit. No Remove obstruction, repair or replace fan and blower unit
— Is fan free of interference from front and/ case, then go to Step 5.
or rear blower unit case?
— Is fan free of foreign material and
obstructions?
• Is fan normal?
4 INSPECT BLOWER UNIT INTAKE VENT Yes Remove obstruction, then go to the next step.
• Are front and/ or rear blower unit intake vent No Inspect if there are any obstructions in passage between
clogged? blower unit and heater unit, then go to the next step.
5 COMFIRM THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
malfunction recurs.
End Of Sie
07
07-03–3
NO.2 NO BLOWN AIR IN AIRFLOW MODE/BLOWN AIR VOLUME DOES NOT CHANGE AT ANY FAN
SPEED.[5R55S]
id070300804304
2 No blown air in airflow mode.Blown air volume does not change at any fan speed.
DESCRIPTION • Malfunction in blower system.
POSSIBLE • Blower motor, resistor, fan switch malfunction (Step 1)
CAUSE • Blower unit malfunction (Steps 2—4)
1 INSPECT BLOWER SYSTEM Yes Go to the next step.
• Inspect the following systems and electrical No Repair or replace malfunctioning part, then go to Step 5.
parts.
— Blower motor
— Resistor
— Fan switch
• Are they okay?
2 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN BLOWER UNIT OR ELSEWHERE No Go to Step 4.
• Turn engine switch to ON position.
• Turn fan switch on.
• Is noise coming from blower unit.
3 INSPECT BLOWER UNIT Yes Go to the next step.
• Inspect fan in blower unit. No Remove obstruction, repair or replace fan and blower unit
— Is fan free of interference from blower unit case, then go to Step 5.
case?
— Is fan free of foreign material and
obstructions?
• Is fan normal?
4 INSPECT BLOWER UNIT INTAKE VENT Yes Remove obstruction, then go to the next step.
• Is blower unit intake vent clogged? No Inspect if there are any obstructions in passage between
blower unit and heater unit, then go to the next step.
5 COMFIRM THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
malfunction recurs.
End Of Sie
07-03–4
NO.3 AIRFLOW MODE DOES NOT CHANGE.[EVEREST]
id070300804403
3 Airflow mode does not change.

DESCRIPTION • Malfunction in front heater unit’s airflow system.
• Malfunction in front heater unit’s airflow mode link, crank, wire or wire clamp (Steps 1, 2)
POSSIBLE
• Bevel gear set (2) in front climate control unit, airflow mode wire or wire clamp malfunction (Step 3)
CAUSE
• Malfunction in one or more front heater unit doors (Steps 4, 5)
1 INSPECT FRONT HEATER UNIT’S AIRFLOW Yes Go to next step.
MODE SYSTEM No Apply grease or install main link, rod, cranks and sub links
• Inspect front heater unit’s airflow mode main securely in their proper positions. Repair or replace wire
link, rod, cranks, sub links, wire, and wire clamp, then go to Step 6.
clamp as follows.
— Is there grease on main link, cranks and
sub links?
— Are main link, rod, cranks and sub links
installed securely in their proper
positions?
— Is wire clamp free of deformation?
• Are above items all okay?
2 VERIFY THAT AIRFLOW MODE WIRE FROM Yes Go to next step.
HEATER UNIT IS POSITIONED SECURELY No Adjust airflow mode wire or install it correctly, then go to
AND CORRECTLY Step 6.
• Is airflow mode wire positioned securely and
correctly in relation to the front heater unit’s
airflow mode main link?
3 INSPECT FRONT CLIMATE CONTROL UNIT Yes Go to next step.
• Inspect front climate control unit as follows. No Properly engage bevel gear set or install airflow mode wire
— Is bevel gear set properly engaged? in correct direction, repair or replace wire clamp, then go to
— Is airflow mode wire properly installed in Step 6.
correct direction on bevel gear?
• Are above items okay?
4 INSPECT FRONT HEATER UNIT’S AIRFLOW Yes Remove obstruction, then go to Step 6.
MODE DOORS No Go to next step.
• Is there any foreign material or obstructions
in any of front heater unit’s doors?
5 VERIFY THAT ALL AIRFLOW MODE DOORS Yes Check each door for cracks or damage, then go to next step.
WITHIN FRONT HEATER UNIT ARE No Install malfunction doors securely in proper position, then go
POSITIONED SECURELY AND PROPERLY to next step.
• Are all doors within front heater unit securely
and properly positioned?
6 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed. Explain repairs to customer.
OCCURS AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if 07
• Does airflow mode change? malfunction recurs.
End Of Sie
07-03–5
NO.4 IMPROPER AIR CIRCULATION AND/OR NO AIR CIRCULATION.[EVEREST]
id070300804503
4 Improper air circulation and/or no air circulation.

DESCRIPTION • Malfunction in front blower unit’s air intake system.
• Malfunction in front blower unit’s air intake crank, link, wire or wire clamp (Steps 1, 2)
POSSIBLE
• Front climate control unit air intake wire or wire clamp malfunction (Step 3)
CAUSE
• Front blower unit air intake door malfunction (Steps 4, 5)
1 INSPECT FRONT BLOWER UNIT’S AIRFLOW Yes Go to next step.
MODE SYSTEM No Apply grease or install crank and link securely in their proper
• Inspect front blower unit’s air intake crank, positions. Repair or replace wire clamp, then go to Step 6.
link and wire clamp as follows.
— Is there grease on crank and link?
— Are crank and link installed securely in
their proper positions?
• Are above items all okay?
2 VERIFY THAT AIR INTAKE WIRE FROM Yes Go to next step.
FRONT BLOWER UNIT IS POSITIONED No Adjust air intake wire or install it correctly, then go to Step 6.
SECURELY AND CORRECTLY
• Is air intake wire positioned securely and
correctly in relation to the front blower unit’s
air intake link?
• Inspect front climate control unit as follows. No Properly install air intake wire in correct direction, repair or
— Is air intake wire properly installed in replace wire clamp, then go to Step 6.
correct direction in relation to the air
intake lever of front climate control unit?
4 INSPECT FRONT HEATER UNIT’S AIRFLOW Yes Remove obstruction, then go to Step 6.
MODE DOOR No Go to next step.
• Is there any foreign material or obstructions
in front blower unit’s door?
5 VERIFY THAT ALL AIR INTAKE DOOR Yes Check door for cracks or damage, then go to next step.
WITHIN FRONT BLOWER UNIT IS No Install malfunction door securely in proper position, then go
POSITIONED SECURELY AND PROPERLY to next step.
• Is door within front blower unit securely and
properly positioned?
OCCURS AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does air circulate? malfunction recurs.
End Of Sie
07-03–6
NO.5 NO TEMPERATURE CONTROL.[EVEREST]
id070300804603
5 No temperature control.
DESCRIPTION • Malfunction in front heater unit’s air mix system.
• Malfunction in front heater unit’s air mix rod, link, cranks, shaft, wire or wire clamp (Steps 2, 3)
POSSIBLE
• Bevel gear set (2) in front climate control unit, air mix wire or wire clamp malfunction (Step 4)
CAUSE
• Front heater unit air mix door malfunction (Steps 5, 6)
1 INSPECT COOLANT TEMPERATURE Yes Go to next step.
• Is coolant sufficiently warmed up? No Warm engine up, then go to Step 7.
2 INSPECT FRONT HEATER UNIT’S AIR MIX Yes Go to next step.
SYSTEM No Apply grease or install rod, link, cranks and shaft securely in
• Inspect front heater unit’s air mix rod, link, their proper positions. Repair or replace wire clamp. Go to
cranks, shaft and wire clamp as follows. Step 7.
— Is there grease on rod, link and cranks?
— Are rod, link, cranks and shaft securely
installed in their proper positions?
3 VERIFY THAT AIR MIX WIRE FROM HEATER Yes Go to next step.
UNIT IS POSITIONED SECURELY AND No Adjust air mix wire or install securely in correct position, then
CORRECTLY go to Step 7.
• Is air mix wire securely installed in the
correct position in relation to front heater
unit’s air mix link?
• Inspect front climate control unit as follows. No Properly engage bevel gear set or install air mix wire in
— Is bevel gear set properly engaged? correct position, repair or replace wire clamp, then go to
— Is air mix wire properly installed in correct Step 7.
position in relation to bevel gear?
5 INSPECT FRONT HEATER UNIT Yes Remove obstruction, then go to Step 7.
• Is there any foreign material or obstructions No Go to next step.
in front heater unit’s air mix door?
6 INSPECT FRONT HEATER UNIT’S AIR MIX Yes Go to next step.
DOOR No Replace malfunction door or install door securely in proper
• Inspect front heater unit’s air mix door as position, then go to next step.
follows.
— Is air mix door free of cracks and
damage?
— Is air mix door securely and properly
installed?
• Are above items okay? 07
• Does unit operate in every temperature malfunction recurs.
setting?
End Of Sie
07-03–7
NO.6 AIR FROM VENT NOT COLD ENOUGH.[EVEREST]
id070300804703
6 Air from vent not cold enough

DESCRIPTION • Magnetic clutch operates but A/C system malfunctions.
• Drive belt malfunction (Step 1)
• Malfunction in front and/or rear blower unit or condenser (Steps 4, 5)
• Malfunction in RECEIVER/DRIER or front expansion valve (valve closes too much) (Step 8, 9)
POSSIBLE • Malfunction in refrigerant lines (Steps 10, 11)
CAUSE • Malfunction in piping connections (Steps 1, 2, 13)
• A/C compressor system malfunction, insufficient compressor oil (Steps 15, 16)
• Compressor oil over-full, malfunction in front expansion valve or heater unit air mix link system (Steps
17—20)
1 INSPECT DRIVE BELT Yes Go to next step.
• Inspect drive belt. No Replace drive belt, then go to Step 21.
• Is it okay?
2 INSPECT REFRIGERANT SYSTEM Yes Operation is normal. (Recheck malfunction symptoms.)
PERFORMANCE No Go to next step.
• Carry out refrigerant system performance
test.
• Is operation normal?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to next step.
HEATER UNIT INTAKE AND CONDENSER OR No Go to Step 6.
ELSEWHERE
• Are refrigerant’s high-pressure and
low-pressure values both high?
4 INSPECT FRONT HEATER UNIT INTAKE Yes Remove obstruction, then go to Step 21. (If air does not
• Is blower unit intake clogged? reach evaporator within cooling unit, heat exchange does
not occur and refrigerant pressure rises. Therefore, removal
of obstruction is necessary.)
No Go to next step.
5 INSPECT CONDENSER Yes Add or subtract refrigerant to make specified amount, then
• Inspect condenser. go to Step 21. (Excessive amount of refrigerant.)
• Is it okay? No Replace condenser, or repair and clean condenser fins,
then go to Step 21.
EXPANSION VALVE, RECEIVER/DRIER AND No Go to Step 14.
REFRIGERANT LINES OR ELSEWHERE
low-pressure values low?
EXPANSION VALVE AND RECEIVER/DRIER No Go to Step 10.
OR ELSEWHERE
• Immediately after A/C compressor operates,
does refrigerant’s high-pressure value
momentarily rise to correct value, then fall
and stay below it? (Is there negative
pressure on low-pressure side?)
EXPANSION VALVE OR RECEIVER/DRIER No Start vacuum pump for 30 minutes and replace condenser,
• Turn A/C switch off and let air conditioner then go to Step 21. (Since RECEIVER/DRIER has become
stop for 10 minutes. saturated with water, replacement is necessary.)
• Start engine.
• Turn both A/C switch and front fan switch on.
• Does malfunction occur after A/C
compressor turns on?
9 INSPECT EXPANSION VALVE Yes Replace front expansion valve, then go to Step 21. (Since
• Is front expansion valve heat-sensing tube valve closes too much, replacement is necessary.)
within front cooling unit securely installed in No Install heat-sensing tube securely, then go to Step 21.
proper position?
07-03–8
10 INSPECT REFRIGERANT LINES Yes Go to next step.
• Inspect refrigerant lines as follows. No If piping or an A/C component is damaged or cracked,
— Is piping free of damage and cracks? replace it. Then go to Step 21.
— Are piping connections free of oil grime? If there is no damage, go to Step 13.
(Visual inspection)
— Are piping connections free of gas
leakage?
— Are piping installation points on
condenser free of gas leakage?
RECEIVER/DRIER free of gas leakage?
— Are piping installation points on A/C
compressor free of gas leakage?
— Are piping installation points on cooling
unit free of gas leakage?
— Perform gas leak inspection using gas
leak tester.
11 INSPECT EVAPORATOR PIPING Yes If the A/C compressor is making noise, add 10 ml {10 cc,
CONNECTIONS IN A/C UNIT FOR GAS 0.338 fl oz} of compressor oil and verify that malfunction
LEAKAGE does not occur.
• Are piping connections for evaporator in Add or subtract refrigerant to make specified amount, then
cooling unit free of gas leakage? go to Step 21.
No If piping is damaged or cracked, replace it. Then go to Step
21.
If there is no damage, go to next step.
12 INSPECT EVAPORATOR PIPING Yes Tighten connections to specified torque. If the A/C
CONNECTIONS IN A/C UNIT FOR LOOSE compressor is making noise, add 10 ml {10 cc, 0.338 fl oz}
• Are piping connections for evaporator in of compressor oil and verify that malfunction does not occur.
cooling unit loose? Add or subtract refrigerant to make specified amount, then
go to Step 21.
No If the A/C compressor is making noise, add 10 ml {10 cc,
0.338 fl oz} of compressor oil and verify that malfunction
does not occur.
Replace O-ring on piping, add or subtract refrigerant to
make specified amount, then go to Step 21.
13 INSPECT PIPING CONNECTIONS FOR Yes Tighten connections to specified torque. If the A/C
LOOSE compressor is making noise, add 10 ml {10 cc, 0.338 fl oz}
• Are piping connections loose? of compressor oil and verify that malfunction does not occur.
Add or subtract refrigerant to make specified amount, then
go to Step 21.
does not occur.
14 VERIFY WHETHER MALFUNCTION IS IN Yes Go to next step. (Pressure hardly increases.)
07
EXPANSION VALVE, AIR MIX ACTUATOR No Go to Step 17.
AND COMPRESSOR OIL OR ELSEWHERE
• Does refrigerant’s high-pressure value hardly
increase?
15 VERIFY WHETHER MALFUNCTION IS IN Yes Return to Step 3.
COMPRESSOR OIL AMOUNT AND A/C No Go to next step.
COMPRESSOR OR ELSEWHERE
• When engine is racing, does high-pressure
value increase?
16 VERIFY WHETHER MALFUNCTION IS IN Yes Troubleshooting completed. (Explain to customer that cause
COMPRESSOR OIL AMOUNT OR A/C was insufficient compressor oil.)
COMPRESSOR No Replace A/C compressor, then go to Step 21. (Cause is
• After compressor oil is replenished each 10 defective A/C compressor.)
ml {10 cc, 0.338 fl oz}, does high-pressure
value increase?
17 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 19.
EXPANSION VALVE OR ELSEWHERE No Go to next step.
• Is only refrigerant low-pressure value high?
07-03–9
18 VERIFY THAT AIR MIX ACTUATOR IS Yes Go to next step.
INSTALLED SECURELY AND PROPERLY No Repair or install rod, link, cranks and shaft securely in
• Are heater unit’s air mix rod, link, cranks and proper position, then go to Step 21.
shaft securely and properly installed?
19 ADJUST COMPRESSOR OIL Yes Go to next step.
• Set the front fan switch at 4th position. No Follow Steps 1 to 10 again until compressor oil is 105 ml
• Turn the A/C switch on. {105 cc, 3.55 fl oz}.
• Set in FRESH mode.
• Set the temperature control to MAX COLD.
• Set in VENT mode.
• Run engine at a constant 1,500 rpm for 10
minutes.
• Run engine at idle speed for 1 minute.
• 1 engine speed cycle is defined as going
from idle speed to 4,000 rpm and back to
idle speed over a period of 12 seconds.
Perform 5 cycles.
• Run engine at idle speed for 30 seconds.
• Remove all compressor oil from A/C
compressor and verify that it is 105 ml {105
cc, 3.55 fl oz}.
• If it is more than 105 ml {105 cc, 3.55 fl oz},
put only 105 ml {105 cc, 3.55 fl oz} back into
A/C compressor.
• Carry out above Steps 1 to 10 again and
verify that compressor oil is 105 ml {105 cc,
3.55 fl oz}.
• Is there 105 ml {105 cc, 3.55 fl oz} of
compressor oil in A/C compressor?
20 INSPECT EXPANSION VALVE Yes Replace front expansion valve, then go to next step. (Since
• Is front expansion valve heatsen-sing tube valve closes too much, replacement is necessary.)
within front cooling unit securely installed in No Install heat-sensing tube securely, then go to next step.
proper position?
• Does cool air blow out? (Are results of malfunction recurs.
refrigerant system performance test okay?)
End Of Sie
07-03–10
NO.6 AIR FROM VENT NOT COLD ENOUGH.[5R55S]
id070300804704
6 Air from vent not cold enough

DESCRIPTION • Magnetic clutch operates but A/C system malfunctions.
• Drive belt malfunction (Step 1)
• Malfunction in blower unit or condenser (Steps 4, 5)
• Malfunction in RECEIVER/DRIER or expansion valve (valve closes too much) (Step 8, 9)
POSSIBLE • Malfunction in refrigerant lines (Steps 10, 11)
CAUSE • Malfunction in piping connections (Steps 1, 2, 13)
• A/C compressor system malfunction, insufficient compressor oil (Steps 15, 16)
• Compressor oil over-full, malfunction in front expansion valve or heater unit air mix link system (Steps
17—20)
1 INSPECT DRIVE BELT Yes Go to next step.
• Inspect drive belt. No Replace drive belt, then go to Step 21.
• Is it okay?
2 INSPECT REFRIGERANT SYSTEM Yes Operation is normal. (Recheck malfunction symptoms.)
PERFORMANCE No Go to next step.
• Carry out refrigerant system performance
test.
• Is operation normal?
HEATER UNIT INTAKE AND CONDENSER OR No Go to Step 6.
ELSEWHERE
low-pressure values both high?
4 INSPECT FRONT HEATER UNIT INTAKE Yes Remove obstruction, then go to Step 21. (If air does not
• Is blower unit intake clogged? reach evaporator within cooling unit, heat exchange does
not occur and refrigerant pressure rises. Therefore, removal
of obstruction is necessary.)
No Go to next step.
5 INSPECT CONDENSER Yes Add or subtract refrigerant to make specified amount, then
• Inspect condenser. go to Step 21. (Excessive amount of refrigerant.)
• Is it okay? No Replace condenser, or repair and clean condenser fins,
then go to Step 21.
EXPANSION VALVE, RECEIVER/DRIER AND No Go to Step 14.
REFRIGERANT LINES OR ELSEWHERE
low-pressure values low?
EXPANSION VALVE AND RECEIVER/DRIER No Go to Step 10.
OR ELSEWHERE 07
• Immediately after A/C compressor operates,
does refrigerant’s high-pressure value
momentarily rise to correct value, then fall
and stay below it? (Is there negative
pressure on low-pressure side?)
EXPANSION VALVE OR RECEIVER/DRIER No Start vacuum pump for 30 minutes and replace condenser,
• Turn A/C switch off and let air conditioner then go to Step 21. (Since RECEIVER/DRIER has become
stop for 10 minutes. saturated with water, replacement is necessary.)
• Start engine.
• Does malfunction occur after A/C
compressor turns on?
9 INSPECT EXPANSION VALVE Yes Replace front expansion valve, then go to Step 21. (Since
• Is front expansion valve heat-sensing tube valve closes too much, replacement is necessary.)
within front cooling unit securely installed in No Install heat-sensing tube securely, then go to Step 21.
proper position?
07-03–11
10 INSPECT REFRIGERANT LINES Yes Go to next step.
• Inspect refrigerant lines as follows. No If piping or an A/C component is damaged or cracked,
— Is piping free of damage and cracks? replace it. Then go to Step 21.
— Are piping connections free of oil grime? If there is no damage, go to Step 13.
(Visual inspection)
— Are piping connections free of gas
leakage?
condenser free of gas leakage?
RECEIVER/DRIER free of gas leakage?
— Are piping installation points on A/C
compressor free of gas leakage?
— Are piping installation points on cooling
unit free of gas leakage?
— Perform gas leak inspection using gas
leak tester.
11 INSPECT EVAPORATOR PIPING Yes If the A/C compressor is making noise, add 10 ml {10 cc,
CONNECTIONS IN A/C UNIT FOR GAS 0.338 fl oz} of compressor oil and verify that malfunction
LEAKAGE does not occur.
• Are piping connections for evaporator in Add or subtract refrigerant to make specified amount, then
cooling unit free of gas leakage? go to Step 21.
No If piping is damaged or cracked, replace it. Then go to Step
21.
If there is no damage, go to next step.
12 INSPECT EVAPORATOR PIPING Yes Tighten connections to specified torque. If the A/C
CONNECTIONS IN A/C UNIT FOR LOOSE compressor is making noise, add 10 ml {10 cc, 0.338 fl oz}
• Are piping connections for evaporator in of compressor oil and verify that malfunction does not occur.
cooling unit loose? Add or subtract refrigerant to make specified amount, then
go to Step 21.
does not occur.
13 INSPECT PIPING CONNECTIONS FOR Yes Tighten connections to specified torque. If the A/C
LOOSE compressor is making noise, add 10 ml {10 cc, 0.338 fl oz}
• Are piping connections loose? of compressor oil and verify that malfunction does not occur.
Add or subtract refrigerant to make specified amount, then
go to Step 21.
does not occur.
14 VERIFY WHETHER MALFUNCTION IS IN Yes Go to next step. (Pressure hardly increases.)
EXPANSION VALVE, AIR MIX ACTUATOR No Go to Step 17.
AND COMPRESSOR OIL OR ELSEWHERE
• Does refrigerant’s high-pressure value hardly
increase?
15 VERIFY WHETHER MALFUNCTION IS IN Yes Return to Step 3.
COMPRESSOR OIL AMOUNT AND A/C No Go to next step.
COMPRESSOR OR ELSEWHERE
• When engine is racing, does high-pressure
value increase?
16 VERIFY WHETHER MALFUNCTION IS IN Yes Troubleshooting completed. (Explain to customer that cause
COMPRESSOR OIL AMOUNT OR A/C was insufficient compressor oil.)
COMPRESSOR No Replace A/C compressor, then go to Step 21. (Cause is
• After compressor oil is replenished each 10 defective A/C compressor.)
ml {10 cc, 0.338 fl oz}, does high-pressure
value increase?
17 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 19.
EXPANSION VALVE OR ELSEWHERE No Go to next step.
• Is only refrigerant low-pressure value high?
07-03–12
18 VERIFY THAT AIR MIX ACTUATOR IS Yes Go to next step.
INSTALLED SECURELY AND PROPERLY No Repair or install rod, link, cranks and shaft securely in
• Are heater unit’s air mix rod, link, cranks and proper position, then go to Step 21.
shaft securely and properly installed?
19 ADJUST COMPRESSOR OIL Yes Go to next step.
• Set the front fan switch at 4th position. No Follow Steps 1 to 10 again until compressor oil is 105 ml
• Turn the A/C switch on. {105 cc, 3.55 fl oz}.
• Set in FRESH mode.
• Set the temperature control to MAX COLD.
• Set in VENT mode.
• Run engine at a constant 1,500 rpm for 10
minutes.
• Run engine at idle speed for 1 minute.
• 1 engine speed cycle is defined as going
from idle speed to 4,000 rpm and back to
idle speed over a period of 12 seconds.
Perform 5 cycles.
• Run engine at idle speed for 30 seconds.
• Remove all compressor oil from A/C
compressor and verify that it is 105 ml {105
cc, 3.55 fl oz}.
• If it is more than 105 ml {105 cc, 3.55 fl oz},
put only 105 ml {105 cc, 3.55 fl oz} back into
A/C compressor.
• Carry out above Steps 1 to 10 again and
verify that compressor oil is 105 ml {105 cc,
3.55 fl oz}.
• Is there 105 ml {105 cc, 3.55 fl oz} of
compressor oil in A/C compressor?
20 INSPECT EXPANSION VALVE Yes Replace front expansion valve, then go to next step. (Since
• Is front expansion valve heatsen-sing tube valve closes too much, replacement is necessary.)
within front cooling unit securely installed in No Install heat-sensing tube securely, then go to next step.
proper position?
• Does cool air blow out? (Are results of malfunction recurs.
refrigerant system performance test okay?)
End Of Sie
07
07-03–13
NO.7 NO COOL AIR.[EVEREST]
id0703008048b6
7 No cool air.
DESCRIPTION • Magnetic clutch does not operate.
• A/C compressor system malfunction (Step 2)
• Incorrect amount of refrigerant (Step 3)
• A/C switch indicator light malfunction (Step 4—6)
• A/C relay system malfunction (Step 7, 11—13)
POSSIBLE • Refrigerant pressure switch malfunction (Step 8)
CAUSE • PCM A/C cut-off control system (Step 9, 22)
• PCM (IG1 signal) system malfunction (Step 10, 21)
• Magnetic clutch system malfunction (Step 14)
• PCM (A/C signal) system malfunction (Step 15, 16)
• Evaporator A/C amplifier, A/C switch malfunction (Step 17—20)
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly
and undamaged.
1 INSPECT AIR BLOW OUT Yes Go to the next step.
• Does air blow out? No Go to Step 1 of troubleshooting indexes 1, 2.
2 INSPECT A/C COMPRESSOR OPERATION Yes Go to Step 1 of troubleshooting index 6.
• Start engine. No Go to the next step.
• Turn both A/C switch and fan switch on.
• Does A/C compressor operate?
3 INSPECT REFRIGERANT AMOUNT Yes Go to the next step.
• Inspect refrigerant amount. No Add or subtract refrigerant to specified level, then go to Step
• Is it okay? 23.
4 CHECK TO SEE WHETHER MALFUNCTION Yes Go to step 7.
IS IN A/C SWITCH OR ELSEWHERE No Go to the next step.
• Does A/C switch indicator light illuminate?
*5 INSPECT A/C SWITCH POWER SUPPLY Yes Go to the next step.
CIRCUIT No Repair wiring harness between fuse block and A/C switch,
• Turn the engine switch to ON position. then go to Step 23.
• Remove airflow mode wire, air intake wire
and air mix wire.
• Remove climate control unit.
• Remove A/C switch from climate control unit
and connect A/C switch connector.
• Measure voltage at A/C switch terminal C
(IG2 signal).
• Is voltage approximately 12 V?
*6 INSPECT A/C SWITCH Yes Inspect wiring harness between A/C switch and resistor,
• Inspect A/C switch. then go to Step 23.
• Is it okay? No Replace A/C switch, then go to Step 23.
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C RELAY POWER SUPPLY OR No Check for short to ground on blown fuse’s circuit.
ELSEWHERE Repair or replace as necessary.
• Are A/C relay power supply fuse okay? Install appropriate amperage fuse.
*8 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect refrigerant pressure switch, then go to Step 23.
IS IN REFRIGERANT PRESSURE SWITCH OR No Undo short, reconnect refrigerant pressure switch
ELSEWHERE connector, then go to the next step.
• Remove radiator grill.
• Disconnect refrigerant pressure switch
connector.
• Short to harness side connector terminal A
and B using a jumper wire.
• Turn both A/C switch and fan switch on with
engine is started.
• Does cool air blow out?
07-03–14
9 INSPECT FOR DTC IN PCM Yes Go to appropriate DTC troubleshooting procedure.
• Connect the current diagnostic tool to DLC-2. No Go to the next step.
• Retrieve the PCM DTC.
• Are accelerator position sensor and ECT
sensor related DTCs displayed?
10 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 15.
IS IN MAGNETIC CLUTCH CONTROL No Go to the next step.
CIRCUIT OR ELSEWHERE
• Turn the engine switch to ON position.
• Does magnetic clutch operate when A/C
relay connector terminal B (IG2 signal) is
grounded?
*11 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C RELAY POWER SUPPLY CIRCUIT No Repair wiring harness between fuse block and A/C relay,
OR ELSEWHERE then go to Step 23.
• Measure voltage at the following A/C relay
connector terminals:
— Terminal A (IG2 signal)
— Terminal C (A/C control signal)
*12 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C RELAY OR ELSEWHERE No Inspect A/C relay, then go to Step 23.
• Start engine.
• Measure the voltage A/C relay terminal D (A/
C control signal).
*13 INSPECT TO SEE WHETHER MALFUNCTION Yes Reconnect refrigerant pressure switch connector, then go to
IS IN A/C CONTROL CIRCUIT OR the next step.
ELSEWHERE No Repair wiring harness between A/C relay and refrigerant
• Disconnect refrigerant pressure switch pressure switch, then go to Step 23.
connector.
• Start engine.
• Measure voltage at refrigerant pressure
switch connector (harness-side) terminal A
(A/C control signal).
*14 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect magnetic clutch, then go to Step 23.
IS IN MAGNETIC CLUTCH OR WIRING No Repair wiring harness between refrigerant pressure switch
HARNESS (BETWEEN REFIRGERANT and magnetic clutch, then go to Step 23.
PRESSURE SWITCH AND MAGNETIC
CLUTCH)
• Start engine.
• Measure voltage at magnetic clutch 07
connector terminal A (A/C control signal).
*15 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 17.
IS IN A/C SIGNAL OR ELSEWHERE No Go to the next step.
• Turn A/C switch off.
• Remove glove compartment.
• Measure voltage at the following A/C
amplifier connector terminal A (A/C signal)
16 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair wiring harness between PCM and A/C amplifier, then
IS IN PCM OR WIRING HARNESS (BETWEEN go to Step 23.
PCM AND A/C AMPLIFIER) No Inspect PCM, then go to Step 23.
• Measure voltage at PCM terminal 239 (A/C
signal).
07-03–15
17 INSPECT TO SEE WHETHER MALFUNCTION Yes Undo short, then go to the next step.
IS IN A/C AMPLIFIER RELATED CIRCUIT OR No Go to Step 19.
ELSEWHERE
• Turn the engine switch to LOCK position.
• Disconnect A/C amplifier connector.
• Short to harness side connector terminal A
and B using a jumper wire.
• Start engine.
• Does cool air blow out?
18 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect A/C amplifier, then go to Step 23.
IS IN A/C AMPLIFIER OR WIRING HARNESS No Repair wiring harness between fuse block and A/C amplifier,
(BETWEEN FUSE BLOCK AND A/C then go to Step 23.
AMPLIFIER)
• Measure voltage at the A/C amplifier terminal
A (IG2 signal).
IS IN A/C SWITCH OR ELSEWHERE No Inspect A/C switch, then go to Step 23.
• Turn the A/C switch on.
• Turn the fan switch off.
• Measure voltage at A/C switch terminal D (A/
C signal).
IS IN WIRING HARNESS (BETWEEN A/C No Repair wiring harness between A/C amplifier and A/C
AMPLIFIER AND A/C SWITCH) OR switch, go to Step 23.
ELSEWHERE
• Measure voltage at A/C amplifier terminal C
(A/C signal).
IS IN WIRING HARNESS (BETWEEN A/C No Repair wiring harness between PCM and A/C relay, then go
RELAY AND PCM) OR ELSEWHERE to Step 23.
• Measure voltage at PCM terminal 128 (A/C
signal).
22 INSPECT A/C CUT-OFF CONTROL RELATED Yes Recheck malfunction symptoms.
SINGAL No Replace input signal components, then go to the next step.
• Connect the current diagnostic tool to DLC-2.
• Monitor following PCM PIDs.
— APP1
— APP2
— ECT
• Are these monitoring value normal?
23 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed. Explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does cool air blow out? (Is refrigerant system malfunction recurs.
performance test result correct?)
End Of Sie
07-03–16
NO.7 NO COOL AIR.[5R55S]
id070300804804
7 No cool air
DESCRIPTION • Magnetic clutch does not operate.
• A/C compressor system malfunction (Step 2)
• Incorrect amount of refrigerant (Step 3)
• A/C switch indicator light malfunction (Steps 4—6)
• PCM A/C cut-off control system (WL, WLT-1, WLT-2: Step 18) (G6: Step 7)
POSSIBLE
• PCM (IG1 signal) system malfunction (WL, WLT-1, WLT-2: Steps 8, 9) (G6: Step 20)
CAUSE
• Themoswitch, A/C switch malfunction (WL,WLT-1, WLT-2: Steps 11, 12, 14, 15) (G6: Step 10—14)
• PCM (A/C signal) system malfunction (WL, WLT-1, WLT-2: Steps 17) (G6: Step 16, 17)
• Refrigerant pressure switch malfunction (WL, WLT-1, WLT-2: Step 26) (G6: Step19)
• A/C relay malfunction (WL, WLT-1, WLT-2: Steps 22—25) (G6: Step 22—24)
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly
and undamaged.
1 INSPECT AIR BLOW OUT Yes Go to next step.
• Does air blow out? No Go to Step 1 of troubleshooting indexes No.1, 2.
2 INSPECT A/C COMPRESOR OPERATION Yes Go to Step 1 of troubleshooting index No. 6.
• Start engine. No Go to next step.
• Does A/C compressor operate?
3 INSPECT REFRIGERANT AMOUNT Yes Go to next step.
• Inspect refrigerant amount. No Add or subtract refrigerant to specified level, then go to Step
• Is it okay? 27.
4 INSPECT A/C SWITCH INDICATOR LIGHT Yes WL or WL-T1, WLT-2: Go to Step 8.
• Does A/C switch indicator light illuminate? G6: Go to Step 7.
No Go to next step.
*5 INSPECT WIRING HARNESS BETWEEN Yes Go to next step.
FUSE BLOCK AND FRONT CLIMATE No Repair wiring harness between fuse block and A/C switch,
CONTROL UNIT FOR CONTINUITY then go to Step 27.
• Turn ignition switch to ON position.
• Remove airflow mode wire and air mix wire
and pull out front climate control unit.
• Test voltage at front climate control unit
terminal C (IG2 signal).
*6 INSPECT A/C SWITCH Yes Inspect wiring harness between A/C switch and resistor,
• Inspect A/C switch. then go to Step 27.
• Is it okay? No Replace A/C switch, then go to Step 27. 07
7 CHECK FOR DTCS IN PCM Yes Go to appropriate inspection procedure. (The throttle
• Check the DTC for the ON-BOARD position sensor (DTC 0120), which sends the PCM’s A/C cut
DIAGNOSTIC (ENGINE CONTROL). off control input signal, may be the cause of the trouble.)
• Are the following DTCs displayed? No Go to Step 10.
— DTC 0120
*8 VERIFY WHETHER MALFUNCTION IS IN Yes Go to next step.
MAGNETIC CLUTCH SYSTEM OR No Go to Step 21.
ELSEWHERE
• Does magnetic clutch operate when A/C
relay connector terminal B (IG2 signal) is
grounded?
*9 VERIFY WHETHER MALFUNCTION IS IN A/C Yes Go to Step 11.
RELAY SYSTEM (COIL-SIDE) OR No Repair wiring harness between A/C relay and PCM, then go
ELSEWHERE to Step 27.
• Turn A/C switch off.
• Test voltage at PCM connector terminal
L(IG1 signal).
07-03–17
*10 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 16.
THEMOSWITCH SYSTEM OR ELSEWHERE No Reconnect refrigerant pressure switch connector, then go to
• Turn ignition switch to LOCK position. next step.
• Remove radiator grille.
• Disconnect refrigerant pressure switch
connector.
• Set front fan switch at first speed.
• Test voltage at the following refrigerant
pressure switch connector terminal B (A/C
signal) on wiring harness side.
• Is voltage approximately 12 V when A/C
switch is off and 0 V when it is on?
*11 VERIFY WHETHER MALFUNCTION IS IN Yes Undo short, then go to next step.
EVAPORATOR TEMPERATURE SENSOR No WL or WL-T1, WLT-2: Undo short, then go to Step 14.
AND WIRING HARNESS (BETWEEN FUSE G6: Undo short, then go to Step 13.
BLOCK AND EVAPORATOR TEMPERATURE
SENSOR FOR CONTINUITY) OR
ELSEWHERE
• Turn ignition switch to LOCK position.
• Remove glove compartment.
• Disconnect evaporator temperature sensor
connector.
• Start engine.
• When evaporator temperature sensor
connector terminals B and C (on wiring
harness side) are shorted, does cool air blow
out?
*12 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect evaporator temperature sensor, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR OR No Repair wiring harness between fuse block and evaporator
WIRING HARNESS (BETWEEN FUSE BLOCK temperature sensor, then go to Step 27.
AND THEMOSWITCH FOR CONTINUITY)
• Test voltage at evaporator temperature
sensor connector terminal A (IG2 signal).
EVAPORATOR TEMPERATURE SENSOR No Repair wiring harness between refrigerant pressure switch
AND REFRIGERANT PRESSURE SWITCH and evaporator temperature sensor, then go to Step 27.
FOR CONTINUITY
• Turn ignition switch to LOCK position.
• Inspect for continuity between evaporator
temperature sensor connector terminal B (A/
C signal) and refrigerant pressure switch
connector terminal B.
*14 VERIFY WHETHER MALFUNCTION IS IN Yes WL or WL-T1, WLT-2: Go to next step.
EVAPORATOR TEMPERATURE SENSOR G6: Inspect wiring harness between evaporator temperature
AND WIRING HARNESS (BETWEEN sensor and A/C switch, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR No Inspect A/C switch, then go to Step 27.
AND A/C SWITCH FOR CONTINUITY) OR
ELSEWHERE
• Turn A/C switch ON.
• Turn fan switch ON.
• Test voltage at A/C switch connector terminal
A (A/C signal).
07-03–18
*15 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 17.
EVAPORATOR TEMPERATURE SENSOR No Repair wiring harness between evaporator temperature
AND WIRING HARNESS (BETWEEN sensor and A/C switch, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR
AND A/C SWITCH FOR CONTINUITY) OR
ELSEWHERE
• Test voltage at evaporator temperature
sensor connector terminal C (A/C signal).
*16 VERIFY WHETHER MALFUNCTION IS IN PCM Yes Go to Step 19.
AND WIRING HARNESS (BETWEEN PCM No Go to next step.
AND REFRIGERANT PRESSURE SWITCH
FOR CONTINUITY) OR ELSEWHERE
• Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (A/C signal).
*17 VERIFY WHETHER MALFUNCTION IS IN PCM Yes WL or WL-T1, WLT-2: Go to next step.
OR WIRING HARNESS (BETWEEN PCM AND G6: Inspect wiring harness between PCM and refrigerant
REFRIGERANT PRESSURE SWITCH FOR pressure switch, then go to Step 27.
CONTINUITY) No Inspect PCM, then go to Step 27.
• Test voltage at the following PCM connector
terminals (A/C signal).
— Terminal G (WL or WL-T1, WLT-2)
— Terminal Q (G6)
*18 VERIFY WHETHER MALFUNCTION IS IN PCM Yes Repair wiring harness between PCM and evaporator
AND WIRING HARNESS (BETWEEN PCM temperature sensor, then go to Step 27.
AND EVAPORATOR TEMPERATURE No Replace input signal components, then go to Step 27.
SENSOR FOR CONTINUITY) OR
ELSEWHERE
• Inspect the following input signal
components:
— Engine coolant temperature sensor,
including PCM wiring harness (A/C cut-off
control)
• Are they okay?
*19 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect refrigerant pressure switch, then go to Step 27.
REFRIGERANT PRESSURE SWITCH OR No Undo short, reconnect refrigerant pressure switch, then go
ELSEWHERE to next step.
• When the following refrigerant pressure
switch connector terminal A and B (on wiring
harness side) are shorted, does cool air blow
out?
*20 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect wiring harness between A/C relay and PCM, then 07
IS IN A/C RELAY OR ELSEWHERE go to Step 27.
• Does magnetic clutch operate when terminal No Go to next step.
B (IG2 signal) of A/C relay connector is
grounded?
*21 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect magnetic clutch, then go to Step 27.
MAGNETIC CLUTCH OR WIRING HARNESS No Go to next step.
(BETWEEN A/C RELAY AND MAGNETIC
CLUTCH FOR CONTINUITY)
• Test voltage at magnetic clutch connector
terminal A (A/C control signal).
22 INSPECT A/C RELAY (SWITCH-SIDE) POWER Yes Go to next step.
SUPPLY FUSE No Inspect for a short to ground on blown fues’s circuit. Repair
• Are A/C relay power supply fuses okay? or replace as necessary.
Install appropriate amperage fuse.
07-03–19
FUSE BLOCK AND A/C RELAY No Repair wiring harness between fuse block and A/C relay,
(SWITCH-SIDE) FOR CONTINUITY then go to Step 27.
• Test voltage at the following A/C relay
connector terminals:
— Terminal A (IG2 signal)
— Terminal C (A/C control signal)
*24 VERIFY WHETHER MALFUNCTION IS IN Yes WL or WL-T1, WLT-2: Go to next step.
MAGNETIC CLUTCH OR WIRING HARNESS G6: Repair wiring harness between A/C relay and magnetic
(BETWEEN A/C RELAY AND MAGNETIC clutch, then go to Step 27.
CLUTCH FOR CONTINUITY) No Inspect A/C relay, then go to Step 27.
• Test voltage at A/C relay connector terminal
D (A/C control signal).
FUSE BLOCK AND A/C RELAY No Repair wiring harness between A/C relay and refrigerant
(SWITCH-SIDE) FOR CONTINUITY pressure switch, then go to Step 27.
• Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (A/C control signal)
*26 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect refrigerant pressure switch, then go to next step.
REFRIGERANT PRESSURE SWITCH OR No Repair wiring harness between refrigerant pressure switch
ELSEWHERE and magnetic clutch, then go to next step.
• When refrigerant pressure switch connector
terminal A and B (on wiring harness side) are
shorted, does cool air blow out?
• Does cool air blow out? (Is refrigerant system malfunction recurs.
performance test result correct?)
End Of Sie
07-03–20
NO.8 NOISE WHILE OPERATING A/C SYSTEM[EVEREST]
id070200812703
8 Noise while operating A/C system

DESCRIPTION • Noise from magnetic clutch, A/C compressor, hose or refrigerant line.
• Magnetic clutch operation noise (Step 3)
POSSIBLE • A/C compressor operation noise (Steps 4—8)
CAUSE • A/C compressor slippage noise (Steps 9—11)
• Hose or refrigerant line interference noise (Step 12)
1 INSPECT A/C COMPRESSOR SLIPPAGE Yes Go to Step 9.
NOISE No Go to next step.
• Is there a squeaking or whirling sound (A/C
compressor slippage noise)?
2 INSPECT A/C COMPRESSOR Yes Go to Step 12.
INTERFERENCE NOISE No Go to next step.
• Is there a rattling or vibrating sound
(interference noise)?
3 INSPECT MAGNETIC CLUTCH OPERATION Yes Adjust clearance between magnetic clutch pressure plate
NOISE and A/C compressor pulley, then go to Step 13.
• Is there clicking sound (magnetic clutch No Go to next step.
operation noise)?
4 INSPECT A/C COMPRESSOR NOISE TIME Yes Go to next step.
• Is noise heard continuously for more than 3 No Condition is normal. (Noise normally occurs for 2–3
seconds after A/C compressor comes on? seconds immediately after A/C compressor turns on.)
5 INSPECT IDLE SPEED Yes Go to next step.
• Inspect idle speed. No Adjust idle speed, then go to Step 13.
• Is it okay?
COMPRESSOR OIL OR A/C COMPRESSOR No Replace A/C compressor, then go to Step 13.
• Drain compressor oil.
• Is it contaminated with metal particles?
7 VERIFY WHETHER MALFUNCTION IS IN Yes Replace entire A/C system (excluding heater), then go to
ENTIRE A/C SYSTEM OR A/C COMPRESOR Step 13.
AND CONDENSER No Go to next step.
• Is compressor oil whitish and mixed with
water?
8 INSPECT COMPRESSOR OIL Yes Replace A/C compressor and RECEIVER/DRIER, then go
• Is compressor oil darker than normal and to Step 13. (Since A/C compressor may be worn and
contaminated with aluminum chips? RECEIVER/DRIER may be clogged, replacement of
RECEIVER/DRIER is necessary.)
No Condition is normal. Recheck malfunction symptoms.
9 INSPECT DRIVE BELT
• Inspect drive belt.
Yes
No
Go to next step.
Adjust or replace drive belt, then go to Step 13.
07
• Is it okay?
10 INSPECT DRIVE BELT CONDITION Yes Remove obstruction, remove oil, or replace drive belt, then
• Is drive belt worn? go to Step 13.
• Does it have foreign material imbedded in it, No Go to next step.
or have oil on it?
11 INSPECT MAGNETIC CLUTCH Yes Replace A/C compressor (excluding pressure plate, A/C
• Inspect magnetic clutch. compressor pulley, and stator), then go to Step 13.
• Is it okay? No Replace magnetic clutch, then go to Step 13.
12 INSPECT A/C COMPRESSOR NOISE Yes Visually inspect A/C compressor, replace appropriate parts
• Is noise coming from A/C compressor? if necessary, then go to next step.
No If noise is coming from refrigerant lines, repair any detached
or missing clips, tighten loose bolts, then go to next step.
• Has A/C compressor noise stopped? malfunction recurs.
End Of Sie
07-03–21
F198-10-05L(07-10).fm 1 ページ２００６年８月３日　木曜日　午後１時４８分
REFRIGERANT SYSTEM
07-10 REFRIGERANT SYSTEM

REFRIGERANT CHARGING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-10–1
End of Toc
REFRIGERANT CHARGING[EVEREST]
WM: REFRIGERANT SYSTEM
id0710008004b7
Caution
• Do not exceed the specification when charging the system with refrigerant. Doing so will decrease
the efficiency of the air conditioner or damage the refrigeration cycle parts.
Charging Recycled R-134a Refrigerant

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s
instructions.
Charging Preparation
1. Install the SSTs (gas charging set).
2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49C061 001).
3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum pump.
5. Connect the SST (49 C061 004) to the refrigerant tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant (approximate quantity)

675 g {23.8 oz}
TAP PIN SIDE AIR PURGE VALVE

49 C061 001
49 C061 004 49 C061 005
REFRIGERANT
TANK
SCALE
VACUUM PUMP
arnffw00001704
Evacuation
1. Open all the valves of the SST (49 C061 001).
Caution
07
• Close the SST (49 C061 001) valve immediately after stopping the vacuum pump. If the valve is left
open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the
efficiency of the air conditioner.
2. Start the vacuum pump and let it operate for 15

min. 49 C061 001
CLOSE
arnffw00001705
07-10–1
REFRIGERANT SYSTEM
3. Verify that high- and low-pressure side readings
of the SST (49 C061 001) are at –101 kPa {–760
49 C061 001
mmHg, –29.9 inHg}. Close each valve of the
SST (49 C061 001).
arnffw00001706
Airtightness Check
1. Stop the vacuum pump and wait for 5 min.
2. Check the high- and low-pressure side readings of the SST (49 C061 001).
• If the reading has changed, inspect for leakage and go to Evacuation. (See 07-10-1 Evacuation.)
• If the reading has not changed, go to Charging New R-134a Refrigerant. (See 07-10-1 Charging Recycled
R-134a Refrigerant.)
Charging New R-134a Refrigerant

1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.
Warning
• If the refrigerant system is charged with a large amount of refrigerant when inspecting for gas
leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In
order to prevent the accidental release of refrigerant which can destroy the ozone layer in the
stratosphere, follow the proper procedures and charge with only a small amount of refrigerant
when inspecting for gas leakage.
• If charging the system with refrigerant using service cans, running the engine with the high-
pressure side valve open is dangerous. Pressure within the service cans will increase and the
cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.
3. Open the low-pressure side valve of the SST (49

C061 001). 49 C061 001
OPEN
arnffw00001707
4. When the low-pressure side reading increases to

0.098 MPa {1.0 kgf/cm2, 14 psi}, close the 49 C061 001
low-pressure side valve of the SST (49 C061
001).
5. Inspect for leakage from the cooler pipe/hose
connections using the SST (49 C061 013).
• If there is no leakage, go to Step 7.
• If leakage is found at a loose joint, tighten the
joint, then go to next step.
arnffw00001708
07-10–2
REFRIGERANT SYSTEM
6. Inspect for leakage again.
• If there is no leakage after tightening the joint, go to next step.
• If there is still a leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
Warning
• If charging the system with refrigerant using service cans, running the engine with the
high-pressure side valve open is dangerous. Pressure within the service cans will increase and
the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.

C061 001) and charge with refrigerant until the 49 C061 001
weight of refrigerant tank has decreased 350 g
{12.4 oz} from the amount in Step 2.
OPEN
arnffw00001707
8. Close the low-pressure side valve of the SST (49

C061 001). 49 C061 001
Warning
• If charging the system with refrigerant
using service cans, running the engine
with the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
arnffw00001709
high-pressure side valve while the engine
is running.
9. Start the engine and actuate the A/C compressor.

C061 001) and charge with refrigerant until the 49 C061 001
weight of the refrigerant tank has decreased
regular amount from the amount in Step 2.
11. Close the low-pressure side valve of the SST (49 OPEN
C061 001) and the valve of the refrigerant tank. 07
12. Stop the engine and A/C compressor.
arnffw00001707
07-10–3
REFRIGERANT SYSTEM
Leak Test
1. Inspect for leakage using the SST (49 C061 013).
• If there is no leakage, go to Step 3.
• If leakage is found at a loose joint, tighten the joint, then go to next step.
2. Inspect for leakage again.
• If there is no leakage after tightening the joint, go to next step.
• If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
3. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves.
4. Install the caps to the charging valves.
End Of Sie
49 C061 007
49 C061 006A
CAP
CAP
arnffw00001710
07-10–4
F198-10-05L(07-11).fm 1 ページ２００６年８月３日　木曜日　午前１１時１５分
BASIC SYSTEM
07-11 BASIC SYSTEM

HVAC BASIC SYSTEM LOCATION REAR EVAPORATOR INSPECTION
INDEX[EVEREST] . . . . . . . . . . . . . . . . . 07-11–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–4
BLOWER UNIT DISASSEMBLY/ASSEMBLY A/C COMPRESSOR
AIR FILTER REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-11–2 REAR COOLER DUCT
AIR FILTER INSPECTION REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-11–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–5
REAR A/C UNIT REMOVAL/INSTALLATION REFRIGERANT LINES
REAR A/C UNIT DISASSEMBLY/ASSEMBLY [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-11–5
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-11–3
End of Toc
HVAC BASIC SYSTEM LOCATION INDEX[EVEREST]
WM: HVAC BASIC SYSTEM
id0711008017b7
3 9
6
4 2
5 7
.
arnffw00001884
07
1 Blower unit 7 Refrigerant lines
(See 07-11-2 BLOWER UNIT DISASSEMBLY/ (See 07-11-5 REFRIGERANT LINES REMOVAL/
ASSEMBLY[EVEREST]) INSTALLATION[EVEREST])
2 Cooling unit 8 Rear cooler duct
3 Heater unit (See 07-11-5 REAR COOLER DUCT REMOVAL/
4 A/C compressor
(See 07-11-4 A/C COMPRESSOR REMOVAL/ 9 Rear A/C unit
INSTALLATION[EVEREST]) (See 07-11-3 REAR A/C UNIT REMOVAL/
5 Condenser (See 07-11-3 REAR A/C UNIT DISASSEMBLY/
6 Heater hose ASSEMBLY[EVEREST])
End Of Sie
07-11–1
BASIC SYSTEM
BLOWER UNIT DISASSEMBLY/ASSEMBLY[EVEREST]
id0711008006b7
2. Assemble in the reverse order of disassembly.
1 Front blower motor
2 Air filter 5
3 Front resistor
4 Blower harness 2
5 Blower case (1)
6 Blower case (2) 6
7 Blower case (3)
End Of Sie
7
4
arnffw00001714
AIR FILTER REMOVAL/INSTALLATION[EVEREST]

id0711008007b7
1. Remove the glove compartment.
2. Remove in the order indicated in the figure.
End Of Sie
AIR FILTER
arnffw00001715
AIR FILTER INSPECTION[EVEREST]

id0711008008b7
1. Inspect for damage, excessive dirt.
• If the air filter is damaged, replace it.
• If the air filter is excessively dirty, clean it. (See 07-11-2 Air Filter Cleaning.)
Air Filter Cleaning

1. Remove dirt and pollen adhering to the surface of the air filter with an air blower or by flushing with water.
Caution
• When flushing the air filter with water use cool water, as hot water may cause deformation.
• When scrubbing the air filter, do not apply excessive force as it could damage it.
2. After thoroughly drying the air filter, install it.

End Of Sie
07-11–2
BASIC SYSTEM
REAR A/C UNIT REMOVAL/INSTALLATION[EVEREST]
id0711008020b7
2. Discharge the refrigerant from the system.
3. Remove the third-row seat.
4. Remove the trunk side trim (LH) and C-pillar trim.
5. Remove the rear cooler duct No.5.
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.

1 Rear evaporator pipe
2 Connector
R A
3 Rear A/C unit
7. Install in the reverse order of removal. R

3
8. Perform the refrigerant system performance test.
End Of Sie 1
8—12 N·m
A {82—122 kgf·cm,
2 71—106 in·lbf}
arnffw00001723
REAR A/C UNIT DISASSEMBLY/ASSEMBLY[EVEREST]

id0711008019b7
10 9 C
B
C
6
4 A
07
8
3
2
A
1
arnffw00001722
1 Rear resistor 5 Case (1)

2 Rear blower relay 6 Case (2)
3 Rear blower motor 7 Case (3)
4 Rear expansion valve 8 Case (4)
07-11–3
BASIC SYSTEM
9 Plate
10 Rear evaporator
(See 07-11-4 Rear Evaporator Assembly Note)
Rear Evaporator Assembly Note

1. When installing a new rear evaporator, add FD46XG compressor oil from the inlet.
Supplemental amount (approximate quantity)

40 ml {40 cc, 1.4 fl oz}
End Of Sie
REAR EVAPORATOR INSPECTION[EVEREST]
id0711008026b7
1. Remove the rear evaporator from the rear A/C unit.
2. Inspect for cracks, damage, and oil leakage.
• There is any malfunction, replace the rear evaporator.
3. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
A/C COMPRESSOR REMOVAL/INSTALLATION[EVEREST]
id0711008010b7
3. Loosen the drive belt and remove it.
Caution
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.
• Do not allow A/C compressor oil to spill. Operating the A/C compressor without sufficient A/C
compressor oil can lead to abnormal noise and cause the A/C compressor to seize up.

1 Cooler hose (HI) 3 8—12 N · m
(See 07-11-5 REFRIGERANT LINES REMOVAL/ R 1 {82—122 kgf · cm,
INSTALLATION[EVEREST]) 71—106 in· lbf}
2 Cooler hose (LO)

(See 07-11-5 REFRIGERANT LINES REMOVAL/
INSTALLATION[EVEREST]) R
3 Connector 4
4 A/C compressor
24—36 N · m
(See 07-11-4 A/C Compressor Installation Note)
{2.5—3.6 kgf · m,
18—26 ft · lbf} 2
5. Install in the reverse order of removal. arnffw00001716
6. Adjust the drive belt.
A/C Compressor Installation Note

1. Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C
compressor.
Compressor oil to be removed (approximate quantity)

180 ml {180 cc, 6.08 fl oz} – compressor oil from old A/C compressor
End Of Sie
07-11–4
BASIC SYSTEM
REAR COOLER DUCT REMOVAL/INSTALLATION[EVEREST]
id0711008031b7
2. Remove the trunk side trim (LH) and C-pillar trim.
3. Remove the headliner.(See 09-17-6 HEADLINER REMOVAL/INSTALLATION[EVEREST].)
2
3
arnffw00001724
1 Rear cooler duct No.1 4 Rear cooler duct No.4

2 Rear cooler duct No.2 5 Rear cooler duct No.5
3 Rear cooler duct No.3

End Of Sie
REFRIGERANT LINES REMOVAL/INSTALLATION[EVEREST]
id0711008011b7
3. Remove the following parts, depending on pipe and hose to be removed.
Cooler pipe/hose to be removed
• Radiator grille
Parts to be removed
07
Front cooler pipe No.1
• Air cleaner box
• Radiator grille
Cooler hose (HI)
• Air cleaner box
Cooler hose (LO) • Air cleaner box
Rear cooler pipe No.2 • Crossmember
Caution
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
• Do not allow A/C compressor oil to spill. Operating the A/C compressor without sufficient A/C
compressor oil can lead to abnormal noise and cause the A/C compressor to seize up.

07-11–5
BASIC SYSTEM
FRONT
3 R
TO REAR LINES
R
A R
C A
R
R B
A
B 2
A TO REAR
LINES B
A
1
R
A
A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}

B: 10—20 N·m {1.1—2.0 kgf·m, 7.4—14.7 ft·lbf}
C: 20—30 N·m {2.1—3.0 kgf·m, 14.8—22.1 ft·lbf}
arnffw00001717
1 Front cooler pipe No.1 3 Cooler hose (LO)

(See 07-11-7 Refrigerant Lines Removal Note) (See 07-11-7 Refrigerant Lines Removal Note)
(See 07-11-7 Refrigerant Lines Installation Note) (See 07-11-7 Refrigerant Lines Installation Note)
2 Cooler hose (HI)
(See 07-11-7 Refrigerant Lines Removal Note)
(See 07-11-7 Refrigerant Lines Installation Note)
07-11–6
BASIC SYSTEM
REAR
TO FRONT LINE
C
1
B
R
C
R 2
TO REAR A/C UNIT
R
B
A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}

3 B: 10—20 N·m {1.1—2.0 kgf·m, 7.4—14.7 ft·lbf}
A C: 20—30 N·m {2.1—3.0 kgf·m, 14.8—22.1 ft·lbf}
arnffw00001719
1 Rear cooler pipe No.1 3 Rear cooler pipe No.3

(See 07-11-7 Refrigerant Lines Removal Note) (See 07-11-7 Refrigerant Lines Removal Note)
(See 07-11-7 Refrigerant Lines Installation Note) (See 07-11-7 Refrigerant Lines Installation Note)
2 Rear cooler pipe No.2
(See 07-11-7 Refrigerant Lines Removal Note)
(See 07-11-7 Refrigerant Lines Installation Note)
Refrigerant Lines Removal Note

1. Loosen the nut with two wrenches, then remove the cooler pipe or hose.
Refrigerant Lines Installation Note

1. When installing a new cooler pipe or hose, add a supplemental amount of FD46XG compressor oil from the
inlet.
Supplemental amount (approximate quantity) 07

10 ml {10 cc, 0.3 fl oz}
2. Apply compressor oil to the O-rings and connect the joints.

3. Tighten the joints.
(1) Tighten the nut or bolt of the joint by hand.
(2) Tighten the joint to the specified torque. If it is a nut joint, tighten the nut with a wrench and torque wrench.
End Of Sie
07-11–7
F198-10-05L(07-40).fm 1 ページ２００６年８月３日　木曜日　午前１１時１６分
CONTROL SYSTEM
07-40 CONTROL SYSTEM

HVAC CONTROL SYSTEM LOCATION REFRIGERANT PRESSURE SWITCH
INDEX[EVEREST] . . . . . . . . . . . . . . . . . 07-40–1 INSPECTION[EVEREST] . . . . . . . . . . . . 07-40–3
REAR BLOWER MOTOR REAR FAN SWITCH
REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-40–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-40–4
REAR BLOWER MOTOR INSPECTION REAR FAN SWITCH
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-40–2 DISASSEMBLY/ASSEMBLY
REAR RESISTOR [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-40–4
REMOVAL/INSTALLATION REAR FAN SWITCH INSPECTION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-40–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 07-40–5
REFRIGERANT PRESSURE SWITCH
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 07-40–3
End of Toc
HVAC CONTROL SYSTEM LOCATION INDEX[EVEREST]
WM: HVAC CONTROL SYSTEM
id0740008036b7
arnffw00001735 07
.
1 Rear blower motor 4 Rear fan switch

(See07-40-2 REAR BLOWER MOTOR REMOVAL/ (See07-40-4 REAR FAN SWITCH REMOVAL/
INSTALLATION[EVEREST]) INSTALLATION[EVEREST])
(See07-40-2 REAR BLOWER MOTOR (See07-40-4 REAR FAN SWITCH DISASSEMBLY/
INSPECTION[EVEREST]) ASSEMBLY[EVEREST])
2 Rear blower relay (See07-40-5 REAR FAN SWITCH
INSPECTION[EVEREST])
3 Rear resistor
(See07-40-2 REAR RESISTOR REMOVAL/
(See07-40-2 REAR BLOWER MOTOR
INSPECTION[EVEREST])
End Of Sie
07-40–1
CONTROL SYSTEM
REAR BLOWER MOTOR REMOVAL/INSTALLATION[EVEREST]
id0740008054b7
3. Remove the trunk side trim (LH).
1 Rear blower motor connector
2 Rear blower motor

End Of Sie
1
2
arnffw00001737
REAR BLOWER MOTOR INSPECTION[EVEREST]

id0740008053b7
1. Connect battery positive voltage to terminal B and ground to terminal A of the rear blower motor.
2. Verify that the rear blower motor operates.
• If there is any malfunction, replace the rear
blower motor. B
End Of Sie A
arnffw00001736
REAR RESISTOR REMOVAL/INSTALLATION[EVEREST]

id0740001133b7
3. Remove the trunk side trim (LH).
1 Rear resistor connector
2 Rear resistor
2
End Of Sie
arnffw00001725
07-40–2
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION[EVEREST]
id0740008026b7
3. Remove the radiator grille.
4. Loosen the refrigerant pressure switch using two spanners.
1 Refrigerant pressure switch connector
1
3
2 Refrigerant pressure switch [dual-pressure]
(See 07-40-3 Refrigerant Pressure Switch 2
Installation Note) R
3 Refrigerant pressure switch [single-pressure] R
(See 07-40-3 Refrigerant Pressure Switch
Installation Note)
arnffw00001730
Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to O-ring and connect the joint.
End Of Sie
REFRIGERANT PRESSURE SWITCH INSPECTION[EVEREST]
id0740008027b7
1. Install the gas charging set.
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the manifold gauge and continuity between the terminals of the
refrigerant pressure switch.
• If there is any malfunction, replace the refrigerant pressure switch.
Dual-pressure Switch
BETWEEN A AND B TERMINALS
0.176—0.216 2.94—3.34
{1.80—2.20, {30.0—34.0,
25.5—31.3} 427—484}
CONTINUITY
NO
CONTINUITY
0.025 0.39—0.79
{0.25, 3.62} {3.98—8.05, MPa
or less 56.6—114.5} {kgf/cm2, psi}
arnffw00001731
07
B A
B A
arnffw00001732
07-40–3
CONTROL SYSTEM
Single-pressure Switch
BETWEEN A AND B TERMINALS
2.65—2.85
{27.1—29.0,
385—413}
CONTINUITY
NO
CONTINUITY 2.06—2.26
{21.0—23.0,
299—327} MPa {kgf/cm2, psi}
arnffw00001733
End Of Sie
B A
B A
arnffw00001734
REAR FAN SWITCH REMOVAL/INSTALLATION[EVEREST]

id0740001136b7
1 Rear fan switch connector
2 Rear fan switch
2
End Of Sie
arnffw00001727
REAR FAN SWITCH DISASSEMBLY/ASSEMBLY[EVEREST]

id0740001137b7
4
1 Dial 2 3
2 Panel
3 Rear fan switch
4 Bulb
4
End Of Sie
1
arnffw00001726
07-40–4
CONTROL SYSTEM
REAR FAN SWITCH INSPECTION[EVEREST]
id0740001138b7
1. Inspect for continuity between the rear fan switch terminals using a tester.
• If there is any malfunction, replace the rear fan switch.
: Continuity F D A
C
* C A
Switch Terminal
F D *
position F A C D
3 2 1
0
0
1
2
3
arnffw00001728 arnffw00001729
End Of Sie
07
07-40–5
F198-10-05L(08-11).fm 1 ページ２００６年８月３日　木曜日　午前１１時１７分
RESTRAINTS 08
SECTION
Toc
SEATof SCT
BELT . . . . . . . . . . . . . . . 08-11
Toc of SCT
08-11 SEAT BELT
LOCATION INDEX[EVEREST] . . . . . . . . 08-11–1 SECOND-ROW BUCKLE
SECOND-ROW SEAT BELT REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 08-11–3
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 08-11–2 THIRD-ROW BUCKLE
THIRD-ROW SEAT BELT REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 08-11–3
End of Toc
LOCATION INDEX[EVEREST]
WM: SEAT BELT
id0811008002b6
1 2
4 3
arnffw00001738
1 Second-row seat belt 3 Third-row buckle

(See 08-11-2 SECOND-ROW SEAT BELT (See 08-11-4 THIRD-ROW BUCKLE REMOVAL/
REMOVAL/INSTALLATION[EVEREST]) INSTALLATION[EVEREST])
2 Third-row seat belt 4 Second-row buckle
(See 08-11-3 THIRD-ROW SEAT BELT REMOVAL/ (See 08-11-3 SECOND-ROW BUCKLE REMOVAL/
08
End Of Sie
08-11–1
SEAT BELT
SECOND-ROW SEAT BELT REMOVAL/INSTALLATION[EVEREST]
id0811008025b6
Caution
• The ELR has a spring that will unwind if the retractor cover is removed. The spring cannot be
rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the
retractor.
1. Remove the rear side trim.

1 Anchor cover
2 Second-row seat belt

End Of Sie 1
BOLT
38.2—78.4 2
{3.90—7.99,
28.2—57.8}
7.65—11.5 N·m
{78.0—118 kgf·cm,
67.8—102 in·lbf}
38.2—78.4
{3.90—7.99,
28.2—57.8}
arnffw00001744
08-11–2
SEAT BELT
THIRD-ROW SEAT BELT REMOVAL/INSTALLATION[EVEREST]
id0811008026b6
Caution
• The ELR has a spring that will unwind if the retractor cover is removed. The spring cannot be
rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the
retractor.
Detachable Type Seat

1 Anchor cover
2 Third-row seat belt

End Of Sie BOLT
38.2—78.4
2
{3.90—7.99,
28.2—57.8}
7.65—11.5 N·m
{78.0—118 kgf·cm,
67.8—102 in·lbf}
38.2—78.4
{3.90—7.99,
28.2—57.8}
arnffw00001745
SECOND-ROW BUCKLE REMOVAL/INSTALLATION[EVEREST]

id0811008021b6
1. Disassemble the second-row seat.
2. Remove the second-row buckle.
End Of Sie
08
08-11–3
SEAT BELT
THIRD-ROW BUCKLE REMOVAL/INSTALLATION[EVEREST]
id0811008023b6
1. Remove the bolt.
BOLT 38.2—78.4
{3.90—7.99,
28.2—57.8}
arnffw00001741
2. Remove the third-row buckle from the third-row

seat.
End Of Sie
THIRD-ROW
BUCKLE
arnffw00001742
08-11–4
F198-10-05L(09-10).fm 1 ページ２００６年８月３日　木曜日　午前１１時１８分
BODY & ACCESSORIES 09

SECTION
Toc
BODYof SCT
PANELS . . . . . . . . . . . . 09-10 EXTERIOR TRIM . . . . . . . . . . . 09-16
DOORS AND LIFTGATE . . . . . 09-11 INTERIOR TRIM . . . . . . . . . . . . 09-17
GLASS/WINDOWS/ LIGHTING SYSTEMS . . . . . . . . 09-18
MIRRORS . . . . . . . . . . . . . . . 09-12 WIPER/WASHER SYSTEM . . . 09-19
SEATS . . . . . . . . . . . . . . . . . . . 09-13 INSTRUMENTATION/
SECURITY AND LOCKS . . . . . 09-14 DRIVER INFO. . . . . . . . . . . . . 09-22
Toc of SCT
09-10 BODY PANELS
BODY PANEL LOCATION INDEX REAR BUMPER
FUEL-FILLER LID [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-10–2
REMOVAL/INSTALLATION REAR BUMPER
FUEL-FILLER LID ADJUSTMENT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-10–3
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-10–2
End of Toc
BODY PANEL LOCATION INDEX[EVEREST]
WM: FUEL-FILLER LID
id0910008023z2
1 2
arnffw00001751
1 Rear bumper 2 Fuel-filler lid

(See 09-10-2 REAR BUMPER REMOVAL/ (See 09-10-2 FUEL-FILLER LID REMOVAL/
(See 09-10-3 REAR BUMPER DISASSEMBLY/ (See 09-10-2 FUEL-FILLER LID
ASSEMBLY[EVEREST]) ADJUSTMENT[EVEREST])
09
End Of Sie
09-10–1
BODY PANELS
FUEL-FILLER LID REMOVAL/INSTALLATION[EVEREST]
id0910008001z2
1 Fuel-filler lid
2 Lift spring

5. Adjust the fuel-filler lid. (See 09-10-2 FUEL-
FILLER LID ADJUSTMENT[EVEREST].)
End Of Sie
GREASE
1
2
arnffw00001747
FUEL-FILLER LID ADJUSTMENT[EVEREST]

id0910008002z2
1. Measure the gap and height between the fuel-filler lid and the body.
2. If not as specified, loosen the fuel-filler lid
installation bolts and reposition the fuel-filler lid.
A
a
Clearance
a: 3.5—5.5 mm {0.14—0.21 in}
b: -1.5—0.5 mm {-0.059—0.02 in}
3. Tighten the bolts. b

End Of Sie A
SEC. A—A
arnffw00001748
REAR BUMPER REMOVAL/INSTALLATION[EVEREST]

id0910008007z2
2. Disconnect the back-up light connector.
1 Screw
D
2 Bolt A
3 Bolt B
4 Rear bumper E 2 6.9—9.8
{71—99, 62—86}
(See 09-10-3 Rear Bumper Removal Note.)
B
A C
4. Install in the reverse order of removal. D
B E
3 6.9—9.8
A {71—99,
62—86}
C
2 6.9—9.8
1 {71—99, 62—86}
4 N·m {kgf·cm, in·lbf}
arnffw00001872
09-10–2
BODY PANELS
Rear Bumper Removal Note
1. Pull the rear bumper rearward to detach it from the bumper slider.
Caution
• If only one side of the rear bumper is detached from the bumper slider and the bumper falls, it
could be damaged. When detaching the rear bumper from the slider, secure the bumper so that it
does not fall.
End Of Sie
BUMPER SLIDER
REAR BUMPER
arnffw00001873
REAR BUMPER DISASSEMBLY/ASSEMBLY[EVEREST]

id0910008008z2
1 6.9—9.8
1 Bolt A {71—99,
6.9—9.8 2.0—2.9
2 Bolt B 2 62—86}
{21—29, 18—25}
{71—99,
3 Fastener 62—86} 4
4 Nut 5
5 Rear bumper (side)
6 Rear over fender
7 Rear bumper

End Of Sie
7
6 3
arnffw00001750
09
09-10–3
F198-10-05L(09-11).fm 1 ページ２００６年８月３日　木曜日　午前１１時１９分
DOORS AND LIFTGATE
09-11 DOORS AND LIFTGATE

DOOR LOCATION INDEX[EVEREST] . . 09-11–1 BACK DOOR REMOVAL/INSTALLATION
REAR DOOR REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-11–3
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-11–2 BACK DOOR DISASSEMBLY/ASSEMBLY
REAR DOOR DISASSEMBLY/ASSEMBLY　 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-11–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-11–2 BACK DOOR ADJUSTMENT
REAR DOOR ADJUSTMENT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-11–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-11–3
End of Toc
DOOR LOCATION INDEX[EVEREST]
WM: DOOR
id0911008066z2
arnffw00001758
1 Back door 2 Rear door

(See 09-11-3 BACK DOOR REMOVAL/ (See 09-11-2 REAR DOOR REMOVAL/
(See 09-11-4 BACK DOOR DISASSEMBLY/ (See 09-11-2 REAR DOOR DISASSEMBLY/
ASSEMBLY[EVEREST]) ASSEMBLY[EVEREST])
(See 09-11-4 BACK DOOR (See 09-11-3 REAR DOOR
ADJUSTMENT[EVEREST]) ADJUSTMENT[EVEREST])
End Of Sie
09
09-11–1
DOORS AND LIFTGATE

REAR DOOR REMOVAL/INSTALLATION[EVEREST]
id0911008003z2
2. To remove the checker, remove the rear door speaker.
17.6—29.4
1 Connector {1.80—2.99, 13.0—21.6}
5 3
2 Checker pin
3 Rear door
4 Checker
5 Rear door hinge
2
4. Install in the reverse order of removal. 1 4
5. Adjust the rear door. (See 09-11-3 REAR DOOR
ADJUSTMENT[EVEREST].)
End Of Sie
8.8—12.7 N·m
{90—129 kgf·cm, 79—112 in·lbf}
arnffw00001756
REAR DOOR DISASSEMBLY/ASSEMBLY[EVEREST]

id0911001139z2
6.9—9.8
1 Inner handle {71—99, 62—86}
2 Door screen A A
3 Rear power window regulator 4
4 Chan-center 5
5 Rear door glass 6
6 Glass run channel
7
3
7 Rear door quarter glass
8 Rear door lock knob 6.9—9.8
{71—99, 62—86}
9 Rear door lock
10 Outer handle 1
11 Side garnish 10
8
End Of Sie 11
4.2—6.2
{43—63, 38—54}
2.0—2.9
{21—29, 18—25}
6.9—9.8
2 9 {71—99, 62—86}
arnffw00001752
09-11–2
DOORS AND LIFTGATE

REAR DOOR ADJUSTMENT[EVEREST]
id0911008015z2
1. Measure the gap and height between the rear door and the body.
2. If not as specified, loosen the rear door hinge
installation bolts or the door lock striker A
A
installation screws, and reposition the door.
Clearance
B
a: 3.5—6.5 mm {0.14—0.25 in} B
b: -1.5—1.5 mm {-0.059—0.059 in} C
C
c: 3.0—7.0 mm {0.12—0.27 in}
d: 0.5—1.5 mm {0.020—0.059 in}
3. Tighten the bolts or screws.

End Of Sie
b d
c
a
SEC. A—A SEC. B—B SEC. C—C
arnffw00001757
BACK DOOR REMOVAL/INSTALLATION[EVEREST]

id0911001140z2
2. Disconnect the vehicle harness connector from the back door harness connector.
3. To remove the bolt B, remove the D-pillar trim. (RH side only)
3
1 Back door harness connector
2 Bolt A
3 Bolt B 5
4 Bolt C
5 Back door 17.6—29.4 17.6—29.4
6 Bolt D {1.80—2.99, 4 {1.80—2.99, 4
13.0—21.6} 13.0—21.6}
7 Stay
8 Bolt E
9 Hinge
1
6. Adjust the back door. (See 09-11-4 BACK DOOR 9
End Of Sie 8
32.5—48.5
{3.32—4.94,
24.0—35.7}
2 7
17.6—29.4 17.6—29.4
6 {1.80—2.99,
{1.80—2.99,
13.0—21.6} 13.0—21.6}

arnffw00001753
09
09-11–3
DOORS AND LIFTGATE

BACK DOOR DISASSEMBLY/ASSEMBLY[EVEREST]
id0911001141z2
1. Remove the back door lower trim.
2. To remove the back door outer handle and back door key cylinder, remove the back door garnish.
3. Disassemble in the order indicated in the table. .
6.9—9.8 N·m
5 {71—99 kgf·cm,
62—86 in·lbf}
SCREW
A 11 32.4—48.5
B {3.31—4.94, 23.9—35.7}
4 D
2 6.9—9.8 N·m
{71—99 kgf·cm,
62—86 in·lbf}
6
A 7 9
12 10 62.7—93.1
8
B 3 {6.40—9.49,
46.3—68.6}
D C 1 N·m {kgf·m, ft·lbf}
arnffw00001754
1 Connector 7 Retainer
2 Bolt A 8 Back door key cylinder
3 Back door latch and lock actuator 9 Nut B
4 Inner handle 10 Spare tire
5 Nut A 11 Bolt C
6 Back door outer handle 12 Spare tire carrier

End Of Sie
BACK DOOR ADJUSTMENT[EVEREST]
id0911001142z2
1. Measure the gap and height between the back door and the body.
2. If not as specified, loosen the back door hinge
installation bolts or the back door striker
installation screws, and reposition the back door.
Clearance
a: 5.5—8.5 mm {0.22—0.33 in} A A B
b: -2.6—0.4 mm {-0.10—0.01 in} B
c: 7.0—11.0 mm {0.28—0.43 in}
3. Tighten the bolts or screws.

End Of Sie
a c
SEC. A—A SEC. B—B
arnffw00001755
09-11–4
GLASS/WINDOWS/MIRRORS
09-12 GLASS/WINDOWS/MIRRORS
GLASS/WINDOWS/MIRRORS LOCATION SIDE WINDOW GLASS REMOVAL
REAR DOOR GLASS SIDE WINDOW GLASS INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-12–2 REAR WINDOW GLASS REMOVAL
REAR DOOR QUARTER GLASS [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-12–5
REMOVAL/INSTALLATION REAR WINDOW GLASS INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-12–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-12–6
End of Toc
GLASS/WINDOWS/MIRRORS LOCATION INDEX[EVEREST]
WM: GLASS/WINDOWS/MIRRORS
id0912008001z2
4
3
2
1
arnffw00001759
1 Rear window glass 3 Rear door quarter glass

(See 09-12-5 REAR WINDOW GLASS (See 09-12-2 REAR DOOR QUARTER GLASS
REMOVAL[EVEREST]) REMOVAL/INSTALLATION[EVEREST])
(See 09-12-6 REAR WINDOW GLASS 4 Side glass
INSTALLATION[EVEREST]) (See 09-12-3 SIDE WINDOW GLASS
2 Rear door glass REMOVAL[EVEREST])
(See 09-12-2 REAR DOOR GLASS REMOVAL/ (See 09-12-3 SIDE WINDOW GLASS
End Of Sie
09
09-12–1
REAR DOOR GLASS REMOVAL/INSTALLATION[EVEREST]
id0912008005z2
1. Fully lower the rear door glass.
2. Remove the rear door trim.
3. Partially peel back the door screen.
4. Remove the glass run channel from the rear door glass guide.
5. Remove the screw.
6. Remove the bolt, then remove the rear door glass
guide.
SCREW
GLASS
RUN CHANNEL
BOLT CHAN-CENTER
6.9—9.8 N·m
{71—99 kgf·m,
62—86 ft·lbf}
arnffw00001760
7. Raise or lower the rear door glass so that the part

connected to the rear door regulator is visible.
8. Detach the connecting part.
9. Insert your hand through the inside of the rear REAR
door and lift out the rear door glass. DOOR GLASS
End Of Sie
REAR
DOOR GLASS
REAR
DOOR REGULATOR
arnffw00001761
REAR DOOR QUARTER GLASS REMOVAL/INSTALLATION[EVEREST]

id0912008072z2
2. Remove the rear door trim.
3. Remove the rear door glass guide. (See09-12-2 REAR DOOR GLASS REMOVAL/
4. Remove the rear door quarter glass.
End Of Sie
GLASS
RUN CHANNEL
REAR DOOR
QUARTER GLASS
arnffw00001776
09-12–2
SIDE WINDOW GLASS REMOVAL[EVEREST]
id0912008038z2
1. Remove the C-pillar trim.
2. Apply protective tape along the edge of the body to protect it from damage.
3. Avoiding pins and spacers, make a hole through SPACER R
the sealant from the inside of the vehicle using an R
awl. SPACER
PIN
SPACER
PIN
R
SPACER R
arnffw00001769
4. Pass the SST (piano wire) through the hole.

49 0305 870A PROTECTIVE
Warning TAPE
• Using a SST (piano wire) with bare hands
can cause injury. Always wear gloves
when using a SST (piano wire).
5. Wind each end of the SST (piano wire) around a

bar.
SEALANT
Note
• Use a long sawing action to spread the work
arnffw00001770
over the whole length of the SST (piano
wire) to prevent it from breaking.
6. Working with another person, saw through the

sealant around the edge of the glass.
7. Remove the side window glass.
End Of Sie
49 0305 870A
arnffw00001771
SIDE WINDOW GLASS INSTALLATION[EVEREST]

id0912008039z2
Caution
• Proper installation of the side window glass may be difficult if sealant is cracked or the glass is
pushed out by air pressure when a door is opened/closed with all the windows closed. Leave all
the windows open until the side window glass is installed completely.
1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around
the circumference of the frame.
Warning 09
• Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approx. 30 min to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
3. Clean and degrease an approx. 50.0 mm {1.97 in} wide strip around the circumference of the glass and the
bonding area on the body.
09-12–3
F198-10-05L(09-12).fm 4 ページ２００６年８月３日　木曜日　午後２時６分
4. Insert the spacers into the body.
SPACER
SPACER
SPACER
0—2.0
{0—0.08} -5.0—5.0
{-0.19—0.19}
SPACER
GLASS END LINE mm {in}
arnffw00001772
5. Use only glass primer on the glass, and body

primer on the body and the molding. Allow it to
dry for approx. 30 min.
B
SEC. A—A
Caution 9.5 9.0 B
• Keep the area free of dirt and grease, and {0.37} {0.35}*1 C
A
do not touch the surface. Otherwise, the A C
primer may not properly bond to the
surface of the glass and body, which may *2
cause leaks to occur. *1 D
13 {0.51}
D
SEC. B—B SEC. C—C SEC. D—D
8 .0 9.0 {0.35}*1 12.5
{0.31} {0.49} 9.0 *2
13 {0.35}*1
{0.51}*1
9.0 8 .0
{0.35}*1 5.0 {0.31}
13 13
{0.19}
*2 {0.51}*1 {0.51}*1
*1 : PRIMER APPLICATION AREA
*2 : POSSIBLE PRIMER APPLICATION AREA mm {in}
arnffw00001773
6. Apply sealant to the areas of the glass surface as

B
shown in the figure.
SEC. A—A B
14 A C
{0.55} 5.0 A C
{0.19}
D
D
SEC. B—B SEC. C—C SEC. D—D

5.0
12.5 17 5.0
{0.19}
{0.49} {0.67} {0.19}
5.0 12.5
{0.19} {0.49}
mm {in}
arnffw00001774
09-12–4
7. Set the side window glass in place and insert the
pins into the body. Install the side window glass.
8. Allow the sealant to harden completely. PIN
Sealant hardening time: 24 h
End Of Sie
PIN
arnffw00001775
REAR WINDOW GLASS REMOVAL[EVEREST]

id0912008015z2
2. Apply protective tape along the edge of the body to protect it from damage.
3. Avoiding pins and spacers, make a hole through
the sealant from the inside of the vehicle using an CENTER
awl.
R R
SPACER SPACER
PIN
arnffw00001762
4. Pass the SST (piano wire) through the hole.

49 0305 870A
Warning
• Using a SST (piano wire) with bare hands PROTECTIVE
can cause injury. Always wear gloves TAPE
when using a SST (piano wire).
5. Wind each end of the SST (piano wire) around a

bar.
SEALANT
Note
• Use a long sawing action to spread the work
arnffw00001763
over the whole length of the SST (piano
wire) to prevent it from breaking.
6. Working with another person, saw through the

sealant around the edge of the glass.
7. Remove the rear window glass.
8. Remove the spacers and pins from the glass.
End Of Sie
49 0305 870A
09
arnffw00001764
09-12–5
REAR WINDOW GLASS INSTALLATION[EVEREST]
id0912008016z2
Caution
• Proper installation of the rear window glass may be difficult if sealant is cracked or the glass is
pushed out by air pressure when a door is opened/closed with all the windows closed. Leave all
the windows open until the rear window glass is installed completely.
1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around
the circumference of the frame.
Warning
• Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approx. 30 min to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
3. Clean and degrease an approx. 50.0 mm {1.97 in} wide strip around the circumference of the glass and the
bonding area on the body.
4. Alien the bottoms of the spacers with the marks, CENTER
then attach the spacers. MARK
Caution
• Keep the area free of dirt and grease, and
do not touch the surface. Otherwise, the MARK
primer may not properly bond to the
surface of the glass and body, which may
cause leaks to occur.
MARK
GLASS END LINE
SPACER
0—2.0
{0—0.08}
-5.0—5.0
{-0.19—0.19} mm {in}
arnffw00001765
5. Use only glass primer on the glass, and body CENTER

primer on the body. Allow it to dry for approx. 30 A R START 8.0 {0.31}
min.
A 9.5
13.0 {0.37}*1
{0.51}*1
C R START
C *2
B SEC. A—A
B
9.0 {0.35}*1
9.0 {0.35}*1
R START 25.0 {0.98} *2
8.0 {0.31}
13.0
{0.51}*1
R START R START
6.33 {0.25}
SEC. B—B
*2
13.0 {0.51}*1 *1 : PRIMER APPLICATION AREA
SEC. C—C *2 : POSSIBLE PRIMER APPLICATION AREA mm {in}
arnffw00001766
09-12–6
6. After the primer has dried, apply 11.0 mm {0.43
CENTER 12.5 {0.49}
in} thickness, 4—6 mm {0.16—0.23 in} width of A
sealant to the areas of the glass surface as shown
in the figure. A
7. Set the position of the rear window glass and
insert the pins into the body. Install the glass. C
C SEC. A—A
B
B 12.5 {0.49}
SEC. B—B
29.0 {1.14}
SEC. C—C mm {in}
arnffw00001767
8. Verify that the gap between the glass and the

GLASS END LINE CENTER
body is 2.0—6.0 mm {0.08—0.23 in} at the top A
and the bottom and is 5.0—9.0 mm {0.19—0.35
5.0—9.0
in} at the D-pillar. {0.19—0.35}
A
9. Press firmly inward on the glass to compress the
sealant.
10. Install the back door lower trim.
11. Allow the sealant to harden completely. B
Sealant hardening time: 24 h B

2.0—6.0
End Of Sie {0.08—0.23}
2.0—6.0
{0.08—0.23}
SEC. A—A SEC. B—B

mm {in}
arnffw00001768
09
09-12–7
F198-10-05L(09-13).fm 1 ページ２００６年８月３日　木曜日　午前１１時２０分
SEATS
09-13 SEATS
SEAT LOCATION INDEX THIRD-ROW SEAT
SECOND-ROW SEAT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-13–3
REMOVAL/INSTALLATION THIRD-ROW SEAT
SECOND-ROW SEAT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-13–3
DISASSEMBLY/ASSEMBLY
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-13–2
End of Toc
SEAT LOCATION INDEX[EVEREST]
WM: SEATS
id0913008025z2
2 1
arnffw00001779
1 Third-row seat 2 Second-row seat

(See 09-13-3 THIRD-ROW SEAT REMOVAL/ (See 09-13-2 SECOND-ROW SEAT REMOVAL/
(See 09-13-3 THIRD-ROW SEAT DISASSEMBLY/ (See 09-13-2 SECOND-ROW SEAT
ASSEMBLY[EVEREST]) DISASSEMBLY/ASSEMBLY[EVEREST])
End Of Sie
09
09-13–1
SEATS
SECOND-ROW SEAT REMOVAL/INSTALLATION[EVEREST]
id0913008027z2
1. Move headrest to the lowest position.
2. Releasing Recliner lever, fold the seat back to
forward.
3. Tumble second-row seat to forward.
RECLINER
LEVER
arnffw00001782
4. Remove the bolts and remove the second-row

seat.
End Of Sie
BOLT
34.3—63.7
BOLT {3.50—6.49,
34.3—63.7 25.3—70.9}
{3.50—6.49,
25.3—70.9} N·m {kgf·m, ft·lbf}
arnffw00001783
SECOND-ROW SEAT DISASSEMBLY/ASSEMBLY[EVEREST]

id0913008026z2
1. Disassemble in the order indicated in the table. . 1
1 Headrest 7
2 Recliner lever
3 Side cover 6
4 Recliner knuckle 38—78
5 Reverse cover {3.9—7.9,
29—57} 8
6 Pole guide 36—54 C
7 Seat back trim {3.7—5.5,
27—39}
10
8 Seat back pad
9 Seat under bracket
13 B
14
10 Seat cushion trim C 15.7—22.5
11 Seat cushion pad {1.61—2.29, A
11.6—16.5}
12 Seat cushion frame 36—54
11
13 Second-row buckle {3.7—5.5, 5
27—39} 4
14 latch
3 B 36—54
2. Assemble in the reverse order of disassembly. 12 A {3.7—5.5,
End Of Sie 9 27—39}
15.7—22.5 2.5—3.5 N·m

{1.61—2.29, {26—35 kgf·cm,
23—30 in·lbf} 2 N·m {kgf·m, ft·lbf}
11.6—16.5}
arnffw00001781
09-13–2
SEATS
THIRD-ROW SEAT REMOVAL/INSTALLATION[EVEREST]
id0913008029z2
Detachable Type
1. Releasing rear cushion lock by operating the rear REAR LOCK LEVER
lock lever, tumble seat to forward.
FRONT LOCK
2. Releasing front lock by operating the front lock
LEVER
lever.
3. Lift the third-row seat to upward and then remove
from the floor.
End Of Sie
THIRD-ROW SEAT
arnffw00001787
THIRD-ROW SEAT DISASSEMBLY/ASSEMBLY[EVEREST]

id0913008028z2
2. Assemble in the reverse order of disassembly. .
36—54 6 4
{3.7—5.5, 3 3 2 1
27—39}
5
2 9
10
11
8
7
7 15.7—22.5
15.7—22.5 {1.61—2.29,
{1.61—2.29, 11.6—16.5}
11.6—16.5} N·m {kgf·m, ft·lbf}
arnffw00001784
1 Lever 7 Front lock

2 Side cover 8 Leg
3 Bracket 9 Seat cushion trim
4 Seat back trim 10 Seat cushion pad
5 Seat back pad 11 Seat cushion frame
6 Seat back frame
End Of Sie
09
09-13–3
F198-10-05L(09-14).fm 1 ページ２００６年８月３日　木曜日　午前１１時２１分
SECURITY AND LOCKS
09-14 SECURITY AND LOCKS

BACK DOOR LOCK ACTUATOR FUEL-FILLER LID OPENER SWITCH
INSPECTION[EVEREST] . . . . . . . . . . . 09-14–1 REMOVAL/INSTALLATION
BACK DOOR LOCK-LINK SWITCH [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-14–2
INSPECTION[EVEREST] . . . . . . . . . . . 09-14–1 FUEL-FILLER LID OPENER SWITCH
BACK DOOR KEY CYLINDER SWITCH INSPECTION[EVEREST] . . . . . . . . . . . . 09-14–2
INSPECTION[EVEREST] . . . . . . . . . . . 09-14–1 FUEL-FILLER LID AND OPENER
FUEL-FILLER LID AND OPENER REMOVAL/INSTALLATION
INSPECTION[EVEREST] . . . . . . . . . . . 09-14–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-14–3
End of Toc
BACK DOOR LOCK ACTUATOR INSPECTION[EVEREST]
WM: SECURITY AND LOCKS
id0914001143z2
1. Apply battery positive voltage to the back door
lock actuator terminals and inspect the operation WITHOUT THEFT-DETERRENT
UNLOCK LOCK SYSTEM
of the back door lock actuator. M
• If not as specified, replace the back door lock
A B
actuator.
Terminal WITH THEFT-DETERRENT
Operation SYSTEM
A B
Lock GND B+
A C
Unlock B+ GND
B D
A B
End Of Sie
arnffw00001789
BACK DOOR LOCK-LINK SWITCH INSPECTION[EVEREST]

id0914001144z2
1. Inspect for continuity between the back door lock-
link switch terminals using a tester. D
• If not as specified, replace the back door lock-
link switch.
A C
UNLOCK LOCK
B D
: Continuity : Resistance
Key cylinder Terminal

position D C
Neutral C
Lock arnffw00001790
Unlock
arnffw00001791
End Of Sie
BACK DOOR KEY CYLINDER SWITCH INSPECTION[EVEREST]
id0914001145z2
1. Inspect for continuity between the back door key
cylinder switch terminals using a tester. B
• If not as specified, replace the back door key
cylinder switch.
B A
: Continuity : Resistance UNLOCK LOCK
Key cylinder Terminal 09

position A B
Neutral
A
Lock R
arnffw00001792
Unlock
R: 950—1050 ohm
arnffw00001793
End Of Sie
09-14–1
SECURITY AND LOCKS

FUEL-FILLER LID AND OPENER INSPECTION[EVEREST]
id0914001147z2
1. Connect battery positive voltage to terminal A and ground to terminal B of the fuel-filler lid opener connector.
2. Verify that the fuel-filler lid opener operates.
• If not as specified, replace the fuel-filler lid A
opener.
A
B
: Continuity
Terminal
Fuel-filler lid operation
A B
OPEN B
CLOSE arnffw00001794
arnffw00001795
End Of Sie
FUEL-FILLER LID OPENER SWITCH REMOVAL/INSTALLATION[EVEREST]
id0914001148z2
1 Fuel-filler lid opener switch
2 Connector

TAB
End Of Sie
1
arnffw00001886
FUEL-FILLER LID OPENER SWITCH INSPECTION[EVEREST]

id0914001149z2
1. Inspect for continuity between the fuel-filler lid
opener switch terminals. D
• If not as specified, replace the fuel-filler lid * *
opener switch.
* F D *
: Continuity
Terminal
Switch position
D F
F
ON
arnffw00001797
OFF
arnffw00001798
End Of Sie
09-14–2
SECURITY AND LOCKS

FUEL-FILLER LID AND OPENER REMOVAL/INSTALLATION[EVEREST]
id0914008118z2
1 Lift spring
2 Connector
3 Fuel-filler lid opener

5. Adjust the fuel-filler lid.
End Of Sie
2
3
1
arnffw00001799
09
09-14–3
F198-10-05L(09-16).fm 1 ページ２００６年８月３日　木曜日　午前１１時２２分
EXTERIOR TRIM
09-16 EXTERIOR TRIM

EXTERIOR TRIM LOCATION INDEX ROOF RAIL REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-16–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
BACK DOOR GARNISH REAR BELTLINE MOLDING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-16–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
OVER FENDER EXTRACTOR CHAMBER
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-16–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
REAR SPOILER ROOF MOLDING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-16–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
End of Toc
EXTERIOR TRIM LOCATION INDEX[EVEREST]
WM: EXTERIOR TRIM
id0916008001z2
7
2 1
4
arnffw00001921
1 Roof rail 5 Over fender

(See 09-16-3 ROOF RAIL REMOVAL/ (See 09-16-2 OVER FENDER REMOVAL/
2 Rear spoiler 6 Rear beltline molding
(See 09-16-2 REAR SPOILER REMOVAL/ (See 09-16-3 REAR BELTLINE MOLDING
INSTALLATION[EVEREST]) REMOVAL/INSTALLATION[EVEREST])
3 Back door garnish 7 Roof molding
(See 09-16-2 BACK DOOR GARNISH REMOVAL/ (See 09-16-3 ROOF MOLDING REMOVAL/
4 Extractor chamber
(See 09-16-3 EXTRACTOR CHAMBER REMOVAL/
End Of Sie 09
09-16–1
EXTERIOR TRIM
BACK DOOR GARNISH REMOVAL/INSTALLATION[EVEREST]
id0916001150z2
2. Remove the nuts. 2.0—2.9
LICENSE LIGHT
3. Disconnect the license light connector. NUT CONNECTOR {21—29,
4. Remove the back door garnish. 2.0—2.9 18—25}
5. Install in the reverse order of removal. {21—29,
18—25}
End Of Sie
NUT
6.9—9.8
{71—99,
62—86}
BACK DOOR GARNISH N·m {kgf·cm, in·lbf}

arnffw00001800
OVER FENDER REMOVAL/INSTALLATION[EVEREST]

id0916008201z2
1. Remove the screws.
2. Pull the over fender outward, then detach clips A
from the body. OVER FENDER
End Of Sie A
A
CLIP A A
SCREW
arnffw00001808
REAR SPOILER REMOVAL/INSTALLATION[EVEREST]

id0916008016z2
1. Remove the headliner.
2. Remove the screws.
3. Disconnect the high-mount brake light connector.
4. Remove the rear spoiler. SCREW
End Of Sie
REAR SPOILER
HIGH-MOUNT BRAKE
LIGHT CONNECTOR
arnffw00001804
09-16–2
EXTERIOR TRIM
ROOF RAIL REMOVAL/INSTALLATION[EVEREST]
id0916008062z2
1. Remove the headliner.
2. Remove the rear spoiler. (vehicles with rear spoiler)
3. Remove the nuts.
4. Pull the roof rail upward, then remove the roof rail
ROOF RAIL
from the body.
5. Install in the reverse order of removal. 6.9—9.8
{71—99,
End Of Sie 62—86}
NUT
6.9—9.8
{71—99,
62—86}
arnffw00001807
REAR BELTLINE MOLDING REMOVAL/INSTALLATION[EVEREST]

id0916008047z2
2. Pull the end of rear beltline molding to detach
REAR BELTLINE MOLDING
tabs A.
3. Pull the rear beltline molding upward, remove
tabs B, then remove the rear beltline molding.
4. Install in the reverse order of removal. A B B B A
End Of Sie
FRONT
TAB A TAB B
arnffw00001805
EXTRACTOR CHAMBER REMOVAL/INSTALLATION[EVEREST]

id0916008015z2
1. Remove the rear bumper.
2. Remove the screws, then remove the extractor
chamber.
End Of Sie
SCREW
EXTRACTOR
CHAMBER
arnffw00001803
ROOF MOLDING REMOVAL/INSTALLATION[EVEREST]

id0916008058z2
1. Pull the rear edge of the roof molding upward, A
A
detach tabs A, then remove the roof molding. ROOF MOLDING
2. Install in the reverse order of removal. A
End Of Sie A
ROOF MOLDING
09
BODY
FRONT
TAB A
arnffw00001806
09-16–3
F198-10-05L(09-17).fm 1 ページ２００６年８月３日　木曜日　午前１１時２３分
INTERIOR TRIM
09-17 INTERIOR TRIM

INTERIOR TRIM LOCATION INDEX TIRE HOUSE TRIM
OVERHEAD CONSOLE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–4
REMOVAL/INSTALLATION REAR END TRIM
REAR SCUFF PLATE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–5
REMOVAL/INSTALLATION BACK DOOR UPPER TRIM
C-PILLAR TRIM REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–5
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-17–3 BACK DOOR SIDE TRIM
D-PILLAR TRIM REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-17–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–5
REAR DOOR TRIM BACK DOOR LOWER TRIM
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-17–4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–5
REAR SIDE TRIM HEADLINER REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-17–4 FLOOR COVERING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-17–7
End of Toc
WM: INTERIOR TRIM
09
09-17–1
INTERIOR TRIM
INTERIOR TRIM LOCATION INDEX[EVEREST]
id0917008002z2
13
1 2 3 4 5 6
9
10
12 11
arnffw00001816
1 Rear door trim 8 Back door lower trim

(See 09-17-4 REAR DOOR TRIM REMOVAL/ (See 09-17-5 BACK DOOR LOWER TRIM
INSTALLATION[EVEREST]) REMOVAL/INSTALLATION[EVEREST])
2 Headliner 9 Rear end trim
(See 09-17-6 HEADLINER REMOVAL/ (See 09-17-5 REAR END TRIM REMOVAL/
3 C-pillar trim 10 Floor covering
(See 09-17-3 C-PILLAR TRIM REMOVAL/ (See 09-17-7 FLOOR COVERING REMOVAL/
4 Rear side trim 11 Tire house trim
(See 09-17-4 REAR SIDE TRIM REMOVAL/ (See 09-17-4 TIRE HOUSE TRIM REMOVAL/
5 D-pillar trim 12 Rear scuff plate
(See 09-17-3 D-PILLAR TRIM REMOVAL/ (See 09-17-3 REAR SCUFF PLATE REMOVAL/
6 Back door upper trim 13 Overhead console
(See 09-17-5 BACK DOOR UPPER TRIM (See 09-17-2 OVERHEAD CONSOLE REMOVAL/
REMOVAL/INSTALLATION[EVEREST]) INSTALLATION[EVEREST])
7 Back door side trim
(See 09-17-5 BACK DOOR SIDE TRIM REMOVAL/
End Of Sie
OVERHEAD CONSOLE REMOVAL/INSTALLATION[EVEREST]
id0917001151z2
1. Remove the fasteners, then remove the overhead
console.
End Of Sie
OVERHEAD
CONSOLE
FASTENER
arnffw00001809
09-17–2
INTERIOR TRIM
REAR SCUFF PLATE REMOVAL/INSTALLATION[EVEREST]
id0917008015z2
1. Remove the screw.
2. Pull the rear scuff plate upward, then detach clips REAR SCUFF PLATE
CLIP A
A and pins B from the body. SCREW
End Of Sie A A
B B
PIN B A
arnffw00001817
C-PILLAR TRIM REMOVAL/INSTALLATION[EVEREST]

id0917008022z2
1. Remove the D-pillar trim.
2. Remove the upper anchor of the second-row seat belt installation bolt.
3. Partially peel back the seaming welt.
4. Remove the fasteners. RH A A A
5. Pull the C-pillar trim outward, then detach clips A A A PIN B
and pin B from the body. B
6. Remove the C-pillar trim. A
C-PILLAR TRIM
End Of Sie
CLIP A
A A
FASTENER
LH
A A A A A PIN B
B
A
C-PILLAR TRIM
A CLIP A
FASTENER FASTENER
arnffw00001819
D-PILLAR TRIM REMOVAL/INSTALLATION[EVEREST]

id0917008023z2
2. Remove the upper anchor of the third-row seat belt installation bolt.
3. Remove the fastener.
4. Pull the D-pillar trim outward, then detach clips A A B
and pin B from the body. A A D-PILLAR TRIM
5. Remove the D-pillar trim.
End Of Sie A
A
CLIP A PIN B
09
FASTENER
arnffw00001820
09-17–3
F198-10-05L(09-17).fm 4 ページ２００６年８月３日　木曜日　午後２時１２分
INTERIOR TRIM
REAR DOOR TRIM REMOVAL/INSTALLATION[EVEREST]
id0917008026z2
2. Disconnect the negative battery cable. INNER HANDLE
3. Remove the inner handle cover. COVER A
4. Remove screw. CLIP A
5. Detach clips A from the rear door using a fastener
A
remover.
6. Disconnect the power window subswitch A
A
connector.
7. Remove the rear door trim. A REAR DOOR TRIM
A
End Of Sie A A
arnffw00001887
REAR SIDE TRIM REMOVAL/INSTALLATION[EVEREST]

id0917008060z2
2. Remove the rear end trim.
3. Remove the tire house trim.
4. Pull the rear side trim outward, then detach clips RH
A and pin B from the body. REAR SIDE TRIM
6. Install in the reverse order of removal. A A BA
A
End Of Sie A
A A
A A
A
A
LH
REAR SIDE TRIM
A
A BA
A A A
A
A A
CLIP A PIN B
A
A
arnffw00001824
TIRE HOUSE TRIM REMOVAL/INSTALLATION[EVEREST]

id0917008027z2
1. Remove the rear scuff plate.
2. Pull the tire house trim outward, then detach clip
A from the body. TIRE HOUSE TRIM CLIP A
3. Detach the connecting part from the body, then A
remove the tire house trim.
End Of Sie TIRE
HOUSE TRIM
arnffw00001822
09-17–4
INTERIOR TRIM
REAR END TRIM REMOVAL/INSTALLATION[EVEREST]
id0917001152z2
1. Pull the rear end trim upward, then detach clips A
and pins B from the body. REAR END TRIM
2. Remove the rear end trim.
3. Install in the reverse order of removal. BA
A
End Of Sie AB
A
A B
PIN B
CLIP A
arnffw00001810
BACK DOOR UPPER TRIM REMOVAL/INSTALLATION[EVEREST]

id0917001153z2
1. Pull the back door upper trim outward, then
detach clips A and pin B from the body. BACK DOOR UPPER TRIM CLIP A
2. Remove the back door upper trim.
A
End Of Sie A A A
A B A
A A
A
PIN B
arnffw00001811
BACK DOOR SIDE TRIM REMOVAL/INSTALLATION[EVEREST]

id0917001154z2
1. Remove the back door upper trim.
2. Remove the fastener.
3. Pull the back door side trim outward, then detach FASTENER
clips A and pin B from the body. CLIP A
4. Remove the back door side trim.
End Of Sie B
A BACK DOOR
SIDE TRIM
A
PIN B
arnffw00001813
BACK DOOR LOWER TRIM REMOVAL/INSTALLATION[EVEREST]

id0917001155z2
1. Remove the back door side trim.
2. Open the cover using a tape-wrapped flathead
small screwdriver.
09
arnffw00001814
09-17–5
INTERIOR TRIM
3. Remove screws A, then remove the handle.
SCREW A
4. Remove screw B, then remove the inner handle
cover.
5. Pull the back door lower trim outward, then BACK DOOR
HANDLE
detach clips A and pins B from the body. LOWER TRIM
A
End Of Sie B A A A
B A
A A
A
A A
A
A
SCREW B INNER CLIP A PIN B

HANDLE
COVER
arnffw00001815
HEADLINER REMOVAL/INSTALLATION[EVEREST]
id0917008016z2
2. Partially peel back the seaming welt and weatherstrip.
3. Remove the D-pillar trims.
4. Remove the C-pillar trims.
5. Remove the B-pillar upper trims.
6. Remove the A-pillar trims.
7. Remove the interior and map light. (See 09-18-4 INTERIOR AND MAP LIGHT REMOVAL/
8. Remove the cargo compartment light. (See 09-18-6 CARGO COMPARTMENT LIGHT REMOVAL/
9. Remove the sunvisors.
10. Remove the overhead console.
11. Remove the assist handles.
12. Remove the ventilator grilles.
13. Remove the rear fan switch.
14. Remove the fasteners.
15. Remove the front headliner.
REAR HEADLINER
16. Remove the rear headliner.
17. Take the headliner out through the back door.
End Of Sie
FASTENER
FRONT HEADLINER
arnffw00001818
09-17–6
INTERIOR TRIM
FLOOR COVERING REMOVAL/INSTALLATION[EVEREST]
id0917008030z2
2. Remove the front seats.
3. Remove the second-row seats.
5. Remove the front scuff plates.
6. Remove the rear scuff plates.
8. Remove the front side trims.
9. Remove the B-pillar lower trims.
10. Remove the lower anchor of the front seat belt installation bolts.
11. Remove the lower anchor of the rear second-row seat belt installation bolts.
12. Remove the lower anchor of the rear third-row seat belt installation bolts.
13. Remove the rear side trims.
14. Remove the tire house trims.
15. Remove the fasteners.
16. Remove the front floor covering and rear floor
covering. FASTENER
17. Take the front floor covering and rear floor
covering out through the back door.
End Of Sie
FRONT FLOOR
COVERING
REAR FLOOR
COVERING
arnffw00001823
09
09-17–7
F198-10-05L(09-18).fm 1 ページ２００６年８月３日　木曜日　午前１１時２４分
LIGHTING SYSTEMS
09-18 LIGHTING SYSTEMS

LIGHTING SYSTEMS LOCATION INDEX INTERIOR AND MAP LIGHT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–1 INSPECTION[EVEREST] . . . . . . . . . . . . 09-18–5
REAR COMBINATION LIGHT REAR MAP LIGHT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-18–5
HIGH-MOUNT BRAKE LIGHT CARGO COMPARTMENT LIGHT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-18–6
LICENSE PLATE LIGHT CARGO COMPARTMENT LIGHT
REMOVAL/INSTALLATION INSPECTION[EVEREST] . . . . . . . . . . . . 09-18–6
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–3 BACK DOOR SWITCH
BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–4 BACK DOOR SWITCH INSPECTION
INTERIOR AND MAP LIGHT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-18–7
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-18–4
End of Toc
LIGHTING SYSTEMS LOCATION INDEX[EVEREST]
WM: LIGHTING SYSTEMS
id0918008001z2
EXTERIOR
4
arnffw00001834
1 High-mount brake light 3 License plate light

(See 09-18-3 HIGH-MOUNT BRAKE LIGHT (See 09-18-3 LICENSE PLATE LIGHT REMOVAL/
REMOVAL/INSTALLATION[EVEREST].) INSTALLATION[EVEREST].)
2 Rear combination light 4 Back-up light
(See 09-18-2 REAR COMBINATION LIGHT (See 09-18-4 BACK-UP LIGHT SWITCH
REMOVAL/INSTALLATION[EVEREST].) REMOVAL/INSTALLATION[EVEREST].)
09
09-18–1
LIGHTING SYSTEMS
INTERIOR
7
6
arnffw00001885
5 Cargo compartment light 7 Back door switch

(See 09-18-6 CARGO COMPARTMENT LIGHT (See 09-18-7 BACK DOOR SWITCH REMOVAL/
(See 09-18-6 CARGO COMPARTMENT LIGHT (See 09-18-7 BACK DOOR SWITCH
INSPECTION[EVEREST].) INSPECTION[EVEREST].)
6 Interior and map light 8 Rear map light
(See 09-18-4 INTERIOR AND MAP LIGHT (See 09-18-5 REAR MAP LIGHT REMOVAL/
(See 09-18-5 INTERIOR AND MAP LIGHT (See 09-18-5 REAR MAP LIGHT REMOVAL/
INSPECTION[EVEREST].) INSTALLATION[EVEREST].)
End Of Sie
REAR COMBINATION LIGHT REMOVAL/INSTALLATION[EVEREST]
id0918008010z2
1 4
1 Screw
2 Rear combination light 2
3 Connector
4 Socket 5
5 Rear turn light bulb 3
6 Brake light/taillight bulb

End Of Sie 6
arnffw00001837
09-18–2
LIGHTING SYSTEMS
HIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATION[EVEREST]
id0918008020z2
2. Remove the rear spoiler.
1 Connector
2 Screw
3 Cover
4 High-mount brake light (See 09-18-3 High-Mount
Brake Light Removal Note.)
4
3
1
2
arnffw00001843
High-Mount Brake Light Removal Note

1. Tie a string to the end of the connector of the
high-mount brake light beforehand so that the REAR SPOILER
connector can be passed easily through the rear
spoiler during installation.
End Of Sie

HARNESS
TIE
arnffw00001844
LICENSE PLATE LIGHT REMOVAL/INSTALLATION[EVEREST]

id0918008011z2
2. Remove the back door garnish.
1 Connector 1
2 Screw
3 License plate light
4 Lens
5 License plate light bulb

End Of Sie
5
3 4
2
arnffw00001838
09
09-18–3
LIGHTING SYSTEMS
BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION[EVEREST]
id0918008002z2
1 Screw
2 Connector
3 Back-up light
4 Socket
5 Back-up light bulb

End Of Sie
2
4
5
3
1
arnffw00001836
INTERIOR AND MAP LIGHT REMOVAL/INSTALLATION[EVEREST]

id0918001156z2
6
1 Lens
(See 09-18-4 Lens Removal Note.)
2 Interior light bulb
3 Map light bulb 5
4 Screw
5 Interior and map light
2 3
6 Connector
4
arnffw00001826
Lens Removal Note

1. Insert a tape-wrapped flathead screwdriver into the lens hole.
2. Twist the screwdriver to remove the lens.
End Of Sie
SERVICE HOLE
arnffw00001827
09-18–4
LIGHTING SYSTEMS
INTERIOR AND MAP LIGHT INSPECTION[EVEREST]
id0918001157z2
1. Remove the interior and map light. (See 09-18-4 INTERIOR AND MAP LIGHT REMOVAL/
2. Inspect for continuity between the interior and
map light terminals using an ohmmeter.
interior and map light. B
: Bulb MAP MAP INTERIOR

LIGHT B A
LIGHT LIGHT
Terminal
Switch position
A B Body GND INTERIOR
MAP MAP LIGHT
Map light ON LIGHT LIGHT SWITCH
switch OFF SWITCH SWITCH
ON
ON OFF
Interior
DOOR
light DOOR
switch A
OFF
arnffw00001829
End Of Sie arnffw00001828
REAR MAP LIGHT REMOVAL/INSTALLATION[EVEREST]

id0918008105z2
1. Remove the rear fanswitch. (See 07-40-4 REAR FAN SWITCH REMOVAL/INSTALLATION[EVEREST].)
1 Lens
(See 09-18-5 Lens Removal Note)
2 Bulb
3 Rear fan switch 2
3
3. Install in the reverse order of removal/
1
2
arnffw00001879
Lens Removal Note

1. Insert a tape-wrapped flathead screwdriver into
the service hole and push it in the direction
indicated by the arrow, then remove the lens.
End Of Sie
SERVICE HOLE
arnffw00001881
09
09-18–5
LIGHTING SYSTEMS
CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION[EVEREST]
id0918008017z2
2. Remove in the order indicated in the table. 4
1 Lens
(See 09-18-5 Lens Removal Note.)
2 Cargo compartment light bulb
5
3 Screw
4 Connector 2
5 Cargo compartment light

1 3
arnffw00001839
Lens Removal Note

1. Insert a tape-wrapped flathead screwdriver into the lens hole.
2. Twist the screwdriver to remove the lens.
End Of Sie SERVICE HOLE
arnffw00001840
CARGO COMPARTMENT LIGHT INSPECTION[EVEREST]

id0918008018z2
1. Remove the cargo compartment light. (See 09-18-6 CARGO COMPARTMENT LIGHT REMOVAL/
2. Inspect for continuity between the cargo
compartment light terminals using an ohmmeter. B
B A
cargo compartment light.
ON OFF
: Bulb
Terminal DOOR
Switch position
A B Body GND
ON A
DOOR arnffw00001841
OFF
arnffw00001842
End Of Sie
09-18–6
LIGHTING SYSTEMS
BACK DOOR SWITCH REMOVAL/INSTALLATION[EVEREST]
id0918001158z2
1 Screw
2 Back door switch 3
3 Connector
2
End Of Sie
1
arnffw00001830
BACK DOOR SWITCH INSPECTION[EVEREST]

id0918001159z2
1. Remove the back door switch.
2. Inspect for continuity between back door switch
terminal A and a body ground using an
ohmmeter. A
back door switch. BODY GND
A
: Continuity
Terminal
Switch condition
A Body GND
arnffw00001832
Pressed
Released
arnffw00001833
End Of Sie
09
09-18–7
F198-10-05L(09-19).fm 1 ページ２００６年８月３日　木曜日　午前１１時２５分
WIPER/WASHER SYSTEM
09-19 WIPER/WASHER SYSTEM

WIPER/WASHER SYSTEM LOCATION REAR WIPER MOTOR INSPECTION
REAR WASHER TANK REAR WASHER MOTOR
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-19–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-19–5
REAR WIPER AND WASHER SWITCH REAR WASHER MOTOR INSPECTION
INSPECTION[EVEREST] . . . . . . . . . . . 09-19–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-19–5
REAR WIPER ARM AND BLADE REAR WASHER NOZZLE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-19–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-19–5
REAR WIPER ARM AND BLADE REAR WASHER NOZZLE
ADJUSTMENT[EVEREST] . . . . . . . . . . 09-19–3 ADJUSTMENT[EVEREST] . . . . . . . . . . 09-19–6
REAR WIPER MOTOR REAR WASHER HOSE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . 09-19–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . 09-19–6
End of Toc
WIPER/WASHER SYSTEM LOCATION INDEX[EVEREST]
WM: WIPER/WASHER SYSTEMS
id0919008001z2
1 7
3 4 5 6
arnffw00001848
1 Rear wiper arm and blade 4 Rear washer tank

(See 09-19-2 REAR WIPER ARM AND BLADE (See 09-19-2 REAR WASHER TANK REMOVAL/
(See 09-19-3 REAR WIPER ARM AND BLADE 5 Rear washer motor
ADJUSTMENT[EVEREST].) (See 09-19-5 REAR WASHER MOTOR REMOVAL/
2 Rear wiper motor INSTALLATION[EVEREST].)
(See 09-19-3 REAR WIPER MOTOR REMOVAL/ (See 09-19-5 REAR WASHER MOTOR
INSTALLATION[EVEREST].) INSPECTION[EVEREST].)
(See 09-19-4 REAR WIPER MOTOR 6 Rear washer hose
INSPECTION[EVEREST].) (See 09-19-6 REAR WASHER HOSE REMOVAL/
3 Rear washer nozzle INSTALLATION[EVEREST].)
(See 09-19-5 REAR WASHER NOZZLE REMOVAL/ 7 Rear wiper and washer switch
INSTALLATION[EVEREST].) (See 09-19-2 REAR WIPER AND WASHER
(See 09-19-6 REAR WASHER NOZZLE SWITCH INSPECTION[EVEREST].) 09
End Of Sie
09-19–1
WIPER/WASHER SYSTEM
REAR WASHER TANK REMOVAL/INSTALLATION[EVEREST]
id0919001160z2
1 Bolt
2 Connector
3 Washer hose
4 Washer tank 4

4.9—6.9
End Of Sie {50—70,
44—61}
1
4.9—6.9 1
{50—70,
44—61} 3 2 N·m {kgf·m, ft·lbf}
arnffw00001845
REAR WIPER AND WASHER SWITCH INSPECTION[EVEREST]

id0919008004z2
1. Remove the wiper and washer switch.
2. Inspect for continuity between the wiper and
washer switch terminals using an ohmmeter. N I
wiper and washer switch.
: Continuity ON
OFF R. WASH
Terminal
Switch position
I N H
R. WASH
R. WASH (Wiper and washer) H
ON (Wiper) * M * E C A
OFF * N L J H F D *
R. WASH (Washer)
arnffw00001877
End Of Sie arnffw00001876
REAR WIPER ARM AND BLADE REMOVAL/INSTALLATION[EVEREST]

id0919008012z2
1 Cap 5
2 Nut
4
3 Rear wiper arm
(See 09-19-3 Rear Wiper Arm Installation Note.)
4 Rear wiper blade 3
5 Rubber brush 1
5.89—9.81
2. Install in the reverse order of removal. {0.60—1.00,
3. Adjust the rear wiper arm and blade. (See 09-19- 4.35—7.23}
2
3 REAR WIPER ARM AND BLADE N·m {kgf·m, ft·lbf}
arnffw00001851
09-19–2
WIPER/WASHER SYSTEM
Rear Wiper Arm Installation Note
1. Clean the rear wiper arm connector shaft using a
wire brush before installing the rear wiper arm.
End Of Sie
REAR WIPER
ARM CONNECTOR
SHAFT
arnffw00001852
REAR WIPER ARM AND BLADE ADJUSTMENT[EVEREST]

id0919008013z2
1. Operate the rear wiper motor to set the wiper in the park position.
2. Set the rear wiper arm onto the ceramics end line.
End Of Sie
CERAMICS END LINE
69mm
{2.7in}
CERAMICS END LINE
arnffw00001853
REAR WIPER MOTOR REMOVAL/INSTALLATION[EVEREST]

id0919008014z2
2. Remove the rear wiper arm and blade. (See 09-19-2 REAR WIPER ARM AND BLADE REMOVAL/
4. Remove in the order indicated in the table. 3.92—6.86
4
{0.40—0.69,
1 Connector 2.89—5.05}
2 Bolt 2
3 Rear wiper motor
4 Outer bushing

6. Adjust the rear wiper arm and blade. (See 09-19-
3 REAR WIPER ARM AND BLADE 3.92—6.86 2
ADJUSTMENT[EVEREST].) {0.40—0.69,
2.89—5.05} 1
End Of Sie N·m {kgf·m, ft·lbf}
arnffw00001854
09
09-19–3
WIPER/WASHER SYSTEM
REAR WIPER MOTOR INSPECTION[EVEREST]
id0919008015z2
3. Disconnect the rear wiper motor connector.
4. Connect battery positive voltage to the rear wiper motor terminal A and the ground to a bare metal part of the
vehicle and the rear wiper motor terminal B.
5. Verify that the rear wiper motor operates.
6. Disconnect the ground to the terminal B while the
rear wiper is operating.
M
B A
AUTO STOP
SWITCH
B A
arnffw00001855
7. Verify that the rear wiper stops in the park

position.
• If not as indicated, replace the rear wiper
motor.
End Of Sie
M
B A
AUTO STOP
SWITCH
B A
arnffw00001856
09-19–4
WIPER/WASHER SYSTEM
REAR WASHER MOTOR REMOVAL/INSTALLATION[EVEREST]
id0919008026z2
2. Remove the rear washer tank.
2
1 Rear washer motor
2 Grommet
1
End Of Sie
arnffw00001860
REAR WASHER MOTOR INSPECTION[EVEREST]

id0919008027z2
2. Remove the rear washer tank.
3. Connect battery positive voltage to the terminal B and ground to the terminal A of the motor.
4. Verify that the rear washer motor operates.
• If the motor does not operate, replace the rear B
washer motor.
End Of Sie
M A
arnffw00001861
REAR WASHER NOZZLE REMOVAL/INSTALLATION[EVEREST]

id0919008022z2
3. Remove the rear wiper motor.
4. Remove the rear washer hose form the rear washer nozzle.
5. Squeeze the tabs of the rear washer nozzle.
6. Pull the rear washer nozzle out to remove it. WASHER HOSE
8. Adjust the rear washer nozzle. (See 09-19-6
REAR WASHER NOZZLE
End Of Sie
TAB
REAR WASHER NOZZLE
arnffw00001858
09
09-19–5
WIPER/WASHER SYSTEM
REAR WASHER NOZZLE ADJUSTMENT[EVEREST]
id0919008023z2
1. Insert a needle or an equivalent tool into the spray
hole of the rear washer nozzle and adjust the
nozzle direction as shown.
End Of Sie 27 {1.06}
88
163
{3.46}
{6.42}
REAR
25 {0.98} WASHER NOZZLE
mm {in}
arnffw00001859
REAR WASHER HOSE REMOVAL/INSTALLATION[EVEREST]

id0919008016z2
3. Remove the washer hose.
4. Install in the reverse order of removal. REAR
End Of Sie WASHER HOSE
arnffw00001857
09-19–6
09-22 INSTRUMENTATION/DRIVER INFO.

LOCATION INDEX WARNING AND FUEL GAUGE SENDER UNIT
INDICATOR SYSTEM[EVEREST]. . . . . 09-22–1 INSPECTION[EVEREST] . . . . . . . . . . . . 09-22–1
End of Toc
LOCATION INDEX WARNING AND INDICATOR SYSTEM[EVEREST]
WM: INSTRUMENTATION/DRIVER INFO
id0922001163z2
arnffw00001862
1 Fuel gauge sender unit

(See 09-22-1 FUEL GAUGE SENDER UNIT
INSPECTION[EVEREST].)
End Of Sie
FUEL GAUGE SENDER UNIT INSPECTION[EVEREST]
id0922008018z2
1. Move the float to the topmost and bottommost
positions, and verify that the resistance between
terminals A and B of the unit and the position of
the float are as indicated in the figure. 24.4 mm
• If they are not as indicated, replace the fuel {0.96 in}
gauge sender unit. TOPMOST 6—14 ohms
POSITION
End Of Sie ARM
FULCRUM
241.5 mm
*
A B {9.508 in}
144—162 ohms
BOTTOMMOST POSITION
arnffw00001863
09
09-22–1
F198-10-05(AI).fm 1 ページ２００６年８月１１日　金曜日　午前１０時３９分
ALPHABETICAL INDEX AI
SECTION
0–9 REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–45
4-WHEEL DRIVE LOCATION INDEX SHIFT MECHANISM
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–1 LOCATION INDEX. . . . . . . . . . . . . . . . . . . . . . . . . 05-14–1
4x4 CONTROL MODULE INSPECTION
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–3
4x4 CONTROL MODULE B
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–5 BACK DOOR ADJUSTMENT
4x4 CONTROL SYSTEM ON-BOARD [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–4
DIAGNOSIS [4x4 control module] . . . . . . . . . . . . . 03-02–2 BACK DOOR DISASSEMBLY/ASSEMBLY
4x4 CONTROL SYSTEM WIRING DIAGRAM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–4
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . 03-02–2 BACK DOOR GARNISH
4x4 CONTROL SYSTEM WIRING DIAGRAM REMOVAL/INSTALLATION
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . 03-03–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–2
4x4 SWITCH INSPECTION BACK DOOR KEY CYLINDER SWITCH
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–2 INSPECTION[EVEREST] . . . . . . . . . . . . . . . . . . . 09-14–1
4x4 SWITCH REMOVAL/INSTALLATION BACK DOOR LOCK ACTUATOR INSPECTION
[AT (5R55S)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-18–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-14–1
BACK DOOR LOCK-LINK SWITCH INSPECTION
A [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-14–1
BACK DOOR LOWER TRIM
REMOVAL/INSTALLATION[EVEREST] . . . . . . . . 09-17–5
A/C COMPRESSOR BACK DOOR REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [EVEREST]. . . . . . . . 07-11–4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–3
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2 BACK DOOR SIDE TRIM
ABS HU/CM INSPECTION REMOVAL/INSTALLATION
ABS LOCATION INDEX BACK DOOR SWITCH INSPECTION
ABS SYSTEM WIRING DIAGRAM BACK DOOR SWITCH
[4W-ABS (EVEREST)]. . . . . . . . . . . . . . . . . . . . . 04-02B–2 REMOVAL/INSTALLATION
ACCELERATOR PEDAL COMPONENT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–7
REMOVAL/INSTALLATION BACK DOOR UPPER TRIM
[WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . . . . . . . . 01-13B–1 REMOVAL/INSTALLATION
AFTER REPAIR PROCEDURE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–5
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–4 BACK-UP LIGHT SWITCH
AIR BLEEDING[EVEREST] . . . . . . . . . . . . . . . . . . . 04-11–3 REMOVAL/INSTALLATION[EVEREST] . . . . . . . . 09-18–4
AIR FILTER INSPECTION BASIC INSPECTION [5R55S] . . . . . . . . . . . . . . . . . 05-03–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2 BLOWER UNIT DISASSEMBLY/ASSEMBLY
AIR FILTER REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–2 BODY PANEL LOCATION INDEX
AIR PRESSURE TEST [5R55S] . . . . . . . . . . . . . . 05-13–10 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-10–1
AT RELAY INSPECTION [5R55S]. . . . . . . . . . . . . 05-13–38 BRAKE PEDAL REMOVAL/INSTALLATION
AT RELAY LOCATION [5R55S] . . . . . . . . . . . . . . 05-13–38 [AT]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–3
AUTOMATIC TRANSMISSION CONTROL BRAKE TECHNICAL DATA
SYSTEM WIRING DIAGRAM [5R55S] . . . . . . . . . 05-02–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-50–1
AUTOMATIC TRANSMISSION BRAKES SST[EVEREST] . . . . . . . . . . . . . . . . . . . . 04-60–1
CONTROL SYSTEM
WIRING DIAGRAM [5R55S] . . . . . . . . . . . . . . . . . 05-03–2
AUTOMATIC TRANSMISSION FLUID C
(ATF) INSPECTION [5R55S]. . . . . . . . . . . . . . . . 05-13–13
AUTOMATIC TRANSMISSION FLUID CALIPER (FRONT)
(ATF) REPLACEMENT [5R55S] . . . . . . . . . . . . . 05-13–16 DISASSEMBLY/ASSEMBLY
AUTOMATIC TRANSMISSION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–11 AI
LOCATION INDEX [5R55S] . . . . . . . . . . . . . . . . . 05-13–2 CARGO COMPARTMENT LIGHT INSPECTION
AUTOMATIC TRANSMISSION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–6
ON-BOARD DIAGNOSTIC CARGO COMPARTMENT LIGHT
FUNCTION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–3 REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–6
AI–1
ALPHABETICAL INDEX
CLUTCH COIL INSPECTION [5R55S]. . . . . . . . . . . 03-16–6 DTC P0775, P0778, P0964,
CONTROL VALVE BODY P0966, P0967 [5R55S] . . . . . . . . . . . . . . . . . . . . 05-02–32
INSTALLATION [5R55S] . . . . . . . . . . . . . . . . . . . 05-13–63 DTC P0791, P0794 [5R55S] . . . . . . . . . . . . . . . . . 05-02–34
CONTROL VALVE BODY DTC P0795, P0798, P0968,
REMOVAL [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-13–61 P0970, P0971 [5R55S] . . . . . . . . . . . . . . . . . . . . 05-02–36
CONVENTIONAL BRAKE SYSTEM DTC P1635 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–38
LOCATION INDEX[EVEREST] . . . . . . . . . . . . . . . 04-11–2 DTC P1700 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–38
CONVENTIONAL BRAKE SYSTEM DTC P1711 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–39
LOCATION INDEX[RANGER (AT)] . . . . . . . . . . . . 04-11–1 DTC P1780 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–40
C-PILLAR TRIM REMOVAL/INSTALLATION DTC P1783 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–42
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–3 DTC TABLE [5R55S]. . . . . . . . . . . . . . . . . . . . . . . . 05-02–5
CRANKSHAFT POSITION (CKP) DTC U0100, U0297 [5R55S]. . . . . . . . . . . . . . . . . 05-02–43
SENSOR REMOVAL/INSTALLATION
[WL-C, WE-C (AT)]. . . . . . . . . . . . . . . . . . . . . . . .01-40B–1
E
D EMISSION SYSTEM LOCATION INDEX
[WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . . 01-16B–1
DIGITAL TRANSMISSION RANGE ENGINE TECHNICAL DATA
(TR) SENSOR ADJUSTMENT [WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . . 01-50B–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–24 ENGINE TUNE-UP
DIGITAL TRANSMISSION RANGE [WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . . . . . . . . 01-10B–2
(TR) SENSOR INSPECTION EXHAUST SYSTEM
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–20 REMOVAL/INSTALLATION
DIGITAL TRANSMISSION RANGE [WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . . 01-15B–4
(TR) SENSOR REMOVAL/INSTALLATION EXHAUST SYSTEM
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–22 REMOVAL/INSTALLATION[WL-C, WE-C
DISC PAD (FRONT) REPLACEMENT (RANGER (AT))] . . . . . . . . . . . . . . . . . . . . . . . . . 01-15B–1
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–11 EXTENSION HOUSING GASKET
DOOR LOCATION INDEX[EVEREST]. . . . . . . . . . . 09-11–1 REPLACEMENT [5R55S] . . . . . . . . . . . . . . . . . . 05-13–58
D-PILLAR TRIM REMOVAL/INSTALLATION EXTERIOR TRIM LOCATION INDEX
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–1
DRIVE BELT INSPECTION EXTRACTOR CHAMBER
[WL-C, WE-C (EVEREST)]. . . . . . . . . . . . . . . . . .01-10B–1 REMOVAL/INSTALLATION
DRIVE PLATE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–71
DRIVELINE/AXLE SST F
[RANGER [5R55S], EVEREST] . . . . . . . . . . . . . . . 03-60–1
DRIVELINE/AXLE TECHNICAL DATA FLOOR COVERING
[RANGER [5R55S], EVEREST] . . . . . . . . . . . . . . . 03-50–1 REMOVAL/INSTALLATION
DTC C1414[4W-ABS (EVEREST)]. . . . . . . . . . . . .04-02B–6 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–7
DTC No.1 [4x4 control module] . . . . . . . . . . . . . . . . 03-02–4 FOREWORD [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-02–3
DTC No.2 [4x4 control module] . . . . . . . . . . . . . . . . 03-02–5 FOREWORD [5R55S] . . . . . . . . . . . . . . . . . . . . . . . 05-03–3
DTC No.3 [4x4 control module] . . . . . . . . . . . . . . . . 03-02–6 FOREWORD[EVEREST] . . . . . . . . . . . . . . . . . . . . 07-03–1
DTC No.4 [4x4 control module] . . . . . . . . . . . . . . . . 03-02–8 FRONT ABS WHEEL-SPEED SENSOR
DTC No.5 [4x4 control module] . . . . . . . . . . . . . . . . 03-02–9 REMOVAL/INSTALLATION
DTC No.6 [4x4 control module] . . . . . . . . . . . . . . . 03-02–11 [4W-ABS (EVEREST)] . . . . . . . . . . . . . . . . . . . . 04-13B–4
DTC No.7 [4x4 control module] . . . . . . . . . . . . . . . 03-02–12 FRONT AXLE LOCATION INDEX
DTC P0657, P0658 [5R55S]. . . . . . . . . . . . . . . . . . . 05-02–7 [EVEREST (4X2)] . . . . . . . . . . . . . . . . . . . . . . . . . 03-11–1
DTC P0705, P0708, P1702, FRONT BRAKE (DISC) INSPECTION
P1704, P1705 [5R55S]. . . . . . . . . . . . . . . . . . . . . . 05-02–9 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–7
DTC P0711, P0712, P0713 [5R55S] . . . . . . . . . . . 05-02–13 FRONT BRAKE (DISC)
DTC P0715, P0717, P0718 [5R55S] . . . . . . . . . . . 05-02–15 REMOVAL/INSTALLATION
DTC P0720, P0721, P0722 [5R55S] . . . . . . . . . . . 05-02–17 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–8
DTC P0731, P0732, P0733, FRONT STABILIZER
P0734, P0735 [5R55S]. . . . . . . . . . . . . . . . . . . . . 05-02–19 REMOVAL/INSTALLATION
DTC P0740, P0741, P0742, [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–6
P0743, P0744 [5R55S]. . . . . . . . . . . . . . . . . . . . . 05-02–20 FRONT SUSPENSION LOCATION INDEX
DTC P0745, P0748, P0960, [EVEREST [4x2]] . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–1
P0962, P0963 [5R55S]. . . . . . . . . . . . . . . . . . . . . 05-02–22 FRONT WHEEL ALIGNMENT
DTC P0750, P0753 [5R55S]. . . . . . . . . . . . . . . . . . 05-02–24 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–2
DTC P0755, P0757, P0758 [5R55S] . . . . . . . . . . . 05-02–26 FUEL GAUGE SENDER UNIT INSPECTION
DTC P0760, P0762, P0763 [5R55S] . . . . . . . . . . . 05-02–28 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-22–1
DTC P0765, P0768 [5R55S]. . . . . . . . . . . . . . . . . . 05-02–30 FUEL SYSTEM LOCATION INDEX
[WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . . 01-14B–1
AI–2
ALPHABETICAL INDEX
FUEL TANK REMOVAL/INSTALLATION LOAD SENSING PROPORTIONING VALVE
[WL-C, WE-C (EVEREST)] . . . . . . . . . . . . . . . . . 01-14B–2 (LSPV) REMOVAL/INSTALLATION
FUEL-FILLER LID ADJUSTMENT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–6
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-10–2 LOCATION INDEX WARNING AND
FUEL-FILLER LID AND OPENER INSPECTION INDICATOR SYSTEM[EVEREST]. . . . . . . . . . . . . 09-22–1
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-14–2 LOCATION INDEX[EVEREST] . . . . . . . . . . . . . . . . 08-11–1
FUEL-FILLER LID AND OPENER
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-14–3 M
FUEL-FILLER LID OPENER SWITCH
INSPECTION[EVEREST] . . . . . . . . . . . . . . . . . . . 09-14–2 MECHANICAL SYSTEM TEST
FUEL-FILLER LID OPENER SWITCH [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–4
REMOVAL/INSTALLATION MOTOR INSPECTION [5R55S] . . . . . . . . . . . . . . . . 03-16–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-14–2 MOTOR REMOVAL/INSTALLATION
FUEL-FILLER LID [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–5
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-10–2
N
G NO.1 INSUFFICIENT BLOWN AIR VOLUME
AND/OR NO BLOWN AIR DEPENDING ON
GLASS/WINDOWS/MIRRORS LOCATION INDEX AIRFLOW MODE.[EVEREST] . . . . . . . . . . . . . . . . 07-03–2
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–1 NO.1 NO RFW OPERATION
[4x4 control module]. . . . . . . . . . . . . . . . . . . . . . . . 03-03–3
NO.1 VEHICLE DOES NOT
H MOVE IN D RANGE,
OR IN R POSITION [5R55S] . . . . . . . . . . . . . . . . . 05-03–9
HEADLINER REMOVAL/INSTALLATION NO.10 FREQUENT SHIFTING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–6 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–15
HIGH-MOUNT BRAKE LIGHT NO.11 SHIFT POINT IS HIGH OR LOW
REMOVAL/INSTALLATION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–15
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–3 NO.12 TORQUE CONVERTER CLUTCH
HVAC BASIC SYSTEM LOCATION INDEX (TCC) NON-OPERATION [5R55S] . . . . . . . . . . . 05-03–16
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–1 NO.13 NO KICKDOWN [5R55S] . . . . . . . . . . . . . . 05-03–17
HVAC CONTROL SYSTEM LOCATION INDEX NO.14 ENGINE FLARES UP OR SLIPS
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–1 WHEN UPSHIFTING OR DOWNSHIFTING
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–17
I NO.15 ENGINE FLARES UP OR SLIPS

WHEN ACCELERATING VEHICLE
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–18
INTERIOR AND MAP LIGHT INSPECTION NO.16 JUDDER UPON TORQUE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–5 CONVERTER CLUTCH (TCC)
INTERIOR AND MAP LIGHT OPERATION [5R55S] . . . . . . . . . . . . . . . . . . . . . 05-03–18
REMOVAL/INSTALLATION NO.17 EXCESSIVE SHIFT SHOCK
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–4 FROM N TO D OR N TO R
INTERIOR TRIM LOCATION INDEX POSITION/RANGE [5R55S] . . . . . . . . . . . . . . . . 05-03–19
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–2 NO.18 EXCESSIVE SHIFT SHOCK IS FELT
INTERMEDIATE SHAFT SPEED (ISS) WHEN UPSHIFTING AND DOWNSHIFTING
SENSOR INSPECTION [5R55S]. . . . . . . . . . . . . 05-13–30 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–20
INTERMEDIATE SHAFT SPEED (ISS) NO.19 EXCESSIVE SHIFT SHOCK ON
SENSOR REMOVAL/INSTALLATION TORQUE CONVERTER CLUTCH (TCC)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–31 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–21
NO.2 4x4/4L INDICATOR DOSE NOT
L ILLUMINATE [4x4 control module]. . . . . . . . . . . . . 03-03–5
NO.2 NO BLOWN AIR IN AIRFLOW
MODE/BLOWN AIR VOLUME DOES NOT
LEAKAGE INSPECTION [5R55S] . . . . . . . . . . . . . 05-13–11 CHANGE AT ANY FAN SPEED.
LICENSE PLATE LIGHT [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–4
REMOVAL/INSTALLATION NO.2 NO BLOWN AIR IN AIRFLOW
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–3
LIGHTING SYSTEMS LOCATION INDEX
MODE/BLOWN AIR VOLUME DOES NOT AI
CHANGE AT ANY FAN SPEED.
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–3
LOAD SENSING PROPORTIONING VALVE NO.2 VEHICLE MOVES
(LSPV) ADJUSTMENT[EVEREST] . . . . . . . . . . . . 04-11–5 IN N POSITION [5R55S] . . . . . . . . . . . . . . . . . . . 05-03–10
LOAD SENSING PROPORTIONING VALVE NO.20 NOISE/VIBRATION FORWARD
(LSPV) INSPECTION[EVEREST] . . . . . . . . . . . . . 04-11–4 OR REVERSE [5R55S] . . . . . . . . . . . . . . . . . . . . 05-03–22
AI–3
ALPHABETICAL INDEX
NO.21 NO ENGINE BRAKING IN OUTPUT SHAFT SPEED (OSS)
1GR POSITION OF MANUAL 1 RANGE SENSOR REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–23 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–33
NO.22 TRANSMISSION OVERHEATS OVER FENDER
NO.23 ENGINE STALLS WHEN [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–2
SHIFTED TO D RANGE, OR IN R POSITION OVERHEAD CONSOLE
NO.24 ENGINE STALLS WHEN DRIVING [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–2
AT SLOW SPEEDS OR STOPPING
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–25
NO.25 STARTER DOES NOT WORK P
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–25
NO.3 AIRFLOW MODE DOES NOT CHANGE. PARKING BRAKE CABLE
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–5 REMOVAL/INSTALLATION
NO.3 NO CHANGE FORM 4x2 TO 4x4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-12–2
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . . 03-03–6 PARKING BRAKE SYSTEM LOCATION INDEX
NO.3 VEHICLE MOVES IN P POSITION, [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-12–1
OR PARKING GEAR DOES NOT PID/DATA MONITOR INSPECTION
DISENGAGE WHEN P IS DISENGAGED [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-02–45
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–10 PRECAUTION [4x4 control module] . . . . . . . . . . . . 03-03–2
NO.4 EXCESSIVE CREEP [5R55S]. . . . . . . . . . . . 05-03–11 PROPELLER SHAFT INSPECTION
NO.4 IMPROPER AIR CIRCULATION [5AT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-15–6
AND/OR NO AIR CIRCULATION. PROPELLER SHAFT LOCATION INDEX
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–6 [5AT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-15–1
NO.4 NO CHANGE FORM 4H TO 4L PROPELLER SHAFT
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . . 03-03–7 REMOVAL/INSTALLATION [5AT] . . . . . . . . . . . . 03-15–2
NO.5 NO CREEP AT ALL [5R55S]. . . . . . . . . . . . . 05-03–11
NO.5 NO TEMPERATURE CONTROL.
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–7
Q
NO.5 NOISE [4x4 control module] . . . . . . . . . . . . . . 03-03–9
NO.6 AIR FROM VENT NOT COLD ENOUGH. QUICK DIAGNOSIS CHART
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–11 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–7
NO.6 AIR FROM VENT NOT COLD ENOUGH.
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–8
NO.6 LOW MAXIMUM SPEED AND
R
POOR ACCELERATION [5R55S] . . . . . . . . . . . . 05-03–12
RADIATOR REMOVAL/INSTALLATION
NO.6 OIL LEAKAGE
[WL-C, WE-C (AT)] . . . . . . . . . . . . . . . . . . . . . . . 01-12B–1
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . 03-03–10
REAR A/C UNIT DISASSEMBLY/ASSEMBLY
NO.7 NO COOL AIR.[5R55S]. . . . . . . . . . . . . . . . . 07-03–17
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–3
NO.7 NO COOL AIR.[EVEREST] . . . . . . . . . . . . . . 07-03–14
REAR A/C UNIT REMOVAL/INSTALLATION
NO.7 NO SHIFTING [5R55S] . . . . . . . . . . . . . . . . . 05-03–13
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–3
NO.8 NO 2ND AND 5TH GEARS
REAR ABS WHEEL-SPEED SENSOR
(MANUAL 2ND IS OK) [5R55S] . . . . . . . . . . . . . . 05-03–14
NO.8 NOISE WHILE OPERATING A/C SYSTEM
[4W-ABS (EVEREST)] . . . . . . . . . . . . . . . . . . . . 04-13B–5
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–21
REAR AXLE LOCATION INDEX
NO.9 ABNORMAL SHIFTING
[RANGER [5R55S], EVEREST] . . . . . . . . . . . . . . 03-12–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-03–14
REAR BELTLINE MOLDING
O [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
REAR BLOWER MOTOR INSPECTION
O/D OFF SWITCH INSPECTION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–2
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–19 REAR BLOWER MOTOR
OIL COOLER FLUSHING [5R55S]. . . . . . . . . . . . . 05-13–67 REMOVAL/INSTALLATION
OIL COOLER [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–2
REMOVAL/INSTALLATION [5R55S] . . . . . . . . . . 05-13–68 REAR BRAKE (DRUM) INSPECTION
OIL SEAL (EXTENSION HOUSING) [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–12
REPLACEMENT [5R55S]. . . . . . . . . . . . . . . . . . . 05-13–57 REAR BRAKE (DRUM)
OIL SEAL (FLUID PUMP) REMOVAL/INSTALLATION
REPLACEMENT [5R55S]. . . . . . . . . . . . . . . . . . . 05-13–56 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-11–13
ON-BOARD DIAGNOSIS[4W-ABS REAR BUMPER DISASSEMBLY/ASSEMBLY
(EVEREST)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-02B–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-10–3
OUTPUT SHAFT SPEED (OSS) REAR BUMPER
SENSOR INSPECTION [5R55S] . . . . . . . . . . . . . 05-13–32 REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-10–2
AI–4
ALPHABETICAL INDEX
REAR COMBINATION LIGHT REAR WASHER NOZZLE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–2 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–5
REAR COOLER DUCT REAR WASHER TANK
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–5 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–2
REAR DIFFERENTIAL OIL REPLACEMENT REAR WINDOW GLASS INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-14–1 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–6
REAR DOOR ADJUSTMENT REAR WINDOW GLASS REMOVAL
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–3 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–5
REAR DOOR DISASSEMBLY/ASSEMBLY　 REAR WIPER AND WASHER SWITCH
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–2 INSPECTION[EVEREST] . . . . . . . . . . . . . . . . . . . 09-19–2
REAR DOOR GLASS REAR WIPER ARM AND BLADE ADJUSTMENT
REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–3
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–2 REAR WIPER ARM AND BLADE
REAR DOOR QUARTER GLASS REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–2 REAR WIPER MOTOR INSPECTION
REAR DOOR REMOVAL/INSTALLATION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-11–2 REAR WIPER MOTOR
REAR DOOR TRIM REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–4 REFRIGERANT CHARGING
REAR END TRIM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-10–1
REMOVAL/INSTALLATION[EVEREST] . . . . . . . . 09-17–5 REFRIGERANT LINES
REAR EVAPORATOR INSPECTION REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-11–5
REAR FAN SWITCH REFRIGERANT PRESSURE SWITCH
DISASSEMBLY/ASSEMBLY INSPECTION[EVEREST] . . . . . . . . . . . . . . . . . . . 07-40–3
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–4 REFRIGERANT PRESSURE SWITCH
REAR FAN SWITCH INSPECTION REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–5 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–3
REAR FAN SWITCH ROAD TEST [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . 05-13–8
REMOVAL/INSTALLATION ROOF MOLDING
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–4 REMOVAL/INSTALLATION
REAR MAP LIGHT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
REMOVAL/INSTALLATION ROOF RAIL REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-18–5 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–3
REAR RESISTOR
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-40–2 S
REAR SCUFF PLATE
REMOVAL/INSTALLATION SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 00-00–4
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–3 SEAT LOCATION INDEX
REAR SHOCK ABSORBER AND LEAF [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–1
SPRING REMOVAL/INSTALLATION SECOND-ROW BUCKLE
REAR SIDE TRIM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–3
REMOVAL/INSTALLATION SECOND-ROW SEAT BELT
REAR SPOILER [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–2
REMOVAL/INSTALLATION SECOND-ROW SEAT
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-16–2 DISASSEMBLY/ASSEMBLY
REAR SUSPENSION LOCATION INDEX [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–2
[RANGER [5R55S], EVEREST] . . . . . . . . . . . . . . 02-14–1 SECOND-ROW SEAT
REAR WASHER HOSE REMOVAL/INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–6 SELECTOR CABLE ADJUSTMENT . . . . . . . . . . . . 05-14–2
REAR WASHER MOTOR INSPECTION SELECTOR CABLE
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–5 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 05-14–3 AI
REAR WASHER MOTOR SELECTOR LEVER INSPECTION . . . . . . . . . . . . . 05-14–2
REMOVAL/INSTALLATION SELECTOR LEVER
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–5 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 05-14–4
REAR WASHER NOZZLE ADJUSTMENT SIDE WINDOW GLASS INSTALLATION
[EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–6 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–3
AI–5
ALPHABETICAL INDEX
SIDE WINDOW GLASS REMOVAL TRANSFER CASE OIL REPLACEMENT
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-12–3 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–2
SOLENOID BODY TRANSFER CASE REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–7
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–35 TRANSFER LOCATION INDEX
SOLENOID VALVE INSPECTION [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–34 TRANSMISSION FLUID TEMPERATURE
SPEED SENSOR INSPECTION (TFT) SENSOR INSPECTION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–3 [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–26
SPEED SENSOR REMOVAL/INSTALLATION TRANSMISSION SST [5R55S] . . . . . . . . . . . . . . . . 05-60–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–4 TRANSMISSION/TRANSAXLE
SUSPENSION TECHNICAL DATA [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-50–1
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-50–1 TROUBLESHOOTING INDEX
SYMPTOM TROUBLESHOOTING [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–2
[4x4 control module] . . . . . . . . . . . . . . . . . . . . . . . . 03-03–2 TROUBLESHOOTING INDEX
SYMPTOM TROUBLESHOOTING [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-03–1
ITEM TABLE [5R55S] . . . . . . . . . . . . . . . . . . . . . . 05-03–5 TURBINE SHAFT SPEED (TSS)
SYSTEM WIRING DIAGRAM SENSOR INSPECTION [5R55S] . . . . . . . . . . . . 05-13–28
[4W-ABS (EVEREST)] . . . . . . . . . . . . . . . . . . . . .04-03B–1 TURBINE SHAFT SPEED (TSS)
SENSOR REMOVAL/INSTALLATION
T [5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–29
TCM INSPECTION [5R55S] . . . . . . . . . . . . . . . . . . 05-13–39 V

TCM REMOVAL/INSTALLATION
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–44 VEHICLE HEIGHT ADJUSTMENT
THIRD-ROW BUCKLE [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–1
REMOVAL/INSTALLATION VEHICLE IDENTIFICATION NUMBER (VIN)
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–4 CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1
THIRD-ROW SEAT BELT VEHICLE IDENTIFICATION NUMBER (VIN)
REMOVAL/INSTALLATION CODE[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–3 VEHICLE IDENTIFICATION NUMBERS (VIN)
THIRD-ROW SEAT [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2
DISASSEMBLY/ASSEMBLY
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–3
THIRD-ROW SEAT W
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-13–3 WHEEL ALIGNMENT PRE-INSPECTION
TIRE HOUSE TRIM [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–2
REMOVAL/INSTALLATION WHEEL AND TIRE SPECIFICATION
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-17–4 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-12–1
TORQUE CONVERTER INSPECTION WHEEL HUB BOLT REPLACEMENT
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–54 [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-11–7
TORQUE CONVERTER WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION INSPECTION[EVEREST] . . . . . . . . . . . . . . . . . . . 03-11–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-13–55 WHEEL HUB, STEERING KNUCKLE
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [EVEREST (4X2)] . . . . . . . . . . . . . . . . . . . . . . . . . 03-11–2
[EVEREST]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-13–2 WIPER/WASHER SYSTEM LOCATION INDEX
TRANSFER CASE OIL INSPECTION [EVEREST] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-19–1
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-16–2
AI–6

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WARNING.

This manual contains "Warnings" and "Cautions" applicable to risks

The procedures recommended and described in this manual are

The contents of this manual, including drawings and specifications, are

Parts should be replaced with genuine Ford replacement parts or with

VEHICLE IDENTIFICATION NUMBERS (VIN)

RANGER Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F198–10–05L

GENERAL INFORMATION 00SECTION

DRIVE PINION GEAR

TORQUE TSS SENSOR ISS SENSOR LOW/REVERSE

OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

TORSION BAR SPRING

TORSION BAR SPRING

STEERING COLUMN AND SHAFT

STEERING GEAR AND LINKAGE

DRIVE PINION GEAR

REAR BRAKE (DRUM)

FRONT BRAKE (DISC)

REAR ABS WHEEL-SPEED

FRONT ABS WHEEL-SPEED

3RD GEAR 5TH GEAR

MAIN DRIVE GEAR

COUNTER REVERSE GEAR REVERSE IDLER GEAR

TORQUE TSS SENSOR ISS SENSOR LOW/REVERSE

OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

Plant W=A. A. Thailand

1= WL-C (2.5 L-DI)

D= 2268—2721 kg {5001—6000 lbs}

Product sorce S= Japan (for Thailand)

World manufacturer identification MNB= FORD (Thailand)

Plant W=A. A. Thailand

Production year 6= 2006, 7= 2007, 8=2008...

1= WL-C (2.5 L-DI)

D= 2268—2721 kg {5001—6000 lbs}

Body style 4= New Wagon

Product sorce S= Japan

L= with Air bag (Driver and Passenger)

World manufacturer identification MNB= FORD (Thailand)

FUEL SYSTEM [WL-C, WE-C]

FUEL METERING VALVE

Fuel Tank Side

FROM INJECTION PUMP

EXHAUST SYSTEM [WL-C, WE-C]

01-15B EXHAUST SYSTEM [WL-C, WE-C]

JOINT PIPE MAIN SILENCER

EXHAUST SYSTEM [WL-C, WE-C]

OXIDATION CATALYTIC CONVERTER

EMISSION SYSTEM [WL-C, WE-C]

01-16B EMISSION SYSTEM [WL-C, WE-C]

EGR SOLENOID VALVE

INTAKE SHUTTER VALVE

EGR CONTROL SOLENOID VALVE

INTAKE SHUTTER SOLENOID VALVE (HALF)

INTAKE SHUTTER SOLENOID VALVE (FULL)

Fuel Tank Side

Toc of SCT . . . . . . . . . . . . . . . . . 02-00

Wheel and tires

02-11 WHEEL ALIGNMENT

DO NOT USE MORE THAN ONE

THE CASTER ANGLE

Camber: 1 mm {0.039 in} shim = 15’

WHEEL AND TIRES

02-12 WHEEL AND TIRES